巴西专利BR112012016818B1 process for manufacturing a wear resistant surface layer

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专利摘要:
bright colored surface layer. the present invention relates to a process for producing a light wear resistant and / or light colored surface layer using a dry powder layer comprising a mixture of refined fibers, binder, droplets and resistant particles wear.
公开号:BR112012016818B1
申请号:R112012016818
申请日:2010-12-22
公开日:2020-04-22
发明作者:Ziegler Göran；Lindgren Kent
申请人:Ceraloc Innovation Belgium；Vaelinge Innovation Ab；
IPC主号:

专利说明:

(54) Title: PROCESS FOR MANUFACTURING A WEAR RESISTANT SURFACE LAYER (51) Int.CI .: E04F 15/10; B05D 3/02; B05D 3/12; B32B 2/21; B32B 21/10; (...)
(52) CPC: E04F 15/10; B05D 3/02; B05D 3/12; B32B 2/21; B32B 21/10; (...)
(30) Unionist Priority: 15/01/2010 SE 10 50037-9.
(73) Holder (s): VÃLINGE INNOVATION AB.
(72) Inventor (s): GÔRAN ZIEGLER; KENT LINDGREN.
(86) PCT Application: PCT SE2010051472 of 12/22/2010 (87) PCT Publication: WO 2011/087422 of 7/21/2011 (85) Date of Beginning of the National Phase: 06/07/2012 (57) Summary: BRIGHT COLORFUL SURFACE LAYER. The present invention relates to a process for producing a light wear resistant and / or light colored surface layer using a dry powder layer comprising a mixture of refined fibers, binder, droplets and resistant particles. wear.
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Descriptive Report of the Invention Patent for PROCESS FOR THE MANUFACTURE OF A WEAR RESISTANT SURFACE LAYER.
Technical Field [0001] The discovery refers generally to the field of fiber-based panels with wear-resistant surface layers for panel construction, preferably floor panels. The discovery concerns building panels with such a wear-resistant surface and the production processes for producing such panels.
Field of Application [0002] The present discovery is particularly suitable for use on floating floors, which are formed of floor panels with a wood fiber core and a decorative wear-resistant surface. The description of the following technique, the problems of known and objective systems and the characteristics of the invention must, therefore, as a non-restrictive example, be aimed above all in this field of application and in particular on floors that are similar to traditional floating floors. based on wood fiber. The discovery does not exclude floors that are glued below a sub floor.
[0003] It needed to be emphasized that the modalities of the discovery can be used as a panel or with a surface layer, which is, for example, glued to a heartwood. The discovery modalities can also be used in applications such as, for example, wall panels, ceilings and furniture components and the like. The modalities could also be used on floors with optional surface materials such as cork or wood to improve the wear and design properties (design).
Background [0004] It is well known to produce laminated panels for buildings
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2/12 with a surface comprising sheets of laminated paper.
[0005] A new type of panel called Fiberglass Floor
Wood (Fiber Floor (WFF)) is described in WO 2009/065769 which presents both compounds and methods for producing such a product. The straight pressed laminate panels for construction usually comprise a core of a 6-12 mm fiber board, a layer of decorative laminate for the top surface with a thickness of 0.2 mm and a layer of a decorative top layer of laminate of 0, 2 mm thick and a 0.1 - 0.2 mm lower balance laminate layer of plastic, paper or similar material.
[0006] A laminated surface usually comprises two sheets of paper, a printed decorative paper 0.1 mm thick and a transparent paper for covering applied 0.05-0.1 mm thick on the decorative paper and with the intention of protecting the decorative paper against abrasion. Printing on non-transparent decorative paper is only 0.01 mm thick. The transparent cover, which is made of refined α-cellulose fibers, comprises small hard and transparent aluminum oxide particles. The refined fibers are quite long, approximately 2-5 mm and this gives the covering paper the necessary strength. To obtain transparency, all natural resins that are present in virgin wood fibers have been removed and the aluminum oxide particles are applied as a very thin layer on the decorative paper. The surface layer of a laminate floor is characterized by the fact that the decorative and wear-resistant properties are generally achieved with two layers separated one above the other.
[0007] Printed decorative paper and cover are impregnated with melamine resin and laminated to a wood fiber based heartwood
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3/12 under heat and pressure.
[0008] The small particles of aluminum oxide could have a size in the range of 20 - 100 microns. The particles could be incorporated into the surface layer in several ways. For example, they could be incorporated into the pulp during the manufacture of the covering paper. They could also be spread over the wet lacquer during the coating impregnation procedure or incorporated into the lacquer used to impregnate the coating.
[0009] The wear layer could also be produced in a cellulose coating. In such a case the melamine resin and the aluminum oxide particles are applied as a lacquer layer directly on the decorative paper with similar methods as described above. Such a wear layer is generally called a liquid coating.
[00010] With this method of production a surface of high wear resistance could be obtained and this type of surface is used mainly in laminate floors, however it could also be used in furniture components and similar applications. High quality laminate floors have a wear resistance of 4000-6000 revolutions, which corresponds to the abrasion classes AC4 and AC5 measured with a Taber Abraser according to an ISO standard.
[00011] It is also known that the wear resistance of a lacquered wood surface could be improved considerably by incorporating aluminum oxide particles into the transparent lacquer that covers the wood surface.
[00012] The most common material for heartwood used in laminate floors is a fiber board with high density and good stability commonly called HDF - High Density Fiberboard. Sometimes also MDF - Medium Density Fiberboard - is used as
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4/12 heartwood. Other heartwood materials such as particle board are also used.
[00013] Floor panels with WFF are free of paper with a surface layer that comprises a substantially homogeneous mixture of wood fibers, binders and wear-resistant particles. The wear resistant particles are preferably aluminum oxide particles and the binders are preferably thermoset resins such as melamine. Wear-resistant particles are supplied throughout the thickness of the surface layer from the top to the bottom and in contact with the core of the panel. Other suitable materials are, for example, silica or silicon carbide. In general, all of these materials are preferably applied in dry form as a mixed powder on a core of HDF and cured under heat and pressure to a surface layer of 0.2 1.0 mm.
Definition of Some Terms [00014] In the text below, the visible surface of the installed floor panel is called the front side, while the opposite side of the panel for the floor, which faces the sub floor, is called the back. The sheet-like material that comprises most of a panel and gives the panel the necessary stability is called core. When the heartwood is coated with a surface layer closer to the front side and preferably also a balance layer closer to the reverse side, it forms a semi-manufactured part (the semi-manufactured one), which is called the floor plate or floor element in the event that the semi-manufactured (semi-manufactured) part, in a subsequent operation, is divided into a large number of floor elements. When floor elements are machined along their edges to achieve their final shape with the joint system, they are called floor panels.
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The surface layer is understood to mean all the layers which provide the panel with its decorative properties and its resistance to wear and which are applied to the heartwood closest to the front side which preferably covers the entire front side of the floor plate. By decorative surface layer is meant a layer, mainly to give the floor its decorative appearance. The wear layer refers to a layer, which is mainly adapted to improve the durability of the front side.
[00015] A horizontal plane means a plane, which extends in parallel to the external part of the surface layer. Horizontally is meant in parallel to the horizontal plane and vertically means perpendicular to the horizontal plane. Above it is understood towards the front side and below towards the reverse side.
Summary of the Invention [00016] A global objective of discovery modalities is to provide a construction panel, preferably a floor panel with a light and / or smooth color, for example, bright white, wear resistant layer that could be produced from a more cost-effective way than the present known technology.
[00017] The methods described in WO 2009/065769 include the use of virgin or recycled wood fibers which have the limitation that while using pigments to provide light colors, for example, a bright white color or very intense colors, the color natural of virgin or recycled wood fiber provides a less light or less colored color result due to the natural resins of the fibers. The natural resin makes it difficult to achieve the desired color and could provide areas that are discolored. The problems of lack of limited color could be solved by increasing the quantity of pigments, but this is a very expensive solution and large shipments of
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6/12 pigment could cause other problems such as a pigment leak.
[00018] The laminated panels of conventional floors have a limitation in obtaining light colored or very intense colored surfaces, due to the limited transparency of the highly wear resistant roofs.
[00019] A solution to the problems is to use a dry powder layer that comprises a mixture of refined fibers, binder, pigment and wear-resistant particles.
[00020] One aspect of the invention is a production process for producing a light wear-resistant surface layer comprising the steps of:
[00021] The application of a dry powder layer comprising a mixture of refined fibers, binder, pigment and wear-resistant particles on a vehicle and [00022] Curing the mixture to a bright white or wear-resistant layer by application heat and pressure to the mixture.
[00023] The binder is preferably a melamine resin and wear resistant aluminum oxide particles. The pigments for obtaining glossy white products are preferably titanium dioxide, lead oxide or commonly used pigments. The pigments for obtaining very colorful products are a wide variety of both inorganic and organic origin.
[00024] The vehicle on which the mixture is applied is preferably an HDF panel and the resulting panel thus has wear-resistant particles throughout the thickness of the surface layer from the top to the bottom and in contact with the core the panel.
[00025] Refined fibers are fibers that are predominantly free of the natural resins typically found in
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7/12 wood or other natural fibers. Such fibers can be obtained by washing, extracting, bleaching or combinations thereof. An example of such a fiber is Technocel® 150 TAB which can be supplied by the company CFF (Germany).
[00026] In a preferred embodiment, the amount of resin compared to the amount of refined fibers, for example, white fibers, in the dry powder layer is higher than approximately 100%, preferably above approximately 120% and more preferably still in the range of approximately 120% to 180%. Such proportions have the effect that processability is increased and stain resistance is improved.
[00027] An sublayer, a layer spread over the heartwood, in combination with the dry powder layer above the sublayer, provides even better processability such as embossing depth and greater gloss. In embodiments, the sublayer comprises wood fibers, preferably natural wood fibers or HDF fibers, although refined fibers and a resin can be used.
[00028] In one preferred, the amount of resin compared to the amount of wood fibers is less than approximately 100%, preferably below approximately 200%, more preferably below approximately 300% and possibly even below approximately 400% .
[00029] A top layer of refined fibers, without aluminum oxide, placed above the dry powder layer also improves stain resistance. It also increases the life of the press plates.
[00030] The discovery modalities include the following combination of layers: (1) an sublayer and a dry powder layer; (2) a layer of dry powder and a top layer and (3) a
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8/12 sublayer a layer of dry powder and a top layer.
[00031] It is also possible to use a mixture of refined fibers and HDF fibers or any natural wood fibers, that is, wood fibers that are not refined, to decrease the cost and or to create other colors.
[00032] Many combinations of ingredients can be made into fully functional products. Two examples are provided to demonstrate two functional prototypes of the innovation.
Brief Description of the Drawings [00033] The following discovery will be described in association with the preferred modalities and in greater detail with reference to the attached drawing example, in which [00034] Figure 1 illustrates a floor panel according to a discovery modality .
Detailed Description of the Modalities [00035] A panel 1 is provided with a core 6, based on wood fiber, a non-transparent homogeneous decorative surface layer 5 and preferably a balance layer. Panel 1 is a modality formed integrally in a production process in which the surface layer, the core and the balance layer are formed in the same pressing operation.
[00036] Figure 1 shows the surface layer 5. This comprises a mixture of refined fibers 14, small hard wear-resistant particles 12, 12 'and a binder 19. The wear-resistant particles 12, 12' are preferably particles of aluminum oxide.
[00037] The surface layer also comprises colored pigments 15 and / or, optionally, other decorative materials or chemicals. Decorative materials include, for example, materials that can affect the design aspect (s) of the layer
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9/12 of surface. Examples of design materials include materials that affect texture, reflectivity, brightness, luminescence, transparency, etc.
[00038] The discovery modalities offer the advantage that the wear-resistant surface layer 5 could be made much thicker than in laminated panels for known floors.
[00039] A preferable binder is melamine or urea formaldehyde resin. Any other binder, preferably synthetic thermosetting resins, could be used.
[00040] In the process according to the modalities of the invention, preferably the same dispersing and pressing units as disclosed in WO 2009/065769 are used, preferably together with a structured press plate in the process.
Example W1: Bright white formulation [00041] On a 9.8 mm HDF plate, two NKR 140 reinforcement papers were attached when attached to the wrong side to balance, a WFF powder formulation was added, which consists of fiber refined to 40% by weight, 10% by weight of aluminum oxide, 10% by weight of titanium dioxide as pigment and 40% by weight of melamine resin. The WFF powder mixture was applied by a machine called diffusion, which distributed the WFF powder material evenly over the HDF surface. The total amount of WFF powder was 625 g / m ² . The WFF powder was fixed on the HDF plate by spraying a solution in water consisting of 97% by weight of deionized water, 1% by weight of BYK-345 (wetting agent added to reduce surface tension) and 2% by weight of Pat 622 / E (release agent) in the WFF powder.
[00042] The above material was placed in a press called DPL. The surface texture consists of a special press plate with protrusions and valleys approximately 300 microns apart
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10/12 at the highest and lowest. This deep press plate cannot be used when compressing DPL and HPL, melamine-impregnated papers crack during pressing. The resulting product is a glossy white construction panel.
[00043] Other examples of powder mixtures are listed below.
Type W1 W2 W3 W4 Sublayer W5 % by weight of HDF Fiber 0 0 0 0 75 0 % by weight of White Fiber 40 40 35 30 0 39 Weight% of Prefere 4865 0 40 45 52 25 0 % by weight of Kauramine 773 40 0 0 0 0 50 TO2% by weight 10 10 10 9 0 11 % by weight of AbOs 10 10 10 9 0 0 Total% by weight 100 100 100 100 100 100
[00044] In the above mixes, Prefere 4865 and Kauramine are used
773, which are examples of melamine formaldehyde resins [00045] For W3 and W4, the proportion of resin compared to White Fibers (refined fibers) is increased. The increased proportion has the effect that the processability is increased and that the stain resistance is improved. In a preferred embodiment the proportion of resin compared to White Fibers is higher than approximately 100%, above approximately 120% and most preferably in the range of approximately 120% to 180%.
[00046] The sublayer, a layer diffused at the heart, in combination with any of the layers W1 - W4 above the sublayer provides even better processability, such as depth of embossing and greater gloss.
[00047] The top layer, such as W5, without aluminum oxide above any of the layers W1 - W4 also improves the
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11/12 stain resistance. It also increases the life of the press plates.
Example R2: Red colored formulation [00048] On a 9.8 mm HDF plate, two NKR 140 reinforcement papers were fixed on the wrong side for balance, a WFF powder formulation was added, consisting of in 42.5% by weight of refined fiber, 10% by weight of aluminum oxide, 5% by weight of Heucosin Spez. Tomatenrot G 10138 as a red pigment and 42.5% by weight of melamine resin. The WFF powder mixture was applied by a machine called a diffusion machine, which distributed the WFF powder material evenly over the HDF surface. The total amount of WFF powder was 625 g / m ² . The powdered WFF was fixed on the HDF plate by spraying a solution in water consisting of 97% by weight of deionized water, 1% by weight of BYK-345 (wetting agent added to reduce surface tension) and 2% by weight of Pat 622 / E (release agent) in the WFF powder.
[00049] The above material was placed in a press called DPL. The surface texture consists of a special press plate with protrusions and valleys approximately 300 microns apart in the upper and lower part. This deep press plate cannot be used when compressing DPL and HPL, melamine-impregnated papers crack during pressing. The resulting product is a flat red colored construction panel that is not easily obtained without the refined fiber.
[00050] The solution in water sprayed on the powdered WFF may include, for example, 80-100% by weight of water, preferably deionized water, 0-10% by weight of a wetting agent and 0-10% by weight. a release agent. More preferably, the solution in water may include, for example, 95-98.5% by weight of water, preferably
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12/12 approximately 97% by weight, 0.5-2% by weight of wetting agent, preferably around 1% by weight and 1 -3% by weight of release agent, preferably around 2% by weight Weight.
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权利要求:
Claims (12)
[1]
1. Process for the manufacture of a wear-resistant surface layer characterized by the fact that it comprises the steps of:
• application of a dry powder layer comprising a mixture of refined fibers (14), binder (19), pigments (15) and wear-resistant particles (12, 12 ') on a vehicle; and • curing the mixture to a resistant light colored layer by applying heat and pressure to the mixture.
[2]
2. Process according to claim 1, characterized by the fact that the wear-resistant layer (5) is joined to a core (6) based on wood fiber to obtain a panel.
[3]
3. Process, according to claim 2, characterized by the fact that the panel is a floor panel.
[4]
4. Process according to any one of the preceding claims, characterized by the fact that the wear-resistant particles (12, 12 ') are made of aluminum oxide.
[5]
5. Process according to any of the preceding claims, characterized by the fact that the light-colored wear-resistant layer is bright white.
[6]
6. Process according to any one of the preceding claims, characterized by the fact that the wear-resistant layer (5) is attached to an HDF panel.
[7]
7. Process according to any one of the preceding claims, characterized by the fact that the proportion of binder (19) compared to refined fibers (14) is higher than 100%.
[8]
8. Process according to any one of the preceding claims, characterized by the fact that the proportion of binder (19) compared to refined fibers (14) is higher than
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2/2 than 120%.
[9]
9. Process according to any one of the preceding claims, characterized by the fact that the proportion of binder (19) compared to refined fibers (14) is in the range of 120% to 180%.
[10]
10. Process according to any one of the preceding claims, characterized by the fact that it additionally comprises a stage of diffusion of an sublayer over the vehicle.
[11]
Process according to any one of the preceding claims, characterized in that it additionally comprises a step of diffusing a top layer above the dry powder layer.
[12]
12. Process according to claim 1, characterized by the fact that the wear-resistant layer is smooth in color.
Petition 870190133132, of 12/13/2019, p. 19/24
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