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EP2743094B1 - Method for the manufacture of a board provided with a decorative layer - Google Patents

Method for the manufacture of a board provided with a decorative layer Download PDF

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Publication number
EP2743094B1
EP2743094B1 EP12196717.8A EP12196717A EP2743094B1 EP 2743094 B1 EP2743094 B1 EP 2743094B1 EP 12196717 A EP12196717 A EP 12196717A EP 2743094 B1 EP2743094 B1 EP 2743094B1
Authority
EP
European Patent Office
Prior art keywords
resin
decorative paper
impregnated
paper
base board
Prior art date
Legal status (The legal status 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 status listed.)
Active
Application number
EP12196717.8A
Other languages
German (de)
French (fr)
Other versions
EP2743094A1 (en
Inventor
Norbert Kalwa
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Flooring Technologies Ltd
Original Assignee
Flooring Technologies Ltd
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
Priority to ES12196717.8T priority Critical patent/ES2543154T3/en
Application filed by Flooring Technologies Ltd filed Critical Flooring Technologies Ltd
Priority to PL12196717T priority patent/PL2743094T3/en
Priority to EP12196717.8A priority patent/EP2743094B1/en
Priority to PCT/EP2013/076366 priority patent/WO2014090939A1/en
Priority to PL13811849T priority patent/PL2931527T3/en
Priority to EP13811849.2A priority patent/EP2931527B1/en
Priority to BR112015012286A priority patent/BR112015012286A2/en
Priority to CN201380065276.1A priority patent/CN104870203B/en
Priority to RU2015126253A priority patent/RU2612647C9/en
Priority to UAA201506479A priority patent/UA111565C2/en
Priority to CA2893820A priority patent/CA2893820C/en
Priority to US14/651,280 priority patent/US9757974B2/en
Priority to ES13811849T priority patent/ES2856879T3/en
Publication of EP2743094A1 publication Critical patent/EP2743094A1/en
Application granted granted Critical
Publication of EP2743094B1 publication Critical patent/EP2743094B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring

Definitions

  • the present invention relates to a method for producing a provided with a decorative layer of a decorative paper material plate.
  • various papers such as e.g. Decorative paper, overlays, Gegenzugpapiere, Underlays, etc., first impregnated in a impregnation with a thermosetting resin, which usually contains water as a solvent.
  • a thermosetting resin which usually contains water as a solvent.
  • the various papers are then subsequently dried back to a defined moisture content of about 5-7% by weight.
  • the papers so completely impregnated are pressed onto wood-based panels in a press in a short-cycle process.
  • US 6,551,694 B1 discloses a method for producing a wood-based panel consisting of a support plate and a decor paper arranged on the support plate, comprising the steps of (a) providing the decor paper, (b) applying at least one resin as impregnating agent only to the decorative paper opposite the decor, wherein the amount of resin applied is between 40 and 70% based on the paper weight of the decorative paper, and wherein a melamine-, urea- or urethane-based resin is used as the impregnating agent, (c) providing the support plate, (d) applying at least one layer at least one adhesive on at least one side of the backing plate, and (e) placing the decorative paper with the impregnated opposite side of the decor on the side of the backing plate provided with the adhesive.
  • Impregnated papers are usually pressed onto a carrier by means of KT (short-cycle press) technology in a press.
  • KT short-cycle press
  • this KT technology also has some disadvantages.
  • the impregnated paper sheets are relatively brittle and may tear or break during processing.
  • the production of the sheets is also prone to jeopardy.
  • this method is also relatively expensive, since a total of three papers are used.
  • a decorative paper is used in the manufacture of a material plate which is only partially impregnated, wherein preferably the entire surface of the non-printed underside of the decorative paper, i. the side opposite the visible side of the decorative paper is evenly provided with the impregnating resin.
  • an aqueous impregnating resin is used as the impregnating resin on the back, i. applied to the non-decorative side of the decorative paper.
  • the decor of the decorative paper can be applied by gravure and / or digital printing.
  • the amount of resin applied to the opposite side of the decor paper is between 30 and 70% by weight, preferably between 40 and 60% by weight, more preferably 50% by weight, based on the paper weight of the decorative paper.
  • 50 g of impregnating resin per m 2 of decorative paper paper weight: 80 g / m 2 , solids content impregnating resin: 50% by weight are applied.
  • the decor paper impregnated on the opposite side of the decor has a swelling in the length in a range of 0.2 to 0.4% and in the width of 0.5 to 0.9% can.
  • the values for fully impregnated papers are in the range of 0.4 to 0.9% in length and 1.2 to 1.8% in width.
  • the amount of impregnating resin used is drastically reduced at this value added stage. This leads to a significantly lower capital commitment in the overall process. Also, the drying process is shortened due to the reduced amount of impregnating compared to fully impregnated decorative papers, since during the impregnation process less resin Wegwarmt and water must be evaporated, so that a higher production speed and thus an energy saving in the manufacturing process is possible.
  • the decorative paper impregnated on one side has a better adhesion and a faster adhesion to the carrier plate compared to a dry decorative paper.
  • the liquid resin or impregnating resin applied to the at least one side of the carrier plate causes a dissolution of the predried impregnating agent on the back side of the decorative paper, which allows faster bonding of the decorative paper to the carrier plate.
  • the impregnating resin activates the impregnation and leads to a rapid caking and a slip-proof connection between the carrier plate and decorative paper. An additional glue line is not required.
  • the decor paper impregnated on the side opposite the decor is dried to a moisture content of 3-10% by weight, preferably 5-7% by weight, particularly preferably 6% by weight. Drying can be done in a convection dryer or near infrared (NIR).
  • NIR near infrared
  • the one-sided and preferably full-surface impregnated decorative paper is rolled up on its underside. This allows storage of the partially impregnated decorative paper for further use.
  • the decor paper impregnated on the side opposite the decor can be applied or pressed onto the carrier plate immediately or immediately after the impregnation.
  • the application or Pressing the partially impregnated decorative paper on the carrier plate which was previously provided with the liquid resin or impregnating resin.
  • impregnating resin according to the invention a melamine-formaldehyde resin, a melamine-urea resin or an acrylate resin having a solids content of 30-50% by weight, preferably 40-50% by weight, in particular having a solids content of 50% by weight.
  • a melamine-formaldehyde resin As impregnating resins, which are to be applied to the at least one side of the support plate, a melamine-formaldehyde resin, a melamine-phenol-formaldehyde resin, a melamine-urea resin or an acrylate resin having a solids content of 55-80 wt %, preferably 60-70% by weight, particularly preferably applied by 60% by weight. Accordingly, the viscosity of the liquid resin applied to the support plate is higher than the resin used as the impregnating agent.
  • the amount of the impregnating resin to be applied to the support plate is 30 to 70 g, preferably 50 g per m 2 of support plate.
  • the impregnating resin contains the usual auxiliaries such as hardeners, wetting agents, defoamers, etc.
  • the impregnating resin to be applied to the carrier plate is applied to the carrier plate by means of a roller and dried after application in order to evaporate part of the water. However, the drying takes place only so far that the impregnating resin still has enough tack to fix the partially impregnated decor paper.
  • This further layer to be applied can consist only of a resin, or it is also possible to use a mixture containing the resin, natural and / or synthetic fibers, wear-reducing particles and optionally further additives.
  • the liquid or impregnating resin to be applied to the decorative paper such as e.g. a melamine resin of the type mentioned above, has a solids content of 60-70% by weight, in particular of 60% by weight.
  • the formulation of impregnating resin, fibers and abrasion-resistant particles is preferably applied in an amount of 50-80 g of solid resin / square meter. This applied to the top of the decorative paper mixture can then be dried in a dryer to a defined residual moisture. Again, the drying can be done in a convection dryer or by near infrared.
  • This method can be repeated several times in other commissioned works and dryers, wherein in one variant abrasion-resistant particles are present in the resin formulation in the first two application units. In another variant, only one order of resin with corundum is provided.
  • liquid resin liquid resin
  • natural and / or synthetic resins natural and / or synthetic resins
  • abrasion-resistant particles optionally further additives the application of a further mixture of impregnating resin, fibers, glass spheres and auxiliaries.
  • a total of two to four further orders of this mixture can be made, so that in this case the formation of a so-called liquid overlay takes place.
  • At least one overlay in particular a resin-impregnated overlay (overlay impregnate), is applied to this first application of the mixture of liquid resin or liquid resin, fibers, particles and optionally further additives.
  • At least one overlay in particular a resin-impregnated overlay, after placing the decorative paper impregnated on the opposite side of the decor onto the carrier plate in an alternative further step f1).
  • the natural and / or synthetic fibers are preferably selected from a group of bleached cellulose fibers or organic polymer fibers.
  • the abrasion-resistant particles are preferably selected from the group comprising aluminum oxides, corundum, boron carbides, silicon dioxides, silicon carbides and glass beads, with corundum and glass beads being particularly preferred.
  • At least one color pigment selected from a group comprising titanium dioxide, zinc oxides, iron oxide pigments or metallic effect pigments.
  • the variability and the design options are unlimited.
  • this at least one additive may be selected from a group comprising conductive substances, flame retardants, luminescent substances and metals.
  • carbon fibers and nanoparticles, in particular carbon nanotubes are named as conductive substances.
  • Typical flame retardants are selected from the group comprising phosphates, borates, in particular ammonium polyphosphate, tris (tri-bromneopentyl) phosphate, zinc borate or boric acid complexes of polyhydric alcohols.
  • fluorescent and phosphorescent substances particular attention is drawn to zinc sulfite and alkaline earth aluminates.
  • the layer structure of support plate, decor paper, and optionally further resin layers is then preferably pressed.
  • the pressing of the layer structure preferably takes place in a continuous press.
  • the pressing of the layer structure leads to the formation of a surface structure above the decoration, optionally in conformity with the decoration, in the form of a so-called "emboss in register".
  • At least one counter-pull is applied to the opposite side of the carrier plate not provided with the decorative paper.
  • the carrier plate consists of a wood material, or a wood material-plastic mixture, in particular chip, medium-density fiber (MDF), high-density fiber (HDF) - coarse chip (OSB) or plywood plates are preferred.
  • MDF medium-density fiber
  • HDF high-density fiber
  • OSB coarse chip
  • the coated by the present process plate is then transferred together with a Schmidtpapier in a short-cycle press and cured the synthetic resins at high pressure and high temperature, wherein, as already mentioned above, in a variant, the application of a Schutzoverlays in the form of an overlay impregnate is possible.
  • the latter can also be done to achieve increased wear resistance. This may be necessary in particular when using the floor coverings in highly stressed objects.
  • the material plates produced by the present method are preferably used as laminate panels.
  • the present method offers a number of advantages:
  • the partial impregnation or one-sided impregnation of the decorative paper leads to a lower capital commitment on this value chain.
  • the partially-impregnated paper is already pre-swollen so as to reduce length and width repeat problems typically encountered with the use of dry decorative paper.
  • the roll processing is significantly cheaper and the flexibility of production increases.
  • Another advantage of the present method is its high variability, which is based on the later use of the products.
  • a printing base paper (paper weight: 80 g / m 2 ) is unrolled by a unwinding device and printed by gravure and / or digital printing and then impregnated in the back with a melamine resin in an impregnator.
  • a melamine resin in an impregnator.
  • about 50 g of melamine resin / m 2 are applied with a solids content of about 50%.
  • the paper is then dried in a convection dryer or by NIR (near-infrared) to a moisture content of about 6% by weight.
  • NIR near-infrared
  • the impregnate is then pressed in a continuous press on a melamine resin precoated plate (application rate: 50 g melamine resin / m 2 , solids content impregnating resin: 60 wt%).
  • the melamine resin contained on the plate contains the usual auxiliaries (hardener, wetting agent, defoamer, etc.) and has been pre-dried after application with a roller by convection or NIR.
  • a mixture of melamine resin (solids content impregnating resin: 60% by weight), cellulose and corundum in an amount of 50-80 g impregnating resin / m 2 - depending on the desired wear class - is then also applied to the decorative paper in the roll application.
  • the mixture is dried in a convection dryer or by near infrared.
  • a decorative paper (paper weight: 80 g / m 2 ) is unrolled by a unwinding device and impregnated at the back in an impregnator with a urea resin. About 50 g of urea resin / m 2 are applied (solids content: 50% by weight).
  • the paper is then dried in a convection dryer or by NIR to a moisture content of about 6%.
  • the one-sided impregnated paper is pressed in a continuous press on a melamine resin precoated plate (application rate: 50 g melamine resin / m 2 , solids content: 60% by weight).
  • the melamine resin on the plate contains the usual auxiliaries (hardener, wetting agent, defoamer, etc.) and has been pre-dried after application with a roll by convection or NIR.
  • the mixture is dried in a convection dryer or by near infrared.
  • the moisture of the coating is about 6% by weight after the drying process.
  • a completely resin-impregnated decor paper (resin application: 100% by weight) and a resin-impregnated overlay (paper weight: 30 g / m 2 , final weight: 150 g / m 2 ) is placed.
  • corundum was a wear-inhibiting agent.
  • a recycled paper (paper weight: 100 g / m 2 , resin application: 120% by weight) is used. The entire assembly is pressed in a KT press at 30 bar and 200 ° c.
  • a strand of HDF boards is continuously coated with an impregnating resin based on melamine in roll application. 100 g of melamine resin / m 2 are applied (solids content: 60% by weight).
  • the Tränkharzrezeptur contains the usual auxiliary materials such as hardener, wetting and release agent.
  • the impregnating resin is pre-dried after application with the help of a convection dryer or NIR to evaporate a part of the water.
  • the drying process need only be conducted to the point where the resin retains its stickiness or penetration into a paper.
  • a dry decorative paper (paper weight: 80 g / m 2 ) is unrolled by a rolling device and rolled into the still flowable resin. It is ensured by several on the top of successively arranged rollers that no wrinkles or ripples occur in the paper.
  • the paper is then pressed onto the melamine resin precoated plate in a continuous press.
  • a mixture of melamine resin (solids content impregnating resin: 60% by weight), cellulose and corundum in an amount of 50-80 g impregnating resin / m 2 - depending on the desired wear class - is then also applied to the decorative paper in the roll application.
  • the mixture is dried in a convection dryer or by near infrared. The moisture of the coating is about 6% by weight after the drying process.
  • Embodiments 1 and 2 made according to the method of the present invention using a partially impregnated decorative paper differ in the product of Embodiment 3 made using a fully impregnated decorative paper in that they are in terms of their storage time significantly better behavior.
  • a fully impregnated paper must be processed within a few months.
  • the partially impregnated papers can still be used after one year.
  • Embodiment 4 made with a dry decorative paper
  • a unilateral impregnation according to the invention in a impregnation channel is much easier to accomplish than the "pressing in” of glue into the backside of a paper, as in the case of the dry decorative paper. This is made difficult by the various parameters (density of the paper, pigment content, etc.). In addition, there is significantly more time available for the impregnation process compared to pressing, which makes the process less critical.

Landscapes

  • Laminated Bodies (AREA)
  • Paper (AREA)

Description

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung einer mit einer Dekorschicht aus einem dekorativen Papier versehenen Werkstoffplatte.The present invention relates to a method for producing a provided with a decorative layer of a decorative paper material plate.

Beschreibungdescription

Bei der Herstellung von Werkstoffplatten, insbesondere in Form von laminierten Werkstoffplatten, werden typischerweise verschiedene Papiere wie z.B. Dekorpapier, Overlays, Gegenzugpapiere, Underlays usw. zunächst in einer Imprägnieranlage mit einem duroplastischen Harz imprägniert, welches üblicherweise Wasser als Lösemittel enthält. Die verschiedenen Papiere werden dann anschließend auf eine definierte Feuchtigkeit von ca. 5-7 Gew% zurückgetrocknet. Zur Herstellung der Laminatplatten werden die so vollständig imprägnierten Papiere in einer Presse in einem Kurztaktverfahren auf Holzwerkstoffplatten aufgepresst.In the manufacture of material plates, especially in the form of laminated material plates, typically various papers such as e.g. Decorative paper, overlays, Gegenzugpapiere, Underlays, etc., first impregnated in a impregnation with a thermosetting resin, which usually contains water as a solvent. The various papers are then subsequently dried back to a defined moisture content of about 5-7% by weight. For the production of the laminate plates, the papers so completely impregnated are pressed onto wood-based panels in a press in a short-cycle process.

Bei der kontinuierlichen Verarbeitung von dekorativen Papieren zur Herstellung der verschiedensten Produkte werden unterschiedliche Verfahren eingesetzt. Während für Möbelanwendungen relativ einfache lackierte Finishfolien, d.h. geleimte Papiere mit wenig Leimanteil eingesetzt werden, werden bei Fussboden-Anwendungen wegen der höheren mechanischen Belastungen in der Nutzung höher beharzte Papiere bzw. Imprägnate verwendet, welche eine höhere Spaltfestigkeit garantieren. Dabei hat der kontinuierliche Prozess gegenüber den diskontinuierlichen Verfahren wie z.B. in der Kurztaktpresse hinsichtlich der Verarbeitung erhebliche Vorteile. Es ist effizienter, es treten geringere Materialverluste durch Bruch auf und die Anlagen sind mechanisch weniger aufwändig.In the continuous processing of decorative papers for the production of various products, different methods are used. While for furniture applications relatively simple painted finish foils, i. For glued papers with low glue content, higher-impact papers or impregnates are used in floor applications because of the higher mechanical loads in use, which guarantee a higher gap strength. In doing so, the continuous process has contrasted with the discontinuous processes, e.g. in the short-cycle press in terms of processing significant benefits. It is more efficient, there are less material losses due to breakage and the equipment is mechanically less complicated.

Ein immer gravierenderes Problem ist, dass in den letzten Jahren die geforderte Produktqualität immer höhere Ansprüche an die Fertigungsprozesse stellt. Dies gilt für die gesamte Wertschöpfungskette in der Herstellung von Laminatböden. Bei den Imprägnierprozess, bei dem die verschiedenen Papiere, die für die Laminatbodenherstellung verwendet werden, mit einem duroplastischen Harz imprägniert werden, treten erhebliche Probleme durch das Quellen der Papiere auf. Dies betrifft insbesondere die Dekorpapiere. Sie verändern ihre Abmessungen infolge der Wasseraufnahme in Längs- und Querrichtung. Wird die Dekorschicht nun anschließend mit der Holzwerkstoffplatte verpresst, schmilzt das als Imprägniermittel verwendete Harz auf und verbindet das Dekorpapier mit dem Kern der Bauplatte. Für die weitere Bearbeitung einer mit einer vollständig imprägnierten Dekorpapierschicht versehenen Holzwerkstoffplatte ist es jedoch wesentlich, das Quellmaß der Dekorschicht zu berücksichtigen, um eine möglichst gute Übereinstimmung des Dekors mit dem Format der fertigen Diele zu erreichen ( Längen- und Breitenrapport ). Dies ist allerdings wegen der stark unterschiedlichen Quellungen der Dekorpapiere in Länge und Breite im Imprägnierprozess sehr aufwendig und oft nicht möglich.An ever more serious problem is that in recent years, the required product quality is placing ever higher demands on the production processes. This applies to the entire value chain in the production of laminate flooring. In the impregnation process, where the various papers used for laminate flooring are impregnated with a thermosetting resin, there are considerable problems due to paper swelling. This concerns in particular the decor papers. They change their dimensions due to the water absorption in the longitudinal and transverse direction. If the decorative layer is then subsequently pressed with the wood-based panel, the resin used as impregnating agent melts and connects the decorative paper to the core of the building board. For the further processing of a provided with a fully impregnated decorative paper layer wood-based panel, however, it is essential to consider the Quellmaß the decorative layer to achieve the best possible match of the decor with the format of the finished plank (length and width repeat). However, this is very expensive and often not possible because of the very different swelling of the decorative papers in length and width in the impregnation process.

Zur Verringerung bzw. Vermeidung dieses Quellproblems einer vollständig imprägnierten Dekorpapierlage wurde in der Vergangenheit die Verwendung von trockenen Dekorpapieren vorgeschlagen. So wird z.B. in der DE 10 2007 026 170 A1 kein imprägniertes bzw. höher beharztes Papier verwendet, sondern ein Rohpapier, das unter Verwendung eines wasserhaltigen Leims auf den Träger aufgeklebt wird. Auch in der EP 1 977 909 B1 ist vorgesehen, das Dekorpapier trocken auf einer auf die Oberseite einer Trägerplatte aufgebrachten Melaminharzschicht aufzulegen, anschließend diese mit einer Melaminharzschicht abzudecken und diesen Aufbau abschließend zu verpressen. Hierbei wird durch die Verwendung des trocknen Papiers das Problem der Papierquellung minimiert.To reduce or avoid this swelling problem of a fully impregnated decorative paper ply, the use of dry decorative papers has been proposed in the past. For example, in the DE 10 2007 026 170 A1 no impregnated or higher resinated paper used, but a base paper, which is adhered using a water-based glue on the carrier. Also in the EP 1 977 909 B1 it is intended to place the decorative paper dry on a melamine resin layer applied to the upper side of a carrier plate, then to cover it with a melamine resin layer and finally to press this structure. In this case, the use of the dry paper minimizes the problem of paper swelling.

Bei den zuletzt beschriebenen Varianten treten allerdings beim Verarbeiten beim Kontakt mit den wässrigen Harzen Probleme durch Quellprozesse im Papier auf, welche zu Faltenbildung führen können. Um dies zu vermeiden muss die Führung und Fixierung der Papierbahn sehr exakt gestaltet werden. Weiterhin kann der Prozess durch die erhebliche Menge Wasser, die durch den Leim auf den Träger aufgebracht wird zu Quellungen in der Deckschicht der HWS-Platte führen. Dies führt zu einer Verschlechterung der technologischen Eigenschaften der Deckschicht (Deckschicht- abhebefestigkeit). Dieser Effekt ist um so gravierender je länger das Wasser vor der Weiterveredelung auf die Platte einwirkt (Anlagenstillstände, Programmwechsel usw.)In the case of the last-described variants, however, during processing on contact with the aqueous resins, problems arise due to swelling processes in the paper, which can lead to wrinkling. To avoid this, the guidance and fixation of the paper web must be designed very precisely. Furthermore, the process may result in swelling in the cover layer of the cervical spine due to the substantial amount of water applied to the carrier by the glue. This leads to a deterioration of the technological properties of the cover layer (covering layer resistance). This effect is all the more serious the longer the water acts on the plate before further refining (plant stoppages, program change, etc.)

Die beschriebenen Varianten scheinen das Problem des Papierwachstums durch Quellung auf den ersten Blick zu lösen. Allerdings entsteht ein neues Problem, wenn Dekore einmal unter Verwendung von trockenen Dekorpapierbahnen und einmal nach dem Standardverfahren unter Verwendung von vollständig imprägnierten Dekorpapierbahnen verarbeitet werden. Wie bereits oben beschrieben, sind die imprägnierten Papiere im Rahmen des Imprägnierprozesses gequollen und besitzen damit eine andere Länge und Breite als die direkt auf den Träger aufgeklebten trockenen Papiere. Wenn daraus nun die gleichen Produkte im gleichen Format hergestellt werden, können wiederum Probleme mit dem Längen- und Breitenrapport entstehen.The variants described seem to solve the problem of paper growth by swelling at first sight. However, a new problem arises when decors are once processed using dry decorative paper webs and once by the standard method using fully impregnated decorative paper webs. As already described above, the impregnated papers are swollen during the impregnation process and thus have a different length and Width than the dry papers glued directly to the support. If the same products are now produced in the same format, problems with the length and width repeat can again arise.

US 6,551,694 B1 offenbart ein Verfahren zur Herstellung einer Holzwerkstoffplatte bestehend aus einer Trägerplatte und einem auf der Trägerplatte angeordnetem Dekorpapier, umfassend die Schritte (a) Bereitstellen des Dekorpapiers, (b) Auftragen von mindestens einem Harz als Imprägniermittel lediglich auf die dem Dekor gegenüberliegende Seite des Dekorpapiers, wobei die Menge an aufgetragenen Harz zwischen 40 und 70% bezogen auf das Papiergewicht des Dekorpapiers beträgt, und wobei als Imprägniermittel ein Melamin-, Harnstoff-, oder Urethanbasiertes Harz verwendet wird, (c) Bereitstellen der Trägerplatte, (d) Auftragen von mindestens einer Schicht von mindestens einem Klebstoff auf mindestens eine Seite der Trägerplatte, und (e) Auflegen des Dekorpapieres mit der dem Dekor gegenüberliegenden imprägnierten Seite auf die mit dem Klebstoff versehenen Seite der Trägerplatte. US 6,551,694 B1 discloses a method for producing a wood-based panel consisting of a support plate and a decor paper arranged on the support plate, comprising the steps of (a) providing the decor paper, (b) applying at least one resin as impregnating agent only to the decorative paper opposite the decor, wherein the amount of resin applied is between 40 and 70% based on the paper weight of the decorative paper, and wherein a melamine-, urea- or urethane-based resin is used as the impregnating agent, (c) providing the support plate, (d) applying at least one layer at least one adhesive on at least one side of the backing plate, and (e) placing the decorative paper with the impregnated opposite side of the decor on the side of the backing plate provided with the adhesive.

Imprägnierte Papiere werden üblicherweise mittels der KT(Kurztaktpresse)- Technologie in einer Presse auf einen Träger gepresst. Diese KT-Technologie besitzt aber ebenfalls einige Nachteile. Erstens sind die imprägnierten Papierbögen relativ spröde und können bei der Verarbeitung reißen bzw. zerstört werden. Zweitens ist die Herstellung der Bögen ebenfalls ausschussanfällig. Insgesamt ist dieses Verfahren auch relativ teuer, da insgesamt drei Papiere verwendet werden.Impregnated papers are usually pressed onto a carrier by means of KT (short-cycle press) technology in a press. However, this KT technology also has some disadvantages. First, the impregnated paper sheets are relatively brittle and may tear or break during processing. Second, the production of the sheets is also prone to jeopardy. Overall, this method is also relatively expensive, since a total of three papers are used.

Ausgehend von diesem technologischen Hintergrund soll ein Verfahren entwickelt werden, dass die Nachteile der oben beschriebenen Verfahren reduziert bzw. eliminiert.Based on this technological background, a method is to be developed that reduces or eliminates the disadvantages of the methods described above.

Diese Aufgabe wird durch die Bereitstellung eines Verfahrens mit den Merkmalen des Anspruchs 1 gelöst.This object is achieved by providing a method having the features of claim 1.

Erfindungsgemäß wird lediglich die nicht bedruckte Unterseite des dekorativen Papiers bzw. Dekorpapiers mit einem Harz imprägniert. Vorliegend wird somit ein Dekorpapier bei der Herstellung einer Werkstoffplatte verwendet, das nur teilweise imprägniert ist, wobei bevorzugt die gesamte Fläche der nicht bedruckten Unterseite des Dekorpapiers, d.h. die der Sichtseite gegenüberliegende Seite des Dekorpapiers, gleichmäßig mit dem Imprägnierharz versehen ist. Um dies zu erreichen, wird ein wässriges Tränkharz als Imprägnierharz rückseitig, d.h. auf die nicht mit einem Dekor versehene Seite des Dekorpapiers aufgetragen. Das Dekor des dekorativen Papiers kann durch Tief- und/oder Digitaldruck aufgebracht sein.According to the invention, only the non-printed underside of the decorative paper or decorative paper is impregnated with a resin. In the present case, therefore, a decorative paper is used in the manufacture of a material plate which is only partially impregnated, wherein preferably the entire surface of the non-printed underside of the decorative paper, i. the side opposite the visible side of the decorative paper is evenly provided with the impregnating resin. To achieve this, an aqueous impregnating resin is used as the impregnating resin on the back, i. applied to the non-decorative side of the decorative paper. The decor of the decorative paper can be applied by gravure and / or digital printing.

Erfindungsgemäß beträgt die Menge an auf die dem Dekor gegenüberliegenden Seite des Dekorpapiers aufgebrachten Harzes zwischen 30 und 70 Gew%, bevorzugt zwischen 40 und 60 Gew%, insbesondere bevorzugt 50 Gew% bezogen auf das Papiergewicht des Dekorpapiers. So werden z.B. 50 g Imprägnierharz pro m2 Dekorpapier (Papiergewicht: 80 g/m2, Feststoffgehalt Tränkharz: 50 Gew%) aufgetragen.According to the invention, the amount of resin applied to the opposite side of the decor paper is between 30 and 70% by weight, preferably between 40 and 60% by weight, more preferably 50% by weight, based on the paper weight of the decorative paper. For example, 50 g of impregnating resin per m 2 of decorative paper (paper weight: 80 g / m 2 , solids content impregnating resin: 50% by weight) are applied.

Demgegenüber wird im Falle eines konventionell vollständig imprägnierten Dekorpapiers eine Harzmenge von 90-110 Gew% bezogen auf das Papiergewicht des Dekorpapiers auf das Selbige aufgetragen, wobei sich die Menge des Imprägnierharzes hierbei üblicherweise an der der Overlay-Imprägnierung orientiert.In contrast, in the case of a conventionally completely impregnated decorative paper, a resin amount of 90-110% by weight, based on the paper weight of the decorative paper, is applied to the same, with the amount of the impregnating resin usually being based on that of the overlay impregnation.

In verschiedenen Varianten des vorliegenden Verfahrens wurde festgestellt, dass das auf der dem Dekor gegenüberliegenden Seite imprägnierte Dekorpapier eine Quellung in der Länge in einem Bereich von 0,2 bis 0,4% und in der Breite von 0,5 bis 0,9 % besitzen können. Im Vergleich dazu liegen die Werte bei vollständig imprägnierten Papieren in der Länge in einem Range von 0,4 bis 0,9% und in der Breite bei 1,2 bis 1,8%.In various variants of the present method, it has been found that the decor paper impregnated on the opposite side of the decor has a swelling in the length in a range of 0.2 to 0.4% and in the width of 0.5 to 0.9% can. By comparison, the values for fully impregnated papers are in the range of 0.4 to 0.9% in length and 1.2 to 1.8% in width.

Die Verwendung eines lediglich teilweise, einseitig imprägnierten Dekorpapiers weist sowohl gegenüber der Verwendung eines vollständig imprägnierten Dekorpapiers als auch gegenüber der Verwendung eines trockenen Dekorpapiers mehrere Vorteile auf.The use of only partially, one-sided impregnated decorative paper has several advantages over both the use of a fully impregnated decorative paper and the use of a dry decorative paper.

So wird im Vergleich zu einem vollständig imprägnierten Dekorpapier die Menge an verwendetem Imprägnierharz auf dieser Wertschöpfungsstufe drastisch reduziert. Dies führt zu einer deutlich niedrigeren Kapitalbindung im Gesamtprozess. Auch wird der Trocknungsprozess aufgrund der reduzierten Menge an Imprägniermittel im Vergleich zu vollständig imprägnierten Dekorpapieren verkürzt, da beim Imprägnierprozess weniger Harz durchwärmt und Wasser verdunstete werden muss, so dass eine höhere Produktionsgeschwindigkeit und damit eine Energieeinsparung im Herstellungsprozess möglich ist.Thus, compared to a fully impregnated decorative paper, the amount of impregnating resin used is drastically reduced at this value added stage. This leads to a significantly lower capital commitment in the overall process. Also, the drying process is shortened due to the reduced amount of impregnating compared to fully impregnated decorative papers, since during the impregnation process less resin durchwarmt and water must be evaporated, so that a higher production speed and thus an energy saving in the manufacturing process is possible.

Im Vergleich zu der Verwendung von trockenem Dekorpapier erfolgt ein Vorquellen des Dekorpapiers, so dass die mit dem Quellprozess bei der Verwendung von trockenen Dekorpapieren während der Herstellung der Werkstoffplatten verbundenen Nachteile vermieden werden.In comparison with the use of dry decorative paper, a pre-swelling of the decorative paper takes place, so that the disadvantages associated with the swelling process when using dry decorative papers during the production of the material plates are avoided.

Darüber hinaus weist das einseitig imprägnierte Dekorpapier gegenüber einem trockenen Dekorpapier eine bessere Haftung und ein schnelleres Ankleben auf der Trägerplatte auf. So bedingt das auf die mindestens eine Seite der Trägerplatte aufgetragene Flüssigharz bzw. Tränkharz ein Anlösen des vorgetrockneten Imprägniermittels auf der Rückseite des Dekorpapiers, wodurch ein schnelleres Ankleben des Dekorpapiers auf der Trägerplatte ermöglicht wird. Mit anderen Worten: das Tränkharz aktiviert die Imprägnierung und führt zu einem schnellen Anbacken und zu einer verrutschsicheren Verbindung zwischen Trägerplatte und Dekorpapier. Ein zusätzlicher Leimstrich ist nicht erforderlich.In addition, the decorative paper impregnated on one side has a better adhesion and a faster adhesion to the carrier plate compared to a dry decorative paper. Thus, the liquid resin or impregnating resin applied to the at least one side of the carrier plate causes a dissolution of the predried impregnating agent on the back side of the decorative paper, which allows faster bonding of the decorative paper to the carrier plate. In other words, the impregnating resin activates the impregnation and leads to a rapid caking and a slip-proof connection between the carrier plate and decorative paper. An additional glue line is not required.

Es ist ebenfalls bevorzugt, wenn das auf der dem Dekor gegenüberliegenden Seite imprägnierte Dekorpapier auf eine Feuchte von 3-10 Gew%, bevorzugt 5-7 Gew%, insbesondere bevorzugt von 6 Gew% getrocknet wird. Das Trocknen kann in einem Konvektionstrockner oder mittels Nahinfrarot (NIR) erfolgen.It is likewise preferred if the decor paper impregnated on the side opposite the decor is dried to a moisture content of 3-10% by weight, preferably 5-7% by weight, particularly preferably 6% by weight. Drying can be done in a convection dryer or near infrared (NIR).

In einer Variante des vorliegenden Verfahrens wird das auf seiner Unterseite einseitig und bevorzugt vollflächig imprägnierte dekorative Papier aufgerollt. Dies ermöglicht eine Lagerung des teilimprägnierten Dekorpapiers für eine weitere Verwendung.In a variant of the present method, the one-sided and preferably full-surface impregnated decorative paper is rolled up on its underside. This allows storage of the partially impregnated decorative paper for further use.

Es ist weiterhin auch möglich, dass das auf der dem Dekor gegenüberliegenden Seite imprägnierte Dekorpapier sofort bzw. unmittelbar im Anschluss an die Imprägnierung auf die Trägerplatte aufgebracht bzw. aufgepresst wird. Hierbei erfolgt das Aufbringen bzw. Aufpressen des teilimprägnierten Dekorpapiers auf die Trägerplatte, die vorhergehend mit dem Flüssigharz bzw. Tränkharz versehen wurde. Als Imprägnierharz wird erfindungsgemäß ein Melamin-Formaldehyd-Harz, ein Melamin-Harnstoff-Harz oder ein Acrylat-Harz mit einem Feststoffgehalt zwischen 30-50 Gew%, bevorzugt 40-50 Gew%, insbesondere mit einem Feststoffgehalt von 50 Gew% verwendet.Furthermore, it is also possible for the decor paper impregnated on the side opposite the decor to be applied or pressed onto the carrier plate immediately or immediately after the impregnation. Here, the application or Pressing the partially impregnated decorative paper on the carrier plate, which was previously provided with the liquid resin or impregnating resin. As impregnating resin according to the invention, a melamine-formaldehyde resin, a melamine-urea resin or an acrylate resin having a solids content of 30-50% by weight, preferably 40-50% by weight, in particular having a solids content of 50% by weight.

Als Tränkharze, die auf die mindestens eine Seite der Trägerplatte aufzutragen sind, werden ein Melamin-Formaldehyd-Harz, ein Melamin-Phenol-Formaldehyd-Harz, ein Melamin-Harnstoff-Harz oder ein Acrylat-Harz mit einem Feststoffgehalt zwischen 55-80 Gew%, bevorzugt 60-70 Gew%, insbesondere bevorzugt von 60 Gew% aufgetragen. Entsprechend ist die Viskosität des auf die Trägerplatte aufgetragenen Flüssigharzes höher als des als Imprägniermittel verwendeten Harzes.As impregnating resins, which are to be applied to the at least one side of the support plate, a melamine-formaldehyde resin, a melamine-phenol-formaldehyde resin, a melamine-urea resin or an acrylate resin having a solids content of 55-80 wt %, preferably 60-70% by weight, particularly preferably applied by 60% by weight. Accordingly, the viscosity of the liquid resin applied to the support plate is higher than the resin used as the impregnating agent.

Die Menge des auf die Trägerplatte aufzutragenden Tränkharzes beträgt 30 bis 70 g, bevorzugt 50 g pro m2 Trägerplatte. Das Tränkharz enthält die üblichen Hilfsstoffe wie Härter, Netzmittel, Entschäumer usw.The amount of the impregnating resin to be applied to the support plate is 30 to 70 g, preferably 50 g per m 2 of support plate. The impregnating resin contains the usual auxiliaries such as hardeners, wetting agents, defoamers, etc.

Das auf die Trägerplatte aufzutragende Tränkharz wird mittels einer Walze auf die Trägerplatte aufgetragen und nach dem Auftrag getrocknet, um ein Teil des Wassers zu verdunsten. Allerdings erfolgt die Trocknung nur soweit, dass das Tränkharz noch genügend Klebrigkeit zur Fixierung des teilimprägnierten Dekorpapiers besitzt.The impregnating resin to be applied to the carrier plate is applied to the carrier plate by means of a roller and dried after application in order to evaporate part of the water. However, the drying takes place only so far that the impregnating resin still has enough tack to fix the partially impregnated decor paper.

Nach Auftragen und ggf. Zwischentrocknen des teilimprägnierten Dekorpapiers auf der Trägerplatte kann eine weitere Veredelung der Oberfläche vorgenommen werdenAfter application and optionally intermediate drying of the partially impregnated decorative paper on the support plate, a further refinement of the surface can be made

So wird in einer weiteren Ausführungsform des vorliegenden Verfahrens nach dem Auflegen des auf der dem Dekor gegenüberliegenden Seite imprägnierten Dekorpapiers auf die Trägerplatte und ggf. einer Zwischentrocknung in einem weiteren Schritt f) mindestens eine weitere Schicht eines Harzes auf die Oberseite bzw. Sichtseite des Dekorpapiers, d.h. die mit dem Dekor versehenen Seite des dekorativen Papiers, die nicht imprägniert ist, aufgetragen.Thus, in a further embodiment of the present method, after placing the decor paper impregnated on the opposite side of the decor on the support plate and optionally an intermediate drying in a further step f) at least one further layer of a resin on the top or visible side of the decorative paper, ie the decorative side of the decorative paper, which is not impregnated, is applied.

Diese weitere aufzutragende Schicht kann lediglich aus einem Harz bestehen, oder es ist auch möglich ein Gemisch enthaltend das Harz, natürliche und/oder synthetische Fasern, verschleißreduzierende Partikel und ggf. weitere Additive zu verwenden.This further layer to be applied can consist only of a resin, or it is also possible to use a mixture containing the resin, natural and / or synthetic fibers, wear-reducing particles and optionally further additives.

Das auf das Dekorpapier aufzutragende Flüssig- bzw. Tränkharz, wie z.B. ein Melaminharz der oben genannten Art, weist einen Feststoffgehalt von 60-70 Gew%, insbesondere von 60 Gew% auf. Die Rezeptur aus Tränkharz, Fasern und abriebfesten Partikel wird bevorzugt in einer Menge von 50-80 g Festharz/ Quadratmeter aufgetragen. Diese auf die Oberseite des Dekorpapiers aufgetragene Mischung kann dann in einem Trockner auf eine definierte Restfeuchte getrocknet werden. Auch hier kann das Trocknen in einem Konvektionstrockner oder durch Nahinfrarot erfolgen.The liquid or impregnating resin to be applied to the decorative paper, such as e.g. a melamine resin of the type mentioned above, has a solids content of 60-70% by weight, in particular of 60% by weight. The formulation of impregnating resin, fibers and abrasion-resistant particles is preferably applied in an amount of 50-80 g of solid resin / square meter. This applied to the top of the decorative paper mixture can then be dried in a dryer to a defined residual moisture. Again, the drying can be done in a convection dryer or by near infrared.

Dieses Verfahren kann in weiteren Auftragswerken und Trocknern mehrfach wiederholt werden, wobei in einer Variante sich in den ersten beiden Auftragswerken abriebfeste Partikel in der Harzrezeptur befinden. In einer anderen Variante wird nur ein Auftrag von Harz mit Korund vorgesehen.This method can be repeated several times in other commissioned works and dryers, wherein in one variant abrasion-resistant particles are present in the resin formulation in the first two application units. In another variant, only one order of resin with corundum is provided.

Entsprechend dieser möglichen Varianten kann auf das erste Gemisch aus Flüssigharz, natürlichen und/oder synthetischen Harzen, abriebfesten Partikeln und gegebenenfalls weiteren Additiven der Auftrag eines weiteren Gemisches aus Tränkharz, Fasern, Glaskugeln und Hilfsstoffen erfolgen. Insgesamt können zwei bis vier weitere Aufträge dieses Gemisches vorgenommen werden, so dass hierbei die Ausbildung eines sogenannten Flüssig-Overlays erfolgt.According to these possible variants, it is possible to apply to the first mixture of liquid resin, natural and / or synthetic resins, abrasion-resistant particles and optionally further additives the application of a further mixture of impregnating resin, fibers, glass spheres and auxiliaries. A total of two to four further orders of this mixture can be made, so that in this case the formation of a so-called liquid overlay takes place.

Es ist aber ebenfalls auch möglich und von Vorteil, wenn auf diesen ersten Auftrag des Gemisches aus Flüssigharz oder Flüssigharz, Fasern, Partikeln und gegebenenfalls weiteren Additiven mindestens ein Overlay, insbesondere ein harzimprägniertes Overlay (Overlay-Imprägnat) aufgebracht wird.However, it is likewise possible and advantageous if at least one overlay, in particular a resin-impregnated overlay (overlay impregnate), is applied to this first application of the mixture of liquid resin or liquid resin, fibers, particles and optionally further additives.

Gemäß einer weiteren Ausführungsform ist es auch möglich, nach dem Auflegen des auf der dem Dekor gegenüberliegenden Seite imprägnierten Dekorpapiers auf die Trägerplatte in einem alternativen weiteren Schritt f1) mindestens ein Overlay, insbesondere ein harzimprägniertes Overlay, aufzubringen.According to a further embodiment, it is also possible to apply at least one overlay, in particular a resin-impregnated overlay, after placing the decorative paper impregnated on the opposite side of the decor onto the carrier plate in an alternative further step f1).

Die natürlichen und / oder synthetischen Fasern sind bevorzugt ausgewählt aus einer Gruppe gebleichte Zellulosefasern oder organische Polymerfasern.The natural and / or synthetic fibers are preferably selected from a group of bleached cellulose fibers or organic polymer fibers.

Die abriebfesten Partikel werden bevorzugt ausgewählt aus der Gruppe umfassend Aluminiumoxide, Korund, Borcarbide, Siliziumdioxide, Siliziumcarbide und Glaskugeln, wobei Korund und Glaskugeln besonders bevorzugt sind.The abrasion-resistant particles are preferably selected from the group comprising aluminum oxides, corundum, boron carbides, silicon dioxides, silicon carbides and glass beads, with corundum and glass beads being particularly preferred.

Es ist ebenfalls möglich, dem Gemisch mindestens ein Farbpigment ausgewählt aus einer Gruppe umfassend Titandioxid, Zinkoxide, Eisenoxidpigmente oder Metalleffektpigmente zuzusetzen. Der Variabilität und den Gestaltungsmöglichkeiten sind dabei keine Grenzen gesetzt.It is also possible to add to the mixture at least one color pigment selected from a group comprising titanium dioxide, zinc oxides, iron oxide pigments or metallic effect pigments. The variability and the design options are unlimited.

Wie bereits oben erwähnt, ist es auch möglich, dem Gemisch weitere Additive aus Flüssigharz, Fasern und abriebfesten Partikeln zuzusetzen. Dabei kann dieses mindestens eine Additiv ausgewählt sein aus einer Gruppe umfassend leitfähige Substanzen, Flammschutzmittel, lumineszierende Stoffe und Metalle. Als leitfähige Substanzen werden dabei Kohlefasern und Nanopartikel, insbesondere Kohlenstoffnanoröhren benannt. Typische Flammschutzmittel sind ausgewählt aus der Gruppe umfassend Phosphate, Borate, insbesondere Ammoniumpolyphosphat, Tris(tri-bromneopentyl)phosphat, Zinkborat oder Borsäurekomplexe von mehrwertigen Alkoholen. Als fluoreszierende und phosphoreszierende Stoffe sei insbesondere auf Zinksulfit und Erdalkali-Aluminate hingewiesen.As already mentioned above, it is also possible to add further additives of liquid resin, fibers and abrasion-resistant particles to the mixture. In this case, this at least one additive may be selected from a group comprising conductive substances, flame retardants, luminescent substances and metals. In this case, carbon fibers and nanoparticles, in particular carbon nanotubes, are named as conductive substances. Typical flame retardants are selected from the group comprising phosphates, borates, in particular ammonium polyphosphate, tris (tri-bromneopentyl) phosphate, zinc borate or boric acid complexes of polyhydric alcohols. As fluorescent and phosphorescent substances, particular attention is drawn to zinc sulfite and alkaline earth aluminates.

In einem weiteren Schritt g) wird dann der Schichtaufbau aus Trägerplatte, Dekorpapier, und ggf. weiteren Harzschichten vorzugsweise verpresst. Vorzugsweise erfolgt das Verpressen des Schichtaufbaus in einer Durchlaufpresse. Durch das Verpressen des Schichtaufbaus kommt es zur Ausbildung einer Oberflächenstruktur oberhalb des Dekors, optional in Übereinstimmung mit dem Dekor, in Form eine so genannten "emboss in register".In a further step g), the layer structure of support plate, decor paper, and optionally further resin layers is then preferably pressed. The pressing of the layer structure preferably takes place in a continuous press. The pressing of the layer structure leads to the formation of a surface structure above the decoration, optionally in conformity with the decoration, in the form of a so-called "emboss in register".

In einer weiteren Variante des Verfahrens wird auf die nicht mit dem Dekorpapier versehene gegenüberliegende Seite der Trägerplatte mindestens ein Gegenzug aufgebracht.In a further variant of the method, at least one counter-pull is applied to the opposite side of the carrier plate not provided with the decorative paper.

In einer weiteren Ausführungsform besteht die Trägerplatte aus einem Holzwerkstoff, oder einem Holzwerkstoff-Kunststoffgemisch, wobei insbesondere Span-, mitteldichte Faser (MDF)-, hochdichte Faser (HDF)- Grobspan (OSB) oder Sperrholzplatten bevorzugt sind.In a further embodiment, the carrier plate consists of a wood material, or a wood material-plastic mixture, in particular chip, medium-density fiber (MDF), high-density fiber (HDF) - coarse chip (OSB) or plywood plates are preferred.

Die mittels des vorliegenden Verfahrens beschichtete Platte wird anschließend zusammen mit einem Gegenzugpapier in eine Kurztaktpresse überführt und die Kunstharze bei hohem Druck und hoher Temperatur ausgehärtet, wobei wie bereits oben erwähnt, in einer Variante das Auflegen eines Schutzoverlays in Form eines Overlayimprägnats möglich ist. Letzteres kann auch zur Erreichung einer erhöhten Verschleißfestigkeit vorgenommen werden. Dies kann insbesondere bei Einsatz der Bodenbeläge in hochbeanspruchten Objekten nötig sein.The coated by the present process plate is then transferred together with a Gegenzugpapier in a short-cycle press and cured the synthetic resins at high pressure and high temperature, wherein, as already mentioned above, in a variant, the application of a Schutzoverlays in the form of an overlay impregnate is possible. The latter can also be done to achieve increased wear resistance. This may be necessary in particular when using the floor coverings in highly stressed objects.

Die mit dem vorliegenden Verfahren hergestellten Werkstoffplatten werden bevorzugt als Laminatpaneele verwendet.The material plates produced by the present method are preferably used as laminate panels.

Insgesamt bietet das vorliegende Verfahren eine Reihe von Vorteilen: So wird führt die Teilimprägnierung bzw. einseitigen Imprägnierung des dekorativen Papiers zu einer geringeren Kapitalbindung auf dieser Wertschöpfungskette. Auch ist das teilimprägnierte Papier bereits vorgequollen, so dass Längen- und Breitenrapportprobleme verringert werden, die typischerweise bei der Verwendung von trockenem Dekorpapier auftreten können. Darüber hinaus ist die Rollenverarbeitung deutlich günstiger und die Flexibilität der Produktion steigt.Overall, the present method offers a number of advantages: Thus, the partial impregnation or one-sided impregnation of the decorative paper leads to a lower capital commitment on this value chain. Also, the partially-impregnated paper is already pre-swollen so as to reduce length and width repeat problems typically encountered with the use of dry decorative paper. In addition, the roll processing is significantly cheaper and the flexibility of production increases.

Ein weiterer Vorteil des vorliegenden Verfahrens ist deren hohe Variabilität, die sich an der späteren Verwendung der Produkte orientiert. So ist es neben den bereits angeführten Ausführungsformen möglich, zwischen den einzelnen Auftragsprozessen noch Druckwerke zu installieren, in die Harzrezepturen Effektpigmente einzuarbeiten, Hilfsstoffe zur Verbesserung der Produkteigenschaften (wie z.B. Leitfähigkeit, Trittschall usw.) zu verwenden und andere Funktionsschichten zu integrieren wie z.B. druckempfindliche Schichten.Another advantage of the present method is its high variability, which is based on the later use of the products. Thus, in addition to the already mentioned embodiments, it is also possible to install printing units between the individual application processes, to incorporate effect pigments into the resin formulations, to use auxiliaries for improving the product properties (such as conductivity, impact sound, etc.) and to integrate other functional layers, such as e.g. pressure-sensitive layers.

Die vorliegende Erfindung wird nachfolgend anhand von mehreren Ausführungsbeispielen zum besseren Verständnis erläutert und beschrieben.The present invention will be explained and described below with reference to several embodiments for a better understanding.

Ausführungsbeispiel 1:Embodiment 1

Ein Druckbasispapier (Papiergewicht: 80 g/m2) wird von einer Abrollvorrichtung abgerollt und im Tiefdruck- und/oder Digitaldruckverfahren bedruckt und dann in einer Imprägniervorrichtung rückseitig mit einem Melaminharz imprägniert. Dabei werden ca. 50 g Melaminharz /m2 mit einem Feststoffgehalt von ca. 50% aufgetragen.A printing base paper (paper weight: 80 g / m 2 ) is unrolled by a unwinding device and printed by gravure and / or digital printing and then impregnated in the back with a melamine resin in an impregnator. In this case, about 50 g of melamine resin / m 2 are applied with a solids content of about 50%.

Das Papier wird anschließend in einen Konvektionstrockner oder durch NIR ( Nahinfrarot ) auf eine Feuchte von ca. 6 Gew% getrocknet.The paper is then dried in a convection dryer or by NIR (near-infrared) to a moisture content of about 6% by weight.

Dann wird das Imprägnat in einer kontinuierlich arbeitenden Presse auf eine mit Melaminharz vorbeschichtete Platte (Auftragsmenge: 50 g Melaminharz /m2, Feststoffgehalt Tränkharz: 60 Gew%) aufgepresst. Das auf der Platte befindliche Melaminharz enthält die üblichen Hilfsstoffe (Härter, Netzmittel, Entschäumer usw.) und ist nach dem Auftrag mit einer Walze durch Konvektion bzw. NIR vorgetrocknet worden.The impregnate is then pressed in a continuous press on a melamine resin precoated plate (application rate: 50 g melamine resin / m 2 , solids content impregnating resin: 60 wt%). The melamine resin contained on the plate contains the usual auxiliaries (hardener, wetting agent, defoamer, etc.) and has been pre-dried after application with a roller by convection or NIR.

Auf das Dekorpapier wird anschließend ebenfalls im Walzenauftrag ein Gemisch aus Melaminharz (Feststoffgehalt Tränkharz: 60 Gew%), Zellulose und Korund in einer Menge von 50 - 80 g Tränkharz / m2 - je nach gewünschter Verschleißklasse - aufgebracht. Das Gemisch wird in einem Konvektionstrockner oder durch Nahinfrarot getrocknet.A mixture of melamine resin (solids content impregnating resin: 60% by weight), cellulose and corundum in an amount of 50-80 g impregnating resin / m 2 - depending on the desired wear class - is then also applied to the decorative paper in the roll application. The mixture is dried in a convection dryer or by near infrared.

Anschließend erfolgen weitere Harzaufträge (zwischen 2 und 4), wobei ein Gemisch aus Melaminharz, Zellulose und Glaskugeln aufgetragen wird. Der Feststoffgehalt der Flotten liegt dabei ebenfalls bei ca. 60%. Die Trocknung wird wie oben beschrieben realisiert.Subsequently, further resin applications (between 2 and 4) are carried out, wherein a mixture of melamine resin, cellulose and glass beads is applied. The solids content of the liquors is also about 60%. The drying is realized as described above.

Am Ende dieses Prozesses wird die Beschichtung auf eine Restfeuchte von ca. 6 Gew% getrocknet. Danach wird die Beschichtung in einer KT-Presse oder in einer kontinuierlich arbeitenden Presse durchgehärtet ( p= 30 Bar, T= 200 °C ), wobei sich auf der Rückseite der Platte entweder ein harzimprägniertes Gegenzugpapier oder ein ebenfalls im Flüssigverfahren aufgebrachtes und vorgetrocknetes Harz befindet.At the end of this process, the coating is dried to a residual moisture content of about 6% by weight. Thereafter, the coating is cured in a KT press or in a continuous press (p = 30 bar, T = 200 ° C), wherein on the back of the plate is either a resin-impregnated Gegenzugpapier or also applied by liquid and pre-dried resin ,

Ausführungsbeispiel 2:Embodiment 2:

Ein Dekorpapier (Papiergewicht: 80 g/m2) wird von einer Abrollvorrichtung abgerollt und rückseitig in einer Imprägniervorrichtung mit einem Harnstoffharz imprägniert. Dabei werden ca. 50 g Harnstoffharz / m2 aufgetragen (Feststoffgehalt: 50 Gew%).A decorative paper (paper weight: 80 g / m 2 ) is unrolled by a unwinding device and impregnated at the back in an impregnator with a urea resin. About 50 g of urea resin / m 2 are applied (solids content: 50% by weight).

Das Papier wird anschließend in einem Konvektionstrockner oder durch NIR auf eine Feuchte von ca. 6% getrocknet.The paper is then dried in a convection dryer or by NIR to a moisture content of about 6%.

Dann wird das einseitig imprägnierte Papier in einer kontinuierlich arbeitenden Presse auf eine mit Melaminharz vorbeschichtete Platte (Auftragsmenge: 50 g Melaminharz /m2, Feststoffgehalt: 60 Gew%) aufgepresst. Das auf der Platte befindliche Melaminharz enthält die üblichen Hilfsstoffe ( Härter, Netzmittel, Entschäumer usw. ) und ist nach dem Auftrag mit einer Walze durch Konvektion bzw. NIR vorgetrocknet worden.Then the one-sided impregnated paper is pressed in a continuous press on a melamine resin precoated plate (application rate: 50 g melamine resin / m 2 , solids content: 60% by weight). The melamine resin on the plate contains the usual auxiliaries (hardener, wetting agent, defoamer, etc.) and has been pre-dried after application with a roll by convection or NIR.

Auf das Dekorpapier wird anschließend ebenfalls im Walzenauftrag ein Gemisch aus Melaminharz (Feststoffgehalt: 60 Gew%), Zellulose und Korund in einer Menge von 50 - 80 g Tränkharz / m2 -je nach gewünschter Verschleißklasse - aufgebracht. Das Gemisch wird in einem Konvektionstrockner oder durch Nahinfrarot getrocknet. Die Feuchte der Beschichtung liegt nach dem Trocknungsprozess bei ca. 6 Gew%.A mixture of melamine resin (solids content: 60% by weight), cellulose and corundum in an amount of 50-80 g impregnating resin / m 2, depending on the desired wear class, is then also applied to the decorative paper in the roll application. The mixture is dried in a convection dryer or by near infrared. The moisture of the coating is about 6% by weight after the drying process.

Anschließend wird ein harzimprägniertes Schutzoverlay aufgelegt (Papiergrammatur: 25 g/m2 Endgewicht: 100g/m2). Danach wird die Beschichtung in einer KT-Presse oder in einer kontinuierlich arbeitenden Presse durchgehärtet (p= 30 Bar, T= 200°C), wobei auf der Rückseite entweder ein harzimprägnierter Gegenzug oder eine im Flüssigverfahren aufgetragene Harzschicht mit ausgehärtet werden.Subsequently, a resin-impregnated protective overlay is applied (paper grammage: 25 g / m 2 final weight: 100 g / m 2 ). Thereafter, the coating is through-hardened in a KT press or in a continuously operating press (p = 30 bar, T = 200 ° C.), with either a resin-impregnated counter-coating or a resin-applied resin layer being cured on the reverse side.

Ausführungsbeispiel 3 (Vergleichsbeispiel)Embodiment 3 (Comparative Example)

Auf eine HDF-Platte wird ein vollständig harzimprägniertes Dekorpapier ( Harzauftrag: 100 Gew% ) und ein harzimprägniertes Overlay (Papiergewicht: 30 g/m2, Endgewicht: 150 g/ m2) aufgelegt. In der Harzrezeptur, die für die Imprägnierung des Overlays verwendet wurde befand sich Korund als verschleisshemmendes Mittel. Als Gegenzug wird ein Recyclingpapier (Papiergewicht: 100 g/m2, Harzauftrag: 120 Gew% ) eingesetzt. Der gesamte Aufbau wird in einer KT-Presse bei 30 bar und 200°c verpresst.On a HDF board, a completely resin-impregnated decor paper (resin application: 100% by weight) and a resin-impregnated overlay (paper weight: 30 g / m 2 , final weight: 150 g / m 2 ) is placed. In the resin formulation used to impregnate the overlay, corundum was a wear-inhibiting agent. In return, a recycled paper (paper weight: 100 g / m 2 , resin application: 120% by weight) is used. The entire assembly is pressed in a KT press at 30 bar and 200 ° c.

Ausführungsbeispiel 4 (Vergleichsbeispiel)Embodiment 4 (Comparative Example)

Ein Strang aus HDF-Platten wird kontinuierlich mit einem Tränkharz auf Basis Melamin im Walzenauftrag beschichtet. Dabei werden 100 g Melaminharz / m2 aufgetragen (Feststoffgehalt: 60 Gew% ). Die Tränkharzrezeptur enthält die üblichen Hilfsstoffe wie Härter, Netz- und Trennmittel.A strand of HDF boards is continuously coated with an impregnating resin based on melamine in roll application. 100 g of melamine resin / m 2 are applied (solids content: 60% by weight). The Tränkharzrezeptur contains the usual auxiliary materials such as hardener, wetting and release agent.

Das Tränkharz wird nach dem Auftrag mit Hilfe von einem Konvektionstrockner oder NIR vorgetrocknet um einen Teil des Wassers zu verdunsten. Allerdings muss der Trockenprozess nur bis zu dem Punkt geführt werden, bei dem das Harz seine Klebrigkeit bzw. die Möglichkeit der Penetration in ein Papier behält.The impregnating resin is pre-dried after application with the help of a convection dryer or NIR to evaporate a part of the water. However, the drying process need only be conducted to the point where the resin retains its stickiness or penetration into a paper.

Ein trockenes Dekorpapier (Papiergewicht: 80 g/m2) wird von einer Abrollvorrichtung abgerollt und in das noch fließfähige Harz eingewalzt. Dabei ist durch mehrere auf der Oberseite hintereinander angeordneten Walzen sicherzustellen, dass keine Falten oder Welligkeiten im Papier entstehen.A dry decorative paper (paper weight: 80 g / m 2 ) is unrolled by a rolling device and rolled into the still flowable resin. It is ensured by several on the top of successively arranged rollers that no wrinkles or ripples occur in the paper.

Dann wird das Papier in einer kontinuierlich arbeitenden Presse auf die mit Melaminharz vorbeschichtete Platte aufgepresst. Auf das Dekorpapier wird anschließend ebenfalls im Walzenauftrag ein Gemisch aus Melaminharz (Feststoffgehalt Tränkharz: 60 Gew%), Zellulose und Korund in einer Menge von 50 - 80 g Tränkharz / m2 - je nach gewünschter Verschleißklasse - aufgebracht. Das Gemisch wird in einem Konvektionstrockner oder durch Nahinfrarot getrocknet. Die Feuchte der Beschichtung liegt nach dem Trocknungsprozess bei ca. 6 Gew%.The paper is then pressed onto the melamine resin precoated plate in a continuous press. A mixture of melamine resin (solids content impregnating resin: 60% by weight), cellulose and corundum in an amount of 50-80 g impregnating resin / m 2 - depending on the desired wear class - is then also applied to the decorative paper in the roll application. The mixture is dried in a convection dryer or by near infrared. The moisture of the coating is about 6% by weight after the drying process.

Anschließend wird ein harzimprägniertes Overlay aufgelegt (Papiergrammatur: 25 g/m2, Endgewicht: 100 g/m2). Danach wird die Beschichtung in einer KT-Presse oder in einer kontinuierlich arbeitenden Presse durchgehärtet (p= 30 Bar, T= 200°C), wobei auf der Rückseite entweder ein harzimprägnierter Gegenzug oder eine im Flüssigverfahren aufgetragene Harzschicht mit ausgehärtet.Subsequently, a resin-impregnated overlay is applied (paper grammage: 25 g / m 2 , final weight: 100 g / m 2 ). Thereafter, the coating is through-hardened in a KT press or in a continuously operating press (p = 30 bar, T = 200 ° C.), with either a resin-impregnated counter-coating or a resin-applied resin layer being cured on the reverse side.

Die Produkte der Ausführungsbeispiele 1 und 2, die gemäß dem erfindungsgemäßen Verfahren unter Verwendung eines teilimprägnierten Dekorpapiers hergestellt wurden, unterscheiden sich bezüglich des Produktes des Ausführungsbeispiels 3, das unter Verwendung eines vollständig imprägnierten Dekorpapiers hergestellt wird, dahingehend, dass sie sich im Hinblick auf ihre Lagerzeit deutlich günstiger verhalten. Ein vollständig imprägniertes Papier muss innerhalb weniger Monate verarbeitet werden. Die teilimprägnierten Papiere sind noch nach einem Jahr einsetzbar.The products of Embodiments 1 and 2 made according to the method of the present invention using a partially impregnated decorative paper differ in the product of Embodiment 3 made using a fully impregnated decorative paper in that they are in terms of their storage time significantly better behavior. A fully impregnated paper must be processed within a few months. The partially impregnated papers can still be used after one year.

Auch tritt bei der Verarbeitung von Rolle zu Rolle bzw. von der Rolle weniger Verschnitt und Materialverlust auf.Also occurs in the processing of roll to roll or by the role of less waste and material loss.

In Bezug auf das Produkt des Ausführungsbeispiels 4 hergestellt mit einem trockenen Dekorpapier ist festzustellen, dass eine erfindungsgemäße einseitige Imprägnierung in einem Imprägnierkanal deutlich einfacher zu bewerkstelligen ist, als das "Einpressen" von Leim in die Rückseite eines Papieres, wie im Falle des trockenen Dekorpapiers. Dies wird durch die verschiedensten Parameter erschwert (Dichte des Papieres, Pigmentgehalt usw.). Zudem steht für den Imprägnierprozess im Vergleich zu dem Einpressen auch deutlich mehr Zeit zur Verfügung, was den Prozess unkritischer macht.With respect to the product of Embodiment 4 made with a dry decorative paper, it is noted that a unilateral impregnation according to the invention in a impregnation channel is much easier to accomplish than the "pressing in" of glue into the backside of a paper, as in the case of the dry decorative paper. This is made difficult by the various parameters (density of the paper, pigment content, etc.). In addition, there is significantly more time available for the impregnation process compared to pressing, which makes the process less critical.

Claims (15)

  1. Method for producing a board of wood-based material, consisting of a base board and of a decorative paper disposed on the base board, comprising the steps of
    a) providing the decorative paper,
    b) applying at least one resin as impregnating agent solely to the side of the decorative paper opposite from the decoration, for provision of a solely single-sidedly impregnated decorative paper, where the amount of resin applied is between 30% and 70%, based on the paper weight of the decorative paper, and where the impregnating agent used is a melamine-formaldehyde resin, melamine-phenolformaldehyde resin, a melamine-urea resin, a polyurethane resin or an acrylate resin having a solids content of between 30% to 50%,
    c) providing the base board,
    d) applying at least one layer of at least one impregnating resin to at least one side of the base board, and
    e) placing the decorative paper with the impregnated side opposite from the decoration onto the side of the base board provided with the impregnating resin.
  2. Method according to Claim 1, characterized in that the decorative paper impregnated on the side opposite from the decoration is dried to a moisture content of 3-10 wt%, preferably 5-7 wt%, especially preferably of 6 wt%.
  3. Method according to Claim 1 or 2, characterized in that the amount of liquid resin applied to the side of the decorative paper opposite from the decoration is between 40% and 60%, preferably 50%, based on the paper weight of the decorative paper.
  4. Method according to any of the preceding claims, characterized in that the decorative paper impregnated on the side opposite from the decoration exhibits a swelling in the length in a range between 0.2% and 0.4% and in the width in a range between 0.5% to 0.9%.
  5. Method according to any of the preceding claims, characterized in that the decorative paper impregnated on the side opposite from the decoration is rolled up before being placed onto the base board.
  6. Method according to any of Claims 1 to 4, characterized in that the decorative paper impregnated on the side opposite from the decoration is placed onto the base board immediately following the impregnation.
  7. Method according to any of the preceding claims, characterized in that the impregnating agent is a melamine-formaldehyde resin, melamine-phenolformaldehyde resin, a melamine-urea resin, a polyurethane resin or an acrylate resin having a solids content of between 40% to 50%, preferably of 50%.
  8. Method according to any of the preceding claims, characterized in that the impregnating resin for application to the at least one side of the base board is a melamine-formaldehyde resin, melamine-phenol-formaldehyde resin, a melamine-urea resin, a polyurethane resin or an acrylate resin having a solids content of between 55% to 80%, preferably 60% to 70%, especially preferably of 60%.
  9. Method according to any of the preceding claims, characterized in that following the placement of the decorative paper, impregnated on the side opposite from the decoration, onto the base board, in a further step f) at least one further layer of a resin is applied to the top face of the decorative paper.
  10. Method according to Claim 9, characterized in that the resin for application to the decorative paper further comprises natural and/or synthetic fibres, abrasion-resistant particles and optionally further additives.
  11. Method according to Claim, 9, characterized in that after interim drying, at least one further application of a mixture of liquid resin, natural and/or synthetic fibres, abrasion-resistant particles and optionally further additives takes place or at least one overlay is applied, more particularly a resin-impregnated overlay.
  12. Method according to any of Claims 1 to 8, characterized in that after the placement of the decorative paper, impregnated on the side opposite from the decoration, onto the base board, in a further step f1) at least one overlay is applied, more particularly a resin-impregnated overlay.
  13. Method according to any of the preceding claims, characterized in that at least one backing is applied to the opposite side of the base board, not provided with the decorative paper.
  14. Method according to any of the preceding claims, characterized in that in a further step g) the layer system composed of base board, decorative paper and optionally further resin layers is compressed.
  15. Method according to any of the preceding claims, characterized in that the base board is made of a wood-based material or of a wood-based material/plastic mixture, and more particularly is a chipboard, medium-density fibreboard (MDF), high-density fibreboard (HDF) or oriented strand board (OSB) or plywood board.
EP12196717.8A 2012-12-12 2012-12-12 Method for the manufacture of a board provided with a decorative layer Active EP2743094B1 (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
PL12196717T PL2743094T3 (en) 2012-12-12 2012-12-12 Method for the manufacture of a board provided with a decorative layer
EP12196717.8A EP2743094B1 (en) 2012-12-12 2012-12-12 Method for the manufacture of a board provided with a decorative layer
ES12196717.8T ES2543154T3 (en) 2012-12-12 2012-12-12 Procedure for manufacturing a material plate provided with a decorative layer
CN201380065276.1A CN104870203B (en) 2012-12-12 2013-12-12 Method for manufacturing the plate of material provided with decorative layer
EP13811849.2A EP2931527B1 (en) 2012-12-12 2013-12-12 Method for the manufacture of a board provided with a decorative layer
BR112015012286A BR112015012286A2 (en) 2012-12-12 2013-12-12 process for producing a sheet of material with a decorative layer
PCT/EP2013/076366 WO2014090939A1 (en) 2012-12-12 2013-12-12 Method for producing a material plate provided with a decorative layer
RU2015126253A RU2612647C9 (en) 2012-12-12 2013-12-12 Method of wood board production, provided with decorative layer
UAA201506479A UA111565C2 (en) 2012-12-12 2013-12-12 Method for producing wood plate, provided with decorative layer
CA2893820A CA2893820C (en) 2012-12-12 2013-12-12 Method for producing a wood-based board provided with a decorative layer
US14/651,280 US9757974B2 (en) 2012-12-12 2013-12-12 Method for producing a material plate provided with a decorative layer
ES13811849T ES2856879T3 (en) 2012-12-12 2013-12-12 Procedure for the manufacture of a material plate with a decorative layer
PL13811849T PL2931527T3 (en) 2012-12-12 2013-12-12 Method for the manufacture of a board provided with a decorative layer

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP12196717.8A EP2743094B1 (en) 2012-12-12 2012-12-12 Method for the manufacture of a board provided with a decorative layer

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EP2743094B1 true EP2743094B1 (en) 2015-06-03

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EP (2) EP2743094B1 (en)
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CA (1) CA2893820C (en)
ES (2) ES2543154T3 (en)
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PL2743094T3 (en) 2016-01-29
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US9757974B2 (en) 2017-09-12
EP2743094A1 (en) 2014-06-18
CA2893820C (en) 2018-06-12
ES2543154T3 (en) 2015-08-17
US20150314639A1 (en) 2015-11-05
UA111565C2 (en) 2016-05-10
ES2856879T3 (en) 2021-09-28
EP2931527A1 (en) 2015-10-21
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CN104870203A (en) 2015-08-26
WO2014090939A1 (en) 2014-06-19
RU2015126253A (en) 2017-01-18

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