WO2005097380A1 - An improved process for the manufacturing of decorative laminate - Google Patents
An improved process for the manufacturing of decorative laminate Download PDFInfo
- Publication number
- WO2005097380A1 WO2005097380A1 PCT/SE2005/000484 SE2005000484W WO2005097380A1 WO 2005097380 A1 WO2005097380 A1 WO 2005097380A1 SE 2005000484 W SE2005000484 W SE 2005000484W WO 2005097380 A1 WO2005097380 A1 WO 2005097380A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- process according
- decor
- resin
- wear layer
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 31
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 7
- 239000002245 particle Substances 0.000 claims abstract description 27
- 229920005989 resin Polymers 0.000 claims abstract description 14
- 239000011347 resin Substances 0.000 claims abstract description 14
- 238000005299 abrasion Methods 0.000 claims abstract description 6
- 229920003180 amino resin Polymers 0.000 claims description 15
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 9
- 229920001187 thermosetting polymer Polymers 0.000 claims description 9
- 229920002678 cellulose Polymers 0.000 claims description 8
- 239000001913 cellulose Substances 0.000 claims description 8
- 229920000877 Melamine resin Polymers 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 6
- 239000002023 wood Substances 0.000 claims description 5
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 4
- 229920001807 Urea-formaldehyde Polymers 0.000 claims description 4
- GZCGUPFRVQAUEE-SLPGGIOYSA-N aldehydo-D-glucose Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O GZCGUPFRVQAUEE-SLPGGIOYSA-N 0.000 claims description 4
- 238000003475 lamination Methods 0.000 claims description 4
- 229920001568 phenolic resin Polymers 0.000 claims description 4
- 229920005992 thermoplastic resin Polymers 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- 229910052814 silicon oxide Inorganic materials 0.000 claims description 3
- 239000000835 fiber Substances 0.000 claims description 2
- 239000003292 glue Substances 0.000 claims description 2
- 239000012943 hotmelt Substances 0.000 claims description 2
- -1 methylol amino Chemical group 0.000 claims description 2
- 229920002635 polyurethane Polymers 0.000 claims description 2
- 239000004814 polyurethane Substances 0.000 claims description 2
- 239000003086 colorant Substances 0.000 description 5
- 235000019646 color tone Nutrition 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 239000004579 marble Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 235000003385 Diospyros ebenum Nutrition 0.000 description 1
- 241000792913 Ebenaceae Species 0.000 description 1
- 235000009984 Pterocarpus indicus Nutrition 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 241000533793 Tipuana tipu Species 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 1
- 239000010438 granite Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
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
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/10—Layered products comprising a layer of synthetic resin 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
-
- 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
- B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
-
- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/08—Impregnating
-
- 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
-
- 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
-
- 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
- B32B2255/00—Coating on the layer surface
- B32B2255/12—Coating on the layer surface on paper 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
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
-
- 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
- B32B2386/00—Specific polymers obtained by polycondensation or polyaddition not provided for in a single one of index codes B32B2363/00 - B32B2383/00
-
- 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
- B32B2451/00—Decorative or ornamental articles
Definitions
- the present invention relates to an improved process for the manufacturing of a decorative laminate with increased dimension stability of decor sections.
- thermosetting laminate most often consist of a number of base sheets with a decor sheet placed closest to the surface.
- the decor sheet can be provided with a pattern by desire. Common patterns usually visualise different kinds of wood or mineral such as marble and granite.
- the substrate carrying the decor often consist of a cellulose sheet on which the decor is printed. It is also known to use polymeric or polymer/cellulose blend materials as a decor carrier on which the decor is printed.
- the decor sheet is in most cases impregnated with a thermosetting resin. The dimension of the decor sheet will change during this process. This will cause problems in cases where decor matching is desired.
- the invention relates to a process for the manufacturing of a decorative laminate having a base layer, a decorative layer and a wear layer.
- a decor is printed on a decor layer.
- the decor layer is constituted of paper which is impregnated with resin prior to the printing process.
- a bonding layer is arranged between said base layer and said decor layer.
- the wear layer constitutes an abrasion resistant layer which is arranged on top of the decor layer, said wear layer comprising resin and hard particles.
- the different layers are bonded together through means of heat and pressure.
- the printed decor comprises a printing ink while the wear layer comprises a thermosetting resin selected from the group consisting of; melamine-formaldehyde resin, phenol-formaldehyde resin, urea formaldehyde resin and mixtures thereof-
- a thermosetting resin selected from the group consisting of; melamine-formaldehyde resin, phenol-formaldehyde resin, urea formaldehyde resin and mixtures thereof-
- An amount of amino resin is hereby mixed into the printing ink in order to increase the bond between the decor layer, printing ink and the wear layer when the layers are laminated together in a laminate press under increased temperature and pressure .
- the printing ink is suitably an alkyde based ink or a polyester-acrylate based ink.
- the amino resin is an etherified amino resin or a methylol amino resin.
- the main part of the base layer comprises a wood based board selected from the group consisting of; a particle board, a fibre board and a oriented strand board.
- the base layer may according to certain embodiments of the invention further comprise a supporting paper layer arranged between the board and the decor layer.
- the wear layer may according to one embodiment of the invention be comprised of a high viscosity amino resin applied on top of the decorative layer prior to the lamination.
- the wear layer is comprised of an amino resin / cellulose mixture.
- the wear layer is comprised of one or more amino resin impregnated cellulose layer or layers.
- the wear layer also comprises hard particles with an average particle size in the range 50nm - 150 ⁇ m in order to further improve the abrasion resistance.
- the upper portion of the wear layer may suitably be provided with hard particles with an average particle size in the range 50nm - 30 ⁇ m while the inner portion of the wear layer is provided with hard particles with an average particle size in the range 31 ⁇ m - 150 ⁇ m.
- the smaller particles near the surface will improve scratch resistance while keeping wear of pressing equipment like press plates at a moderate level.
- the hard particles is preferably selected from the group consisting of; silicon oxide, silicon carbide and aluminium oxide.
- the wear layer is suitably provided with a surface structure that enhances the realistic impression of the decor during or after the lamination. This is suitably achieved by any known method of embossing.
- the bonding layer comprises a thermosetting resin.
- the thermosetting resin is suitably selected from the group consisting of; melamine formaldehyde resin, phenol formaldehyde resin, urea formaldehyde resin and combinations thereof.
- the bonding layer is comprises a thermoplastic resin.
- the thermoplastic resin may for example be a polyurethane based hotmelt glue.
- the decor is achieved by digitisation of an actual archetype or by partly or completely being created in a digital media.
- the digitised decor is stored digitally in order to be used as a control function and original, together with possible control programs, when printing the decor.
- the decor may accordingly be obtained by making a high resolution or selected resolution digital picture of the desired decor. This is suitably made by means of a digital camera or scanner.
- the most common decor will of course be different kinds of wood and minerals like marble, as these probably will continue to be preferred surface decoration in home and public environments. It is, however, possible to depict anything that is visible.
- the digitised version of the decor is then edited to fit the size of the supporting core.
- the digital decor is used together with guiding programs to control a printer.
- the printer may be of an electrostatic type or an ink -jet type printer.
- the colours yellow, magenta, cyan and black will be sufficient for the printing process, but in some cases it might be advantageous to add white.
- Some colours are difficult to achieve using the colours yellow, magenta, cyan, black and white whereby the colours light magenta and light cyan may be added.
- spot colours where specific colour tones are difficult to achieve or where only certain parts of the colour spectrum with intermixing shades is desired.
- the resolution needed is much depending on the decor that is to be simulated, but resolutions of 10 - 1500 dots per inch (dpi) is the practical range in which most decors will be printed. Under normal conditions a resolution of 300 - 800 dpi is sufficient when creating simulations of even very complex decorative patterns and still achieve a result that visually is very difficult to separate from the archetype without close and thorough inspection.
- the translucent wear layer is suitably constituted of melamine-formaldehyde resin / cellulose blend, high viscosity melamine- formaldehyde or one or more sheets of cellulose which are impregnated with melamine-formaldehyde resin.
- This wear layer is joined with the core and decor under heat and pressure whereby the resin cures. It is advantageous to add hard particles with an average particle size in the range 50 nm - 150 ⁇ m to the wear layer.
- the particles in the range 10 ⁇ m - 150 ⁇ m, preferably 30 ⁇ m - 150 ⁇ m is foremost used to achieve abrasion resistance while the smaller of the particles, in the range 50 nm - 30 ⁇ m, preferably 50 nm - 10 ⁇ m, is used to achieve scratch resistance.
- the smaller particles is hereby used on, or very close to, the top surface while the larger particles may be distributed in the wear layer.
- the particles advantageously are constituted of silicon carbide, silicon oxide, aluminium oxide.
- the wear layer is hereby suitably pressed together with the rest of the decorative laminate in a continuos belt press with two steel belts. It is also possible to utilise a discontinuous process where one or a number of surface elements can be pressed at the same time.
Landscapes
- Laminated Bodies (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0400945A SE527165C2 (en) | 2004-04-07 | 2004-04-07 | An improved process for making decorative laminate |
SE0400945-2 | 2004-04-07 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005097380A1 true WO2005097380A1 (en) | 2005-10-20 |
Family
ID=32173715
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/SE2005/000484 WO2005097380A1 (en) | 2004-04-07 | 2005-04-04 | An improved process for the manufacturing of decorative laminate |
Country Status (2)
Country | Link |
---|---|
SE (1) | SE527165C2 (en) |
WO (1) | WO2005097380A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2268487A1 (en) * | 2008-03-31 | 2011-01-05 | 3M Innovative Properties Company | Decorative sheet |
WO2011036142A1 (en) * | 2009-09-23 | 2011-03-31 | Theodor Hymmen Holding Gmbh | Method for producing a digitally printed workpiece |
EP2455229A3 (en) * | 2010-11-17 | 2013-02-27 | Pergo (Europe) AB | Method for manufacturing a surface element |
EP2894044B1 (en) * | 2014-01-10 | 2017-12-13 | Agfa Graphics Nv | Manufacturing of decorative laminates by inkjet |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6465046B1 (en) * | 1999-12-23 | 2002-10-15 | Pergo (Europe) Ab | Process for achieving decor on a surface element |
WO2003061967A1 (en) * | 2002-01-25 | 2003-07-31 | Pergo(Europe) Ab | A process of matching decor sections of surface panels |
WO2003080337A1 (en) * | 2002-03-27 | 2003-10-02 | Pergo (Europe) Ab | A process for the manufacture of a decorative laminate |
-
2004
- 2004-04-07 SE SE0400945A patent/SE527165C2/en not_active IP Right Cessation
-
2005
- 2005-04-04 WO PCT/SE2005/000484 patent/WO2005097380A1/en active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6465046B1 (en) * | 1999-12-23 | 2002-10-15 | Pergo (Europe) Ab | Process for achieving decor on a surface element |
WO2003061967A1 (en) * | 2002-01-25 | 2003-07-31 | Pergo(Europe) Ab | A process of matching decor sections of surface panels |
WO2003080337A1 (en) * | 2002-03-27 | 2003-10-02 | Pergo (Europe) Ab | A process for the manufacture of a decorative laminate |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2268487A1 (en) * | 2008-03-31 | 2011-01-05 | 3M Innovative Properties Company | Decorative sheet |
EP2268487A4 (en) * | 2008-03-31 | 2013-06-12 | 3M Innovative Properties Co | Decorative sheet |
WO2011036142A1 (en) * | 2009-09-23 | 2011-03-31 | Theodor Hymmen Holding Gmbh | Method for producing a digitally printed workpiece |
EP2455229A3 (en) * | 2010-11-17 | 2013-02-27 | Pergo (Europe) AB | Method for manufacturing a surface element |
US8591696B2 (en) | 2010-11-17 | 2013-11-26 | Pergo (Europe) Ab | Method for manufacturing a surface element |
EP2894044B1 (en) * | 2014-01-10 | 2017-12-13 | Agfa Graphics Nv | Manufacturing of decorative laminates by inkjet |
Also Published As
Publication number | Publication date |
---|---|
SE0400945D0 (en) | 2004-04-07 |
SE0400945L (en) | 2005-10-08 |
SE527165C2 (en) | 2006-01-10 |
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