WO2020141384A2 - Panneau et procédé de fabrication de panneau - Google Patents

Panneau et procédé de fabrication de panneau Download PDF

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Publication number
WO2020141384A2
WO2020141384A2 PCT/IB2019/060901 IB2019060901W WO2020141384A2 WO 2020141384 A2 WO2020141384 A2 WO 2020141384A2 IB 2019060901 W IB2019060901 W IB 2019060901W WO 2020141384 A2 WO2020141384 A2 WO 2020141384A2
Authority
WO
WIPO (PCT)
Prior art keywords
layer
accordance
panel
aluminum layer
substrate
Prior art date
Application number
PCT/IB2019/060901
Other languages
English (en)
Other versions
WO2020141384A3 (fr
Inventor
Koen NEL
Original Assignee
Unilin, Bvba
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Unilin, Bvba filed Critical Unilin, Bvba
Priority to EP19839668.1A priority Critical patent/EP3906158A2/fr
Publication of WO2020141384A2 publication Critical patent/WO2020141384A2/fr
Publication of WO2020141384A3 publication Critical patent/WO2020141384A3/fr

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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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/10—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/095—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyurethanes
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • 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
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • 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
    • B32B21/08—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 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B32B2037/1215—Hot-melt adhesive
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B2037/1253—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives curable adhesive
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/06—Coating on the layer surface on metal 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
    • B32B2255/08—Coating on the layer surface on 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
    • 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
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/41—Opaque
    • 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
    • B32B2307/584—Scratch 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional 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
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls

Definitions

  • This invention relates to a panel and a method for producing a panel.
  • the invention relates to a panel that comprises a wood-based substrate, wherein said panel has an aluminum layer on at least one side thereof. Even more specifically, it relates to load-bearing panels, and in particular mezzanine panels or mezzanine floor panels, or other similar industrial floor panels.
  • the invention hereby aims both at a particular method for producing such panels and panels obtained by said method as well as, independently of the method, a number of particular embodiments of such panels, with the latter therefore not necessarily having to be obtained according to the above-mentioned method.
  • mezzanine panels or mezzanine floor panels are therefore an important application of the invention.
  • These are panels intended to be applied to a frame in order to form floors and/or stocking surfaces at desired heights. As is known, these are commonly used for the furnishing of warehouses and storage facilities in order thus to form stocking spaces at various levels.
  • the frames usually consist of steel constructions that comprise horizontal beams placed at short distances from one another at the desired levels that support the mezzanine floor panels placed on them.
  • mezzanine floor panels from a substrate formed by chip board. It is also known to apply an aluminum layer to the underside of the chip board, usually in order to increase flame resistance, more specifically in order to cause the panel to show resistance to burning through and/or collapsing during a fire for a longer period than it would if no particular measures had been taken for this purpose and/or in order to minimize smoke production at least at the beginning of a fire.
  • a coating layer to the upper side of such a mezzanine floor panel that can have various purposes, such as providing a well-maintained appearance, more specifically in a specified color, for example grey, providing greater resistance to abrasion, for example to abrasion resulting from motor vehicles moving over the panel, such as e.g. forklift trucks and AGVs (automated guided vehicles), increasing slip resistance, reduction of the adhesion of dirt and/or material deposition resulting from the wheels of transport vehicles, obtaining an easily cleanable surface; and so forth.
  • the coating layer can be of various types. According to known possibilities, it can for example be a laminate layer that is pressed onto the substrate or a vinyl coating that is glued to the surface by means of an adhesive.
  • the above-mentioned aluminum layer is glued to the underside of the mezzanine floor panel by means of an adhesive.
  • PVAC adhesive is used for this purpose.
  • Gluing to the underside by means of PVAC adhesive involves a time-consuming step in the production of the mezzanine floor panels and/or the production of a base plate from which such a mezzanine floor panel can be realized. Moreover, the adhesion is not always optimal.
  • the present invention is intended to remedy these drawbacks.
  • the invention provides methods for efficiently realizing panels that are provided with an aluminum layer.
  • it is also intended to provide panels comprising an aluminum layer that is bonded to the substrate in an efficient and/or advantageous manner, wherein this is or is not carried out by using the above-mentioned method.
  • the invention also relates to a method for producing a panel, more specifically a load-bearing panel, and even more specifically a mezzanine floor panel, wherein said panel comprises a wood-based substrate and said panel, on at least one side thereof, in the case of a floor panel preferably the underside thereof, is provided with an aluminum layer, characterized in that in production, the aluminum layer and the substrate are bonded to each other by pressing with the intermediary of a bonding layer, using a flat press.
  • a flat press uniform pressing over a large surface is achieved, thus obtaining a high-performing product, and one can operate at relatively high production speeds.
  • a“flat press” is understood to mean a press that has a flat pressing component, i.e. has a real two-dimensional pressing surface, this in contrast to pressure rollers, which mainly provide pressing on one line.
  • the term “flat press” does not exclude the possibility that one or both pressing surfaces of the press is/are provided with a structure, for example for the forming of a relief on an outer surface of a panel.
  • the flat press with its pressing surface, covers at least the surface of the panel. This is advantageous in that uniform pressing of the aluminum layer over the entire surface of the panel is obtained.
  • such a panel is formed from a plate of such a wood-based substrate, wherein one or more of such panels is/are formed from this plate, and the flat press, with its pressing surface, covers all or substantially all of the surface of the plate.
  • the flat press with its pressing surface, covers all or substantially all of the surface of the plate.
  • a daylight press is used, also referred to as a KT press (an abbreviation of the German for“short cycle press”), and preferably a daylight press of the type that is suitable for laminating a substrate with a thermosetting laminate.
  • the above-mentioned flat press is heated.
  • the bonding layer a heat activatable and/or meltable bonding layer, which directly or indirectly provides a bonding between the aluminum layer and the substrate.
  • a heat activatable and/or meltable bonding layer which directly or indirectly provides a bonding between the aluminum layer and the substrate.
  • an aluminum foil is preferably used, as a foil is relatively easily processable, and in particular pressable.
  • annealed aluminum is used, whether as a foil or in another form.
  • Annealed aluminum has the property of having fewer internal stresses, and during pressing, it also less rapidly gives rise to internal stresses that can lead to deformations in the end product.
  • an aluminum foil is used for the aluminum layer that is provided with perforations, more specifically perforations that are distributed over the surface.
  • perforations more specifically perforations that are distributed over the surface.
  • Various advantages can be achieved by means of the perforations. For example, better adhesion can be striven for, e.g. in that the adhesive agent penetrates into the perforations. Another important advantage is that this can lead to better flame resistance. Indeed, in the case of high heat as a result of fire, a number of gases and/or vapors can then initially escape via the perforations from the substrate and/or the bonding layer, with the result that the aluminum layer is not pushed loose as quickly and thus provides resistance for a longer period.
  • aluminum having a thickness of 10 to 100 pm is preferably used, although both lesser and greater thicknesses are not excluded.
  • the range of 10 to 100 pm allows easy processing on the one hand and provides flame resistance on the other, and this with an economically acceptable material and processing cost.
  • one preferably uses a thickness about 50 pm or more while for standard applications, a thickness of less than 30 pm is preferably used, and preferably of 20 to 25 pm.
  • the aluminum layer has a thickness of less than 60 pm, more preferably between 30 and 50 pm. Unless special measures are taken, an aluminum layer with a thickness of less than 10 pm is no longer easily processable because of the increased risk of tearing.
  • the substrate is provided on one side with the above- mentioned aluminum layer, while on the other side another coating layer is provided.
  • This allows the panel to be optimized on both sides in accordance with the intended purpose.
  • a coating to both sides, i.e. the flat upper side and the flat underside, by means of the aluminum layer inter alia on the one hand and the above-mentioned other coating layer on the other, a more balanced structure is also obtained.
  • the above-mentioned method i.e. the method according to the first aspect of the invention, is particularly interesting when the above-mentioned other coating layer on the one hand and the aluminum layer and bonding layer on the other hand are applied to the wood-based substrate by means of one and the same pressing cycle, whether or not together with still other material layers.
  • the pressing cycle is then indeed optimally used, in view of the fact that simultaneously with the application of the aluminum layer, a coating layer is also applied to the other side of the substrate.
  • the above-mentioned other coating layer comprises at least one laminate layer and/or resin-based layer that is applied by pressing to the relevant side of the substrate, preferably via a classical lamination process of the type wherein the above-mentioned laminate layer consists of a carrier provided with a resin, more specifically a thermosetting resin, and preferably a melamine resin or phenolic resin that is bonded to the substrate together with pressing of the aluminum layer, and thus in the same pressing cycle.
  • the entire unit In cases where one or more material layers is/are present on both sides of the substrate, i.e. at least the aluminum layer on one side and a coating layer on the other, it is preferable for the entire unit to be pressed to be placed in the press used with the aluminum layer facing downward.
  • the aluminum layer In this case, or generally in all cases where the aluminum layer is located on the underside of the substrate during pressing, it is possible, at least in cases where the aluminum layer and the substrate are supplied to the press as separate layers, to use means that ensure that at least a temporary adhesive effect is realized between the aluminum and the substrate located above it, so that the aluminum layer can be easily brought into the press with the substrate.
  • adhesive means that therefore are at least temporarily active, at least until the press is closed.
  • the method of the invention is characterized in that the above-mentioned bonding layer is at least formed by providing an adhesive agent in accordance with one or more of the following techniques:
  • various materials can be used for the above-mentioned bonding layer by means of which the aluminum layer is directly or indirectly bonded to the substrate. According to two preferred embodiments, however, the invention gives priority to two techniques.
  • a polyurethane-based bonding layer is used, i.e. a polyurethane-based adhesive agent is used.
  • a polyurethane-based adhesive agent is used.
  • the polyurethane-based adhesive agent it is preferable for the polyurethane-based adhesive agent to be in direct contact with the aluminum, and more preferably also in direct contact with the wood-based substrate. More specifically, it is preferable for the polyurethane-based bonding layer to be a heat activatable and/or meltable and subsequently curing bonding layer that directly or indirectly provides a bonding between the aluminum layer and the substrate layer.
  • the polyurethane-based bonding layer can be based on either thermoplastic or thermosetting polyurethane.
  • the polyurethane-based bonding layer consists of or is based on hot melt polyurethane.
  • a hot melt polyurethane can in turn also be thermosetting or thermoplastic.
  • thermosetting resin for the bonding layer or adhesive agent respectively, a thermosetting resin is used.
  • the bonding layer is in direct contact with the wood-based substrate, while on the other side it is in direct or indirect contact with the aluminum of the above-mentioned aluminum layer;
  • thermosetting resin is applied to a carrier, more specifically a sheet of paper, for example in that the carrier is impregnated therewith;
  • the bonding layer of thermosetting resin more specifically the above- mentioned resin-coated carrier, on the one hand, and the aluminum layer, on the other, are mutually bonded to each other by means of a bonding agent prior to or at the time of pressing onto the substrate, more specifically so that the bonding agent provides bonding to the aluminum layer, while the adhesive agent provides bonding to the substrate;
  • a carrier having one side coated with resin while the opposite side is not resin coated or resin coated to a lesser degree, with the latter side being bonded by the above-mentioned bonding agent to the aluminum layer; a carrier is used that prior to pressing is provided with both the adhesive agent and the bonding agent, wherein on one side thereof at least the adhesive agent is present, while on the opposite side at least the bonding agent is present;
  • the above-mentioned bonding agent is polyethylene (PE) or polypropylene (PP), or is at least based thereon;
  • the aluminum layer and the resin-coated carrier are bonded to each other prior to pressing, with this being carried out by applying the bonding agent between them in a liquid or viscous state and then allowing it to harden.
  • kraft paper is preferably applied.
  • the wood-based substrate itself is preferably free of fire-retardant additives.
  • the aluminum layer indeed provides a sufficient fire-retardant effect to meet most of the demands made in practice.
  • this does not exclude the possible use of fire-retardant additives in the substrate in order to provide increased performance.
  • a substrate is used that is mainly formed from pressed wood composite, i.e. wood particles that are pressed with a bonding agent into a plate-shaped substrate. More specifically, it is preferable for the wood-based substrate to consist of chip board or mainly consist of chip board, whether or not consisting of multiple layers.
  • the chip board consists of multiple layers and consists for this purpose of at least a base layer and a cover layer located on one side thereof that is realized from finer chips than the base layer, wherein the aluminum layer is applied to the side of the panel that is provided with the above-mentioned cover layer.
  • the method is characterized in that the chip board used consists of at least three layers, namely a base layer and on both sides thereof a cover layer, wherein the cover layers are realized from finer chips than the base layer.
  • OSB oriented strand board
  • other wood-based substrates can also be used, such as e.g. wood-based substrate composed of wood fiberboard, more specifically MDF (medium density fiberboard) or HDF (high density fiberboard).
  • the adhesives common in the industry can be used for the bonding agent of the wood particles, i.e. the adhesives common in the manufacture of chip board, OSB and wood fiberboard such as MDF or HDF are used.
  • bonding agents for the wood particles that comprise MDI (methylene diphenyl diisocyanate) or consist of MDI and are preferably free of formaldehyde are to be used.
  • the panel is realized with a total thickness of 20 to 50 mm, and preferably in the range of 30 or 38 mm.
  • the above-mentioned method of the invention can also be characterized in that the bonding layer is applied prior to pressing of the panel onto the substrate and/or a carrier and/or the aluminum layer, or the aluminum foil respectively, by using one or more of the following techniques: application using a roller, more specifically an screen roller; application by means of curtain coating; application by means of spraying or squirting; application by means of spreading; application by means of impregnation or immersion; application by means of one of the preceding techniques combined with the use of a spreading element or calibrating element, for example a doctor blade.
  • the panels that are or are not to be further divided can have relatively large dimensions.
  • the panel can be characterized in that it is rectangular and has dimensions of more than 2 m in width and more than 5 m in length.
  • another flat press can also be used, such as e.g. a belt press, more specifically a double belt press.
  • such a panel is provided on the edges thereof with a tongue and groove profiling.
  • unprofiled sides such as straight sides, are not excluded.
  • the aluminum layer is provided on its visible side with a permanent coating layer, preferably a protective layer, for example against oxidation and/or for improved scratch resistance.
  • the aluminum layer is provided on its visible side with a coating layer in the form of a lacquer or a polyester layer that is or is not transparent or partially transparent.
  • the aluminum layer on its visible side, comprises a light color, more specifically is white or whitish, obtained for example by means of a lacquer, and more specifically is further characterized in that the aluminum layer consists of so-called white aluminum.
  • such a coating layer can cause the aluminum to reflect light too brightly, and the reflection can result in diffuse light distribution.
  • the aluminum layer is provided on its visible side with a paper layer.
  • This paper layer can have no resin coating, be partially resin coated, or be resin coated. This-complete or partial-resin coating can for example be carried out with urea formaldehyde resin, with melamine formaldehyde resin, with melamine urea formaldehyde resin or with acrylate resin.
  • this paper layer has a weight of between 10 and 120 g/m 2 , more preferably between 30 and 60 g/m 2 .
  • This paper layer can be bonded to the aluminum layer by means of a bonding layer.
  • This bonding layer can be applied to the aluminum layer or to the paper layer. More preferably, this bonding layer is polyurethane- or isocyanate-based.
  • This paper layer is preferably pressed onto the aluminum layer, more preferably together with pressing of the aluminum layer onto the wood-based substrate.
  • the aluminum layer and/or the coating layer optionally applied thereto is/are provided with a structured surface, for example with a random motif or with a soft motif that gives a matting effect or for example with a wood grain motif.
  • the method is characterized in that a so-called release film, more specifically a protective film that can be removed by peeling, is applied, whether on the side to which the aluminum layer is applied, the opposite side, and more specifically to a coating layer that is applied there, or both sides.
  • a so-called release film more specifically a protective film that can be removed by peeling
  • the invention still according to the first aspect, also relates to a panel that is obtained according to the method of the invention.
  • the invention also relates to a number of particular embodiments of panels, in particular mezzanine panels, independently of the production method. These are mainly two embodiment concepts of panels that will be described below as the second independent aspect and third independent aspect of the invention. Moreover, these panels, according to various preferred embodiments, can show various subordinate features, i.e. characteristics, as explained below.
  • the invention relates to a panel, more specifically a load-bearing panel, and even more specifically a mezzanine floor panel, with an underside and an upper side, wherein said panel at least comprises a wood-based substrate and wherein the panel is provided on the underside with an aluminum layer, characterized in that the aluminum layer is directly or indirectly bonded to the substrate by means of a polyurethane-based bonding layer.
  • a polyurethane-based bonding layer in such load-bearing panels, and in particular in mezzanine floor panels, offers various advantages. For example, this not only provides particularly good adhesion of the aluminum layer to the substrate, but the inventor also found that even in the case of fire, this adhesion provides relatively long- lasting resistance sufficient to meet common requirements. The adhesion by means of the polyurethane-based bonding layer also allows efficient industrial production.
  • a panel of the second aspect can further show one or more of the following preferred features summarized below, which, at least provided they do not conflict, can be combined with one another as desired, wherein every mathematically conceivable combination must be considered part of the current specification:
  • the polyurethane-based bonding layer is originally a heat activatable and/or meltable bonding layer, which directly or indirectly provides a bonding between the aluminum layer and the substrate layer, and thus provides the adhesion as a result of the activating and/or melting;
  • the aluminum layer is applied to the wood-based substrate by pressing, more specifically by pressing with a flat press, and in particular by means of a daylight press, also referred to as a KT press, and preferably a daylight press of the type that is suitable for laminating a substrate with a thermosetting laminate; in the latter case, this means that the polyurethane-based bonding layer is of the type that allows adhesion to be achieved in heated pressing;
  • the polyurethane-based bonding layer consists of or is based on thermoplastic or thermosetting polyurethane
  • the polyurethane-based bonding layer consists of or is based on hot melt polyurethane
  • the aluminum layer is an aluminum foil
  • the aluminum layer consists of annealed aluminum; - the aluminum layer is perforated, preferably with perforations distributed largely over the entire surface;
  • the above-mentioned aluminum layer has a thickness of 10 to 100 pm;
  • the aluminum layer has a thickness of less than 30 pm, and preferably 20 to 25 pm;
  • the aluminum layer has a thickness of less than 60 pm; and preferably between 30 and 50 pm;
  • the substrate is provided on one side with the above-mentioned aluminum layer, while on the other side, which thus forms the upper side, another coating layer is provided;
  • the other coating layer mentioned in the previous paragraph is a layer applied by consolidation by means of pressing, wherein the aluminum layer and bonding layer are also preferably applied to the wood-based substrate by means of the same pressing cycle as that by means of which the above- mentioned other coating layer is applied, whether or not together with still other material layers;
  • the above-mentioned other coating layer consists of at least one laminate layer and/or resin-based layer, which is preferably applied by pressing to the relevant side of the substrate, whether or not with the intermediary of other layers;
  • the above-mentioned laminate layer is formed from a carrier provided with a resin, more specifically a thermosetting resin, and preferably a melamine resin or phenolic resin;
  • the wood-based substrate is free of fire-retardant additives, or alternatively, it indeed comprises fire-retardant additives;
  • the above-mentioned substrate is a wood-based substrate that is mainly formed from pressed wood composite, i.e. wood particles that are pressed with a bonding agent into a plate-shaped substrate;
  • the wood-based substrate consists of chip board or mainly of chip board, whether or not consisting of multiple layers; alternatively, it is not excluded to use OSB or wood fiberboard, for example MDF or HDF;
  • the chip board from which the substrate is formed consists of multiple layers and consists for this purpose at least of a base layer and a cover layer located on one side thereof that is realized from finer chips than the base layer, wherein the aluminum layer is bonded to a side of the panel that comprises such a cover layer;
  • the chip board from which the substrate is formed consists of at least three layers, namely a base layer and on both sides thereof a cover layer, wherein the cover layers are realized from finer chips than the base layer;
  • the bonding agent that binds the wood particles to one another comprises or consists of MDI and is preferably free of formaldehyde;
  • the panel has a total thickness of 20 to 50 mm and the total thickness is preferably in the range of 30 or 38 mm;
  • the panel is provided on the edges thereof with a tongue and groove profiling
  • the aluminum layer is provided with perforations distributed over the surface thereof;
  • the aluminum layer is provided on its visible side with a permanent coating layer, for example a protective layer, for example against oxidation and/or with a view to better scratch resistance;
  • a permanent coating layer for example a protective layer, for example against oxidation and/or with a view to better scratch resistance;
  • the aluminum layer is provided on its visible side with a lacquer or a polyester layer that is or is not transparent or partially transparent, wherein the lacquer or polyester layer is preferably of a type that remains pressable under heat;
  • the aluminum layer is provided on its visible side with a paper layer; this paper layer can have no resin coating, be partially resin coated, or be resin coated. This-complete or partial-resin coating can for example be carried out with urea formaldehyde resin, with melamine formaldehyde resin, with melamine urea formaldehyde resin or with acrylate resin; preferably, this paper layer has a weight of between 10 and 120 g/m 2 , more preferably between 30 and 60 g/m 2 .
  • This paper layer can be bonded to the aluminum layer by means of a bonding layer. This bonding layer can be applied to the aluminum layer or to the paper layer. More preferably, this bonding layer is polyurethane- or isocyanate-based.
  • the aluminum layer on its visible side, shows a light color, more specifically is white or whitish, obtained for example by means of a lacquer, and more specifically, the panel is characterized in that the aluminum layer consists of so-called white aluminum;
  • the aluminum layer and/or the coating layer optionally applied thereto is provided with a structured surface;
  • the structure here can have any motif; it can be a defined decorative pattern, but it can just as well be a more technical motif, for example a motif that gives a matting effect in order to counteract intense light reflection;
  • the panel has a so-called release film, more specifically a protective film that can be removed by peeling, whether on the side to which the aluminum layer is applied, the opposite side, and more specifically to a coating layer that is applied there, or both sides; such a release film forms a protection that is present during handling of the panels but is intended to be removed when the panels are used, preferably after the placement thereof.
  • release film more specifically a protective film that can be removed by peeling, whether on the side to which the aluminum layer is applied, the opposite side, and more specifically to a coating layer that is applied there, or both sides; such a release film forms a protection that is present during handling of the panels but is intended to be removed when the panels are used, preferably after the placement thereof.
  • the invention relates to a panel, more specifically a load-bearing panel, and even more specifically a mezzanine floor panel, with an underside and an upper side, wherein said panel at least comprises a wood-based substrate and wherein the panel is provided on the underside with an aluminum layer, characterized in that the aluminum layer is directly or indirectly bonded to the substrate by means of a resin-based bonding layer, preferably based on a thermosetting resin.
  • a panel of the third aspect can further show one or more of the following preferred features summarized below, which, at least provided they do not conflict, can be combined with one another as desired, wherein every mathematically conceivable combination must be considered part of the current specification:
  • the bonding layer is in direct contact with the wood-based substrate, while on the other side it is in direct or indirect contact with the aluminum of the above-mentioned aluminum layer;
  • the resin-based bonding layer is originally a heat activatable and/or meltable bonding layer, which directly or indirectly provides a bonding between the aluminum layer and the substrate layer, and thus provides adhesion as a result of the activating and/or melting;
  • the aluminum layer is a layer that is applied to the wood-based substrate by pressing, more specifically by pressing with a flat press, and in particular by means of a daylight press, also referred to as a KT press, and preferably a daylight press of the type that is suitable for laminating a substrate with a thermosetting laminate;
  • the above-mentioned resin of the resin-based bonding layer is located on a carrier, more specifically a sheet of paper, preferably in that the carrier is impregnated therewith;
  • the above-mentioned carrier is resin coated on one side thereof, while the opposite side is not resin coated or is resin coated to a lesser degree, with the latter side being bonded by the above-mentioned bonding agent to the aluminum layer;
  • the above-mentioned bonding agent consists of polyethylene (PE) or polypropylene (PP), or is at least realized based thereon;
  • the aluminum layer is an aluminum foil
  • the aluminum layer consists of annealed aluminum
  • the aluminum layer is perforated, preferably largely over the entire surface
  • the above-mentioned aluminum layer has a thickness of 10 to 100 pm; it is noted that from a practical standpoint, for heavier applications, one rather prefers a thickness about 50 pm, while for standard applications, a thickness of 20 to 25 pm is preferably used;
  • the aluminum layer has a thickness of less than 30 pm, and preferably 20 to 25 pm;
  • the aluminum layer has a thickness of less than 60 pm; and preferably between 30 and 50 pm;
  • the substrate is provided on one side with the above-mentioned aluminum layer, while on the other side, which thus forms the upper side, another coating layer is provided;
  • the other coating layer mentioned in the previous paragraph is a layer applied by consolidation by means of pressing, wherein the aluminum layer and bonding layer are also preferably applied to the wood-based substrate by means of one and the same pressing cycle as that by means of which the above-mentioned other coating layer is applied, whether or not together with still other material layers;
  • the above-mentioned other coating layer consists of at least one laminate layer and/or resin-based layer, which is preferably applied by pressing to the relevant side of the substrate;
  • the above-mentioned laminate layer consists of a carrier provided with a resin, more specifically a thermosetting resin, and preferably a melamine resin or phenolic resin, that is preferably bonded to the substrate together with the pressing of the aluminum layer;
  • the wood-based substrate is free of fire-retardant additives, or alternatively, it indeed comprises fire-retardant additives;
  • the above-mentioned substrate is a wood-based substrate that is mainly formed from pressed wood composite, i.e. wood particles that are pressed with a bonding agent into a plate-shaped substrate;
  • the wood-based substrate consists of chip board or mainly of chip board, whether or not consisting of multiple layers; alternatively, the use of OSB (oriented strand board) or wood fiberboard, for example MDF (medium density fiberboard) or HDF (high density fiberboard) is not excluded;
  • the above-mentioned chip board has multiple layers and consists for this purpose at least of a base layer and a cover layer located on one side thereof that is realized from finer chips than the base layer, wherein the aluminum layer is bonded to a side of the panel that comprises such a cover layer;
  • the chip board from which the substrate is formed consists of at least three layers, namely a base layer and on both sides thereof a cover layer, wherein the cover layers are realized from finer chips than the base layer;
  • the bonding agent that binds the wood particles to one another comprises or consists of MDI and is preferably free of formaldehyde;
  • the panel has a total thickness of 20 to 50 mm and the total thickness is preferably in the range of 30 or 38 mm;
  • the panel is provided on the edges thereof with a tongue and groove profiling; according to an alternative, straight edges are also not excluded;
  • the aluminum layer is provided with perforations distributed over the surface thereof;
  • the aluminum layer is provided on its visible side with a permanent coating layer, for example a protective layer, for example against oxidation and/or with a view to better scratch resistance;
  • a permanent coating layer for example a protective layer, for example against oxidation and/or with a view to better scratch resistance;
  • the aluminum layer is provided on its visible side with a lacquer or a polyester layer that is or is not transparent or partially transparent, wherein the lacquer or polyester layer is preferably of a type that remains pressable under heat;
  • the aluminum layer is provided on its visible side with a paper layer; this paper layer can have no resin coating, be partially resin coated, or be resin coated; this-complete or partial-resin coating can for example be carried out with urea formaldehyde resin, with melamine formaldehyde resin, with melamine urea formaldehyde resin or with acrylate resin; preferably, this paper layer has a weight of between 10 and 120 g/m 2 , more preferably between 30 and 60 g/m 2 .
  • This paper layer can be bonded to the aluminum layer by means of a bonding layer. This bonding layer can be applied to the aluminum layer or to the paper layer. More preferably, this bonding layer is polyurethane- or isocyanate-based.
  • the aluminum layer shows a light color on its visible side, more specifically is white or whitish, obtained for example by means of a lacquer, and more specifically, the panel is characterized in that the aluminum layer consists of so-called white aluminum;
  • the aluminum layer and/or the coating layer optionally applied thereto is provided with a structured surface;
  • the structure here can have any motif; it can be a defined decorative pattern, but it can just as well be a more technical motif, for example a motif that gives a matting effect in order to counteract intense light reflection;
  • the panel has a so-called release film, more specifically a protective film that can be removed by peeling, whether on the side to which the aluminum layer is applied, the opposite side, and more specifically to a coating layer that is applied there, or both sides; such a release film forms a protection that is present during handling of the panels but is intended to be removed when the panels are used, preferably after the placement thereof.
  • release film more specifically a protective film that can be removed by peeling, whether on the side to which the aluminum layer is applied, the opposite side, and more specifically to a coating layer that is applied there, or both sides; such a release film forms a protection that is present during handling of the panels but is intended to be removed when the panels are used, preferably after the placement thereof.
  • the term“bonding layer” should be broadly interpreted; the layer itself, or at least the adhesive agent used therein, need not be a continuous uniform layer; the layer or the adhesive agent can indeed also be present in the form of a grid, for example with lines, dots, etc.;
  • a“load-bearing panel” is understood to be a panel for forming a load-bearing surface, more specifically a panel that is intended to be supported only over a part of its surface, and nevertheless to form a floor construction that can support a load;
  • another metal can also be used instead of aluminum, or a metal alloy, optionally including aluminum;
  • the aluminum layer can also be intended to form the upper side of the panel instead of the underside;
  • this coating layer per se can comprise either one or multiple layers; it can consist for example of a laminate layer that is composed of a decorative layer and a so- called overlay; the decorative layer can hereby be configured in one defined color or in multiple colors, and can either have or not have a motif; on the upper side, for example in the overlay, materials can be present that increase the abrasion resistance, such as corundum or other hard particles; on the upper side of the panels, anti-slip provisions of any kind may be made; a possibility is the provision of an uneven surface by means of indentations that are made for example during pressing; inter alia , good results are obtained with indentations having a depth of more than 100 pm and even better more than 150 pm;
  • the panels are preferably rectangular;
  • the panels in mezzanine floor panels, it is preferable for the panels to have dimensions of more than 2 m in width and more than 5 m in length.
  • a resin-based bonding layer is used in the method of the first aspect, or where one speaks of a resin-based bonding layer in the third aspect
  • a polymerization resin of the type such as that known to have an A stage, a B stage and a C stage, such that during elevated-temperature pressing, the resin can be converted from a B stage to a C stage in order to provide the required adhesion.
  • the invention relates to a coating layer for panels, more specifically in order to realize panels of the third aspect, i.e. a semi-finished product for realizing the panels of the third aspect, characterized in that it is composed of at least an aluminum layer and a resin-based bonding layer that is directly or indirectly present thereon.
  • the resin-based layer is located on a carrier and the carrier is bonded to the aluminum layer, preferably by means of a bonding agent.
  • the materials preferably used for this and the structure thereof are as described above with respect to the third aspect.
  • a method for producing the coating layer of the fourth aspect mainly consists in bonding a resin-coated carrier via a bonding agent to an aluminum layer.

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé de production de panneau, plus particulièrement d'un panneau porteur, et de façon encore plus précise, d'un panneau de plancher de mezzanine, ledit panneau comprenant un substrat à base de bois et ledit panneau, sur au moins un de ses côtés, dans le cas d'un panneau de plancher, de préférence son côté inférieur, étant pourvu d'une couche d'aluminium, caractérisé en ce que, en cours de production, la couche d'aluminium et le substrat sont liés l'un à l'autre par pression par l'intermédiaire d'une couche de liaison, à l'aide d'une presse plate. L'invention concerne en outre des panneaux porteurs, en particulier des panneaux de mezzanine, une couche d'aluminium étant liée à un substrat au moyen d'une couche de liaison à base de polyuréthane ou à base de résine.
PCT/IB2019/060901 2019-01-03 2019-12-17 Panneau et procédé de fabrication de panneau WO2020141384A2 (fr)

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Application Number Priority Date Filing Date Title
EP19839668.1A EP3906158A2 (fr) 2019-01-03 2019-12-17 Panneau et procédé de fabrication de panneau

Applications Claiming Priority (2)

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US201962787966P 2019-01-03 2019-01-03
US62/787,966 2019-01-03

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WO2020141384A3 WO2020141384A3 (fr) 2020-08-20

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU2009221638A1 (en) * 2008-03-03 2009-09-11 Depco-Trh Pty Ltd Heat reflective laminate

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WO2020141384A3 (fr) 2020-08-20

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