WO2022139766A1 - A board structure that can be used instead of chipboard and mdf - Google Patents

A board structure that can be used instead of chipboard and mdf Download PDF

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Publication number
WO2022139766A1
WO2022139766A1 PCT/TR2021/051482 TR2021051482W WO2022139766A1 WO 2022139766 A1 WO2022139766 A1 WO 2022139766A1 TR 2021051482 W TR2021051482 W TR 2021051482W WO 2022139766 A1 WO2022139766 A1 WO 2022139766A1
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WO
WIPO (PCT)
Prior art keywords
board structure
plastic layer
structure according
plastic
styrene
Prior art date
Application number
PCT/TR2021/051482
Other languages
French (fr)
Inventor
Seda KÖKSAL YEĞİN
Haluk AKÇALI
Original Assignee
Farel Plasti̇k Elektri̇k Ve Elektroni̇k İmalat Sanayi̇ Anoni̇m Şi̇rketi̇
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 Farel Plasti̇k Elektri̇k Ve Elektroni̇k İmalat Sanayi̇ Anoni̇m Şi̇rketi̇ filed Critical Farel Plasti̇k Elektri̇k Ve Elektroni̇k İmalat Sanayi̇ Anoni̇m Şi̇rketi̇
Publication of WO2022139766A1 publication Critical patent/WO2022139766A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B27WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27NMANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N7/00After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • B27N7/005Coating boards, e.g. with a finishing or decorating layer

Definitions

  • the present invention relates to a board structure that is a substitute product for chipboard and MDF and can be used in all fields where they are used, especially in furniture.
  • the present invention relates to a board structure that consists of a laminate layer consisting of a plastic layer and the integration of at least one Kraft paper and a melamine-impregnated decor paper.
  • the formaldehyde emission can be dangerous and harmful, to process, workers, and environmental health. Cutting trees is required for production. If there is no tree cutting, production will not be possible.
  • a method for reducing the formaldehyde content and formaldehyde emission in particleboard is disclosed in European Patent application numbered EP1419038B1. It is a method to reduce the formaldehyde content and emission in the particle board according to the invention, wherein the particleboard manufacturing process is carried out in the known standard way, by known procedure, by applying the known amino resin glue, by adding known hardening agents and/or possible additional formaldehyde binding agents, by flat pressing or by continuous pressing and cooling.
  • the distinguishing feature is to expose this particle board after pressing, before cooling, to a short rest period between a few hours and several tens of hours, preferably 8-16 hours, at 70-1100 depending on the expected reduction rate of formaldehyde content and emission and the applied manufacturing process parameters.
  • Turkish Patent application numbered TR2020/09888 relates to high performance and decorative composite products by coating papers impregnated with various resins on wood-based board products and the manufacturing method of these products.
  • This invention is a new production methodology that is developed for the patterned or solid color resin-impregnated laminated sheet-laminate coating of the surfaces of wood-based board products (MDF, LDF, HDF, Particleboard-YL, OSB, Plywood, LVL, Solid Panel) and the final product.
  • MDF, LDF, HDF, Particleboard-YL, OSB, Plywood, LVL, Solid Panel wood-based board products
  • the current chip and MDF board production is not suitable for sustainable production for the environment and human health. It can lead to deterioration of the ecological balance and air pollution. It is an inappropriate process in terms of efficient use of resources since the measures taken to prevent this require the use of resources.
  • the present invention is related to a board structure which fulfills the abovementioned requirements, eliminates all disadvantages and brings some additional advantages.
  • the main aim of the invention is to develop a product with higher sustainability for the environment and human health than chipboard and particle board and more resistant to deformation when exposed to water.
  • One aim of the invention is to realize a product that eliminates the need to use synthetic adhesives and glues.
  • Another aim of the invention is to prevent the problems of blistering and swelling of the upper surface areas caused by the products being exposed to water.
  • the inventive board structure consists of a laminate layer consisting of a plastic layer and the integration of at least one kraft paper and a melamine-impregnated decorative paper.
  • Figure 1 is a schematic view of the inventive board structure.
  • the invention is a board (plate) construction used instead of Particleboard and MDF.
  • the inventive board structure comprises a laminate layer consisting of a plastic layer (10) and the integration of at least one Kraft paper (20) and a melamine-impregnated decorative paper (30).
  • the plastic layer (10) consists of polyethylene, acrylonitrile butadiene styrene, styrene butadiene styrene, styrene ethylene butadiene styrene, polyamide and/or polypropylene raw materials according to a preferred embodiment of the invention.
  • the plastic layer (10) additionally contains additives of maleic anhydride, talc, calcite, glass fiber, basalt and/or glass balls according to a preferred embodiment of the invention.
  • the plastic layer (10) consists of a polyethylene raw material containing at least 0.1% by weight maleic anhydride additive.
  • the polyethylene plastic layer (10) may contain a different plastic raw material additive up to 30% by weight.
  • Polyethylene plastic layer (10) preferably may contain styrene butadiene styrene and/or styrene ethylene butadiene styrene raw material between 1 -10% by weight.
  • plastic layer (10) contains maleic anhydride is for better adhesion of the parts (20 or 30) that become in contact with the plastic.
  • Melamine-impregnated decorative paper (30) has a structure providing visuality and has been made resistant to heat and scratches due to melamine impregnation.
  • Impregnation is the process of impregnating the wood with various chemical substances so as to prevent it from rotting by protecting it from harmful fungi and insects.
  • Kraft paper (20) is positioned between the plastic part (10) and the melamine-coated decorative paper (30) so as to obtain higher levels of resistance against burning.
  • the inventive polymer board structure production method comprises the following process steps: i. forming the material mixture for the plastic layer (10) containing maleic anhydride additive, ii. feeding the formed plastic material mixture to the injection machine, iii. placing the board in the injection mold so as to make injection onto the kraft paper
  • HPL laminate is produced by pressing impregnated melamine coated decor paper (30) and kraft paper (20) in special presses under high temperature and pressure. HPL laminates show high abrasion and scratch resistance, and gain an antibacterial and hygienic surface feature with its non-porous surface structure with this technology.
  • CPL laminate is produced by pressing melamine coated decor paper (30) and Kraft paper (20) impregnated under different conditions with rollers under high pressure and temperature. Apart from similar properties with HPL laminate, there are natural surface options.
  • the melamine impregnated paper will be located on the visible upper part of the board. It can be selected in the desired pattern and color. The melamine impregnated surface ensures that the board is resistant to scratching, burning and staining.

Abstract

The present invention relates to a board structure that consists of a laminate layer consisting of a plastic layer (10) and the integration of at least one Kraft paper (20) and a melamine-impregnated decorative paper (30), can be used instead of chipboard and MDF.

Description

A BOARD STRUCTURE THAT CAN BE USED INSTEAD OF CHIPBOARD AND MDF
Field of the Invention
The present invention relates to a board structure that is a substitute product for chipboard and MDF and can be used in all fields where they are used, especially in furniture.
In particular, the present invention relates to a board structure that consists of a laminate layer consisting of a plastic layer and the integration of at least one Kraft paper and a melamine-impregnated decor paper.
State of the Art
The current process steps of making particleboard (chipboard) and MDF (medium-density fiberboard) are explained below. Trees selected according to the desired characteristics are stored and dried in two classifications according to their special breaker chip sizes. Special synthetic adhesive and hardening chemicals are used to bond the sawdust, which is divided into two classes, to each other. The chemically added mixture is dried. After the two pressing stages, the cooling process is applied. The edges are sanded and made ready for use. There is significant energy consumption since there are many process steps with energy consumption in this production process. However, the special adhesive and hardening chemicals used are given below;
Melamine-formaldehyde (MF)
Melamine-urea formaldehyde (MUF) Urea-formaldehyde (UF) Phenol formaldehyde (PF)
The formaldehyde emission can be dangerous and harmful, to process, workers, and environmental health. Cutting trees is required for production. If there is no tree cutting, production will not be possible.
The following applications are encountered in the literature regarding the subject matter: A method for reducing the formaldehyde content and formaldehyde emission in particleboard is disclosed in European Patent application numbered EP1419038B1. It is a method to reduce the formaldehyde content and emission in the particle board according to the invention, wherein the particleboard manufacturing process is carried out in the known standard way, by known procedure, by applying the known amino resin glue, by adding known hardening agents and/or possible additional formaldehyde binding agents, by flat pressing or by continuous pressing and cooling. The distinguishing feature is to expose this particle board after pressing, before cooling, to a short rest period between a few hours and several tens of hours, preferably 8-16 hours, at 70-1100 depending on the expected reduction rate of formaldehyde content and emission and the applied manufacturing process parameters.
Turkish Patent application numbered TR2020/09888 relates to high performance and decorative composite products by coating papers impregnated with various resins on wood-based board products and the manufacturing method of these products. This invention is a new production methodology that is developed for the patterned or solid color resin-impregnated laminated sheet-laminate coating of the surfaces of wood-based board products (MDF, LDF, HDF, Particleboard-YL, OSB, Plywood, LVL, Solid Panel) and the final product. The process performed in two processes in the state of the art is completed in a single process with this invention.
In short, the current chip and MDF board production is not suitable for sustainable production for the environment and human health. It can lead to deterioration of the ecological balance and air pollution. It is an inappropriate process in terms of efficient use of resources since the measures taken to prevent this require the use of resources.
As a result, due to the abovementioned disadvantages and the insufficiency of the current solutions regarding the subject matter, a development is required to be made in the relevant technical field.
Brief Description of the Invention
The present invention is related to a board structure which fulfills the abovementioned requirements, eliminates all disadvantages and brings some additional advantages. The main aim of the invention is to develop a product with higher sustainability for the environment and human health than chipboard and particle board and more resistant to deformation when exposed to water.
One aim of the invention is to realize a product that eliminates the need to use synthetic adhesives and glues.
Another aim of the invention is to prevent the problems of blistering and swelling of the upper surface areas caused by the products being exposed to water.
In order to fulfill the above-mentioned aims, the inventive board structure consists of a laminate layer consisting of a plastic layer and the integration of at least one kraft paper and a melamine-impregnated decorative paper.
The structural and characteristic features of the present invention will be understood clearly by the following drawings and the detailed description made with reference to these drawings and therefore the evaluation shall be made by taking these figures and the detailed description into consideration.
Figures Clarifying the Invention
Figure 1, is a schematic view of the inventive board structure.
The figures are not required to be scaled and the details which are not necessary for understanding the present invention may be neglected. Moreover, the elements that are at least substantially identical or have at least substantially identical functions are shown by the same number.
Description of the References
10. Plastic layer
20. Kraft paper
30. Melamine impregnated decorative paper Detailed Description of the Invention
In this detailed description, the inventive structure is described only for clarifying the subject matter in a manner such that no limiting effect is created.
The invention is a board (plate) construction used instead of Particleboard and MDF.
The inventive board structure comprises a laminate layer consisting of a plastic layer (10) and the integration of at least one Kraft paper (20) and a melamine-impregnated decorative paper (30).
The plastic layer (10) consists of polyethylene, acrylonitrile butadiene styrene, styrene butadiene styrene, styrene ethylene butadiene styrene, polyamide and/or polypropylene raw materials according to a preferred embodiment of the invention.
The plastic layer (10) additionally contains additives of maleic anhydride, talc, calcite, glass fiber, basalt and/or glass balls according to a preferred embodiment of the invention.
According to a preferred embodiment of the invention, the plastic layer (10) consists of a polyethylene raw material containing at least 0.1% by weight maleic anhydride additive. The polyethylene plastic layer (10) may contain a different plastic raw material additive up to 30% by weight. Polyethylene plastic layer (10) preferably may contain styrene butadiene styrene and/or styrene ethylene butadiene styrene raw material between 1 -10% by weight.
The reason that the plastic layer (10) contains maleic anhydride is for better adhesion of the parts (20 or 30) that become in contact with the plastic.
Melamine-impregnated decorative paper (30) has a structure providing visuality and has been made resistant to heat and scratches due to melamine impregnation.
Impregnation is the process of impregnating the wood with various chemical substances so as to prevent it from rotting by protecting it from harmful fungi and insects.
Kraft paper (20) is positioned between the plastic part (10) and the melamine-coated decorative paper (30) so as to obtain higher levels of resistance against burning. The inventive polymer board structure production method comprises the following process steps: i. forming the material mixture for the plastic layer (10) containing maleic anhydride additive, ii. feeding the formed plastic material mixture to the injection machine, iii. placing the board in the injection mold so as to make injection onto the kraft paper
(20) surface in the laminate layer, iv. closing the injection mold and injecting the molten plastic mixture onto the surface of the Kraft paper (20) in the laminate layer, v. removing formed board structure from the mold by opening the mold.
There are two types of laminate for use. These are HPL and CPL laminate types. HPL laminate is produced by pressing impregnated melamine coated decor paper (30) and kraft paper (20) in special presses under high temperature and pressure. HPL laminates show high abrasion and scratch resistance, and gain an antibacterial and hygienic surface feature with its non-porous surface structure with this technology.
CPL laminate; is produced by pressing melamine coated decor paper (30) and Kraft paper (20) impregnated under different conditions with rollers under high pressure and temperature. Apart from similar properties with HPL laminate, there are natural surface options. The melamine impregnated paper will be located on the visible upper part of the board. It can be selected in the desired pattern and color. The melamine impregnated surface ensures that the board is resistant to scratching, burning and staining.
In addition to forming structures that can be used instead of particle board (chipboard) and MDF with the inventive product, the following advantages are also provided;
• shortens the production time in seconds,
• reduces energy consumption,
• provides cost advantage as it eliminates many processes,
• reduces the machine park area required for production.

Claims

CLAIMS A board structure that can be used instead of chipboard and MDF, characterized in that; the board structure comprises a laminate layer consisting of a plastic layer (10) and the integration of at least one Kraft paper (20) and a melamine-impregnated decorative paper (30). A board structure according to claim 1 , characterized in that; the plastic layer (10) consists of polyethylene, acrylonitrile butadiene styrene, styrene butadiene styrene, styrene ethylene butadiene styrene, polyamide and/or polypropylene raw materials. A board structure according to claim 1 , characterized in that; the plastic layer (10) additionally contains additives of maleic anhydride, talc, calcite, glass fiber, and basalt and/or glass balls. A board structure according to claim 1 , characterized in that; the plastic layer (10) consists of a polyethylene raw material containing at least 0.1% by weight maleic anhydride additive. A board structure according to claim 4, characterized in that; the polyethylene plastic layer (10) may contain a different plastic raw material additive up to 30% by weight. A board structure according to claim 5, characterized in that; polyethylene plastic layer (10) preferably may contain styrene butadiene styrene and/or styrene ethylene butadiene styrene raw material between 1 -10% by weight. A board structure according to claim 1 , characterized in, comprising the following process steps; i. forming the material mixture for the plastic layer (10) containing maleic anhydride additive, ii. feeding the formed plastic material mixture to the injection machine, iii. placing the board in the injection mold so as to make injection onto the Kraft paper
(20) surface in the laminate layer, iv. closing the injection mold and injecting the molten plastic mixture onto the surface of the Kraft paper (20) in the laminate layer, v. removing formed board structure from the mold by opening the mold.
6
PCT/TR2021/051482 2020-12-24 2021-12-24 A board structure that can be used instead of chipboard and mdf WO2022139766A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2020/21613 2020-12-24
TR2020/21613A TR202021613A2 (en) 2020-12-24 2020-12-24 MAKING A SHEET THAT CAN BE USED INSTEAD OF CHIPBOARD AND MDF

Publications (1)

Publication Number Publication Date
WO2022139766A1 true WO2022139766A1 (en) 2022-06-30

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ID=75576379

Family Applications (1)

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PCT/TR2021/051482 WO2022139766A1 (en) 2020-12-24 2021-12-24 A board structure that can be used instead of chipboard and mdf

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TR (1) TR202021613A2 (en)
WO (1) WO2022139766A1 (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0993934A2 (en) * 1998-10-14 2000-04-19 Premark RWP Holdings, Inc. Methods for making a contoured solid surface laminate
WO2015002050A1 (en) * 2013-07-01 2015-01-08 住友ベークライト株式会社 Decorative board and decorative board set
TR201904794A2 (en) * 2019-03-29 2019-05-21 Farel Plastik Elektrik Ve Elektronik Imalat Sanayi Anonim Sirketi THE PRODUCTION METHOD OF THE WHITE GOODS TOP TABLE AND THE TOP TABLE

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0993934A2 (en) * 1998-10-14 2000-04-19 Premark RWP Holdings, Inc. Methods for making a contoured solid surface laminate
WO2015002050A1 (en) * 2013-07-01 2015-01-08 住友ベークライト株式会社 Decorative board and decorative board set
TR201904794A2 (en) * 2019-03-29 2019-05-21 Farel Plastik Elektrik Ve Elektronik Imalat Sanayi Anonim Sirketi THE PRODUCTION METHOD OF THE WHITE GOODS TOP TABLE AND THE TOP TABLE

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TR202021613A2 (en) 2021-01-21

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