Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
  • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
  • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B21/06—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B29/00—Layered products comprising a layer of paper or cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/043—Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
  • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/18—Paper- or board-based structures for surface covering
  • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
  • D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
  • D21H27/28—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures treated to obtain specific resistance properties, e.g. against wear or weather
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/02—Composition of the impregnated, bonded or embedded layer
  • B32B2260/026—Wood layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/04—Impregnation, embedding, or binder material
  • B32B2260/046—Synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/554—Wear resistance
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2317/00—Animal or vegetable based
  • B32B2317/12—Paper, e.g. cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2391/00—Waxes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2419/00—Buildings or parts thereof
  • B32B2419/04—Tiles for floors or walls
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/33—Synthetic macromolecular compounds
  • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D21H17/47—Condensation polymers of aldehydes or ketones
  • D21H17/49—Condensation polymers of aldehydes or ketones with compounds containing hydrogen bound to nitrogen
  • D21H17/51—Triazines, e.g. melamine
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/63—Inorganic compounds
  • D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
  • Y10T428/24372—Particulate matter

Definitions

• This invention relates to a decorative laminate with an abrasion-resistant surface coating for laminate bodies that have been or are to be coated with it, especially laminate floor boards or panels based on wood materials, according to the preamble of claim 1 .
• this invention relates to the production of the new decorative laminate that has an abrasion-resistant surface coating and that is intended for floor boards, panels, and the like.
• Such classic overlays consist of thin, especially transparent special papers that are impregnated with duroplastic resins, such as especially melamine resins. These papers are located on or over the surface film and wear film of the decorative web and are pressed with the latter with the decorative web and ultimately with the substrate based on a wood-based material into the laminate intended for laying of floors and are of decisive importance for ease of cleaning of laminate floors.
• the laminate base production process consists in that a fibrous material web, especially a paper web provided with some printed decoration, is impregnated with a thermosettable resin, more preferably with a possibly modified melamine, formaldehyde and/or urea resin, and optionally directly afterwards or even later—optionally with the interposition of a possibly multilayer paper web likewise impregnated with a thermosettable resin—as a decorative laminate web with an abrasion-resistant surface layer is bonded to a substrate such as especially a wood chipboard or fiberboard under the action of heat and pressure.
• a fibrous material web especially a paper web provided with some printed decoration
• a thermosettable resin more preferably with a possibly modified melamine, formaldehyde and/or urea resin, and optionally directly afterwards or even later—optionally with the interposition of a possibly multilayer paper web likewise impregnated with a thermosettable resin—as a decorative laminate web with an abrasion-resistant surface layer is bonded to
• the technique predominates of subjecting the resin of the decorative laminate web and possibly present core layer web(s) in each case only to partial setting and of bonding the laminate that has been preset in this way under the action of heat and pressure by means of the resin that is then cured completely ultimately to the wood material substrate provided in each case.
• DE 28 58 182 C2 discloses a decorative web for producing decorative boards with high abrasion-resistance in which there is a thin, abrasion-resistant coating that is located over the decoration and that contains an abrasion-resistant mineral and furthermore a binder for the latter, and the binder is to be compatible with the resin mass used and permeable to this resin.
• the production of a decorative laminate can proceed, as follows from, e.g., DE 2 800 762, such that first an aqueous suspension of aluminum oxide particles stabilized with microcrystalline cellulose is applied to the unimpregnated decorative web, after which drying takes place. Then, impregnation with a melamine-formaldehyde resin solution is undertaken, and finally this decorative wear web is hot-pressed with a core web and the substrate board.
• the abrasion-resistant fine mineral particles are displaced by the microcrystalline cellulose to the outside or surface, the surface resin layer, and then in part protrude out of it and thus cause unwanted roughness of this surface, and, as is much more serious, increased wear of the sheets of the pressing tools used in the production of the laminates as a result of inevitable damage to the sheet surface.
• U.S. Pat. No. 3,135,643 A discloses a laminate production method according to which the decorative web is first impregnated with a resin suspension, and the latter is coated still wet with a dispersion comprising melamine resin, quartz, cellulose, cellulose derivatives and water. The complete jacketing of the particles of the abrasive substance with resin that is essential for protecting the pressing plates and belts cannot be ensured with this method either, as shown.
• EP 472 036 A1 discloses a two-stage “wet-in-wet” process for producing abrasion-resistant decorative laminates, according to which it is provided that the decorative web itself in any case within the framework of the first impregnation with resin is impregnated with a melamine resin dispersion containing particles of abrasive material up to a percentage desired in each case.
• the disadvantage of this type of addition of particles of abrasive material directly onto and into the paper web of the decorative laminate is that within the decorative cover layer, the distribution of particles is not homogeneous, so that in this first production step, local stiffening occurs.
• the resin dispersion likewise containing the abrasive substances is applied. The aforementioned zones of stiffening of the decorative web as a result of penetration of abrasive particles into the latter then in any case disrupt the flexibility of the decorative web in the actual coating process.
• EP 732 449 A1 should be mentioned, according to which abrasion-resistant laminates are obtained by a decorative paper sheet that is to be coated or a web of this type first being impregnated with resin, after which drying to certain residual moisture content values takes place, after which then a resin mass containing the particles of abrasive substance, cellulose, resin and additives is applied to the impregnation layer that has been partially dried in this way.
• the disadvantage of this coating method is that genuine bonding of the impregnation resin bodies to the surface coating resin bodies that contain the particles of abrasive substance, which bonds can be mechanically highly loaded, is not achieved.
• microcrystalline cellulose there has the purpose of producing a uniform distribution of particles of abrasive material in the surface resin layer, which leads, however, to corners or edges of the particles that are located near the outer surface of the surface layer protruding beyond it and thus being able to damage the surface of the pressing sheets.
• This US-A also discloses use of polyethylene wax as a surface-active component that increases slip.
• U.S. Pat. No. 4,449,137 A and U.S. Pat. No. 4,567,087 A disclose a laminate in which finely dispersed polyethylene wax is incorporated in the vicinity of its surface or actually on its surface. The objective there is specifically that the wax “blooms” during hot-pressing, therefore migrates to the surface. This is achieved there in that the polyethylene wax is applied in its own working step and not as a component integrated into the impregnation and coating resin mass.
• the object of the invention is to devise a decorative laminate or substrate body coated with the latter for the most varied applications, but especially for floor boards, panels and the like, which on the visible side that is used has a surface coating that meets high or extremely high requirements in its clarity and decorative reproduction quality and that can be controlled in its wear properties to the highest abrasion values.
• the production process is to be fault-proof and economical, and is to take place within the framework of production methods that have been proven in the past in practice, and is to be able to be implemented on existing systems without extensive re-arrangements and modifications at essentially the same production rates.
• the subject matter of this invention is thus a decorative laminate with an abrasion-resistant surface coating for laminate bodies that have been or are to be coated with it, especially laminate floor boards or panels based on wood materials, of the initially named type according to the preamble of claim 1 .
• the ratio of polyethylene and/or polypropylene—that is/are present in addition to other components and/or modifiers and/or additives or the like—to polyamide can vary within wide limits of between 0.1 to 10 and 100 to 0.1.
• the ratio is advantageously in the range of between 50 to 100 and 100 to 50.
• a laminate whose partially set resin impregnation and coating masses is formed with a special wax blend in the compound according to claim 2 is especially preferred.
• Polyamides in the compound that has been incorporated into the resin mass or in its wax components support not only the described new feel, but furthermore contribute to increased resistance of the coating, especially also with respect to the prevention of cracking.
• One measure that unexpectedly supports the specific “settling effect” of the particles of abrasive material that has been desired for a long time and that has now been achieved according to the invention surprisingly consists in adding spherules of silicate material, especially glass, to the resin mass that contains the abrasive material according to claim 5 .
• the action of the glass spherules can be explained, for example, by the fact that they ensure, so to speak, a thickness of the surface or wear layer resin film between one another that corresponds to their diameter, which means effective material coverage for the particles of abrasive material that as a result of using the above-described wax-PVP compound have the inherently unexpected tendency that is used anyway according to the invention to settle within the surface layer toward the decorative web, by which the above-explained protrusion of regions of particles of abrasive material that lie only in the micron range over the surface level of the surface layer is prevented.
• sugars mentioned in this claim can play an important part within the impregnation and coating resin mass, specifically because they have 8 free OH groups per molecule that are heavily incorporated into the resulting combination of molecules when the laminating resin, such as, e.g., melamine resin, condenses, and can modify them in the direction in which a possible tendency to residual cracking that is exceptionally low anyway is extremely effectively suppressed.
• the laminating resin such as, e.g., melamine resin, condenses
• the p-toluene sulfonic acid amide furthermore named in claim 6 forms an advantageous additional modifier for the condensation process in the formation of melamine resin, which can be attributed to its tautomer properties that lead to the fact that chain breaks occur within the framework of resin condensation over a long condensation period, and thus the formation of large molecular chains that, as has been found, cause and intensify cracking to a significant degree is greatly reduced.
• the natural substances named in claim 7 can perform good additional support services.
• a novel process for producing the new, cracking-free laminates finished to be abrasion-resistant as defined initially according to the preamble of claim 10 that comprises the features and measures named in the characterizing portion of this claim relates to another important subject of the invention.
• claim 11 names the resin masses that are to be more advantageously used and that due to their properties with respect to improvement of protection of pressing sheets and belts and suppression of cracking contain the especially preferred components and additives named there.
• wax blend polyethylene wax basis (e.g., from the PORO, Pointner und RothWardl Company, Salzburg)
• the application values of the described resin-abrasive particle mixture were 70 g/m 2 decorative paper with a final weight of roughly 210-220 g/m 2 .
• the resulting resin-impregnated, surface-coated decorative web with abrasive particles applied was brought to a residual moisture content of from 6% to 6.5%. There would be a risk of agglutination of the resin film at a residual moisture content of more than 7%.
• the decorative web obtained after partial setting was applied directly on a “Hymmen” unit at 37 m/minute of feed to floor panel boards made of fine fiber wood material and was hot-pressed at 240° C. and a pressure of 20 bar.
• the “xanthene solution” that is used is a 1% solution of xanthene in water to which 0.3% formaldehyde is added to stabilize the solution.
• the mixture according to “Formulation 38” is a melamine resin emulsion with 250 kg of 50% melamine resin, 4.8 kg of etherified melamine resin as the modifier, 0.4 kg of Alton MF 179 (WIZ Company, Italy) as the wetting and separating agent, 0.7 kg of Alton 1263 (WIZ Company, Italy) as a transparency enhancer, 0.3 kg of hardener 529 (BASF, Germany) and 2.0 kg of hardener 806 (KS Deurotex) based on diethanolamine.
• Silane Z 6020 (Dow Chemicals, USA) is an amino silane.
• the “ZWSK corundum” used as the abrasive substance bears this designation due to the special manner of its production, the attached numbers 220 and 180 designating the average grain size in ⁇ m.
• This “wax blend” is produced as follows:
• the important components intended for this purpose e.g., based on polyethylene and polyethylene derivative thermoplastics, or, generally speaking, polyalkylene or polyalkylene derivative thermoplastics, are cast into blocks, which are crushed after cooling, and starting with a certain size are ground or micronized in a jet mill.
• Each of the components is brought to the grain sizes desired in each case, e.g., by screening, classifying or the like, and in each case, e.g., two or more different grain size fractions of the different materials are mixed with one another in a corresponding ratio to one another. Screening characteristics and the component mixing ratios are known to the manufacturer.
• the “Hypersal VXT 3797” (Solutia Company, Germany) used in the resin impregnation and coating mass is a commercial wetting agent.
• polyvinyl pyrrolidones used here, generally called “cross-linked polyvinyl pyrrolidones” (BASF, Germany) have the commercial names “Luvicross” and “Luvicross M” and contain up to 6.0% of water, 11.0 to 12.8% of nitrogen, 0.5% of ash and less than 50 mg/kg of heavy metals. They are supplied in powder form. Their molecular weight can only be given as an order of magnitude.
• the p-toluene sulfonic acid amide that can be used within the framework of the invention and the example is known as a chain stopper and can, as has been found, contribute to a certain extent to preventing the above-described, unwanted cracking in the overlay film-free laminate surface layer.
• the new floor laminates produced on the basis of the aforementioned data are characterized by highly wear-resistant surface films. They can be easily produced within conventional laminate pressing times and under the conditions that are otherwise common in laminate production.

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Citations (8)

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• 2003
  • 2003-09-08 AT AT0140703A patent/AT500083B1/de not_active IP Right Cessation
• 2004
  • 2004-09-08 SI SI200432191T patent/SI1663669T1/sl unknown
  • 2004-09-08 WO PCT/AT2004/000306 patent/WO2005023561A1/de active Application Filing
  • 2004-09-08 CN CN200480025692XA patent/CN1849225B/zh not_active Expired - Fee Related
  • 2004-09-08 PT PT47610282T patent/PT1663669E/pt unknown
  • 2004-09-08 CA CA2538166A patent/CA2538166C/en not_active Expired - Fee Related
  • 2004-09-08 EP EP04761028.2A patent/EP1663669B1/de active Active
  • 2004-09-08 JP JP2006525564A patent/JP5074029B2/ja not_active Expired - Fee Related
  • 2004-09-08 US US10/570,951 patent/US20070116927A1/en not_active Abandoned
  • 2004-09-08 ES ES04761028.2T patent/ES2518319T3/es active Active
  • 2004-09-08 PL PL04761028T patent/PL1663669T3/pl unknown
  • 2004-09-08 AU AU2004270284A patent/AU2004270284B2/en not_active Ceased

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