EP1274594B2 - Decorative paper and method for impregnating one such decorative paper - Google Patents

Decorative paper and method for impregnating one such decorative paper Download PDF

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Publication number
EP1274594B2
EP1274594B2 EP01913818.9A EP01913818A EP1274594B2 EP 1274594 B2 EP1274594 B2 EP 1274594B2 EP 01913818 A EP01913818 A EP 01913818A EP 1274594 B2 EP1274594 B2 EP 1274594B2
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EP
European Patent Office
Prior art keywords
resin
fibers
spheres
balls
paper
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EP01913818.9A
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German (de)
French (fr)
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EP1274594A1 (en
EP1274594B1 (en
Inventor
Dieter DÖHRING
Anton Ott
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Lignum Technologies AG
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Kronoplus Technical AG
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18Paper- or board-based structures for surface covering
    • D21H27/22Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • D21H27/26Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
    • D21H27/28Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures treated to obtain specific resistance properties, e.g. against wear or weather
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24372Particulate matter

Definitions

  • the invention relates to a method for impregnating a decorative paper and a process according impregnated decorative paper.
  • the invention further relates to the preparation and provision of plates using the decorative paper.
  • a method for impregnating decorative paper is from the document WO 00/44984 known.
  • Decorative paper is first moistened with an amino resin and so impregnated.
  • the amount of resin is controlled by metering rollers.
  • a layer of an amino resin in special dispersion is applied to the moistened wet decorative paper, the final basis weight, based on the dry weight of the base paper, being 100% to 250%.
  • the applied dispersion contains abrasive substances such as silicon carbide or corundum.
  • the impregnated decorative paper is used for the production of panels, in particular for the production of panels.
  • a panel known for example from the publication EP 090 6994 A1 , is a generally elongated, thin plate, which can be connected laterally, so on the longitudinal and transverse sides, for example, via grooves and springs with other panels. So interconnected panels are used in particular as a floor covering or wall cladding.
  • a panel is according to the prior art u. a. produced by a pressing method as follows.
  • a resin-soaked sheet-like layer called a "counteracting paper” is provided above the countertraction paper.
  • a carrier plate is arranged above the countertraction paper.
  • the "decor paper” is applied to the support plate so that the decor with the abrasion-resistant materials corundum or silicon carbide facing outwards, so it is visible from the outside.
  • a layer consisting of cellulose and amino resin is additionally applied.
  • the cellulosic layer is called an "overlay".
  • the decor paper is then located between the carrier plate and the additional overlay layer. Subsequently, the backing paper, backing plate, decor paper and additional layer are pressed together at a temperature of the order of 200 ° C.
  • the resin used starts to flow and polycondenses into a stiff network. When the layer system leaves the press, the resin solidifies and a panel base is completed. Sawing and milling produce panels of the desired dimensions, side-mounted springs and grooves.
  • the carrier plate gives the panel the mechanical stability.
  • the decor on the decorative paper determines the appearance of the later wall or floor surface.
  • the consisting of corundum or silicon carbide layer provides good resistance to abrasion and the like.
  • the counteracting paper counteracts a distortion of the carrier plate during the pressing.
  • the overlay protects a surface of the press from the otherwise protruding hard silicon carbide or corundum grains and embeds them in amino resin.
  • a Doppelbandlaminierstrom is preferably used for cost and quality reasons.
  • Two metal bands are each driven in a similar way to a production line with the help of two rollers. The bands are pressed against each other and heated. The above-described layer system is inserted between the bands and compressed.
  • GB 1201 071 discloses a method corresponding to the preamble of claim 1.
  • the object of the invention is to provide improved decorative papers for the cost-effective production of plates.
  • decorative paper is impregnated and provided on one side not only with abrasion-resistant particles such as silicon carbide or corundum particles, but also with balls or balls and fibers.
  • the fibers and balls are made of soft materials, namely polyester, polyamide or glass, in comparison to the abrasion-resistant particles.
  • the balls protect a press belt during the compression of a layer system, which includes the decor paper, from damage.
  • Providing an overlay above a layer with abrasion-resistant particles can be dispensed with. It saves about 1/3 of the costs incurred for the impregnation of the decor paper together with applying a layer with the overlay in the prior art.
  • the impregnation of the decorative paper comprises in particular the following steps.
  • the decorative paper is impregnated with resin, in particular an amino resin, and abrasion-resistant particles are applied on one side with the decor. Subsequently, the balls or the fibers and balls are applied thereto. This ensures that the balls form a protective covering layer above the abrasion-resistant particles in a pressing device.
  • the method Before applying the balls or the fibers and balls, the method can be configured as follows.
  • the decor paper is first moistened with an amino resin and thereby impregnated.
  • the amount of resin is controlled by metering rollers.
  • a layer of an amino resin in a special dispersion is applied to the moistened, wet decor paper, the final basis weight, based on the dry weight of the base paper, being 100% to 250%.
  • the dispersion disappointeddüsen has been found to be advantageous, as the document WO 00/44984 can be seen. Subsequently, it is expedient to ensure by means of rollers smoothing and uniform distribution of the deposited dispersion.
  • the abovementioned dispersion preferably consists of 100 parts of an amino resin, 20 to 95 parts of abrasive, ie abrasion-resistant substance, 0.5 to 2.5 parts of a silane coupling agent, 5 to 25 parts of a flow aid, 0, 1 to 0.4 parts of a wetting agent, 0.05 to 0.4 parts of a release agent and an amino resin hardener.
  • the amino resin is in particular a melamine resin, as a flow aid, for example polyglycol ether, e-caprolactam or butanediol and as an abrasive substance, for example silicon carbide having an average particle size of 60 to 160 microns or alumina in the form of corundum or from the melt with a grain size of 60 to 160 / ⁇ m used. Any mixture of silicon carbide and aluminum oxide may also be provided.
  • the thickness of the fibers or the diameter of the balls are preferably to be chosen so that during the pressing of a corresponding layer system for the production of plates, the corundum or silicon carbide particles are kept away from the corresponding surface of the press. Damage due to hard silicon carbide or corundum particles are thus avoided.
  • the average diameter of the balls is preferably larger than the average diameter of the fibers when both fibers and balls are used.
  • the balls then ensure the desired protective distance between the abrasion-resistant particles and, for example, a press belt.
  • the fibers provide in particular for a fixation of resin and counteract cracking.
  • the respective affected surface of a press is protected by the invention in an improved and in a particularly cost-effective manner from damage by abrasion-resistant particles, so for example hard corundum or silicon carbide.
  • abrasion-resistant particles so for example hard corundum or silicon carbide.
  • the processing of the affected surfaces in a press - for example, a press belt of a so-called DoppelbandLaminierstrom - takes place at a correspondingly greater time intervals, so that costs associated with the work-up and production losses are reduced. Overall, there are considerable cost savings.
  • Typical fiber lengths are at least 0.5 mm, but preferably at least a few millimeters, for example 2 mm, 4 mm or 5 mm.
  • An upper limit of the fiber length is given in particular by the associated increase in viscosity. If the viscosity of a resin-fiber mixture is too high, it can no longer be processed.
  • the diameter of the fibers is for example at a few 10 microns or at 100 microns and more.
  • a typical diameter of the balls is 30 to 200 microns.
  • the visual impression is not adversely affected by the fibers or spheres, if they have the aforementioned dimensions and are embedded in the resin.
  • the balls according to the invention consist of polyester, polyamide or glass. These materials fulfill the properties required during production as well as after production. During production, they behave sufficiently stable. Polyester, polyamide or glass are sufficiently soft materials in the context of the invention to avoid damage to a pressing device. In a finished plate, a sufficient transparency is created by the aforementioned materials, so that the visual impression of the decoration is not adversely affected.
  • the materials advantageously allow relatively large, workable fiber lengths that significantly exceed the length of fibers consisting of cellulose used according to the invention. The increase in viscosity with increasing fiber length of artificial polymers such as polyester, polyamide fibers or of glass fibers is in fact small compared to increasing fiber length of cellulose fibers.
  • the fibers and / or balls may consist of different materials.
  • polyester fibers, polyamide fibers and glass fibers can be used at the same time.
  • Fibers prevent cracking in the surface.
  • balls hollow glass balls are preferably added to reinforce the protective effect, which in particular have a diameter of 30 to 200 microns for the aforementioned reasons.
  • the decorative paper preferably has a solids mass of 30 to 300 g / m 2 .
  • the fiber content is then in particular 5 to 100 g / m 2 .
  • hollow glass microspheres are advantageously provided for reinforcing up to 80 g / m 2 balls.
  • the fibers are in the form of a nonwoven.
  • the fibers are interwoven, so to speak.
  • a fleece reinforces and protects in a particularly good way. The risk of cracking is further reduced and thus the risk of damage to the respective affected surface.
  • the resin is particularly well fixed during the application of a resin-fiber mixture. The resin then contributes particularly well in addition to the protection in a pressing device.
  • the protective effect is additionally improved when providing a nonwoven by the inventive introduction of balls.

Description

Die Erfindung betrifft ein Verfahren zur Imprägnierung eines Dekorpapiers sowie ein verfahrensgemäß imprägniertes Dekorpapier. Die Erfindung betrifft ferner die Her- und Bereitstellung von Platten unter Verwendung des Dekorpapiers.The invention relates to a method for impregnating a decorative paper and a process according impregnated decorative paper. The invention further relates to the preparation and provision of plates using the decorative paper.

Ein Verfahren zum Imprägnieren von Dekorpapier ist aus der Druckschrift WO 00/44984 bekannt. Dekorpapier wird zunächst mit einem Aminoharz angefeuchtet und so imprägniert. Die Menge des Harzes wird mittels Dosierwalzen geregelt. Auf das angefeuchtete nasse Dekorpapier wird zusätzlich eine Schicht aus einem Aminoharz in spezieller Dispersion aufgedüst, wobei die endgültige Flächenmasse - bezogen auf die Trockenmasse des Rohpapiers - 100% bis 250% beträgt. Die aufgedüste Dispersion enthält abrasive Substanzen wie Siliziumkarbid oder Korund.A method for impregnating decorative paper is from the document WO 00/44984 known. Decorative paper is first moistened with an amino resin and so impregnated. The amount of resin is controlled by metering rollers. In addition, a layer of an amino resin in special dispersion is applied to the moistened wet decorative paper, the final basis weight, based on the dry weight of the base paper, being 100% to 250%. The applied dispersion contains abrasive substances such as silicon carbide or corundum.

Das imprägnierte Dekorpapier wird zur Herstellung von Platten und zwar insbesondere zur Herstellung von Paneelen verwendet.The impregnated decorative paper is used for the production of panels, in particular for the production of panels.

Ein Paneel, zum Beispiel bekannt aus der Druckschrift EP 090 6994 A1 , ist eine in der Regel längliche, dünne Platte, die seitlich, also an den Längs- und Querseiten zum Beispiel über Nuten und Federn mit weiteren Paneelen verbunden werden kann. So miteinander verbundene Paneele werden insbesondere als Fußbodenbelag oder als wandverkleidung eingesetzt.A panel, known for example from the publication EP 090 6994 A1 , is a generally elongated, thin plate, which can be connected laterally, so on the longitudinal and transverse sides, for example, via grooves and springs with other panels. So interconnected panels are used in particular as a floor covering or wall cladding.

Ein Paneel wird gemäß dem Stand der Technik u. a. durch ein Pressverfahren wie folgt hergestellt. Eine mit Harz getränkte folienartige Schicht, welche "Gegenzugpapier" genannt wird, wird bereitgestellt. Oberhalb des Gegenzugpapiers wird eine Trägerplatte angeordnet. Das "Dekorpapier" wird auf die Trägerplatte so aufgebracht, dass das Dekor mit den abriebfesten Materialien Korund oder Siliziumkarbid nach außen weist, also von außen sichtbar ist. Auf die Seite mit dem Siliziumkarbid oder Korund wird zusätzlich eine aus Cellulose und Aminoharz bestehende Schicht aufgebracht. Die Celluloseschicht wird als "Overlay" bezeichnet.A panel is according to the prior art u. a. produced by a pressing method as follows. A resin-soaked sheet-like layer called a "counteracting paper" is provided. Above the countertraction paper, a carrier plate is arranged. The "decor paper" is applied to the support plate so that the decor with the abrasion-resistant materials corundum or silicon carbide facing outwards, so it is visible from the outside. On the side with the silicon carbide or corundum, a layer consisting of cellulose and amino resin is additionally applied. The cellulosic layer is called an "overlay".

Das Dekorpapier befindet sich dann zwischen der Trägerplatte und der zusätzlichen, das Overlay aufweisenden Schicht. Anschließend werden Gegenzugpapier, Trägerplatte, Dekorpapier und zusätzliche Schicht bei einer Temperatur in der Größenordnung von 200°C miteinander verpresst. Das eingesetzte Harz fängt an zu fließen und polykondensiert zu einem steifen Netzwerk. Verlässt das Schichtsystem die Presse, so verfestigt sich das Harz und ein Paneelgrundkörper ist fertiggestellt. Durch Sägen und Fräsen werden hieraus Paneele mit den gewünschten Maßen, seitlich angebrachten Federn und Nuten hergestellt.The decor paper is then located between the carrier plate and the additional overlay layer. Subsequently, the backing paper, backing plate, decor paper and additional layer are pressed together at a temperature of the order of 200 ° C. The resin used starts to flow and polycondenses into a stiff network. When the layer system leaves the press, the resin solidifies and a panel base is completed. Sawing and milling produce panels of the desired dimensions, side-mounted springs and grooves.

Die Trägerplatte verleiht dem Paneel die mechanische Stabilität. Das Dekor auf dem Dekorpapier bestimmt das Aussehen der späteren Wand- oder Fußbodenoberfläche. Die aus Korund oder Siliziumkarbid bestehende Schicht sorgt für eine gute Festigkeit gegenüber Abrieb und dergleichen. Das Gegenzugpapier wirkt einem Verzug der Trägerplatte während des Verpressens entgegen. Das Overlay schützt eine Oberfläche der Presse vor den andernfalls hervorstehenden harten Siliziumkarbid- oder Korundkörnern und bettet diese in Aminoharz ein.The carrier plate gives the panel the mechanical stability. The decor on the decorative paper determines the appearance of the later wall or floor surface. The consisting of corundum or silicon carbide layer provides good resistance to abrasion and the like. The counteracting paper counteracts a distortion of the carrier plate during the pressing. The overlay protects a surface of the press from the otherwise protruding hard silicon carbide or corundum grains and embeds them in amino resin.

Als Presse wird aus Kosten- und Qualitätsgründen bevorzugt eine Doppelbandlaminieranlage eingesetzt. Zwei Metallbänder werden jeweils analog zu einem Fließband mit Hilfe von je zwei Walzen angetrieben. Die Bänder werden gegeneinander gepresst und erhitzt. Das oben beschriebene Schichtsystem wird zwischen die Bänder eingeführt und dabei verpresst.As a press, a Doppelbandlaminieranlage is preferably used for cost and quality reasons. Two metal bands are each driven in a similar way to a production line with the help of two rollers. The bands are pressed against each other and heated. The above-described layer system is inserted between the bands and compressed.

Trotz des Overlays werden die Metallbänder durch die Korund- oder Siliziumkarbid-Partikel beschädigt. Die Metallbänder müssen dann aufgearbeitet werden. Die Aufarbeitung der Bänder ist teuer und stoppt unter Umständen die Produktion während der Aufarbeitungszeit. Die Celluloseschicht ist ferner teuer. GB 1201 071 offenbart ein Verfahren, das dem Oberbegriff des Anspruchs 1 entspricht.Despite the overlay, the metal bands are damaged by the corundum or silicon carbide particles. The metal bands must then be worked up. The processing of the tapes is expensive and may stop production during the work-up time. The cellulosic layer is also expensive. GB 1201 071 discloses a method corresponding to the preamble of claim 1.

Aufgabe der Erfindung ist die Bereitstellung verbesserter Dekorpapiere zur preiswerten Herstellung von Platten.The object of the invention is to provide improved decorative papers for the cost-effective production of plates.

Die Aufgabe der Erfindung wird durch ein Verfahren mit den Merkmalen des ersten Anspruchs sowie durch eine Platte mit den Merkmalen des achten Anspruchs gelöst. Vorteilhafte Ausgestaltungen ergeben sich aus den Unteransprüchen.The object of the invention is achieved by a method having the features of the first claim and by a plate having the features of the eighth claim. Advantageous embodiments emerge from the subclaims.

Verfahrensgemäß wird Dekorpapier imprägniert und dabei auf einer Seite nicht nur mit abriebfesten Partikeln wie Siliziumkarbid- oder Korundpartikeln, sondern zusätzlich mit Kugeln oder mit Kugeln und Fasern versehen. Die Fasern und Kugeln bestehen im Vergleich zu den abriebfesten Partikeln aus weichen Materialien, nämlich Polyester, Polyamid oder Glas. Die Kugeln schützen ein Pressband während des Verpressens eines Schichtsystems, welches das Dekorpapier umfasst, vor Beschädigungen. Auf Vorsehen eines Overlays oberhalb einer Schicht mit abriebfesten Partikeln kann verzichtet werden. Es werden so ca. 1/3 der Kosten eingespart, die für das Imprägnieren des Dekorpapiers nebst Aufbringen einer Schicht mit dem Overlay beim Stand der Technik anfallen.According to the method decorative paper is impregnated and provided on one side not only with abrasion-resistant particles such as silicon carbide or corundum particles, but also with balls or balls and fibers. The fibers and balls are made of soft materials, namely polyester, polyamide or glass, in comparison to the abrasion-resistant particles. The balls protect a press belt during the compression of a layer system, which includes the decor paper, from damage. Providing an overlay above a layer with abrasion-resistant particles can be dispensed with. It saves about 1/3 of the costs incurred for the impregnation of the decor paper together with applying a layer with the overlay in the prior art.

Die Imprägnierung des Dekorpapiers umfasst insbesondere folgende Schritte. Das Dekorpapier wird mit Harz, insbesondere einem Aminoharz getränkt, und auf einer Seite mit dem Dekor werden abriebfeste Partikel aufgebracht. Anschließend werden hierauf die Kugeln oder die Fasern und Kugeln aufgebracht. So wird erreicht, dass die Kugeln eine schützende Deckschicht oberhalb der abriebfesten Partikel in einer Pressvorrichtung bilden.The impregnation of the decorative paper comprises in particular the following steps. The decorative paper is impregnated with resin, in particular an amino resin, and abrasion-resistant particles are applied on one side with the decor. Subsequently, the balls or the fibers and balls are applied thereto. This ensures that the balls form a protective covering layer above the abrasion-resistant particles in a pressing device.

Vor dem Aufbringen der Kugeln oder der Fasern und Kugeln kann das Verfahren wie folgt ausgestaltet sein.Before applying the balls or the fibers and balls, the method can be configured as follows.

Das Dekorpapier wird zunächst mit einem Aminoharz angefeuchtet und dadurch imprägniert. Die Menge des Harzes wird dabei mittels Dosierwalzen geregelt. Auf das angefeuchtete, nasse Dekorpapier wird zusätzlich eine Schicht aus einem Aminoharz in spezieller Dispersion aufgedüst, wobei die endgültige Flächenmasse - bezogen auf die Trockenmasse des Rohpapiers - 100 % bis 250 % beträgt. Die Dispersion aufzudüsen, hat sich als vorteilhaft herausgestellt, wie der Druckschrift WO 00/44984 zu entnehmen ist. Nachfolgend ist es zweckmäßig, mittels Walzen eine Glättung und Gleichverteilung der aufgedüsten Dispersion sicherzustellen.The decor paper is first moistened with an amino resin and thereby impregnated. The amount of resin is controlled by metering rollers. In addition, a layer of an amino resin in a special dispersion is applied to the moistened, wet decor paper, the final basis weight, based on the dry weight of the base paper, being 100% to 250%. The dispersion aufzudüsen, has been found to be advantageous, as the document WO 00/44984 can be seen. Subsequently, it is expedient to ensure by means of rollers smoothing and uniform distribution of the deposited dispersion.

Die vorgenannte Dispersion besteht bevorzugt aus 100 Teilen eines Aminoharzes, 20 bis 95 Teilen abrasiver, also abriebfester Substanz, 0,5 bis 2,5 Teilen eines Silanhaftvermittlers, 5 bis 25 Teilen eines Fließhilfsstoffes, 0, 1 bis 0,4 Teilen eines Netzmittels, 0,05 bis 0,4 Teilen eines Trennmittels und eines Aminoharzhärters.The abovementioned dispersion preferably consists of 100 parts of an amino resin, 20 to 95 parts of abrasive, ie abrasion-resistant substance, 0.5 to 2.5 parts of a silane coupling agent, 5 to 25 parts of a flow aid, 0, 1 to 0.4 parts of a wetting agent, 0.05 to 0.4 parts of a release agent and an amino resin hardener.

Als Aminoharz wird insbesondere ein Melaminharz, als Fließhilfsstoff zum Beispiel Polyglycolether, E-Caprolactam oder Butandiol sowie als abrasive Substanz zum Beispiel Siliziumkarbid mit einer durchschnittlichen Korngröße von 60 bis 160 µm oder Aluminiumoxid in Form von Korund oder aus der Schmelze mit einer Korngröße von 60 bis 160 / µm verwendet. Es kann auch eine beliebige Mischung aus Siliziumkarbid und Aluminiumoxid vorgesehen werden.The amino resin is in particular a melamine resin, as a flow aid, for example polyglycol ether, e-caprolactam or butanediol and as an abrasive substance, for example silicon carbide having an average particle size of 60 to 160 microns or alumina in the form of corundum or from the melt with a grain size of 60 to 160 / μm used. Any mixture of silicon carbide and aluminum oxide may also be provided.

Das anschließende Aufbringen von Kugeln oder Fasern und Kugeln geschieht zweckmäßig folgendermaßen. Es wird eine Mischung aus einem Harz, den Kugeln bzw. den Kugeln und Fasern hergestellt und die Mischung auf das in vorgenannter Weise behandelte Dekorpapier aufgetragen. Das Vorsehen einer Mischung verbessert den Schutz in einer Pressvörrichtung weiter, da dann auch das zusätzliche Harz zum Schutz beiträgt.The subsequent application of balls or fibers and balls is done appropriately as follows. A mixture of a resin, the balls or balls and fibers is prepared and the mixture is applied to the decor paper treated in the aforementioned manner. The provision of a mixture further improves the protection in a Pressvörrichtung, since then the additional resin contributes to the protection.

Die Dicke der Fasern oder der Durchmesser der Kugeln sind vorzugsweise so zu wählen, dass während des Pressens eines entsprechenden Schichtsystems zur Herstellung von Platten die Korund- oder Siliziumkarbid-Partikeln von der entsprechenden Oberfläche der Presse ferngehalten werden. Beschädigungen auf Grund von harten Siliziumkarbid- oder Korundpartikeln werden so vermieden.The thickness of the fibers or the diameter of the balls are preferably to be chosen so that during the pressing of a corresponding layer system for the production of plates, the corundum or silicon carbide particles are kept away from the corresponding surface of the press. Damage due to hard silicon carbide or corundum particles are thus avoided.

Der mittlere Durchmesser der Kugeln ist bevorzugt größer als der mittlere Durchmesser der Fasern, wenn sowohl Fasern als auch Kugeln eingesetzt werden. Die Kugeln stellen dann den gewünschten schützenden Abstand zwischen den abriebfesten Partikeln und beispielsweise einem Pressband sicher. Die Fasern sorgen insbesondere für eine Fixierung von Harz und wirken einer Rissbildung entgegen.The average diameter of the balls is preferably larger than the average diameter of the fibers when both fibers and balls are used. The balls then ensure the desired protective distance between the abrasion-resistant particles and, for example, a press belt. The fibers provide in particular for a fixation of resin and counteract cracking.

Die jeweils betroffene Oberfläche einer Presse wird durch die Erfindung in verbesserter und in besonders preiswerter Weise vor Beschädigungen durch abriebfeste Partikel, also zum Beispiel harte Korund- oder Siliziumkarbidpartikel geschützt. Die Aufarbeitung der betroffenen Oberflächen in einer Presse - so zum Beispiel ein Pressband einer sogenannten DoppelbandLaminieranlage - erfolgt in entsprechend größeren zeitlichen Abständen, so dass mit der Aufarbeitung verbundene Kosten und Produktionsausfälle verringert werden. Insgesamt ergeben sich beträchtliche Kostenersparnisse.The respective affected surface of a press is protected by the invention in an improved and in a particularly cost-effective manner from damage by abrasion-resistant particles, so for example hard corundum or silicon carbide. The processing of the affected surfaces in a press - for example, a press belt of a so-called DoppelbandLaminieranlage - takes place at a correspondingly greater time intervals, so that costs associated with the work-up and production losses are reduced. Overall, there are considerable cost savings.

Typische Faserlängen betragen wenigstens 0,5 mm, bevorzugt jedoch wenigstens einige Millimeter, so zum Beispiel 2 mm, 4mm oder 5 mm. Je länger die Faser ist, desto besser vermag diese die Oberfläche einer Platte vor Rissbildung zu schützen. Eine Obergrenze der Faserlänge ist insbesondere durch den damit verbundenen Viskositätsanstieg gegeben. Bei zu hoher Viskosität einer Harz-Faser-Mischung kann diese nicht mehr verarbeitet werden. Der Durchmesser der Fasern liegt beispielsweise bei einigen 10 µm oder auch bei 100 µm und mehr.Typical fiber lengths are at least 0.5 mm, but preferably at least a few millimeters, for example 2 mm, 4 mm or 5 mm. The longer the fiber, the better it can protect the surface of a plate from cracking. An upper limit of the fiber length is given in particular by the associated increase in viscosity. If the viscosity of a resin-fiber mixture is too high, it can no longer be processed. The diameter of the fibers is for example at a few 10 microns or at 100 microns and more.

Ein typischer Durchmesser der Kugeln liegt bei 30 bis 200 µm. Hierdurch wird einerseits der gewünschte Abstand zwischen den Korund- oder Siliziumkarbid-Partikeln zur entsprechenden Oberfläche in einer Presse gewährleistet. Andererseits sind die Kugeln klein genug, um nicht mit bloßem Auge wahrgenommen zu werden.A typical diameter of the balls is 30 to 200 microns. As a result, on the one hand the desired distance between the corundum or silicon carbide particles is ensured to the corresponding surface in a press. On the other hand, the balls are small enough not to be perceived by the naked eye.

Der optische Eindruck wird durch die Fasern bzw. Kugeln nicht nachteilig beeinträchtigt, wenn diese die vorgenannten Maße aufweisen und im Harz eingebettet sind.The visual impression is not adversely affected by the fibers or spheres, if they have the aforementioned dimensions and are embedded in the resin.

Die Kugeln bestehen erfindungsgemäß aus Polyester, Polyamid oder Glas. Diese Materialien erfüllen die Eigenschaften, die während der Produktion sowie nach der Herstellung erforderlich sind. Während der Produktion verhalten sie sich hinreichend stabil. Polyester, Polyamid oder Glas sind hinreichend weiche Materialien im Sinne der Erfindung, um Beschädigungen einer Pressvorrichtung zu vermeiden. Bei einer fertigen Platte wird durch die vorgenannten Materialien eine hinreichende Transparenz geschaffen, sodass der optische Eindruck des Dekors nicht nachteilhaft beeinträchtigt wird. Die Materialien ermöglichen vorteilhaft relativ große, verarbeitbare Faserlängen, die die Länge von aus Cellulose bestehenden, erfindungsgemäß eingesetzten Fasern deutlich übersteigen. Der Viskositätsanstieg mit zunehmender Faserlänge von künstlichen Polymeren wie Polyester-, Polyamidfasern oder von Glasfasern ist nämlich im Vergleich zu zunehmender Faserlänge von Cellulosefasern gering.The balls according to the invention consist of polyester, polyamide or glass. These materials fulfill the properties required during production as well as after production. During production, they behave sufficiently stable. Polyester, polyamide or glass are sufficiently soft materials in the context of the invention to avoid damage to a pressing device. In a finished plate, a sufficient transparency is created by the aforementioned materials, so that the visual impression of the decoration is not adversely affected. The materials advantageously allow relatively large, workable fiber lengths that significantly exceed the length of fibers consisting of cellulose used according to the invention. The increase in viscosity with increasing fiber length of artificial polymers such as polyester, polyamide fibers or of glass fibers is in fact small compared to increasing fiber length of cellulose fibers.

Lange Fasern vermögen eine Presse vor Beschädigungen besser im Vergleich zu kurzen Fasern zu schützen. Dies ist insbesondere dann der Fall, wenn die Fasern in Form eines Vlieses vorliegen, wie weiter unten dargelegt wird.Long fibers can better protect a press from damage compared to short fibers. This is especially the case when the fibers are in the form of a nonwoven, as set forth below.

Die Fasern und/oder Kugeln können aus unterschiedlichen Materialien bestehen. Es können also zum Beispiel Polyesterfasern, Polyamidfasern und Glasfasern zugleich eingesetzt werden.The fibers and / or balls may consist of different materials. Thus, for example, polyester fibers, polyamide fibers and glass fibers can be used at the same time.

Fasern vermeiden Rissbildungen in der Oberfläche. Als Kugeln werden bevorzugt aus Glas bestehende Hohlkugeln zur Verstärkung der Schutzwirkung zugefügt, die insbesondere einen Durchmesser von 30 bis 200 µm aus vorgenannten Gründen aufweisen.Fibers prevent cracking in the surface. As balls hollow glass balls are preferably added to reinforce the protective effect, which in particular have a diameter of 30 to 200 microns for the aforementioned reasons.

Das Dekorpapier weist bevorzugt eine Feststoffmasse von 30 bis 300 g/m2 auf. Der Faseranteil beträgt dann insbesondere 5 bis 100 g/m2. Vorteilhaft werden zur Verstärkung bis zu 80 g/m2 Kugeln, insbesondere Mikroglashohlkugeln vorgesehen.The decorative paper preferably has a solids mass of 30 to 300 g / m 2 . The fiber content is then in particular 5 to 100 g / m 2 . For reinforcing up to 80 g / m 2 balls, in particular hollow glass microspheres are advantageously provided.

In einer weiteren vorteilhaften Ausgestaltung liegen die Fasern in Form eines Vlieses vor. Die Fasern sind sozusagen miteinander verwebt. Ein Vlies verstärkt und schützt in besonders guter Weise. Die Gefahr einer Rissbildung wird weiter herabgesetzt und damit die Gefahr von Beschädigungen der jeweils betroffenen Oberfläche. Durch das Flies wird bei Aufbringen einer Harz-Faser-Mischung das Harz während des Pressens besonders gut fixiert. Das Harz trägt dann besonders gut ergänzend zum Schutz in einer Pressvorrichtung bei.In a further advantageous embodiment, the fibers are in the form of a nonwoven. The fibers are interwoven, so to speak. A fleece reinforces and protects in a particularly good way. The risk of cracking is further reduced and thus the risk of damage to the respective affected surface. By the fleece, the resin is particularly well fixed during the application of a resin-fiber mixture. The resin then contributes particularly well in addition to the protection in a pressing device.

Die schützende Wirkung wird bei Vorsehen eines Vlieses durch das erfindungsgemässe Einbringen von Kugeln zusätzlich verbessert.The protective effect is additionally improved when providing a nonwoven by the inventive introduction of balls.

Im Folgenden wird ein Referenz-Beispiel beschrieben:

  • Bedrucktes Dekorpapier mit einer Masse von 70 g/m2 wird durch ein Aminoharzbad so geführt, dass ein Auftrag von 70 g/m2 an Harz (Feststoffgehalt) erfolgt. Es wird dabei ein handelsübliches Aminoharz eingesetzt. Auf die Dekoroberseite wird ein Korundschicht von 15 g/m2 gleichmäßig aufgetragen. Die nun nasse Papierbahn wird einem Schwebetrockner zugeführt. Im Trockner herrscht eine Temperatur von 170 °C. Auf die so behandelte Bahn wird eine Mischung aus einem handelsüblichen Aminoharz und Polyesterfasern auf die Dekoroberseite dosiert aufgetragen. Die Feststoffmasse des Auftrags beträgt 70 g/m2. In der Mischung liegt der Faseranteil bei 30 Masse-%. Die mittlere Läge der Fasern beträgt 5 mm. Der mittlere Durchmesser liegt bei 80 µm. Anschließend wird ein zweiter Trocknungsschritt bei 160 °C durchgeführt, bis die Restfeuchte bei 7% liegt. Das so imprägnierte Dekorpapier wird in eingangs genannter Weise zu einer Platte und zwar insbesondere zu einem Paneel für Fußböden weiterverarbeitet.
The following is a reference example:
  • Printed decorative paper with a mass of 70 g / m 2 is passed through an amino resin bath so that an order of 70 g / m 2 of resin (solids content) takes place. It is a commercial amino resin used. On the top of the decor a corundum layer of 15 g / m 2 is applied evenly. The now wet paper web is fed to a floating dryer. The dryer has a temperature of 170 ° C. On the thus treated web, a mixture of a commercially available amino resin and polyester fibers is metered onto the decorative top. The solids mass of the order is 70 g / m 2 . In the mixture, the fiber content is 30 mass%. The average length of the fibers is 5 mm. The mean diameter is 80 μm. Subsequently, a second drying step is carried out at 160 ° C until the residual moisture content is 7%. The so-impregnated decorative paper is further processed in the manner mentioned above to a plate, and in particular to a panel for floors.

Claims (8)

  1. Method for impregnating a decor paper, comprising the steps:
    - application of resin and abrasion-resistant particles onto the decor paper;
    - application of spheres onto the abrasion-resistant particles,
    characterized in that
    the spheres consist of polyester, polyamide or glass.
  2. Method according to one of the preceding claims, wherein the spheres are applied in a mixture with a resin.
  3. Method according to one of the preceding claims, wherein the decor paper in the end is dehumidified at a temperature of more than 100 °C in a dryer.
  4. Method according to one of the preceding claims, characterized in that the diameter of the spheres is 30 to 200 µm.
  5. Method according to one of the preceding claims, characterized in that the impregnated decor paper is manufactured in that it comprises a mass of solid matter of 30 to 300 g/m2.
  6. Method according to one of the preceding claims, characterized in that the decor paper comprises up to 80 g/m2 of the spheres.
  7. Method according to one of the preceding claims, characterized in that corundum- or silicon-carbide particles are sprayed onto the decor paper and, in succession, the sprayed corundum- or silicon-carbide particles are spread and/or planed by means of rolls.
  8. Panel, which consists essentially of a wood material, wherein a decor paper layer, resin and abrasion-resistant particles and on top spheres are applied at the upper side of the panel
    characterized in that
    the spheres consist of polyester, polyamide or glass.
EP01913818.9A 2001-02-20 2001-02-20 Decorative paper and method for impregnating one such decorative paper Expired - Lifetime EP1274594B2 (en)

Applications Claiming Priority (1)

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PCT/EP2001/001862 WO2002066265A1 (en) 2001-02-20 2001-02-20 Decorative paper and method for impregnating one such decorative paper

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EP1274594B1 EP1274594B1 (en) 2013-12-18
EP1274594B2 true EP1274594B2 (en) 2017-09-20

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US (1) US20030113513A1 (en)
EP (1) EP1274594B2 (en)
CN (1) CN100473544C (en)
ES (1) ES2452572T5 (en)
PT (1) PT1274594E (en)
WO (1) WO2002066265A1 (en)

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US7614958B2 (en) * 2001-11-16 2009-11-10 Creative Kingdoms, Llc Interactive quest game
DE10161093B4 (en) * 2001-12-12 2008-04-17 Ackner, Friedrich Scratch and abrasion resistant decorative film and process for its preparation
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ITMI20041578A1 (en) * 2004-07-30 2004-10-30 Tocchio S R L METHOD FOR THE REALIZATION OF DECORATIVE AND LAMINATED PAPERS WITH HIGH ABRASION RESISTANCE, IN PARTICULAR FOR FLOORING.
ITMI20041579A1 (en) * 2004-07-30 2004-10-30 Tocchio S R L METHOD OF REALIZATION OF DECORATIVE LAYERS RESISTANT TO ABRASION, IN PARTICULAR FOR LAMINATES FOR COATING AND / OR FLOORING, AND DECORATIVE LAYER AND LAMINATE RESISTANT TO ABRASION REALIZED WITH THIS METHOD.
DE102004038197B4 (en) * 2004-08-05 2010-06-17 Bene_Fit Gmbh Decorative paper and use of aluminum silicate for the production of decorative paper
DE102007019179A1 (en) 2007-04-20 2008-10-30 Center For Abrasives And Refractories Research & Development C.A.R.R.D. Gmbh Wear protection layer
DE102007047636A1 (en) * 2007-10-04 2009-04-09 Dakor Melamin Imprägnierungen Gmbh Process for producing an abrasion-resistant film and finishing film which can be produced by this process
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DE102008057262B4 (en) * 2008-11-13 2012-12-13 Flooring Technologies Ltd. Method for producing a wood-based panel from a wood-based panel with a wear layer and wood-based panel
DE102009030101A1 (en) 2008-12-08 2010-07-15 Center For Abrasives And Refractories Research & Development C.A.R.R.D. Gmbh Wear protection layer based on a synthetic resin matrix, process for their preparation and their use
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EP1274594A1 (en) 2003-01-15
EP1274594B1 (en) 2013-12-18
ES2452572T5 (en) 2018-02-05
US20030113513A1 (en) 2003-06-19
CN100473544C (en) 2009-04-01
WO2002066265A1 (en) 2002-08-29
CN1418154A (en) 2003-05-14
ES2452572T3 (en) 2014-04-02
PT1274594E (en) 2014-02-11

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