巴西专利BR112013025558B1 method of making a building panel

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专利摘要:
The present invention relates to a method for producing a construction panel comprising a decorative surface layer, a core and a balance and / or protection layer that is described.
公开号:BR112013025558B1
申请号:R112013025558-7
申请日:2012-04-11
公开日:2021-01-12
发明作者:Niclas Hakansson；Hans Persson；Jan Jacobsson
申请人:Välinge Innovation AB；
IPC主号:

专利说明:

[0001] [001] The present invention relates in general to the field of panels with a decorative surface layer and a balancing and / or protective layer, preferably floor and wall panels. The description refers to production methods for producing such panels. APPLICATION FIELD
[0002] [002] Modalities of the present invention are particularly suitable for use in the production of floating floors, which are formed of floor panels comprising a core and a decorative wear-resistant solid surface layer comprising fibers, binders and wear-resistant particles that have been applied. in the core as a powder as described in WO 2009/065769. The field of application comprises products with other types of decorative layers such as laminated paper-based panels (DPL), where a balancing and / or protective layer is used. The following description of the technique, known and objective system problems and aspects of the modalities of the invention, therefore, as a non-restrictive example, will be intended above all in this field of application and in particular on floors that are similar to laminate floors traditional floating wood fiber. The invention does not exclude floors that are glued to a subfloor. Modalities of the invention can also be used in construction panels such as, for example, wall panels, ceilings, furniture components, and the like. BACKGROUND
[0003] [003] Wood fiber based straight pressed laminate flooring (DPL) typically comprises a 6 - 12 mm fiber board core, a 0.2 mm thick top decorative laminate surface layer and a balancing layer and / or lower protection of 0.1 - 0.2 mm in thickness of laminate, plastic, paper or similar material.
[0004] [004] The surface layer of a laminate floor is characterized by the fact that the decorative and wear properties are generally obtained with two layers separated on top of each other. The decorative layer is usually a printed paper and the wear layer is a transparent coating layer, which comprises small particles of aluminum oxide.
[0005] [005] The printed decorative paper and the coating are impregnated with melamine-formaldehyde resin and laminated in a core based on wood fiber under heat and pressure. The balancing layer is used to keep the panel flat after production and when the panel is exposed to variations in humidity conditions that cause the surface layer to swell and shrink.
[0006] [006] Recently, new types of "paper-free" Wood Fiber Flooring have been developed with solid surfaces comprising a substantially homogeneous mixture of fibers, binders and wear-resistant particles.
[0007] [007] In the prior art, as, for example, in US2009155612 it is revealed that a spreading station is used to apply a first layer, comprising the equilibrium layer, on a conveyor. A second layer, comprising the core layer, is applied over the equilibrium layer in the same way.
[0008] [008] Already in US2010300030 it appears that a spreading station is used to apply a first layer, comprising the equilibrium layer, on a conveyor. A second layer, comprising the core layer, is applied over the equilibrium layer in the same way.
[0009] [009] In turn, EP1209199 discloses a laminated product reinforced with granite of a thermosetting aminoplastic composed of fibrous material, granules based on the (semi) curing resin of ground-colored aminoplastic and a mixture of thermosetting aminoplastic resin as a matrix. The laminar product can be used, after removing the carrier sheets, in a closed mold process.
[0010] [0010] The wear-resistant particles are preferably aluminum oxide particles, the binders are preferably thermosetting resins such as amine resins and the fibers are preferably wood-based. Other suitable wear-resistant materials are, for example, silica or silicon carbide. In most applications, decorative particles such as, for example, colored pigments are included in the homogeneous mixture. In general all of these materials are preferably applied in dry form as a powder mixed in an HDF core and cured under heat and pressure in a solid layer of 0.1 - 1.0 mm.
[0011] - a camada de superfície resistente ao desgaste, que é uma mistura homogênea, pode ser feita muito mais espessa e uma resistência ao desgaste é obtida, que é consideravelmente maior. - novos e muito avançados efeitos decorativos podem ser obtidos com gravação profunda e por materiais decorativos separados, que podem ser incorporados na camada de superfície homogênea e coordenados com a gravação em relevo. - uma resistência de impacto aumentada pode ser alcançada com uma camada de superfície homogênea, que é mais espessa e tem uma densidade maior. - a camada de superfície homogênea pode compreender partículas que têm um impacto positivo em propriedades de som e umidade. - os custos de produção podem ser reduzidos na medida em que o baixo custo e mesmo materiais reciclados podem ser usados e as várias etapas de produção podem ser eliminadas. [0011] Several advantages over known technology and especially over conventional laminate floors can be obtained: - the wear-resistant surface layer, which is a homogeneous mixture, can be made much thicker and a wear resistance is obtained, which is considerably higher. - new and very advanced decorative effects can be obtained with deep engraving and with separate decorative materials, which can be incorporated into the homogeneous surface layer and coordinated with the embossing. - increased impact resistance can be achieved with a homogeneous surface layer, which is thicker and has a higher density. - the homogeneous surface layer can comprise particles that have a positive impact on sound and moisture properties. - production costs can be reduced to the extent that low cost and even recycled materials can be used and the various production steps can be eliminated.
[0012] [0012] Powder technology is very suitable for producing the solid decorative surface layer, which is much thicker than conventional laminated surface layers. Such solid powder-based layers create a much greater tension on the panel when they contract (or swell) during curing and balancing is a problem. Therefore, it is difficult to produce a panel with a thick, high-quality surface, which is also well balanced after pressing as well as stable and flat under varying humidity conditions. Definition of Some Terms
[0013] [0013] "Surface layer" means all types of surface layers, which give the panel its decorative properties and resistance to wear. By a "WFF mixture" is meant a mixture of materials comprising fibers, binders, wear-resistant particles and, optionally, a colored substance, which is preferably applied as a powder on a support.
[0014] [0014] By "WFF flooring" is meant a floor panel comprising a solid surface, which is obtained by a mixture of WFF which is preferably applied as a dry powder to a core, such as, for example, HDF, and cured under heat and pressure. Known Technique and Problems
[0015] [0015] The new "paper-free" WFF floors with a solid surface comprising a WFF blend of fibers, preferably wood fibers, small hard wear-resistant particles and a binder are produced according to a production method where the mixture WFF is applied as a powder to a core. Wood fibers are generally refined, mechanically worked, and of the same type as used in HDF and particle board, this is treated in a way that the lignin content is essentially immutable. They comprise natural resins such as lignin. The wear resistant particles are preferably aluminum oxide particles. The surface layer preferably also comprises colored pigments or other decorative or chemical materials. Processed fibers, for example, bleached wood fibers can also be used. The processed fibers can be semitransparent, and are preferably transparent in a cured binder.
[0016] [0016] A preferred binder is melamine resin or urea-formaldehyde. Any other binder, preferably thermosetting or thermoplastic synthetic resins, can be used. The WFF layer is generally dispersed as a dry powder in a wood based core, such as, for example, HDF.
[0017] [0017] The rear side of the core is covered by a balancing layer, which comprises one or more papers impregnated with melamine resin in order to obtain a balanced product after pressing. The panel is generally produced with a surface that is slightly convex in order to be able to remain flat even in very dry conditions.
[0018] [0018] The total accumulation with the decorative layer, core and balancing or protective layer is transferred to a press, where the decorative layer and the balancing or protective layer are cured, under the influence of heat and pressure.
[0019] [0019] A protective layer means a layer adapted to protect the back side of the core.
[0020] [0020] The curing of a melamine-formaldehyde (MF) resin involves dispersion of the MF resin matrix and the balancing layer is necessary to balance the dispersion forces of the decorative layer.
[0021] [0021] Paper-based coating materials can create problems as the paper always has a dominant fiber direction either in the production direction or perpendicular to the production direction, the contraction during curing is always greater in the transversal direction of the fibers as the fibers can be packed together closer in this direction. The implication of this behavior is that the balance layer has a different contraction in the production direction compared to the transversal direction.
[0022] [0022] As the coating is used to balance the decorative layer, which can as an example comprise a powder mix with random fiber direction, the consequence is that an optimized balance can only be achieved in one direction, both along and perpendicular to the production direction. It is also complicated to adapt the thickness of the paper to different thicknesses of the surface layer.
[0023] [0023] However, the paper-based balancing layer offers the advantages that paper is instead easy to transport together with the core under the dispersion units and in a press.
[0024] [0024] It is known from WO 2009/065769 that the balance layer can be created with a powder layer that is applied to the back side of the core. This known description does not show how a layer of powder on the rear side of a core must be manipulated to allow economical production, especially when batch presses are used that require the core with its powder-based layers to be fed into high speed with clamping devices on a press.
[0025] [0025] The above description of several known aspects is the characterization of the applicants for such, and it is not an admission that any description is the prior art. OBJECTIVES AND SUMMARY
[0026] [0026] An objective of certain embodiments of the invention is to provide a construction panel, preferably a floor panel with a decorative surface layer and a balancing and / or protective layer that can be produced in an economical manner.
[0027] - aplicar uma primeira camada de uma primeira mistura à base de pó, compreendendo fibras de madeira e um aglutinante de termocura em um núcleo; - aplicar uma substância líquida na primeira mistura à base de pó; - secar a primeira mistura à base de pó; - girar o núcleo com a primeira mistura à base de pó seca tal que a primeira mistura à base de pó aponta para baixo; - aplicar uma segunda camada na parte superior do núcleo; e - curar as primeira e segunda camadas simultaneamente fornecendo calor e pressão, em que a primeira camada forma a camada de balanceamento e/ou protetora e a segunda camada forma a camada de superfície decorativa no painel de construção. [0027] A first aspect of the invention is a method of manufacturing a construction panel with a decorative surface layer, a core and a balancing and / or protective layer. The method comprises the steps below and is preferably carried out in the listed sequence: - apply a first layer of a first powder-based mixture, comprising wood fibers and a thermoset binder in a core; - apply a liquid substance to the first powder-based mixture; - dry the first powder-based mixture; - rotate the core with the first dry powder-based mixture such that the first powder-based mixture points downwards; - apply a second layer on the top of the core; and - cure the first and second layers simultaneously by providing heat and pressure, where the first layer forms the balancing and / or protective layer and the second layer forms the decorative surface layer on the construction panel.
[0028] [0028] The method offers the advantages that a balance or protection layer based on dust can be applied in an economical way by dispersion in a core. The powder can be fixed to the core with a liquid substance that swells, partially dissolves or dissolves the resin, thereby making the powder sticky and sticky. The drying step removes part of the water thus leaving the powder stuck not only on itself, but also on the core. The fixation makes the first layer stable such that the core with the first layer can be rotated and fed under dispersion units and inside a press. The drying layer removes part of the water thus leaving the powder stuck not only on itself, but also on the core. The fixation makes the first layer stable such that the core with the first layer can be rotated and fed under dispersion units and in a press. A paper-based balancing or protection layer can be replaced in an economical way by a wood fiber-based layer with random fiber direction that has dispersion properties like the decorative surface layer.
[0029] [0029] The construction panel can be a floor panel.
[0030] [0030] The core can be an HDF or MDF board.
[0031] [0031] The second layer may comprise a varnish layer. In this way, the varnish layer forms the decorative surface layer. The second layer may comprise a layer of laminated wood. A curable lacquer can be applied on top of the varnish layer.
[0032] [0032] The second layer may comprise a first sheet of paper. In this embodiment, the second layer forming the decorative surface layer is a laminate such as DPL (direct pressed laminate) or HPL (high pressure laminate).
[0033] [0033] The second layer may further comprise a second sheet of paper.
[0034] [0034] The first and / or second sheet of paper can be impregnated with a thermosetting resin such as melamine formaldehyde.
[0035] [0035] The first sheet of paper may be arranged such that the fiber direction of the first sheet of paper is extending in a first direction, and the second sheet of paper may be arranged such that the fiber direction of the second sheet of paper it is extending in a second direction, said second direction being transversal to the first direction.
[0036] [0036] The second layer may comprise a second powder-based mixture comprising wood fibers, binders, preferably a thermoset binder, and wear resistant particles. In this way, the second layer can be applied in the same way as the powder-based balancing or protection layer dispersing in the core.
[0037] [0037] The method can also include the step of applying an impression or colored substance in a second mixture.
[0038] - aplicar uma primeira camada de uma primeira mistura à base de pó, compreendendo fibras de madeira e um aglutinante de termocura em um suporte, de preferência de um material fino com uma espessura que não excede a espessura da camada de superfície decorativa; - colocar o material de núcleo na primeira mistura à base de pó; - aplicar uma segunda camada na parte superior do núcleo; e - curar as primeira e segunda camadas fornecendo calor e pressão em que a primeira camada forma a camada de balanceamento e/ou protetora e a segunda camada forma a camada de superfície decorativa do painel de construção. [0038] A second aspect of the invention is a method of manufacturing a construction panel with a decorative surface layer, a core and a layer and balancing and / or protection. The method comprises the steps below and is preferably carried out in the sequence listed: - applying a first layer of a first powder-based mixture, comprising wood fibers and a thermoset binder on a support, preferably of a thin material with a thickness that does not exceed the thickness of the decorative surface layer; - put the core material in the first powder-based mixture; - apply a second layer on the top of the core; and - cure the first and second layers by providing heat and pressure where the first layer forms the balancing and / or protective layer and the second layer forms the decorative surface layer of the construction panel.
[0039] [0039] The method offers the advantages that a powder-based balancing or protection layer can be applied in an economical way by dispersing it in a support that keeps the powder-based balancing or protection layer connected to the core during transport for the device that applies the surface layer and finally when the core is fed into the press.
[0040] [0040] The construction panel can be a floor panel.
[0041] [0041] The core can be an HDF or MDF board.
[0042] [0042] The support can be a fiber-based material.
[0043] [0043] The second layer may comprise a varnish layer. In this way, the varnish layer forms the decorative surface layer. A curable lacquer or powder mix layer can be applied on top of the varnish layer.
[0044] [0044] The second layer may comprise a first sheet of paper. In this embodiment, the second layer forming the decorative layer is a laminate such as DPL (direct pressed laminate) or HPL (high pressure laminate).
[0045] [0045] The second layer may also comprise a second sheet of paper.
[0046] [0046] The first and / or second sheet of paper can be impregnated with a thermosetting resin such as melamine formaldehyde.
[0047] [0047] The first sheet of paper may be arranged such that the fiber direction of the first sheet of paper is extending in a first direction, and the second sheet of paper may be arranged such that the fiber direction of the second sheet of paper it is extending in a second direction, said second direction being transversal to the first direction.
[0048] [0048] The second layer may comprise a second powder-based mixture comprising wood fibers, binders, preferably a thermoset binder, and wear resistant particles. In this way, the second layer can be applied in the same way as the powder-based balancing or protection layer dispersing in the core.
[0049] [0049] The method can also include the step of applying an impression or colored substance in a second mixture.
[0050] - aplicar uma mistura de pó compreendendo fibras e um aglutinante de termocura em um suporte; - aplicar umidade na mistura de pó tal que a mistura de pó é conectada junto com uma camada de balanceamento e/ou proteção não curada essencial; e - liberar a camada de balanceamento e/ou proteção não curada do suporte. [0050] A third aspect is a method of manufacturing a separate and continuous powder-based balancing and / or protection layer, which is essentially uncured. The method comprises the steps below and is preferably carried out in the sequence listed: - applying a powder mixture comprising fibers and a thermoset binder on a support; - apply moisture to the powder mixture such that the powder mixture is connected together with a balance layer and / or essential uncured protection; and - release the balancing layer and / or uncured protection from the support.
[0051] - colocar uma camada de balanceamento e/ou proteção não curada sob o material de núcleo; - aplicar uma camada de superfície no material de núcleo; e - curar a camada de superfície e a camada de balanceamento e/ou protetora sob calor e pressão. [0051] The separate, continuous powder-based balancing or protective layer can be used in a method to produce a construction panel whose method comprises the steps below and is preferably carried out in the sequence listed: - place a balancing layer and / or uncured protection under the core material; - applying a surface layer to the core material; and - cure the surface layer and the balancing and / or protective layer under heat and pressure.
[0052] [0052] The method offers the advantages that the powder-based balancing or protection layer can be produced as a separate uncured layer that can be manipulated as a paper-based balancing or protection layer. The moisture, which preferably comprises water, can be sprayed onto the powder such that the binder, preferably melamine resin, swells with moisture, partially dissolves or dissolves the resin, thereby making the powder sticky and sticky. The fibers in the mixture will be connected to each other when the water dries. The fibers can also be connected by applying heat, for example, infrared heating, thereby removing moisture and connecting the fibers in the mixture. An uncured powder-based balancing or protection layer can be formed as a flexible thin sheet, and a core material can be placed on top of the balancing or protective layer.
[0053] [0053] The surface layer may comprise a powder-based surface layer, at least one sheet of paper or a layer of varnish.
[0054] [0054] A fourth aspect of the invention is a separate and continuous powder-based balancing and / or protection layer, which is essentially uncured. The separated layer comprises a powder mixture comprising connected fibers and an essentially uncured heat-curing binder.
[0055] [0055] The dust-based balancing or protection layer is preferably produced according to the method of the third aspect.
[0056] [0056] A fifth aspect of the invention is a construction panel, comprising a core, preferably a wood-based core such as MDF or HDF panel, a decorative surface layer arranged on a first surface of said core, the layer decorative surface comprising at least one layer of paper, and a balancing layer arranged on a second surface of said core, said second surface being opposite to said first surface, wherein the balancing layer is formed of a mixture based on powder comprising wood fibers and a thermoset binder.
[0057] [0057] The construction panel is preferably produced according to the first or second aspect of the invention. BRIEF DESCRIPTION OF THE DRAWINGS
[0058] [0058] The following invention will be described in connection with preferred modalities and in more detail with reference to the accompanying exemplary drawings, in which:
[0059] [0059] figures 1a-e illustrate a method for forming a balancing and / or protective layer;
[0060] [0060] figures 2a-e illustrate a method for forming a balancing and / or protective layer;
[0061] [0061] figure 3 shows a construction panel in which the decorative layer is laminated;
[0062] [0062] figure 4 illustrates a construction panel in which the decorative layer is a varnish layer. DETAILED DESCRIPTION OF MODALITIES
[0063] [0063] The powder intended to be used as a balancing and / or protective layer 3 is applied as a first powder mixture in a core 2, preferably an MDF or HDF material, preferably by one or more dispersion units 11 as shown in figure 1a.
[0064] [0064] Figure 1b shows that the powder is thereafter pre-established by a fluid 7, preferably based on water, which is applied by a stabilizing device 9. The first layer of powder is then said to be dry. Such drying can be carried out offline in a controlled environment or in line by applying heat 8 with a heating device 10 to the powder mixture 3. The heating device 10 can comprise infrared light. The water-based fluid 7 and the following drying 8, leave the powder layer 3 in the core 2 to such an extent that the core 2 with the powder can be rotated 180 ° to place the balance or protective layer based on the powder 3 downwards, as shown in figure 1c, so that it can be transported along the production line or stacked on a pallet for intermediate storage before further production takes place.
[0065] [0065] Oversized or undersized fibers from the hammer mill that produces the fibers for the surface layer can be used in the balance or protection layer mixture. The fiber size is not critical when in a powder-based surface chamber and can vary from a fiber length of several mm to less than 0.1 mm. The most preferred average fiber length is 0.1 - 1.0 mm.
[0066] [0066] A second powder-based surface layer mixture 1 is thereafter applied to the upper side of the core 2 as shown in figure 1d. A digital print 4 can be printed on the surface layer 1, the surface layer 1 preferably also comprises wood fibers, a colored substance, thermoset binders and aluminum oxide particles.
[0067] [0067] The wood fibers in both the first and second powder mixtures in all embodiments of the invention can be virgin, unrefined, refined and / or processed, comprising lignin and without lignin, for example a-cellulose or holocellulose fibers . A mixture of refined and unrefined fibers can also be used. It is also considered that plant fibers such as jute, linen, flax fiber, cotton, bamboo, bagasse and sisal can be used. Mineral fibers and carbon fibers can also be used.
[0068] [0068] As an alternative to the second powder-based surface layer mixture, the second layer forming the decorative surface layer can comprise at least one sheet of paper 21 adapted to form a laminate, which is shown in figure 3. A said at least one sheet of paper 21 may be arranged on the upper side of the core. Preferably, the second layer comprises a first sheet of paper 21 and a second sheet of paper 22. The first and second sheets of paper 21, 22 can be arranged such that the fiber direction of the first sheet of paper 21 is extending in a first direction, and the fiber direction of the second sheet of paper 22 extending in a second direction being opposite to the first direction. Laying the fiber direction of the sheets transversely, the second layer has fiber directions in more than one direction. In this way, during shrinkage, the second layer obtains properties more similar to the balancing or protection layer having a random fiber direction purchased with a surface layer having only one dominant fiber direction.
[0069] [0069] The first sheet of paper 21 can be a printed paper. The second sheet of paper 22 can be a transparent coating paper. The second sheet of paper 22 can form a wear layer and can comprise small particles of aluminum oxide. The first and second sheets of paper 21, 22 can be impregnated with melamine resin such that they can be laminated to the core under heat and pressure simultaneously in order to cure the balancing and / or protective layer. The second sheet of paper 22 can be arranged on top of the first sheet of paper 21.
[0070] [0070] Alternatively, the second layer may comprise a layer of varnish 23 or layer in the form of a wood veneer arranged on the upper side of the core, which is shown in figure 4, the second layer may further comprise a layer of curable lacquer applied to the top of the veneer layer or layer in the shape of a wooden sheet. The curable lacquer layer can be cured simultaneously by curing the balancing and / or protective layer.
[0071] [0071] Other decorative layers can also be used as a second layer, such as cork, rubber, plastic, especially a thermoplastic decoration layer.
[0072] [0072] The core 2 with the surface layer 1 and the balancing or protection layer 3 is thereafter fed into a press where the layers are cured under heat and pressure. The balance layer can be optimized in thickness and material composition in order to create a perfect balance of the surface layer. The fiber orientation in the layers can be essentially the same.
[0073] [0073] Fibers recycled from the machining of the panels, for example, when a mechanical locking system is formed, it can be used in the mixing of balance or protection layer.
[0074] [0074] The balancing or protective layer 3 may preferably comprise a homogeneous powder mixture comprising about 50% by weight of recycled MDF fibers with a moisture content preferably 3-8% and about 50% by weight. melamine-formaldehyde resin (MF) (Prefer 4865, Dynea). The amount of MF resin can vary between 30-70% by weight, preferably 4065% by weight and more preferably 45-60% by weight. The fiber content can vary between 30 to 70%, more preferably between 40 to 55%.
[0075] [0075] If necessary, the powder formulation can be modified so that thermosetting particles, pigments, hard particles, release agents, wetting agents, and similar materials are included in the mixture. The thermosetting plastic particles can be mixed randomly into the powder or applied as a separate thin layer and can be used to provide a seal against moisture penetrating the core.
[0076] [0076] The core of an HDF board preferably has a moisture content of 0-8%.
[0077] [0077] The dispersion unit 11 can have a dispersion capacity of 100 - 1000 g / m2 with a tolerance of ± 5% as measured using a calibration cup with an area of 100 x 100 mm in the transverse and longitudinal direction of the plate , the amount of stabilizing fluid can vary between 0 to 200 g / m2.
[0078] [0078] The dispersion unit 11 can comprise a needle belt and a dispersion roller 12. The dispersion roller is provided with needles in the range of about 30-120, preferably about 50100, and more preferably about 70 -90 needles per cm2. The needle length is about 0.5 - 2.5 mm, preferably about 1-2 mm and more preferably about 1.5 mm. Various dispersion units 11 can be used to level the differences in the applied powder mixture.
[0079] [0079] Furthermore, the dispersion unit can be provided with a needle belt with needles with a preferred length of about 15-20 mm, a preferred frequency in the range of 5001000 rpm, preferably about 1000 rpm, and a travel length of about ± 3 mm.
[0080] [0080] The stabilizing device 9 and the heating device 8 can be used to stabilize the surface layer 1 and / or the balancing or protection layer 3.
[0081] [0081] The stabilizing device and the heating device 8 can be used to stabilize the surface layer 1 and / or the balance or protection layer 3.
[0082] [0082] The stabilizing device 9 can stabilize the powder using steam, nozzle spray coating or ultrasonic spray coating.
[0083] [0083] The stabilizing fluid may comprise solvents such as non-polar solvents, polar aprotic solvents and polar protic solvents or mixtures thereof. Preferred solvents are polar protic solvents such as isopropanol, ethanol and water. The most preferred is water.
[0084] [0084] The stabilizing fluid may further comprise additives such as wetting agents, anti-foaming agents, release agents, anti-slip agents and catalysts.
[0085] [0085] Figures 2a-2e shown as a balance or protection layer can be applied by applying the powder-based balance or protection layer as a first mixture 3 in a support 5. The core is applied in the mixture (figure 2c) and a powder-based surface layer 1 is applied to the core 2. alternatively, a surface layer of at least one sheet of paper 21 or varnish layer 23 is applied to the core to form a decorative surface layer, as described above with reference to figures 3 and 4. The stabilization and / or heating of the balancing and / or surface layers can be done as described above. The core and layers are fed into a press and cured under heat and pressure on a construction panel as shown in figure 2e.
[0086] [0086] The support can be a paper with a weight of, for example, 100-200 g. It can also be a non-woven fiber-based material or a plate.
[0087] [0087] Powder can also be applied to a support which is preferably a conveyor belt 11 and stabilized with fluid and dried so that it can be released from the conveyor 11 and manipulated as a separate sheet without the support 5 as shown in figure 2b. Such a separate, continuous sheet or layer is essentially uncured. The sheet or layer can be flexible such that it can be curved. The powder may comprise fibers, preferably wood fibers, and a thermoset binder. EXAMPLE
[0088] [0088] In example 1 below the powder formulation for the balance layer used comprising 50% by weight of recycled MDF fiber (Välinge Innovation Sweden), 50% by weight of melamine-formaldehyde resin (Prefer 4865, Dynea). Example 1: Powder-based product obtained by heat compression of product produced with a powder-based balancing layer and a powder treated as a decorative layer.
[0089] [0089] A balancing layer was formed by dispersing 500 g / m2 of powder in a 9.7 mm HDF core
[0090] [0090] 40 g / m2 of stabilizing fluid with 5% by weight of wetting agent, 6% by weight of release agent and 3% by weight of catalyst was applied by spraying on the powder-based balance layer mixture.
[0091] [0091] The powder and stabilization fluid were applied at a line speed of 2.7 m / min. The powder-based balancing layer was dried on the same IR speed line with an effect of 19 kW.
[0092] [0092] The resulting intermediate product with a stabilized powder-based balancing layer was rotated 180 ° and stacked on a pallet before use in the next operation where a 500 g / m2 decorative surface layer was applied in powder form on core.
[0093] [0093] The core with the balancing surface and layers was pressed in a press with a pressure of 40 kg / cm2, for 25 seconds. The upper press table applied 170 ° C heat to the surface layer and the lower press table applied 175 ° C heat to the balancing layer.
[0094] [0094] A panel with a small pre-tension to the rear and a slightly convex surface was obtained.
[0095] [0095] In example 2 below, the powder formulation for the balancing layer used comprising 42% by weight of recycled MDF fiber (Välinge Innovation Sweden), 58% by weight of melamine-formaldehyde resin (Prefer 4865, Dynea) . Example 2: powder-based product obtained by heat compression of the product produced with the powder-based balancing layer and a powder treated as a decorative layer.
[0096] [0096] A balancing layer was formed by dispersing 320 g / m2 of powder in a 9.7 mm HDF core
[0097] [0097] 40 g / m2 of stabilizing fluid with 1% by weight of wetting agent, 6% by weight of release agent and 1% by weight of catalyst was applied by spraying on the powder-based balance layer mixture.
[0098] [0098] The powder and stabilization fluid were applied at a line speed of 2.0 m / min. The powder-based balancing layer was dried on the same IR speed line with an effect of 19 kW.
[0099] [0099] The resulting intermediate product with a stabilized powder-based balancing layer was rotated 180 ° and stacked on a pallet before use in the next operation where a 550 g / m2 decorative surface layer was applied in powder form on core.
[0100] [00100] The core with the balancing surface and layers was pressed in a press with a pressure of 40 kg / cm2, for 37 seconds. The upper press table applied 184 ° C heat to the surface layer and the lower press table applied 175 ° C heat to the balance layer.
[0101] [00101] A panel with a small pre-tension to the rear and a slightly convex surface was obtained.
[0102] [00102] It is considered that there are numerous modifications to the modalities described here, which are still within the scope of the invention as defined by the appended claims.
[0103] [00103] For example, it is considered that the balance layer can be provided with guidance in some modalities. Wood fibers based on the balancing layer generally have a random fiber direction. However, in order to form a balancing layer having similar properties as the decorative surface layer, an orientation can be formed in the balancing layer. Such guidance can be provided by means of dispersing the powder in a specific pattern, by a pattern on the press plate, or by means of a rake forming a pattern.
[0104] [00104] The steps of the method claim do not necessarily have to be performed in the order described above. For example, it is considered that the second layer can be applied before the first layer, and that the core is rotated after the second layer has been applied. After this the first layer is applied, liquid is applied, the first powder-based mixture is dried and the core is rotated with the first dry powder-based mixture such that the first powder-based mixture points downwards.

权利要求:
Claims (13)
[0001]
Method of making a construction panel (6) with a decorative surface layer (1), a core (2) and a balancing and / or protective layer (3 '), in which the method is characterized by the fact that it comprises the phases: - apply a first layer (3) of a first powder-based mixture, comprising wood fibers and a thermoset binder in a core (2); - apply a liquid substance to the first powder-based mixture; - after applying the liquid substance in the first powder mixture, dry the first powder based mixture; - rotate the core (2) with the first dry powder-based mixture such that the first powder-based mixture points downwards; - apply a second layer (1) on the top of the core (2); and - cure the first (3) and second (1) layers by providing heat and pressure, where the first layer (3) forms the balancing and / or protective layer (3 ') and the second layer (1) forms the layer of decorative surface (1) on the building panel (6).
[0002]
Method according to claim 1, characterized by the fact that the construction panel (6) can be a floor panel.
[0003]
Method according to claim 1 or 2, characterized by the fact that the core (2) can be an HDF or MDF board.
[0004]
Method according to any one of claims 1 to 3, characterized in that the step of applying said second layer (1) comprises applying a layer of varnish (23).
[0005]
Method according to any one of claims 1 to 3, characterized in that the step of applying said second layer (1) comprises applying a first sheet of paper (21).
[0006]
Method according to claim 5, characterized in that the step of applying said second layer (1) still comprises a second sheet of paper (22).
[0007]
Method according to claim 6, characterized in that the step of applying said first and second sheets of paper (21, 22) comprises arranging said first sheet of paper (21) such that the fiber direction of the first sheet of paper (21) is extending in a first direction, and arranging said second sheet of paper (22) such that the fiber direction of the second sheet of paper (22) is extending in a second direction, said second direction being transversal to the first direction.
[0008]
Method according to any one of claims 1 to 3, characterized in that the step of applying the second layer (1) comprises a second powder-based mixture (1) comprising wood fibers, binders, preferably a binder thermosetting, and wear-resistant particles.
[0009]
Method according to claim 8, characterized in that the method comprises the additional step of applying an impression (4) or colored substance in a second mixture (1).
[0010]
Method of making a construction panel (6) with a decorative surface layer (1), a core (2) and a balancing and / or protective layer (3 '), characterized by the fact that the method comprises the steps of : - apply a first layer (3) of a first powder-based mixture, comprising wood fibers and a thermoset binder on a support (5), preferably of a thin material with a thickness that does not exceed the thickness of the decorative surface (1); - place the core (2) in the first powder-based mixture, where the core (2) is an HDF or MDF board; - apply a second layer (1) on the top of the core (2); and - cure the first (3) and second (1) layers by providing heat and pressure where the first layer (3) forms the balancing and / or protective layer (3 ') and the second layer (1) forms the surface layer (1) of the building panel (6).
[0011]
Method according to claim 10, characterized in that the construction panel (6) can be a floor panel.
[0012]
Method according to claim 10 or 11, characterized in that the step of applying said second layer (1) comprises applying a first sheet of paper (21).
[0013]
Method according to claim 10 or 11, characterized in that the step of applying said second layer (1) comprises applying a second powder-based mixture (1) comprising wood fibers, binders, preferably a binder thermosetting, and wear-resistant particles.

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同族专利:

公开号 | 公开日

EP2697060B1|2020-06-10|

PL2697060T3|2020-11-02|

US9085905B2|2015-07-21|

US20120263965A1|2012-10-18|

AU2012243457B2|2015-07-16|

EP2697060A1|2014-02-19|

NZ615287A|2015-09-25|

CA2832040C|2020-08-25|

CN103459145A|2013-12-18|

WO2012141647A1|2012-10-18|

MX342546B|2016-10-03|

US10214913B2|2019-02-26|

CN103459145B|2016-06-29|

RU2013148006A|2015-05-20|

BR112013025558A2|2016-12-27|

US20150275526A1|2015-10-01|

ZA201307461B|2015-01-28|

CA2832040A1|2012-10-18|

MX2013011536A|2013-12-06|

RU2591466C2|2016-07-20|

EP2697060A4|2014-11-12|

MY161172A|2017-04-14|

AU2012243457A1|2013-09-26|

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