• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    panel formation. a method for forming a construction panel with a surface that includes a thermosetting resin such that the stress created during surface hardening is reduced or eliminated. 20609916v1
    公开号:BR112014004486B1
    申请号:R112014004486-4
    申请日:2012-09-07
    公开日:2021-04-13
    发明作者:Darko Pervan；Tony Pervan
    申请人:Ceraloc Innovation Ab；
    IPC主号:
    专利说明:

    Technical field
    [001] The invention relates generally to the field of panel formation, for example, construction panels. More particularly, the invention relates to a method for forming floor panels and the floor panels produced by the method. Known technology
    [002] Traditional laminated panels, intended to be used for cladding or furniture components, for example, are produced by the following steps: applying a kraft paper impregnated with melanin formaldehyde resin as a balance layer on one side of a core wood fiber-based material, for example, HDF; apply a printed decorative paper impregnated with melanin formaldehyde resin on the other side of the core; apply a transparent covering paper impregnated with melanin formaldehyde resin with wear-resistant particles, for example, aluminum oxide, on the decorative paper; and hardening the resin by applying heat and pressure in a continuous or batch press to obtain a laminated product.
    [003] Typical pressing parameters are a pressure of 40 bars and a temperature of 160 to 200 ° C with a pressing time of 12 to 30 seconds. The surface layer is generally 0.1 to 0.2 mm thick, the thickness of the HDF core varies between 6 to 12 mm and the equilibrium layer is about 0.1 to 0.2 mm thick.
    [004] This production method and the product produced by these methods are generally referred to as the DPL process and the DPL products (Direct pressure laminates).
    [005] Recently new panels with a surface based on wood dust have been developed. The powder comprising powdered wood fibers, preferably melanin particle binders, aluminum oxide particles and color pigments are dispersed on an HDF plate and pressed under heat and pressure in a continuous or batch press to obtain a product with a solid, paper-free surface layer. The injection parameters are similar to DPL. A higher pressure of 40 to 80 bars and a pressing time of 20 to 40 seconds can be used when the surface is formed by deep drawing and a thickness of, for example, 0.4 to 0.6 mm. The pressing temperature is generally 160 to 200 ° C. Such wood fiber-based floors, generally referred to as WFF floors, have considerably better properties than traditional laminate floors since a wear-resistant, impact-resistant and thicker surface can be produced effectively.
    [006] Figures 1a to 1d show the production of a WFF laminate or floor panel according to the known technology.
    [007] A layer of the surface 2 of an impregnated coating and a decorative paper or a powder layer is applied over the top of an HDF core 3. A balancing paper or powder support layer 4 is applied on the back side of the HDF core, as shown in figure 1a. The core 3 with the top 2 and bottom 4 layers is transferred to a press and pressed under heat and pressure in such a way that the layers are hardened and bonded to the plate, as shown in figure 1b.
    [008] The layers on the front face and the back face are exposed to a first shrinkage when the thermosetting resin in the top and bottom layer hardens during pressing. The backing layer on the rear face balances the tension that is created by the front face surface layer and the panel is substantially flat with a small convex fold backwards when exiting the press. Such first shrinkage and balance of the panel are referred to below as "press balance". The second temperature shrinkage, when the panels are cooled from about 160 to 200 ° C to room temperature, is also balanced by the support layer and the panel 1 is essentially flat, as shown in figure 1b. The second equilibrium is hereinafter referred to as "cooling equilibrium". A small backward convex bend is preferred (not shown) as this neutralizes the upward bend of the edges in dry conditions, when the relative humidity can drop to 20% or less during the winter.
    [009] The problem is that this essentially flat panel comprises tension forces caused by the reduction of the surface and the layers of equilibrium.
    [0010] The panel is generally cut into several elements and formed into floor panels with locking systems on the long and short edges, as shown in figure 1c. The locking system can comprise, for example, in general, a tongue 10 and a tongue groove 9 for vertical locking and a strip 6 with a locking element 8 that cooperates with a locking groove 14 for horizontal locking.
    [0011] The surface and core will swell in the summer, when the internal humidity is high, and decrease in the winter, when the internal humidity is low. The panels will shrink and expand and an excavation of the margins can take place. The balance layer is used to neutralize such excavation. This balance is referred to as "climate balance".
    [0012] Figure 1d shows that the internal tension can cause problems when the locking system is formed and, especially, when the panel is installed in a dry climate, which causes the layers to shrink. A so-called edge covering can occur when the internal tension opens the groove 9 and folds the tongue part 10 upwards, due to the fact that these parts are no longer balanced when the locking system is formed. The internal tension can also cause a backward bend of the strip 6, which decreases the locking force and the quality of the locking system. The tension can be greater than the internal bonding resistance of the core, which can cause cracks C, mainly in grooves that extend horizontally, such as the groove of the tongue 9.
    [0013] Such internal voltage may require a higher-than-normal quality of the board, and this may increase costs.
    [0014] It would be a great advantage if the stress caused by temperature hardening and shrinkage can be reduced or completely eliminated. Such a stress reduction would be especially favorable on WFF floors which generally comprise thick solid surface layers instead with a considerable amount of thermosetting binders or high quality DPL floors for commercial application where the thickness and resin content of the surface layer are greater than on DPL floors for home use. Summary of the Invention and Objects
    [0015] A general objective of the modalities of the present invention is to provide a method for reducing or eliminating stress on panels with a surface comprising thermosetting resins that are hardened and bonded to a core under heat and pressure. The embodiments of the present invention can combine various folding processes and product characteristics as listed below.
    [0016] A first aspect of the invention is a method for the production of a panel, for example, a construction panel, preferably a floor panel, with a wood-based core and a surface layer comprising a resin thermosetting, in which the method comprises the steps of: hardening and bonding the surface layer to the core under heat and pressure, in a first stage of main pressing; apply a bending force on the panel, after the first main pressing step in such a way that it bends back away from the surface layer in hot conditions, and release the bending force so that the panel comes back into a shape essentially flat.
    [0017] In one embodiment, the surface layer can be directly attached to the core. In one embodiment, the surface layer can be connected to an intermediate layer, the intermediate layer being directly connected to the core.
    [0018] The method can also comprise the step of decreasing the surface temperature during bending.
    [0019] The temperature decrease can be about 20 ° C.
    [0020] The temperature decrease can be over 20 ° C.
    [0021] The resin can be a melanin formaldehyde resin.
    [0022] The method can comprise a fold that is at least about 3 cm / m.
    [0023] The surface layer may comprise wood fibers and wear-resistant particles.
    [0024] The surface layer may comprise wood fibers, wear-resistant particles and color pigments.
    [0025] A second aspect of the invention is a floor panel that comprises a wood-based core and a surface layer that comprises a thermosetting resin produced according to the first aspect, and that the panel has no equilibrium layer.
    [0026] The floor panel according to the second aspect can have a back face, which is the wood-based core.
    [0027] The floor panel may be a DPL panel comprising an impregnated paper surface layer attached to an HDF core.
    [0028] The floor panel can be a WFF panel comprising a layer of the powder-based surface. Brief description of the drawings
    [0029] The invention will be described below in relation to the exemplary modalities and in greater detail with reference to the accompanying exemplary drawings, in which:
    [0030] Figures 1a to 1d show the known production of a floor panel according to the known technology.
    [0031] Figures 2a to 2d show the production of a panel according to a first embodiment of the invention.
    [0032] Figures 3a to 3d show the production of a panel according to a second embodiment of the invention.
    [0033] Figures 4a to 4c show a method for measuring the internal voltage in a panel.
    [0034] Figures 5a to 5b show the panel temperature during pressing and cooling.
    [0035] Figures 6a to 6d show a method for obtaining the plastic deformation of a panel. Description of the Modalities of the Invention
    [0036] Figure 2a shows a panel 1 that was pressed with only one layer of surface 2, applied over a core 3. The panel can be a DPL panel or a WFF panel. The shrinkage of the surface layer 2 during pressing, when the thermosetting resin is hardened, causes the edges of panel 1 to bend upwards. The fold can increase even more when the panel 1 is cooled to room temperature. The fold is such that panel 1 cannot be used for the production of floors.
    [0037] The reason is that there is no backing layer that balances the shrinkage of the surface layer 2 during pressing and cooling.
    [0038] The panel has, essentially, the same surface temperature, according to the pressing table when it leaves the press. The normal pressing temperature is about 170 ° C. The core generally has a temperature well below about 80 to 100 ° C. This means that the surface layer will cool down very quickly after pressing. After 10 seconds, the surface temperature can be 120 ° C and, after 15 to 20 seconds, only about 80 ° C. The cooling of the surface and the core is effected by the pressing time. A longer pressing time will increase the core temperature more than a short pressing time.
    [0039] Figure 2b shows that the panel 1 is pressed in a second pressing stage between the curved pressing tables 5, 7, when the surface layer 2 is still hot, after the first pressing stage. If such a pressing post is made at a temperature of about 70 to 90 ° C, it will deform the hot HDF core and create a back pressure that is sufficient to produce a flat panel without a backing layer. Irreversible plastic deformation will occur.
    [0040] A press pole at higher surface temperatures will also elongate and deform the surface layer 2 and eliminate the stress caused by shrinkage in the first stage of the main pressing. This elongation surface is preferably carried out at temperatures of about 140 to 160 ° C.
    [0041] The second step of stretching and pressing the surface is preferably a cold pressing and is an advantage if the panel is moved to the second pressing and bending station as quickly as possible in order to maintain a temperature of the raised initial surface when folding begins. For example, the peak surface temperature can be in the range of 160 to 200 ° C, for example, about 170 ° C during the first press, where the surface layer is attached to the core. When the folding step begins, the surface temperature can be at least 140 ° C, or at least 120 ° C. For example, when the folding step starts the surface temperature can be within 30 ° C, or within 40 ° C, or within 50 ° C, the peak surface temperature during the first pressing, wherein the layer of the surface is connected to the nucleus. The temperature decrease in the folded and elongated position will usually be obtained automatically when the core cools the surface. This will stabilize the surface layer in an elongated position and permanent deformation can be achieved. The internal stress on the panel can be considerably reduced or completely eliminated, and the panel can be completely flat when it is cooled to room temperature, as shown in figure 2c.
    [0042] The production balance and the cooling balance that is done with a support layer can be replaced in part or completely, with plastic deformation.
    [0043] The fold can be such that the panel is convex and folds back when it leaves the second pressing station. The panel can be slightly folded in a third step upward towards the surface in such a way that a predetermined shape is obtained. This type of over-stretching and double-folding can reduce the internal tension completely. The temperatures, bending time and bending magnitude must be adapted to the quality and specification of the surface and core.
    [0044] Heat can be added in the second stage of surface elongation, in order to improve and control elongation and adapt the production method to various thicknesses and resins of the surface. The surface can also be cooled in order to stabilize the panel in a predetermined condition.
    [0045] The second post-pressing operation and panel folding can be done in several ways. It is preferable that the fold and elongation are three-dimensional so that the fold is made along and through the panel. The pressing tables are preferably curved in two perpendicular directions, like an upper part of a ball.
    [0046] The folding backwards can also be done by pressing cylinders, frames, pressing against a rubber or silicone matrix, with rollers and in many other ways in which the panel is folded in hot conditions, after the operation of initial main pressing in which the thermosetting resin is hardened.
    [0047] The thermosetting resin can be adapted in such a way that it is easy to stretch. Resins similar to the types used in the so-called post-forming qualities of laminates can facilitate the surface to extend by bending.
    [0048] The surface layer can also be stretched by lateral pulling forces applied to the edges of the panel.
    [0049] It is also possible to heat the panel again after cooling in a separate production step with, for example, a hot press table, infrared lamps and the like, in order to soften and stretch the surface layer in order to to obtain a flat panel. A first cylinder can bend the panel backwards along the length and a second cylinder can preferably, after an intermediate heating, bend the panel along the width. The panels can also be kept in a folded position in the cooling part after pressing.
    [0050] Figure 2d shows that a moisture barrier 4 can be used, for example, a plastic sheet, treated paper, foam, etc., in order to prevent moisture from entering the panel from the subfloor. Such a support layer can be used to achieve climate balance. In some applications the curvature of the HDF core may be sufficient even for climate equilibrium.
    [0051] The surface elongation process (SSP) according to the modalities of the invention offers one or more or all of the following advantages: a more cost effective plate with less internal bonding force can be used. the cover that causes great wear at the edges and decreases the locking force due to the internal tension can be eliminated. the splitting of the plate in the locking system can be avoided. Cost savings can be achieved by eliminating the support or replacing the paper / melanin support with a thinner or more cost effective material.
    [0052] Figure 3a shows a modality with a thin support layer 4, which is not able to balance panel 1 after initial pressing. Figure 3b shows the folding and preferably also the elongation of the surface layer 2. The result is a flat panel, as shown in figure 3c, with a support layer 4 and reduced internal tension. The backing layer prevents moisture from entering the back side of panel 1 and will stabilize the panel when humidity changes. Figure 3d shows three dimensional folds of panel 1. The magnitude of fold B is preferably about 3 to 6 cm / m or more.
    [0053] Figures 4a to 4c show a method for measuring the internal voltage in a panel. A groove 11 is formed at the edge of the panel. A high internal voltage will separate the edges, as shown in figure 4b. The large difference between the internal thickness of the T1 panel and the external thickness of the T2 panel means that the panel 1 has a great internal tension that can cause coverage and cracks in the locking system, especially in dry conditions. Figure 4c shows a panel 1 with a low internal voltage. For example, a panel with a reduced internal voltage will have a T2 that is lower than the T2 for the same panel, which has no method, such as the folding step, performed on the panel.
    [0054] This measurement method can be used to adjust the bending parameters backwards in the second pressing stage, modifying the initial pressing temperature, the final pressing temperature, pressing time and the magnitude of the bending.
    [0055] Figure 5a shows the temperature curve when pressing a WFF floor panel with a 0.5 mm surface layer. Temperature A is measured in ° C and time B in minutes. The upper curve C is the temperature of the surface layer and the lower curve D is the core temperature measured 3 mm below the surface. The surface temperature is increasing during pressing at 170 ° C and the core temperature of about 110 ° C. The cooling of the surface layer takes place instead of quickly, as can be seen from figure 5b which shows the same temperature curves C and D during the first 60 seconds. For example, the folding step can start within 60 seconds or less, or 90 seconds or less, from the first start of matches. For example, the folding step can start within 30 seconds or less, from when the first pressing step ends. Plastic deformation is preferably carried out when the surface temperature is at least about 140 ° C and when the internal temperature, measured a few millimeters below the surface, is at least about 100 ° C. It is possible to modify the resins in the core and in the surface layer, in such a way that the plastic deformation can be made at lower temperatures, for example, at 120 to 140 ° C for the surface layer and 80 to 100 ° C for the core.
    [0056] Figures 6a to 6d show that vacuum cups 15 with adjustable cylinders 16 can be used to fold the pressed panel 1 after pressing. The vacuum cups can lift the panel immediately after pressing and form them into a predetermined shape, as shown in figures 6b and 6c. Such formation can be done, for example, within 10 to 20 seconds after pressing, when the surface of the panel still has a temperature around and above 140 ° C. The panel is held in the folded position until it cools to a suitable temperature, preferably below 100 ° C, and a permanent non-reversible plastic deformation is obtained so that the panel is essentially flat, at room temperature, as shown in figure 6d .
    权利要求:
    Claims (11)
    [0001]
    1. Method for producing a panel (1) with a wood-based core (3), the core (3) being an HDF core, and a surface layer (2) comprising a layer based on powder, the powder comprising wood fibers and a thermosetting resin, characterized by the fact that the method comprises the steps of: - hardening and bonding the surface layer (2) to the core (3), while applying heat and pressure in a first main pressing step, thereby increasing a temperature of the surface layer above an initial temperature; - apply a bending force (F) on the panel (1), after the first main pressing step to finish the panel in such a way that a higher surface of the panel is convex and a lower surface of the panel is concave, while the panel is still above the initial temperature, in which the bending force is applied to at least two opposite sides of the panel; and - releasing the bending force so that the panel returns to an essentially flat shape.
    [0002]
    2. Method according to claim 1, characterized by the fact that the method further comprises the step of reducing the surface temperature during bending.
    [0003]
    3. Method according to claim 2, characterized by the fact that the decrease in surface temperature is about 20 ° C.
    [0004]
    4. Method according to claim 2, characterized by the fact that the reduction of the surface temperature is more than 20 ° C.
    [0005]
    Method according to any one of claims 1 to 4, characterized in that the thermosetting resin is a melanin formaldehyde resin.
    [0006]
    Method according to any one of claims 1 to 5, characterized in that the curvature (B) is at least about 3 cm / m.
    [0007]
    Method according to any one of claims 1 to 6, characterized in that the powder further comprises wood fibers, wear-resistant particles and pigments.
    [0008]
    8. Method according to any one of the preceding claims, characterized in that the panel is rectangular and the bending force is applied to both sets of opposite edge parts of the panel.
    [0009]
    Method according to any one of the preceding claims, characterized by the fact that the bending force is applied with a first pressing table on the uppermost surface of the panel, and a second pressing table on the lowermost surface of the panel.
    [0010]
    10. Method, according to claim 9, characterized by the fact that the first and second pressing tables are curved in two perpendicular directions, so that the folding along the entire panel is made.
    [0011]
    11. Method according to any of the preceding claims, characterized by the fact that the panel is a construction panel, such as a floor panel.
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    PL2753473T3|2020-05-18|
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    BR112014004486A2|2017-03-14|
    RU2602359C2|2016-11-20|
    IN2014CN02192A|2015-05-29|
    CN108773148A|2018-11-09|
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    EP2753473A1|2014-07-16|
    EP2753473A4|2015-07-29|
    UA112659C2|2016-10-10|
    RU2014111487A|2015-10-20|
    CN103764405A|2014-04-30|
    WO2013036197A1|2013-03-14|
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    UA118967C2|2013-07-02|2019-04-10|Велінге Інновейшн Аб|A method of manufacturing a building panel and a building panel|
    UA120419C2|2013-08-27|2019-12-10|Велінге Інновейшн Аб|A method for producing a lamella core|
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    法律状态:
    2018-04-03| B25A| Requested transfer of rights approved|Owner name: CERALOC INNOVATION AB (SE) |
    2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-10-08| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-10-06| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2021-03-02| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-04-13| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 07/09/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201161532753P| true| 2011-09-09|2011-09-09|
    SE1150814-0|2011-09-09|
    SE1150814|2011-09-09|
    US61/532,753|2011-09-09|
    PCT/SE2012/050947|WO2013036197A1|2011-09-09|2012-09-07|Panel forming|
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