CN102892591A - 制造包括干粉末层的装饰性地板镶板的方法 - Google Patents

制造包括干粉末层的装饰性地板镶板的方法 Download PDF

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CN102892591A
CN102892591A CN2011800243563A CN201180024356A CN102892591A CN 102892591 A CN102892591 A CN 102892591A CN 2011800243563 A CN2011800243563 A CN 2011800243563A CN 201180024356 A CN201180024356 A CN 201180024356A CN 102892591 A CN102892591 A CN 102892591A
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steam
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J·雅各布松
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Valinge Innovation AB
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Abstract

本发明公开了一种用于制造镶板的方法。该方法包括向芯部上的干粉末层施加蒸汽的步骤。此后，向粉末层施加热和压力，以便使粉末结合在一起。

Description

制造包括干粉末层的装饰性地板镶板的方法
技术领域
本发明总体上涉及一种用于制造纤维基建筑镶板、优选地板镶板的方法，并且涉及一种通过所述方法制造的建筑镶板。
背景技术
在WO2009/065769中公开了一种称为木质纤维地板(WFF)的新型镶板，该申请不仅公开了产品，而且公开了制造这种镶板的方法。在WO2009/124704中公开了更多方法和制造设备。
WFF地板镶板是通过在HDF芯部上施加干粉混合物制成的。粉末混合物在热和压力下结合在一起而形成装饰性表面层。
为了使干粉混合物稳定，在WO2009/065769或WO2009/124704中(参见第15页第15-21行；图3)中的制造方法利用纯水或包含添加剂的水的喷洒。
WO2009/065769和WO2009/124704的全部内容在此通过引用结合在本文中，并且特别参考WO2009/124704的第15页第15-21行和图3。
发明内容
本发明的实施例的一个目的是，提供比当前已知技术更有效的制造方法。另一个目的是，制造具有更均匀的颜色或更受控的颜色变化和/或图案的镶板。
当从粉末混合物——例如在WO2009/065769中或在WO2009/124704中公开的WFF混合物——压制表面层时，需要避免的一个问题是，当板在压制前在生产线中被处理时粉末混合物被完全或部分吹走和/或当空气由于压力机的关闭而排出时粉末混合物从压力机吹出。
通过使用水的喷洒来使粉末稳定的已知方案的缺点是，难以控制水的分布和难以避免水滴从喷洒单元意外下落到粉末层上。
不均匀的水分布和/或意外的水滴通常对产品的视觉以及技术性能有负面影响。此外，在进入压力机前用于让水渗入粉末中的等待时间减慢了压制循环并且生产线的总产量降低。
本发明的第一方面是一种制造包括芯部(1)和装饰性表面层(4)的镶板的方法，该方法包括以下步骤：
·在芯部(1)上施加干粉末层(2)；和
·向粉末层施加蒸汽。
蒸汽优选为水蒸汽，最优选为基本上纯水蒸汽，即使该蒸汽可包含一种或多种添加剂。添加剂的示例为润湿剂、脱模剂和/或颜色添加剂。
干粉末层优选为纤维——优选木质纤维——与粘合剂的混合物。粉末层也可包括耐磨颗粒，优选氧化铝。芯部优选为木质纤维基芯部，优选HDF镶板。
蒸汽优选通过蒸汽箱施加。
本发明的第二方面是一种制造包括芯部(1)和带有设计图案的表面层(4)的镶板的方法，该方法包括以下步骤：
·在芯部(1)上施加干粉末层(2)；和
·通过向粉末层的部分施加蒸汽或在粉末层上不均匀地施加蒸汽(例如，在所有粉末层上施加但以不同的量施加)来形成图案。
第一和第二方面中的蒸汽优选为水蒸汽，最优选为基本上纯水蒸汽，即使该蒸汽可包含一种或多种添加剂。该蒸汽(steam)可为薄雾(mist)或水的气相(水蒸气)，优选饱和蒸气(vapour)，且最优选主要包括水的饱和蒸气。
下面公开本发明的第一和第二方面的优选实施例。
本发明的第三方面是一种根据任何一个上述方面制造的镶板。
上述方法可用于其中向芯部施加干粉末层的建筑镶板的任何制造。
附图说明
下文将结合示例性实施例且更详细地参照所附的示例性附图描述本发明，在附图中：
图1示出根据本发明的一个实施例的生产线和方法；
图2a-b示出根据本发明的一个实施例的用于形成设计的方法；
图3示出根据本发明的一个实施例的用于形成设计的方法。
具体实施方式
在图1中，公开了用于制造带有装饰层4的镶板5的生产线的一个实施例。干粉混合物2通过散布而施加在芯部1、优选HDF芯部上。在通过在例如压力机9中施加热和压力来使粉末混合物结合在一起之前，通过施加蒸汽3来使粉末混合物稳定。如果希望形成图案，则在一个实施例中可通过优选旋转的模板6来施加蒸汽。在一个优选实施例中，还向芯部施加平衡层7。
在根据本发明的方法中，优选使用与在WO2009/065769中或在WO2009/124704中公开的相同的散布和压力单元。
在一个实施例中，通过使用位于运输带上方的蒸汽箱8来施加蒸汽，该箱在底部带有一个或多个蒸汽出口。该箱优选以一致的宽度延伸跨越镶板。当板在蒸汽箱下方通过时，均匀的湿气(moisture)分布施加在散布的粉末层2的表面上。由于蒸汽很有效地渗入粉末中，所以可以将板立即移动到压力机中并且关闭压力机9。
合适的蒸汽箱通过外部蒸汽发生器供给，或者蒸汽在蒸汽箱本身中产生。蒸汽箱配备有一层或几层网(net)例如网丝(mesh)并且/或者配备有带孔的板，以使粉末层附近的蒸汽浓度均匀。
图2a和2b示出通过经由例如喷嘴25施加蒸汽3而获得的湿气21的不均匀分布可如何用于设计效果目的。单色粉末但未压制的表面的不同部分中的不同量的湿气21在不同部分提供了视觉色差。通过控制表面上湿气含量在哪里较高，可在镶板的被压制表面24中产生想要的设计效果22(参见图2b)，即使仅在芯部1上施加一层单色粉末层。
通过控制带有粉末混合物层2的芯部1与一个或几个蒸汽出口之间的相对移动，可实现粉末中的湿气21的含量的受控变化。湿气含量的这种变化将在压制后作为准备好的表面24上的色差22可见。
蒸汽出口中的一个或几个可固定在机械臂上，并且然后可在所有方向上控制它们相对于经散布的板的位置。
蒸汽出口41可定位在旋转装置、优选蒸汽管40中，以在粉末层2中产生受控的湿气变化42，参见图3。
作为非限制性示例，用于制造WFF板的步骤可如下：
1)将平衡层——例如浸渍有热固性树脂或木粉与热固性树脂的混合物的纸——放置在运输带上。典型的平衡层为两张DKB140纸。
2)将木质纤维板——典型地为密度典型地为约900kg/m3的约10mm厚HDF板——放置在平衡层的顶部上。
3)使平衡层和板以1-10m/min(典型的值为约3m/min)的速度在散布机下方移动，木质纤维、粘合剂、硬颗粒和颜料的预制混合物散布在板的顶部上。所施加的粉末可在约100-1000g/m2的范围内。典型的值为约700g/m2。
4)使在背面上带有平衡层且在顶面上带有散布的粉末层的板以1-10m/min(典型的值为约3m/min)的速度移动通过具有均匀的蒸汽浓度的蒸汽箱，在这里，包含或不包含添加剂的蒸汽化的水渗入粉末中并且使粉末稳定，以改善进一步的处理并且避免粉末在压力机关闭时吹出。通过蒸汽箱施加的典型的湿气量为3g/m2。
5)将在背面上带有平衡层且在顶面上带有经散布和蒸汽稳定的粉末层的板传送到压力机中。
6)关闭压力机，并且使平衡层和粉末层中的热固性树脂在热和压力下固化。典型的压制参数为30秒压制(范围为例如8-60秒)。可在板上施加40bar压力(范围为例如30-60bar)。顶部和底部压制板上的温度典型地为约170摄氏度(范围为例如150-220摄氏度)。压制板的压制表面可以是平的或具有结构。结构深度典型地为约0.5mm(范围例如为约0-1.5mm)。
在一个替代示例中，在步骤4之后还施加一个或更多个纸板。
通过受控的不均匀湿气分布制造带设计图案的WFF板的示例：
1)将平衡层——例如浸渍有热固性树脂或木粉与热固性树脂的混合物的纸——放置在输送带上。典型的平衡层为两张DKB140纸。
2)将木质纤维板——典型地为密度典型地为约900kg/m3的约10mm厚HDF板——放置在平衡层的顶部上。
3)使平衡层和板以1-10m/min(典型的值为约3m/min)的速度在散布机下方移动，木质纤维、粘合剂、硬颗粒和颜料的预制混合物散布在板的顶部上。所施加的粉末可在约100-1000g/m2的范围内。典型的值为约700g/m2。
4)使在背面上带有平衡层且在顶面上带有散布的粉末层的板以约1-10m/min(典型的值为约3m/min)的速度在一个或几个蒸汽出口下方移动，所述蒸汽出口也可在板经过时侧向(sideways)移动并且打开和关闭，在这里，包含或不包含添加剂的蒸汽化的水以不均匀但受控的方式渗入粉末中，以在粉末层中获得湿气含量的变化。
5)将在背面上带有平衡层且在顶面上带有经散布和蒸汽稳定的粉末层的板传送到压力机中。
6)关闭压力机，并且使平衡层和粉末层中的热固性树脂在热和压力下固化。不同的湿气含量得到压制好的板中的可视设计效果。典型的压制参数为约30秒压制(范围为例如约8-60秒)。可在板上施加约40bar压力(范围为例如30-60bar)。顶部和底部压制板上的温度典型地为约170摄氏度(范围为例如约150-220摄氏度)。压制板的压制表面可以是平的或具有结构。结构深度的值典型地为约0.5mm(范围例如为约0-1.5mm)。
在一个替代示例中，在步骤4之后还施加一个或更多个纸板。

Claims (16)

1.一种制造包括芯部(1)和装饰性表面层(4)的镶板的方法，该方法包括以下步骤：
·在芯部(1)上施加干粉末层(2)；和
·向所述粉末层施加蒸汽。
2.如权利要求1所述的方法，其特征在于，所述蒸汽是包括水的蒸气。
3.如权利要求1所述的方法，其特征在于，所述蒸汽是主要由水组成的饱和蒸气。
4.如前述权利要求中任一项所述的方法，其特征在于，所述方法还包括通过施加热和压力使所述粉末层中的粉末结合在一起并从而形成装饰性表面层的步骤。
5.如前述权利要求中任一项所述的方法，其特征在于，所述干粉末层包括纤维与粘合剂的混合物。
6.如权利要求1所述的方法，其特征在于，所述干粉末层包括木质纤维与粘合剂的混合物。
7.如前述权利要求中任一项所述的方法，其特征在于，所述芯部为木质纤维基芯部。
8.如前述权利要求中任一项所述的方法，其特征在于，所述芯部为HDF或MDF板。
9.如前述权利要求中任一项所述的方法，其特征在于，所述镶板为地板镶板。
10.如前述权利要求中任一项所述的方法，其特征在于，所述粉末层包括耐磨颗粒。
11.如前述权利要求中任一项所述的方法，其特征在于，所述粉末层包括氧化铝。
12.如前述权利要求中任一项所述的方法，其特征在于，固化层的厚度小于约1mm。
13.如前述权利要求中任一项所述的方法，其中，固化层的厚度小于约0.3mm。
14..如前述权利要求中任一项所述的方法，其特征在于，所述蒸汽基本上均匀地施加在所述粉末层上。
15.如权利要求1至13中任一项所述的方法，其特征在于，所述蒸汽不均匀地施加在所述粉末层上，以便获得设计图案。
16.一种根据前述权利要求中任一项所述的方法制造的地板镶板。
CN2011800243563A 2010-05-31 2011-05-31 制造包括干粉末层的装饰性地板镶板的方法 Pending CN102892591A (zh)

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