RU2792211C1 - Method for obtaining matted base material with an anti-fingerprint coating - Google Patents

Abstract

FIELD: manufacture of floor coverings, furniture; materials for wall and ceiling cladding.

SUBSTANCE: method for producing a base material provided with a frosted anti-fingerprint coating includes applying a layer of powdered formaldehyde resin to at least one side of the base material and melting it. Then, a dispersion material containing acrylate is applied to the melted formaldehyde resin layer. The resulting layered structure is dried and cured. The base material is a layer of paper or a board based on wood material. A layer of paper and a plate are also proposed.

EFFECT: group of inventions makes it possible to reduce the gloss level of the material and increase its wear resistance.

25 cl, 5 dwg

Description

The present invention relates to a method for producing a matt base material provided with an anti-fingerprint coating, in particular a patterned wood based board or paper layer.

The use of wood-based boards in the furniture industry as floor coverings or also for wall and ceiling cladding requires surface treatment or improvement of the wood-based boards. For these applications, wood-based boards are usually covered with impregnated decorative paper. There is no limit to the variety of decorative papers with different patterns, so wood-based boards can be purchased in many different patterns, such as stone or wood patterns. To increase the resistance to abrasion, decorative overlays are applied to the decorative paper. Decorative overlays are thin transparent paper, which, as a rule, is already impregnated with melamine resin. It is also possible to obtain decorative caps in which already wear-resistant particles, such as for example corundum particles, are mixed with the resin of the trim to increase the wear resistance of the wood-based laminate or board.

As an alternative to the use of decorative paper on wood-based boards, direct printing on wood-based boards was developed in the past, so printing on paper and further laminating or directly coating the wood-based board is no longer required.

The direct-printed pattern is then coated with several layers of liquid thermosetting resin, which may contain wear-resistant particles to improve abrasion resistance. Such a layer of thermosetting resin is also referred to as a liquid decorative overlay. The thermosetting resin is preferably a formaldehyde-containing resin, in particular a melamine-formaldehyde resin and/or a melamine-urea-formaldehyde resin. The method for producing the described layer of liquid decorative overlay is described, inter alia, in EP 2338693 A1. Here, after cleaning the surface of the wood-based board, the first top resin layer containing particles of corundum is applied to the wood-based board, drying this first resin layer, for example, to a residual moisture content of 6 to 10%, then applying the second resin layer, containing cellulose fibers on a board based on wood material, re-drying or drying the second layer of resin, for example, to a residual moisture content of 6 to 10%, applying at least one third layer of resin containing glass particles on a board based on wood material followed by drying the third resin layer, for example also to a residual moisture content of 4 to 8%, and finally pressing the layered structure under pressure and temperature. Thanks to the use of a liquid decorative overlay, the usually provided overlay paper can be dispensed with. The liquid decorative overlay can be applied to both the top side and the bottom side of the wood-based board.

The disadvantages of using a liquid decorative overlay are the equipment costs and associated space requirements. In particular, the drying steps after each resin application require the use of convection dryers and the necessary exhaust air treatment.

In addition to the issue of providing a layer of resin, the issue of surface design and surface structure of these products is also important. This is especially true when using printed wood-based boards for interior decoration, such as furniture, the surfaces of which are subjected to heavy loads when touched, cleaned, etc. In this case, it is often evaluated especially negatively if the surface design and lighting conditions make it possible to obtain a particularly good visual assessment. A very accurate example of this is glossy fronts in kitchens. In this case, especially on these facades, fingerprints can often be seen when touched. In this case, this applies especially to melamine surfaces. They seem to be particularly prone to leaving fingerprints when touched. The persistence of fingerprints means that surfaces need to be cleaned frequently, which is by no means desirable. With regard to melamine-based surfaces, it should be noted that they have a very high mechanical and chemical resistance, which gives them significant advantages over thermoplastic films or varnishes. In addition, by etching the pressing plate, which is used in the production of melamine resin-coated wood-based boards, almost any surface design can be obtained. As already noted, surface finish is an important aspect of a product. As with almost all products, it depends on fashion trends. A few years ago, gloss was very popular for many products, but now people are more interested in matte surfaces. Of course, on these surfaces, fingerprints after touching are undesirable or considered a disadvantage.

Thus, the present invention is based on the technical problem of providing surfaces that have a low degree of gloss and at the same time are clearly resistant to the visibility of fingerprints. At the same time, this product must be produced in a space-saving and cost-effective way. High wear values, in particular wear classes AC4 to AC6, must also be achieved with at the same time low abrasion of the pressing plate.

The problem is solved in accordance with the present invention by means of a method with the features specified in paragraph 1 of the claims.

Accordingly, a method is provided for producing a patterned wood based board, the method comprising the following steps:

- applying at least one layer of at least one powdered resin on at least one side of the base material;

- melting at least one deposited layer of powdered resin;

- applying at least one dispersion material containing acrylate to the melted resin layer and

- drying and curing of the layered structure.

Accordingly, a multi-step process is provided in which a resin powder, such as melamine resin powder, is first applied to a base material, such as a layer of paper or a wood-based board, and thickened or melted. Thereafter, the acrylate-based dispersion material, for example using a slotted nozzle, is applied, dried and then cured onto the surface, for example using an excimer emitter. This impregnated paper or this coated wood based board can then be pressed in a short cycle press.

The method according to the present invention provides various advantages. In this way, a matt surface with gloss units less than 10, preferably less than 8, particularly preferably less than 5 can be obtained. The treated surface has anti-fingerprint properties and requires minimal cleaning effort compared to conventional surfaces.

In addition, there is provided a method for producing boards based on wood material, in which the use of liquid resin for a layered structure is abandoned, and resin powder is used instead. By replacing the resin powder with the liquid resin that is commonly used, the costly drying required for liquid overlays is eliminated, reducing system cost, exhaust air problems, and space requirements. In general, the method according to the present invention provides a more flexible technology.

In one embodiment of the method according to the present invention, it is provided that the acrylate-based dispersion material contains radiation-curable varnishes containing acrylate. Such radiation-curable varnishes can be (meth)acrylates such as, for example, polyester(meth)acrylate, polyether(meth)acrylate, epoxy(meth)acrylate or urethane(meth)acrylate. It is also possible that the acrylate or acrylate-containing lacquer used is present in substituted or unsubstituted monomers, oligomers and/or polymers, in particular in the form of monomers, oligomers or polymers of acrylic acid, acrylic ether and/or acrylic acid ester. The presence, as determined, of a double bond or an unsaturated group in the acrylate molecule is important for the method according to the present invention. Polyacrylates can also be further functionalized. Suitable functional groups include, but are not limited to, hydroxyl, amino, epoxy and/or carboxyl groups. As already mentioned, these acrylates provide crosslinking in the presence of UV rays or electron beams during curing or drying.

The amount of applied dispersion material containing acrylate is from 30 to 50 fl/m ² , preferably from 30 to 40 fl/m ² . The solids content of the acrylate-containing dispersion material is 40 to 60% by weight, preferably 50% by weight.

The at least one acrylate-containing dispersion material is first dried after application, for example with an IR emitter and then with a UV emitter at wavelengths from 120 to 350 nm, preferably from 150 to 250 nm, particularly preferably from 170 to 200 nm (eg 172 nm), cured under the influence of an inert gas. In this case, it is preferable to cure not the entire acrylate layer, but only a layer of 0.1-0.5 nm. This corresponds to approximately 1 mg/m.

Possible inert gases are nitrogen, argon, krypton, fluorine, xenon, KrCl, ArF, KRF, XeBr, XeCl, XeF, the use of nitrogen being particularly preferred.

In yet another embodiment of the method according to the present invention, at least one base material is in the form of a paper ply, preferably a decorative paper ply or an overlay paper ply.

If a layer of paper is used as the base material, the method according to the present invention includes the following steps:

applying at least one first layer of at least one powdered resin to at least one side of the paper layer and melting at least one applied layer of powdered resin;

- applying at least one dispersion material containing acrylate to the melted resin layer and

- drying and curing of the layered structure.

The paper layer thus coated, such as a decorative paper layer or an overlay paper layer, has a gloss level of less than 10, preferably less than 8, particularly preferably less than 5, and can be pressed with a support board, for example a wood based board such as MDF or HDF.

In another embodiment, the base material is a wood based board, preferably medium density fibreboard (MDF), high density fibreboard (HDF) or oriented strand board (OSB), glulam or wood plastic board. Composite (WPC) or Rock Plastic Composite (SPC) board.

In an additional embodiment, the method according to the present invention includes the following steps:

- applying at least one first layer of at least one powdered resin to at least one side of the base material, in particular board based on wood material, and melting at least one applied layer of powdered resin;

- applying at least one decorative layer to at least one melted resin layer by means of a direct printing method;

applying at least one additional second layer of at least one powdered resin to at least one decorative printed layer;

- melting at least one layer deposited on the decorative layer of powdered resin;

- applying at least one dispersion material containing acrylate to the melted resin layer and

- drying and curing of the layered structure.

In one embodiment of the process according to the present invention, the resin powder is applied in an amount of 10 to 100 g/m ² , preferably 20 to 80 g/m ² , particularly preferably 25 to 70 g/m ^{2 ,} to the base material. This resin powder application amount essentially refers to all layers of resin powder to be applied, whereby they can be adapted in each case. The distribution density is chosen in such a way that opaque layers are formed in each case.

The particle size of the powdered resin is 20 to 100 µm, preferably 40 to 80 µm.

In yet another embodiment of the method according to the present invention, the applied resin powder is a formaldehyde resin, preferably a urea resin or a melamine resin, particularly preferably a melamine-formaldehyde resin. It is preferable to use melamine resin or urea resin for the first resin layer. Preferably only melamine resin is used in the top layers.

"Melting" or "thickening" in the context of this application means that the resin layer is not yet completely polymerized, but rather polymerization is stopped at an intermediate stage, at which further crosslinking or polymerization is still possible at a later point in processing. Therefore, the meaning of "thickening" is usually based on the fact that at a later point in time, additional functional layers must be applied to the already applied protective layer, otherwise the product will be ready only in further processing steps.

Other substances may also be added to the melamine resin powder. It is particularly advantageous here that also because of, for example, effects that affect salting out, thickening, settling, etc., substances can be used that are poorly compatible with the liquid melamine resin. In this case, these can be salts to increase electrical conductivity, organic or inorganic flame retardants, cellulose derivatives, radical scavengers, pigments, UV radiation absorbers, etc.

Accordingly, the resin powder used may contain additive substances such as pigments, electrically conductive substances and cellulose.

When colored pigments are added, the melted resin powder layer can simultaneously serve as a white primer layer for a decorative layer that will subsequently be printed. White pigments such as titanium dioxide (TiO ₂ ) can be used as color pigments. Other color pigments may be calcium carbonate, barium sulfate or barium carbonate. The proportion of colored pigments can be up to 50% by weight of the total powder.

The addition of colored pigments to the first layer of resin powder increases hiding power so that it can be used as a (sole) base or ground coat for a subsequent decorative layer.

The amount of cellulosic fibers that are applied with the resin powder may be from 0.1 to 1 wt.%, preferably from 0.5 to 0.8 wt.% (based on the applied amount of resin) or in the range of 0.1-0 .5 g/m ² , preferably 0.2-0.4 g/m ² , particularly preferably 0.25 g/m ² . Preferably, the cellulose fibers used are colorless and are in the form of a fine or granular, slightly hygroscopic powder.

The electrically conductive materials may be selected from the group consisting of carbon black, carbon fibers, metal powder and nanoparticles, in particular carbon nanotubes. Combinations of these substances can also be used.

The resins used contain preferably in each case additives such as curing agents, wetting agents (surfactants or mixtures thereof), release agents and/or other components.

In a preferred embodiment, the resin powder is applied by means of an electrostatic charge. The application can also be carried out by applying the powder after the tribostatic method. In this case, the applied powder is charged as a result of friction.

The melting of the deposited resin powder layer can take place using an IR emitter, or also microwave systems or the like. The use of IR emitters is particularly preferred.

In one embodiment, the surface of the base material, in particular in the case of wood-based board, may be pre-treated prior to printing to improve the adhesion of subsequent layers. This may be brushing, grinding, which also removes surface irregularities, and/or plasma or corona treatment.

In a preferred embodiment, in the next step, at least one primer coat is applied to the (first) melted layer of resin powder to increase the covering power of the paint.

The ground coat preferably contains casein, corn starch or soy protein and may contain inorganic color pigments and thus serve as a ground coat layer for a decorative layer which will subsequently be printed.

White pigments such as titanium dioxide (TiO ₂ ) can in turn be used as color pigments. Additional color pigments can be calcium carbonate, barium sulfate or barium carbonate, as well as iron oxide pigments (for a brownish primer). In addition to color pigments and casein, corn starch or soy protein, the primer may also contain water as a solvent.

The amount of liquid primer applied can be from 10 to 50 g/m ² , preferably from 15 to 30 g/m ² , particularly preferably from 20 to 25 g/m ² .

It is also possible that the ground coat consists of at least one, preferably of at least two or more layers or coatings applied one after the other (for example, up to five coatings), while the number of applications between layers or coatings is the same or different, i.e. the amount of application for each individual layer may vary.

The primer coat can be applied using a roller to a base material, such as wood-based board, followed by drying. It is also possible to apply a ground coat to the base material using digital printing. Digital ink liquid inks used for groundcoat digital printing are preferably based on liquid UV inks enriched with white pigments. However, it is also possible to use water-based liquid inks for digital printing or so-called hybrid liquid inks. Application using digital printing is preferred because the printing system is much shorter than a roller device and thus saves space, energy and costs.

In yet another embodiment of the method according to the present invention, a primer coat is applied to the primer coat, preferably as a single application followed by drying. The primer layer is particularly useful in the case of the subsequent gravure printing process (using rollers), while it is not necessarily necessary in the digital printing process process.

The amount of liquid primer applied is 10 to 30 g/m ² , preferably 15 to 20 g/m ² . As a primer, it is preferable to use compounds based on polyurethane.

Gravure printing and digital printing methods are preferably used as direct printing methods for printing wood-based boards. The gravure printing method is a printing technology in which elements to be displayed are present as recesses in a printing plate and colored before printing. The printing ink resides mainly in the depressions and is transferred to the printed object, such as, for example, the base material, as a result of the pressing pressure of the printing plate and adhesive forces. When using indirect gravure printing, multiple pressure rollers are used.

In a particularly preferred embodiment, at least one pattern is applied to the base material (surfaced and pre-coated) using a digital printing process. With digital printing, the printed image is transferred directly from a computer to a printing machine such as a laser printer or an inkjet printer. In this case, the use of a static printing form is not necessary. The pattern is printed according to the principle of inkjet printing in one pass, in which the entire width of the upper printed side is covered, while the plates are moved under the printing device. However, it is also possible for the base plate to be printed to be stopped under the printer and for it to pass over the surface at least once during printing.

Printing inks are combined in separate rows of printheads, and each color may have one or two rows of printheads. Liquid ink colors for digital printing are, for example, black, blue, red, tan, greenish yellow, optionally the CMYK color model can also be used. Liquid inks for digital printing are not necessarily based on the same pigments used for analog and/or digital printing with water-based liquid inks. Liquid inks for digital printing are preferably based on liquid UV inks. However, it is also possible to use water-based liquid inks for digital printing or so-called hybrid liquid inks. After printing, the decorative print is dried and/or irradiated.

Printing inks are applied in an amount of 1 to 30 g/m ² , preferably 3 to 20 g/m ² , particularly preferably 3 to 15 g/m ² .

Along with the pattern, the marks necessary for orientation in the press are also applied.

The additional layer of powdered resin deposited and melted on the decorative layer preferably contains a powder based on formaldehyde resin, particularly preferably melamine-formaldehyde resin. The application amount of the resin powder in this step is 10 to 50 g/m ² , preferably 20 to 40 g/m ² .

As mentioned above, additives such as electrically conductive substances or cellulose and additives such as hardeners, wetting agents or release agents can also be added to the resin powder at this stage of the process.

Melting or thickening in this case also takes place preferably using an IR emitter.

After this process step, the printed base material can be sent to intermediate storage. The applied and melted layer of resin powder serves in this case as a protective layer, which, on the one hand, serves to protect the printed surface in the event of intermediate storage, and on the other hand (due to the not yet completely hardened resin layer) allows additional processing. . Particularly in the case of complex machining processes, it is necessary to separate certain work steps for reasons of cost, technology, etc. For example, related product lines can vary greatly in terms of their performance. Then you need to form a buffer warehouse in which the materials are stacked on top of each other. In addition, several cycles may be required on the production line, since the amount of application, etc. cannot be realized in one cycle. In all these cases, dried or hardened surfaces are preferred, since on the one hand they provide protection for the printed surface in case of intermediate storage and, on the other hand, additional processing.

In a further embodiment, the wear resistant particles are uniformly distributed on the decorative layer or on the resin powder layer deposited on the decorative layer.

Corundum (aluminum oxide), boron carbide, silicon dioxide, silicon carbide particles can be used as wear-resistant particles. Corundum particles are especially preferred. In this case, it is preferably high quality electrocorundum (white) with a high degree of transparency, so that the visual effect of the underlying pattern is adversely affected as little as possible. Corundum has an uneven spatial shape.

The amount of wear particles distributed is 7 to 50 g/m ² , preferably 10 to 30 g/m ² , particularly preferably 15 to 25 g/m ² . The amount of wear particles distributed depends on the wear class to be achieved and the grain size. Thus, the amount of wear-resistant particles in the case of wear class AC3 is in the range from 10 to 15 g/m ² , in the case of wear class AC4 from 15 to 20 g/m ² and in the case of wear class AC5 from 20 to 35 g/m ² when using grit size F200. In the present case, the finished boards preferably have wear class AC4.

Use wear-resistant particles with grit classes F180-F240, preferably F200. The grain size of class F180 is in the range of 53-90 µm, F220 - 45-75 µm, F230 - 34-82 µm, F240 - 28-70 µm (according to the FEPA standard). In one embodiment, premium white fused aluminum oxide F180-F240 is used as wear resistant particles, preferably with a main grain size range of 53-90 μm. In a particularly preferred embodiment, corundum grade F180-220 particles are used.

The wear-resistant particles must not be too fine (danger of dust formation) but also not too coarse. Therefore, the size of wear-resistant particles is adaptive.

In the following embodiment, silanized corundum particles can be used. Typical silanizing agents are aminosilanes.

In a further embodiment of the method according to the present invention, at least one third layer of at least one powdered resin is applied, in particular on the layer of wear-resistant particles. This layer serves as a separating layer to enclose wear resistant particles.

The layer of powdered resin deposited and melted in this step, in particular on the wear-resistant particles, preferably contains a powder based on formaldehyde resin, particularly preferably melamine-formaldehyde resin. The application amount of the resin powder in this step is 10 to 50 g/m ² , preferably 20 to 40 g/m ² .

As mentioned above, additives such as electrically conductive substances or cellulose and additives such as hardeners, wetting agents or release agents can also be added to the resin powder at this stage of the process.

Melting or thickening in this case also takes place preferably using an IR emitter.

In a further embodiment of the method according to the present invention, the glass beads are distributed, in particular, on at least one third subfused resin powder layer. The glass beads serve as a separator between the wear particles and the subsequent pressing plate. In this way, wear of the insert can be at least partially reduced.

Preferably the glass beads used have a diameter of 60-120 µm, preferably 80-90 µm. The diameter of the glass beads corresponds to the average size of the applied wear particles in order to provide optimal enclosing for the subsequent pressing plate. Therefore, in the case of corundum F220, glass beads with a diameter of 70-90 µm are used, and in the case of corundum F180, glass beads with a diameter of 80-120 µm are used.

The amount of glass beads is 5 to 30 g/m ² , preferably 8 to 20 g/m ² , particularly preferably 8 to 15 g/m ² .

The glass beads may also be present in silanized form. By silanizing the glass beads, the pressing of the glass beads into the resin matrix is improved.

In a further embodiment of the method according to the present invention, at least one additional, for example, a fourth layer of at least one powdered resin is applied, in particular, to a layer of glass beads. This layer serves to enclose the glass beads and as a finishing layer.

The additional fourth layer of powdered resin deposited and melted in this step, in particular on glass beads, preferably contains powder based on formaldehyde resin, particularly preferably melamine-formaldehyde resin. The application amount of the resin powder in this step is 10 to 50 g/m ² , preferably 20 to 40 g/m ² .

As mentioned above, additives such as electrically conductive substances or cellulose and additives such as hardeners, wetting agents or release agents can also be added to the resin powder at this stage of the process.

Melting or thickening in this case also takes place preferably using an IR emitter.

In yet another embodiment of the method according to the present invention, the laminar structure is pressed in a short cycle press (KT press). The pressing step takes place under pressure and a temperature of 180 to 250°C, preferably 200 to 230°C, particularly preferably at a temperature of 200°C and a pressure of 30 to 60 kg/cm ² , particularly preferably 40 to 50 kg/cm ² . The pressing time is 8 to 30 seconds, preferably 10 to 25 seconds.

Preferably, the coated base material, such as the coated wood based board in the short cycle press, is oriented relative to the structured press plate in the short cycle press, depending on the marks on the wood based board, thus obtaining pattern matching on a board based on wood material and an embossed structure of a pressing plate. This provides a structure that matches the pattern. During pressing, the layers of melamine resin are melted and the laminate is formed during the condensation reaction with the inclusion of components such as corundum/glass/fibers.

On the underside of the wood-based board, a stabilizing layer can be applied, for example, from several layers of resin, without additives or a paper stabilizing layer. This ensures that the tensile forces on the wood-based board created by the applied layers during pressing cancel each other out. The stabilizing layer applied to the bottom side corresponds to the layered structure and the corresponding layer thickness approximately corresponds to the sequence of layers applied to the top side, but without the addition of additives, wear particles or glass beads. The impregnated layer can also be used as a stabilizing layer.

In a preferred first embodiment, the method according to the present invention includes the following steps:

applying at least one first layer of at least one powdered resin to at least one side of the wood-based board and melting the at least one applied layer of powdered resin;

- applying at least one primer coating on the first sub-melted layer of resin powder;

- applying at least one primer layer to at least one primer coat;

- applying at least one decorative layer by means of a direct printing method;

- distribution of wear-resistant particles;

- applying at least one additional layer of at least one powdered resin on at least one layer of wear-resistant particles and melting the applied layer of powdered resin;

- applying, drying and curing at least one dispersion material containing acrylate on the melted resin layer and

- pressing a layered structure.

In a preferred further embodiment, the method according to the present invention includes the following steps:

applying at least one first layer of at least one powdered resin to at least one side of the wood-based board and melting the at least one applied layer of powdered resin;

- applying at least one primer coating on the first sub-melted layer of resin powder;

- applying at least one primer layer to at least one primer coat;

- applying at least one decorative layer by means of a direct printing method;

applying at least one second layer of at least one resin powder to at least one printed decorative layer and melting at least one second layer of resin powder applied to the decorative layer;

- distribution of wear-resistant particles;

- applying at least one additional third layer of at least one powdered resin on at least one layer of wear-resistant particles and melting the applied third layer of powdered resin;

- the distribution of glass beads on at least one third subfused layer of resin powder;

- applying at least one additional fourth layer of at least one powdered resin to the layer of glass beads and melting the applied fourth layer of powdered resin;

- applying, drying and curing at least one dispersion material containing acrylate on the melted resin layer and

- pressing a layered structure.

Thus, the method according to the present invention makes it possible to obtain an abrasion-resistant, decorative-layered and frosted wood-based board with a resin structure with wear-resistant particles. The wood based board according to the invention has a gloss level of less than 10, preferably less than 8, particularly preferably less than 5, for example from 3.4 or 3.8 gloss units.

The wood-based board comprises at least one decorative layer on the top side and a resin multilayer structure containing wear-resistant particles, optionally cellulose fibers and glass beads, the resin multilayer structure having an entire layer thickness of 60 to 200 µm, preferably 90 to 150 µm, particularly preferably 100 to 120 µm.

In one embodiment, the method according to the present invention makes it possible to obtain a wood based wear board with the following layered structure (viewed from bottom to top): optionally a stabilizing layer - wood based board - first resin layer of melted resin powder - decorative layer with applied printing - the second resin layer of melted resin powder (protective layer) - cured acrylate layer.

In yet another embodiment, the method according to the present invention makes it possible to obtain a wear-resistant wood based board with the following layer structure (viewed from bottom to top): optional stabilizing layer - wood based board - first resin layer of melted resin powder - ground coating layer - a primer layer - a printed decorative layer - a layer of wear-resistant particles - a second resin layer of melted resin powder (protective layer) - a cured acrylate layer.

In yet another embodiment, the method according to the present invention provides a possibility to obtain a wear resistant wood based board with the following layered structure (viewed from bottom to top): optional stabilizing layer - wood based board - first resin layer of melted resin powder - ground coat layer - primer layer - printed decorative layer - second resin layer of melted resin powder (protective layer) - layer of wear-resistant particles - third layer of resin of melted resin powder (separation layer) - glass beads (separator) - fourth resin layer of melted resin resin powder - cured acrylate layer.

The protective layer serves to cover the pattern and protect the pattern during intermediate storage (layering, storage, transportation). The additional layers of resin on the top side form an overall protective film that protects the finished laminate from wear and provides structuring that matches the pattern.

The production line for carrying out the method according to the present invention contains the following elements:

- at least one application device for applying a layer of resin powder, which may contain fibers, on the upper side of the base material;

- at least one device for melting the first layer of resin powder, in particular an IR emitter;

at least one applicator for applying at least one acrylate-containing dispersion material to the melted resin layer, and

- at least one device for curing the acrylate-containing layer, in particular a UV emitter.

In one preferred embodiment, the production line according to the present invention contains the following elements:

- at least one application device for applying a first layer of resin powder, which may contain fibers, on the top side of the board based on wood material as a base material and at least one device for melting the first layer of resin powder, in particular , IR emitter;

optionally at least one applicator for applying at least one primer coat;

- optionally at least one application device for applying at least one primer layer;

- at least one printing device;

- optionally at least one application device for applying an additional layer of resin powder, and at least one device for melting the layer of resin powder, in particular an IR emitter;

- optionally at least one device for distributing a predetermined amount of wear-resistant particles;

- optionally at least one application device for applying an additional layer of resin powder, and at least one device for melting the layer of resin powder, in particular an IR emitter;

- optionally at least one device for dispensing a predetermined number of glass beads;

- optionally at least one application device for applying an additional layer of resin powder, and at least one device for melting the first layer of resin powder, in particular an IR emitter;

at least one applicator for applying at least one acrylate-containing dispersion material to the melted resin layer, and at least one applicator for drying and curing the acrylate-containing layer, in particular a UV emitter; And

optionally at least one short cycle press.

Tribo guns can be used as devices provided in the production line according to the present invention for applying layers of resin powder.

The dispensing device for wear-resistant particles and glass beads provided in the production line according to the present invention is suitable for dispersing powder, granules, fibers, and contains an oscillating brush system. The distribution device essentially consists of a storage hopper, a rotating structured roller and a scraper. In this case, the amount of applied wear-resistant material is determined by the speed of rotation of the roller. The distributing device preferably comprises a barbed roller.

In addition, in one embodiment of the production line according to the present invention, it is provided that at least one distribution device is surrounded by at least one chamber, which is provided with at least one means for removing dust arising in the chamber, or located in it. The dust removal means can be in the form of a suction device or also in the form of an air blowing device. Air blowing can be provided by means of nozzles that are installed at the inlet and outlet of the plate and force air into the chamber. In addition, they can prevent the creation of an inhomogeneous distribution curtain of wear-resistant material as a result of air movement.

Removal of wear resistant material dust from the switchgear environment is advantageous because, in addition to the obvious health impacts of workers on the production line, fine dust from wear resistant particles is also deposited on other parts of the production line plant and leads to increased attrition. Therefore, the location of the dispensing device in the chamber not only reduces dust pollution and health effects of the production line, but also prevents premature abrasion.

The spreading device is preferably controlled by means of a light curtain, the light curtain being located in the processing direction in front of a roller (spreading roller) provided below the spreading device. Controlling the spreader with a light curtain makes sense, since there are more or less large gaps between the individual boards based on wood-based material, which starts the spreading process as soon as the board is in front of the spreading roller.

In one embodiment of the present distribution device, at least one bin is provided before the spreading roller to catch excess wear-resistant particles (that is, particles that are not distributed on at least one wood based material board, but are distributed rather before the entry of the wood based material board). by means of a feeder under the spreading roller to the falling wear-resistant particles).

In yet another embodiment, the funnel is connected to at least one conveying device and one screening device, while the excess wear-resistant material collected in the hopper is transported by means of the conveying device to the screening device. The cells in the sieve of the screening device correspond to the largest size of the used grains of material in the form of wear-resistant particles (ie, approximately 80-100 microns). Dirt particles and lumpy material (such as lumpy resin or lumpy wear material) are separated from the collected wear material in the screening device, and the screened wear material can be returned back to the distributor (recycled).

As already explained above, it is also envisaged to selectively add the curing agent to the respective applicators or applicators for the different resin layers for the liquid resin. In one embodiment, the production line according to the present invention is equipped for this purpose with at least one dosing unit for adding hardener to each applicator. The hardener is pumped from the at least one dosing unit into the resin receiver and mixed in the resin receiver, for example with a suitable mixer.

The present invention is explained below in more detail with reference to several embodiments.

Embodiment 1

On a production line which operates at a feed rate of 25 m/min, decorative paper (grammage: 80 g/m ² ) was laid down from a roller. In the applicator, the decorative paper was then top coated with 70 g/m ² melamine resin powder using tribo guns. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. The powder was then melted using infrared radiation.

30 fl/m ² acrylate-based dispersion material (solids content: approximately 50% by weight) was then applied to the top using a slotted nozzle. The dispersion material was dried using IR emitters. The surface was then cured using an excimer emitter (172 nm) under the influence of an inert gas (nitrogen).

The impregnated layer was then pressed over the carrier in a short cycle press. On the reverse side, a decorative impregnated layer without an acrylate coating was used. A chipboard 19 mm thick was used as a support. The pressing conditions were: T=200°C, p=40 kg/cm ² and t=16 s. A pressing plate with a handmade paper texture was used.

After pressing, the degree of gloss was determined (according to DIN EN ISO 2813:2015-02, measurement angle: 85°), whereby the value was 3.8 gloss units.

The impregnated layer, which was impregnated without the acrylate coating, gave a gloss value of 12.3 gloss units when measured.

The tester applied as many fingerprints to the surface and control area as possible. Unlike the control area on the surface, this was not possible with the test formulation.

Embodiment 2

An overlay paper (grammage: 30 g/m ² ) was laid from a roller on a production line that was running at a feed speed of 25 m/min. 20 g of corundum/m ² (F230, FEPA standard) were distributed in the distributor. In the applicator, the overlay paper was then top coated with 20 g/m ² melamine resin powder using tribo guns. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. The powder was then melted using infrared radiation.

Then melamine resin powder in the amount of 80 g/m ² was applied to the backside also by means of an applicator, which, in turn, works with tribostatic guns, and thickened with IR emitters. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc.

The acrylate-based dispersion material was then applied to this melamine resin on the underside using a slotted nozzle in an amount of 30 fl/m ² (solids content: approximately 50% by weight). The dispersion material was dried using IR emitters. The surface was then cured using an excimer emitter (172 nm) under the influence of an inert gas.

The impregnated top layer, with the acrylate coating facing upwards, was then pressed against a 7 mm thick HDF in a short cycle press on the decorative impregnated layer on the top side and the stabilizing layer on the bottom side. The pressing conditions were: T=200°C, p=40 kg/cm ² and t=16 s. A pressing plate with a handmade paper texture was used.

After pressing, the degree of gloss was determined (according to DIN EN ISO 2813:2015-02, measurement angle: 85°), whereby the value was 3.8 gloss units. As a reference, pressing with an impregnated top layer, which was obtained without an acrylate coating, gave a value of 12.3 gloss units when determining the degree of gloss.

The tester applied as many fingerprints to the surface and control area as possible. Unlike the control area on the surface, this was not possible with the test composition.

In an abrasion resistance test according to DIN EN 13329, 2016-08, strength class 32 was found.

Embodiment 3

On the production line, HDF with a thickness of 8 mm was separated, dusted with brushes, and then transported by roller conveyors (feeding system: 30 m/min). In the applicator, they were then coated with 25 g/m ² melamine resin powder using tribostatic guns. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. The powder was then melted using infrared radiation.

The primed slab was then repeatedly coated with a colored primer followed by intermediate drying (circulating air). The colored ground coat was a mixture of casein and pigment (titanium dioxide). The amount of application per application was approximately 5 fl/m ² . Application was repeated at least five times. Then there was the application of the primer (amount of application: 10-20 fl/m ² ) with drying by circulating air. The board was then printed using rollers or a digital printer. The amount of paint application was from 3 to 15 fl/m ² . The paint was dried by means of IR radiation or circulating air. Corundum was dispensed onto the impression using a dispenser (application amount: 20 g corundum/m ² , F230, FEPA standard). Then, the melamine resin powder was applied again with a tribo gun (application amount: 60 g/m ² ). The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. The melamine resin powder was thickened again with an IR emitter. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc.

The acrylate-based dispersion material was then applied to this melamine resin using a slotted nozzle in an amount of 50 fl/m ² (solids content: approximately 50% by weight). The dispersion material was dried using IR emitters. The surface was then cured using an excimer emitter (172 nm) under the influence of an inert gas.

The board was then pressed together with the impregnated layer of the stabilizer layer in a CT press. The pressing conditions were: T=200°C, p=40 kg/cm ² and t=12 s. A pressing plate with a handmade paper texture was used. After pressing, the degree of gloss was determined (according to DIN EN ISO 2813:2015-02, measurement angle: 85°), whereby the value was 3.4 gloss units. The control sample, which was obtained without acrylate coating, gave a value of 12.9 units of gloss when determining the degree of gloss.

The tester applied as many fingerprints to the surface and control area as possible. Unlike the control area on the surface, this was not possible with the test formulation.

A subsequent abrasion resistance test carried out in accordance with DIN EN 15468, August 2018, resulted in strength class 32.

Embodiment 4

On the production line, HDF with a thickness of 8 mm was separated, dusted with brushes, and then conveyed by roller conveyors (feed speed: 30 m/min). In the applicator, they were then coated with 25 g/m ² melamine resin powder using tribostatic guns. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. The powder was then melted using infrared radiation.

Vivapur 302). Порошок меламиновой смолы содержал обычные вспомогательные вещества, такие как отвердители, антиадгезивы и т.п. Снова обеспечивали загустение этого порошка смолы, представляющей собой меламиновую смолу, с помощью ИК-излучателя. Порошок меламиновой смолы содержал обычные вспомогательные вещества, такие как отвердители, антиадгезивы и т.д. Затем с помощью распределительного устройства распределяли стеклянные шарики в количестве приблизительно 8 г/м² (Fa. Potters, GP 065-90). Новое нанесение порошка меламиновой смолы происходило с помощью трибостатических пистолетов (количество нанесения: 40 г/м²). Также в данном случае в порошке меламиновой смолы содержатся обычные вспомогательные вещества. С помощью ИК-излучателя снова обеспечивали загустение смолы.The primed slab was then repeatedly coated with a colored primer followed by intermediate drying (circulating air). The colored ground coat was a mixture of casein and pigment (titanium dioxide). The amount of application per application was approximately 5 fl/m ² . Application was repeated at least five times. Then the primer was applied (application amount: 10-20 fl/m ² with drying by circulating air. Then the board was printed with rollers or a digital printer. The ink application amount was from 3 to 15 fl/m ² . The paint was dried by IR- radiation or circulating air.Then, the melamine resin powder was again applied with a tribostatic gun (application amount: 30 g/m ² ) The melamine resin powder contained conventional auxiliary substances such as hardeners, release agents, etc. resin with an IR emitter Corundum was spread onto the impression using a dispenser (application amount: 20 g corundum/m ² , F230, FEPA standard) Then the melamine resin powder was again applied using a tribostatic gun (application amount: 50 g/m ² ) The melamine resin powder contained approximately 5% by weight of cellulose (Fa. J.

Vivapur 302). The melamine resin powder contained conventional adjuvants such as curing agents, release agents, and the like. This melamine resin resin powder was thickened again with an IR emitter. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. Glass beads were then dispensed using a dispenser in an amount of approximately 8 g/m ² (Fa. Potters, GP 065-90). The new application of the melamine resin powder took place with tribostatic guns (application amount: 40 g/m ² ). Also in this case, conventional auxiliaries are contained in the melamine resin powder. With the help of an IR emitter, the resin was thickened again.

The acrylate-based dispersion material was then applied to this melamine resin using a slotted nozzle in an amount of 40 fl/m ² (solids content: approximately 50% by weight). The dispersion material was dried using IR emitters. The surface was then cured using an excimer emitter (172 nm) under the influence of an inert gas.

The board was then pressed together with the impregnated layer of the stabilizer layer in a CT press. The pressing conditions were: T=200°C, p=40 kg/cm ² and t=15 s. A pressing plate with a handmade paper texture was used. After pressing, the degree of gloss was determined (according to DIN EN ISO 2813: 2015-02, measurement angle: 85°), and the value was 3.8 gloss units. The slab, which was obtained without an acrylate coating, gave a value of 12.0 units of gloss when determining the degree of gloss.

The tester applied as many fingerprints to the surface and control area as possible. Unlike the control area on the surface, this was not possible with the test composition.

A subsequent abrasion resistance test carried out in accordance with DIN EN 15468, August 2018, resulted in strength class 32.

Embodiment 5

On the production line, HDF with a thickness of 8 mm was separated, dusted with brushes, and then transported by roller conveyors (feeding system: 30 m/min). In the applicator, they were then coated with 25 g/m ² melamine resin powder using tribostatic guns. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. In addition, the resin contained 3% by weight of carbon nanotubes. The powder was then melted using infrared radiation.

Vivapur 302). С помощью ИК-излучателя снова обеспечивали загустение этого порошка меламиновой смолы. Порошок меламиновой смолы содержал обычные вспомогательные вещества, такие как отвердители, антиадгезивы и т.д. Затем с помощью распределительного устройства распределяли стеклянные шарики в количестве приблизительно 8 г/м² (Fa. Potters, GP 065-90). Новое нанесение порошка меламиновой смолы происходило с помощью трибостатических пистолетов (количество нанесения: 40 г/м²). Также в данном случае в порошке меламиновой смолы содержатся обычные вспомогательные вещества. С помощью ИК-излучателя снова обеспечивали загустение смолы.The primed slab was then repeatedly coated with a colored primer followed by intermediate drying (circulating air). The colored ground coat was a mixture of casein and pigment (titanium dioxide). The amount of application per application was approximately 5 fl/m ² . Application was repeated at least five times. Then there was the application of the primer (amount of application: 10-20 fl/m ² ) with drying by circulating air. The board was then printed using rollers or a digital printer. The amount of paint application was from 3 to 15 fl/m ² . The paint was dried by means of IR radiation or circulating air. Then, the melamine resin powder was applied again with a tribo gun (application amount: 30 g/m ² ). The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. The melamine resin powder was thickened again with an IR emitter. Corundum was dispensed onto the impression using a dispenser (application amount: 20 g corundum/m ² , F230). Then, the melamine resin powder was applied again with a tribo gun (application amount: 50 g/m ² ). The melamine resin powder contained approximately 5% by weight of cellulose (Fa. J.

Vivapur 302). The melamine resin powder was thickened again with an IR emitter. The melamine resin powder contained common auxiliary substances such as curing agents, release agents, etc. Glass beads were then dispensed using a dispenser in an amount of approximately 8 g/m ² (Fa. Potters, GP 065-90). The new application of the melamine resin powder took place with tribostatic guns (application amount: 40 g/m ² ). Also in this case, conventional auxiliaries are contained in the melamine resin powder. With the help of an IR emitter, the resin was thickened again.

The acrylate-based dispersion material was then applied to this melamine resin using a slotted nozzle in an amount of 40 fl/m ² (solids content: approximately 50% by weight). The dispersion material was dried using IR emitters. The surface was then cured using an excimer emitter (172 nm) under the influence of an inert gas.

The board was then pressed together with the impregnated layer of the stabilizer layer in a CT press. The pressing conditions were: T=200°C, p=40 kg/cm ² and t=15 s. A pressing plate with a handmade paper texture was used. After pressing, the degree of gloss was determined (according to DIN EN ISO 2813:2015-02, measurement angle: 85°), whereby the value was 3.8 gloss units. The slab, which was obtained without an acrylate coating, gave a value of 12.0 units of gloss when determining the degree of gloss.

The tester applied as many fingerprints to the surface and control area as possible. Unlike the control area on the surface, this was not possible with the test formulation.

A subsequent abrasion resistance test carried out in accordance with DIN EN 15468, August 2018, resulted in strength class 32. The measurement of the surface resistance gave a value of 7.8×10 ⁸ ohm.

Claims (57)

1. A method for producing a base material for the furniture industry, flooring, wall and ceiling cladding, provided with at least one matte coating that prevents the preservation of fingerprints, while the base material is a layer of paper or a board based on wood material, including the steps : - applying at least one layer of at least one formaldehyde resin powder to at least one side of the base material; - melting at least one deposited layer of powdered formaldehyde resin; - applying at least one dispersion material containing acrylate to the sub-melted layer of formaldehyde resin and - drying and curing of the layered structure. 2. The method according to claim 1, characterized in that the paper layer is a decorative paper layer or an overlay paper layer. 3. The method of claim 1, wherein the wood based board is medium density fibreboard (MDF), high density fibreboard (HDF) or oriented strand board (OSB), glued board or wood based board. - plastic composite (WPC). 4. Method according to any one of the preceding claims, characterized in that powdered formaldehyde resin is applied to the base material by means of an electrostatic charge. 5. Method according to any one of the preceding claims, characterized in that the powdered formaldehyde resin is a carbamide resin, a melamine resin or a phenolic resin, particularly preferably a melamine-formaldehyde resin. 6. Method according to any one of the preceding claims, characterized in that the formaldehyde resin powder contains pigments, electrically conductive substances and/or cellulose. 7. The method according to any of the previous paragraphs, characterized in that it includes the following steps: applying at least one first layer of at least one powdered formaldehyde resin to at least one side of the base material and melting at least one applied layer of powdered resin; - applying at least one decorative layer to at least one sub-melted layer of formaldehyde resin by means of a direct printing method; applying at least one additional second layer of at least one formaldehyde resin powder to at least one printed decorative layer; - melting at least one layer deposited on the decorative layer of powdered formaldehyde resin; - applying at least one dispersion material containing acrylate on the melted layer of formaldehyde resin and - drying and curing of the layered structure. 8. The method according to claim 7, characterized in that at least one primer coat is applied to the melted layer of formaldehyde resin powder before printing. 9. The method according to claim 8, characterized in that at least one ground coating contains casein, corn starch or soy protein. 10. Method according to claim 8 or 9, characterized in that at least one primer layer is applied to the at least one primer coat before printing, in particular. 11. The method according to any one of paragraphs. 7-10, characterized in that wear-resistant particles are evenly distributed on the decorative layer or on the melted layers of the formaldehyde resin powder. 12. Method according to claim 11, characterized in that at least one additional third layer of at least one formaldehyde resin powder is applied, in particular, to the layer of wear-resistant particles. 13. Method according to claim 12, characterized in that the glass beads are distributed, in particular, on at least one additional third subfused layer of formaldehyde resin powder. 14. Method according to claim 13, characterized in that at least one additional fourth layer of at least one formaldehyde resin powder is applied, in particular, to a layer of glass beads. 15. Method according to any one of the preceding claims, characterized in that at least one acrylate-containing dispersion material comprises a radiation-curable lacquer containing acrylate, in particular selected from polyester(meth)acrylate, polyether(meth) acrylate, epoxy(meth)acrylate or urethane(meth)acrylate. 16. A method according to any of the preceding claims, characterized in that at least one dispersion material containing acrylate is cured under the influence of an inert gas after application using a UV emitter at wavelengths from 120 to 350 nm, preferably from 150 to 250 nm, particularly preferably from 170 to 200 nm. 17. A method according to any one of the preceding claims, characterized in that the layered structure is pressed in a short cycle press. 18. The method according to any one of paragraphs. 1-6, 15-17, characterized in that it includes the following steps: applying at least one first layer of at least one formaldehyde resin powder to at least one side of the paper layer and melting at least one applied layer of formaldehyde resin powder; - applying at least one dispersion material containing acrylate on the melted layer of formaldehyde resin and - drying and curing of the layered structure. 19. A layer of paper obtained in the method according to any one of the preceding paragraphs, characterized in that the degree of gloss is less than 10. 20. A paper layer according to claim 19, characterized in that said paper layer is a decorative paper layer or an overlay paper layer. 21. Paper layer according to claim 19 or 20, characterized in that the degree of gloss of said paper layer is less than 8, preferably less than 5. 22. The method according to any one of paragraphs. 1-6, 15-17, characterized in that it includes the following steps: applying at least one first layer of at least one formaldehyde resin powder to at least one side of the wood based board and melting the at least one applied layer of formaldehyde resin powder; - applying at least one primer coating on the sub-melted layer of formaldehyde resin powder; - applying at least one primer layer to at least one primer coat; - applying at least one decorative layer by means of a direct printing method; - distribution of wear-resistant particles; - applying at least one additional layer of at least one powdered formaldehyde resin to at least one layer of wear-resistant particles and melting the applied layer of powdered formaldehyde resin; - applying, drying and curing at least one dispersion material containing acrylate on the subfused layer of formaldehyde resin and - pressing a layered structure. 23. The method according to any one of paragraphs. 1-6, 15-17, characterized in that it includes the following steps: applying at least one first layer of at least one formaldehyde resin powder to at least one side of the wood based board and melting the at least one applied layer of formaldehyde resin powder; - applying at least one ground coat on the melted first layer of formaldehyde resin powder; - applying at least one primer layer to at least one primer coat; - applying at least one decorative layer by means of a direct printing method; applying at least one additional second layer of at least one formaldehyde resin powder to at least one printed decorative layer and melting at least one second layer of formaldehyde resin powder applied to the decorative layer; - distribution of wear-resistant particles; - applying at least one additional third layer of at least one powdered formaldehyde resin to at least one layer of wear-resistant particles and melting the applied third layer of powdered formaldehyde resin; - the distribution of glass beads on at least one third subfused layer of formaldehyde resin powder; - applying at least one additional fourth layer of at least one powdered formaldehyde resin to the layer of glass beads and melting the applied fourth layer of powdered formaldehyde resin; - applying, drying and curing at least one dispersion material containing acrylate on the melted resin layer and - pressing a layered structure. 24. Board based on wood material obtained in the method according to any one of paragraphs. 1-17, 22, 23, characterized in that the degree of gloss is less than 10. 25. Wood-based board according to claim 24, characterized in that said wood-based board has a gloss level of less than 8, preferably less than 5.