CN105873762A - 生产带单板构件的方法 - Google Patents

生产带单板构件的方法 Download PDF

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Publication number
CN105873762A
CN105873762A CN201580003661.2A CN201580003661A CN105873762A CN 105873762 A CN105873762 A CN 105873762A CN 201580003661 A CN201580003661 A CN 201580003661A CN 105873762 A CN105873762 A CN 105873762A
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CN
China
Prior art keywords
subgrade
ply
base material
veneer
pressure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201580003661.2A
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English (en)
Inventor
G·齐格勒
P·尼格伦
T·梅耶尔
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Valinge Innovation AB
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Valinge Innovation AB
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Publication date
Application filed by Valinge Innovation AB filed Critical Valinge Innovation AB
Priority to CN202011186324.0A priority Critical patent/CN112297574A/zh
Publication of CN105873762A publication Critical patent/CN105873762A/zh
Pending legal-status Critical Current

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Abstract

本公开内容涉及一种制造带单板构件(10)的方法，包括提供基材(1)，将亚层(2)施加至基材(1)的表面上，将单板层(3)施加至亚层(2)上，和在单板层(3)和/或基材(1)上施加压力，从而使得亚层(2)的至少一部分亚层(2a)渗透通过单板层(3)。本公开内容还涉及该带单板构件(10)。

Description

生产带单板构件的方法
技术领域
本公开内容涉及一种生产带单板(veneer)构件的方法和该带单板构件。
技术背景
具有木质表面的地板覆盖物可具有若干种不同类型。实木地板覆盖物由呈板形式的木实心件形成。工程木地板由与芯胶合的木表面层形成。芯可为层状芯或者木基板如胶合板、MDF或HDF。作为实例，木质表面层可具有2-10mm的厚度。
木质地板覆盖物还可通过将木单板与芯(例如木基板，如刨花板、MDF或HDF)胶合而形成。木单板为薄木层，其例如具有0.2-1mm的厚度。具有与例如HDF或胶合板的芯胶合的独立表面层的地板比实木地板更潮湿稳定。
与实木和工程木地板相比，木单板地板由于仅使用薄木层而可以以更低的成本生产。然而，木单板不能像实木或工程木地板那样打磨。
作为木地板的替代品，还可使用层压地板。直接压制的层压地板通常包括6-12mm纤维板的芯、0.2mm厚的层压装饰性上表面层和0.1-0.2mm厚的层压板、塑料、纸或类似材料的下平衡层。
层压表面通常包括两个纸板，0.1mm厚的装饰性印刷纸和0.05-0.1mm厚的旨在保护所述装饰性纸以免磨损的透明覆盖物。由α-纤维素纤维制成的透明覆盖物包含小的硬质和透明氧化铝颗粒，其赋予表面层以高耐磨性。
用蜜胺树脂浸渍装饰性印刷纸和覆盖物并在热和压力下层压成木纤维基芯。所述两种纸在压制之前具有约0.3mm的总厚度，且它们在压制后被压缩至约0.2mm。
木单板可能具有比层压地板更低的抗冲击性，且与层压地板相比，当使用高质量的单板时，生产成本高。
最近开发了具有固体表面的新颖“无纸”型地板，其包含基本上均匀的纤维、粘合剂和耐磨颗粒的粉末混合物，该地板称为WFF(木纤维地板)。将所述混合物施加至木基板如MDF或HDF上，随后对该混合物施加热和压力，从而在所述板上形成表面层。该地板和方法描述于WO2009/065769中。
WO2009/065769还公开了一种薄表面层如木单板，其施加在包含例如混合有粘合剂的软木或木纤维的亚层上。所述亚层施加在木纤维基芯上。
US2,831,794公开了一种生产单板板块的方法。将新鲜(green)单板施加至树脂涂覆的木素纤维颗粒的芯颗粒的垫层上。在该单板上施加胶粘剂以使单板与纤维芯结合，且在纤维芯中形成致密的表面区域。芯的材料用于填充单板中的节孔或开口瑕疵。当施加热和压力时，其结果是无论在单板中是否存在瑕疵或孔洞，均形成具有颗粒填充物的表面层的板。
US2,419,614公开了一种经涂覆的木产品，其中用由锯末和合成树脂的混合物组成的遮盖材料或覆盖材料涂覆胶合板。用遮盖材料或覆盖材料涂覆单板，从而使得该单板不再可见。所述覆盖物形成该产品的最上层。
上文描述已参照地板描述了不同类型的产品。然而，相同的材料和问题同样适用于其他类型的建筑板如墙板、天花板，且适用于家具组件。
概述
至少本发明实施方案的目的是提供相对于上述技术和已知技术的改进。
至少本发明实施方案的另一目的是改进单板表面的耐磨性。
至少本发明实施方案的另一目的是降低具有诱人设计的表面的生产成本。
至少本发明实施方案的另一目的是使用低质量和/或薄厚度的单板。
至少本发明实施方案的另一目的是提供具有实木表面外观的木单板表面。
至少本发明实施方案的另一目的是提供一种具有诱人设计的单板表面。
至少本发明实施方案的另一目的是控制单板表面的设计。
将由说明书悉知的这些和其他目的以及优点中的至少一些由一种制造带单板构件的方法实现，其包括：
-提供基材，
-将亚层施加至基材的第一表面上，
-将单板层施加至亚层上，和
-在单板层和/或基材上施加压力，从而使得至少一部分亚层渗透通过该单板层。
所述至少一部分亚层可至少部分渗透通过单板层，或者可完全渗透通过单板层。
优选地，所述方法进一步包括通过控制亚层通过单板层的渗透而控制单板层的设计。优选地，单板层设计的控制通过确定亚层渗透通过单板层的水平进行。渗透水平的确定可包括选择或调节渗透。这可包括在施加压力时选择或调节亚层的流体压力。
“控制”意指确定、选择和/或调节。
“确定”例如意指通过单板层设计的视觉印象确定。
优选地，至少一部分亚层在背对基材的单板层表面处是可见的。
基材优选为预制基材。优选地，基材在先前生产工艺中生产。
至少某些实施方案的优点是所述带单板构件的表面设计可通过渗透通过单板的一部分亚层而改变或变化。通过在单板层和/或基材上施加压力，一部分亚层流过单板的孔或裂缝或孔洞，从而使得一部分亚层在背对基材的单板表面处变得可见。由此改变单板的设计，尤其是当亚层包含颜料时。可产生新的设计，或者单板的结构体如裂缝和节可由于在该单板表面上可见的亚层而强化。
单板层形成带单板构件的可见表面。被至少一部分亚层渗透的单板层的设计形成带单板构件的设计。
单板层也可因设置在亚层上而被增强。此外，单板层可因被亚层至少部分浸渍而获得改善的耐磨性。设置在单板层下方的亚层也可改善单板的抗冲击性。亚层可包含赋予单板以改善的耐磨性的粘合剂或漆。亚层还可包含耐磨颗粒。
由于亚层在压制期间还流入基材中，因此亚层提供了改善的冲击性、表面坚固性、胶粘剂容量、降低的溶胀等。
此外，至少某些实施方案的优点是亚层可填充单板层的任何裂缝、孔或节。由此，没有或至少部分降低用油灰堵塞单板层裂缝、孔洞或节的需要。由此，通过在将单板压至基材上时将单板层置于亚层上而省去或者至少部分减少通常由手动进行的昂贵操作。
通过将单板置于亚层上且通过至少一部分亚层流经单板以使得裂缝、孔隙或节被亚层填充，可使用更薄的单板，或者可使用更低质量的单板，例如包含更多不规则物和缺陷的单板。
此外，通过在亚层中包含颜料，可将单板着色。可获得釉化效果、虹光(lazuring)效果和/或染色效果。
通过在亚层中包含添加剂，可改变单板层的性质。例如，可在亚层中添加吸声填料，例如软木颗粒，从而改善带单板构件的吸声性能。可在亚层中添加抗静电剂。还可添加改善带单板构件的传热的填料。
在基材为芯的实施方案中，所述芯和与该芯结合的带单板构件形成建筑板或家具组件。所述建筑板可为地板、天花板、墙板、门板、工作台、踢脚板、模塑品、镶边用型材等。
在一个实施方案中，带单板构件作为独立的构件形成，其随后可与组件粘合。基材可为单板层和亚层的载体，或者可为临时性载体，随后由其移除单板层和亚层。
所述方法可进一步包括控制亚层通过单板层的渗透。在此处和下文中，“控制”意指确定、选择和/或调节。由此可通过改变和控制流体压力、粘合剂浓度、粘合剂类型、填料浓度、单板性质等而改变和控制表面的设计和外观。通过控制这些参数，可控制渗透单板层的亚层的量，由此可以以受控方式改变单板层的设计。
所述方法可进一步包括在单板层和/或基材上施加压力之前通过磨削加工而处理单板层。所述方法可进一步包括在单板层和/或基材上施加压力之前刷处理(brushing)单板层。通过磨削加工单板层，单板层的材料被机械移除。
在一个实施方案中，亚层通过单板层的渗透的控制可包括在单板层和/或基材上施加压力之前对单板层进行磨削加工。
在一个实施方案中，亚层通过单板层的渗透的控制可包括在单板层和/或基材上施加压力之前刷处理单板层。
通过磨削加工和/或刷处理单板层，在单板层中形成孔洞、孔隙和/或裂缝。单板层的磨削加工和/或刷处理可扩大已有的孔洞、孔隙和/或裂缝，和/或形成新的孔洞、孔隙和/或裂缝。通过形成孔洞、孔隙和裂缝或扩大已有的孔洞、孔隙和裂缝，亚层更容易渗透通过单板层。由此提高亚层通过单板层的渗透，且可控制和改变单板层的设计。
在施加至亚层之前或者在施加至亚层时，可刷处理单板层。这同样适用于单板层的磨削加工和/或处理。
单板层的磨削加工可通过研磨工具进行。研磨工具可为刷处理设备。研磨工具可为刷丝、研磨带、打磨带、打磨盘、磨轮、切割工具如水喷射等。
可借助研磨工具对单板层进行处理，从而移除具有低密度的单板材料，然而保留具有较高密度的单板材料。研磨工具可比至少一部分单板层更坚硬。
可对单板层的两个表面或仅一个表面进行磨削加工。可对适于面对亚层的单板层下表面进行加工。可对适于朝上的单板层上表面进行加工。通过磨削加工单板层的上表面，亚层在平行于单板层表面的方向的流动得以提高。通过磨削加工单板层的下表面，亚层可填充在单板层下表面中形成的孔隙。
磨削加工可在单板层中以不同水平实施。孔隙、孔洞和/或裂缝可延伸通过单板层，或者可部分延伸通过单板层。孔隙、孔洞和/或孔隙的深度可基本上等于单板层的厚度，或者可小于单板层的厚度。
在施加压力之前实施的单板层的加工也可与在施加压力以形成带单板构件之后实施的加工组合。
单板层的磨削加工和/或处理可例如包括刷处理、打磨、研磨、喷砂、局部压缩、撕裂、割裂、压缩空气等。
亚层通过单板层的渗透的控制可包括在单板层和/或基材上施加压力之前对单板层进行处理。该处理可包括在单板层和/或基材上施加压力之前将单板加热(例如通过热辐射、对流加热和/或传导加热、汽蒸)和/或干燥。渗透也可通过在单板层上施加添加剂以调节亚层通过单板层的渗透而控制。作为实例，可施加降低(例如通过堵塞渗透)亚层通过单板层的渗透的添加剂。替代或者组合地，还可在单板层上施加分解单板层的添加剂，由此提高渗透。
亚层通过单板层的渗透的控制可包括在将单板施加至亚层之前压缩单板。通过压缩单板，至少部分单板的密度得以提高，由此降低亚层在压制期间通过至少部分单板层的渗透。压缩可借助具有压花的压板和/或辊进行。压缩(优选结合加热，优选结合加热至超过100℃的温度)可导致密度额外提高。
亚层通过单板层的渗透的控制可包括在压制期间控制亚层的流体压力。亚层的流体压力通过在单板层和/或基材上施加压力而形成。在一个实施方案中，当施加至基材上时，亚层可呈流体形式，或者可通过施加热和压力而转化成流体形式，例如以粉末形式施加热固性粘合剂的情况。通过提高流体压力，较大量的亚层渗透通过单板层，和/或沿更长的路径通过单板层，和/或沿平行于单板层平面的方向渗入单板层中，从而使得更大的亚层斑点在单板层的表面可见。此外，当亚层包含热固性粘合剂时，交联反应导致形成缩合水，其在所施加的热和压力下转化成蒸汽，由此提高流体压力。交联还导致一部分亚层固化，由此进一步挤压亚层剩余的未固化粘合剂。
亚层流体压力的控制可包括调节亚层中的粘合剂浓度。通过提高亚层中的粘合剂浓度，在施加热和压力时流动的亚层部分增多，由此更大部分的亚层可渗透通过单板层。当粘合剂流动时，该粘合剂将任何颜料携带至单板的上部。
亚层流体压力的控制可包括调节亚层中所用的粘合剂的类型。不同的粘合剂具有不同的性质，例如粘合剂的固化和硬化速度。当使用快速固化的粘合剂时，与更慢固化的粘合剂(由此在更长时间内呈液体形式且允许渗透通过单板层)相比，亚层的渗透更少。
带单板构件的设计也可通过控制亚层的颜料与粘合剂之比而进行。通过调节粘合剂浓度以及颜料/粘合剂之比，可控制渗透通过单板层的颜料量。当粘合剂在压制期间流动时，该粘合剂会携带颜料。渗透通过单板层的颜料量也可通过选择颜料颗粒的尺寸而控制和调节。较小的颜料颗粒比较大的颜料颗粒更易渗透通过单板层。
流体压力的控制可包括调节亚层的水分含量。通过提高亚层的水分含量，在施加热和压力时形成更多的蒸汽，这形成了提高的流体压力和由此提高的亚层通过单板的渗透。相反，如果希望较少的渗透，则可降低亚层的水分含量，例如通过在压制前进行干燥。
流体压力的控制可包括调节施加在单板层和/或基材上的压力。通过提高压力，亚层的流体压力得以提高。如上文所述，通过提高流体压力，更大量的亚层渗透通过单板层。
流体压力的控制可包括在亚层中产生气体压力。气体压力提高了亚层的流体压力，由此导致亚层以提高的程度渗透通过亚层。
气体压力的产生可包括在亚层中包含化学和/或物理发泡剂。在反应时，化学和/或物理发泡剂在亚层中形成气体压力。
亚层通过单板层的渗透的控制可包括在亚层中包含填料。通过提高亚层中的填料量，更少的亚层渗透通过单板层。填料可降低亚层的流动，从而使得亚层更难以渗透通过单板层。此外，一些填料(例如木颗粒)会在一定程度上吸收粘合剂，由此降低可渗透通过单板层的游离粘合剂的量，且由此还降低流体压力。填料可包括木颗粒，例如木素纤维颗粒和/或纤维素颗粒。木颗粒可为至少部分漂白的。
亚层通过单板层的渗透的控制可包括调节亚层的厚度，例如通过调节所施加的亚层的量。如果亚层作为粉末施加，则亚层通过单板层的渗透的控制可通过调节施加以形成亚层的粉末的量而控制。通过施加更大量的粉末来形成亚层，亚层以提高的程度渗透通过单板层。
亚层通过单板层的渗透的控制可包括在单板层中形成孔洞和/或裂缝。孔洞和/或裂缝有助于使亚层渗透通过单板层。孔洞和裂缝的形成降低了亚层渗透通过单板层的阻力。孔洞、孔隙和/或裂缝的形成可通过在单板层和/或基材上施加压力之前刷处理而进行。所述孔洞、裂缝和孔隙可为预先存在的但经扩大的，和/或可为新形成的孔洞、裂缝和孔隙。
亚层通过单板层的渗透的控制可包括控制单板层的厚度。单板层越薄，则直至亚层在单板层的上表面上可见时亚层需要传输的距离就越短。
所述至少一部分亚层可渗透通过单板层的孔。单板为多孔结构，包括亚层可在其中渗透的孔。
所述至少一部分亚层可渗透通过单板层的裂缝和孔洞。
单板层可包括木单板、软木单板，或石单板。单板层具有多孔结构，且一部分亚层可渗透通过该单板层。木单板可为切割的单板、锯开的单板、旋转切割的单板和/或半圆切割的单板。
亚层可包含粘合剂。
亚层可包含热固性粘合剂。热固性粘合剂可为氨基树脂，例如蜜胺-甲醛、脲醛、酚醛或其组合。热固性粘合剂同时结合单板层与亚层。当在亚层上施加热和压力时，热固性粘合剂在发生交联前变为流体。所施加的热和压力导致亚层的热固性粘合剂固化，同时使单板层与亚层结合。
亚层可包含热塑性粘合剂。热塑性粘合剂可为聚氯乙烯(PVC)、聚乙烯(PE)、聚丙烯(PP)、聚氨酯(PU)、聚乙烯醇(PVOH)、聚乙烯醇缩丁醛(PVB)和/或聚乙酸乙烯酯(PVAc)，或其组合。热塑性粘合剂同时使单板层与亚层结合。
亚层可基本上不含甲醛。
亚层可进一步包含颜料。由此，单板层可被渗透通过该单板层的亚层部分着色。可将亚层着色为一种或数种不同的颜色。通过使用含有不同颜色的亚层，可获得具有不同颜色的不同单板层部分和/或不同的单板。颜料可被可流动的粘合剂携带至单板层的上部。颜料可提供比单板的自然颜色更深或更浅的颜色。颜料可为白色的，例如TiO2。白色颜料如TiO2可与例如至少部分漂白的木颗粒组合，从而形成更浅色的单板。
亚层可包含耐磨颗粒。被亚层粘合剂携带至单板层上部的耐磨颗粒为该单板层提供了耐磨性。
基材可为木基板，例如基于木纤维基板如MDF或HDF，或胶合板。基材可为木塑复合材料(WPC)。基材可为矿物复合板。基材可为纤维水泥板。基材可为氧化镁水泥板。基材可为陶瓷板。基材可为塑料板，例如热塑性塑料板。
基材可为片材，例如纸片。
流体压力可均匀分布。由此，如果单板层具有基本上均匀的结构，则可实现亚层基本上均匀地渗透通过单板层。如果单板层具有基本上均匀的结构，则还可实现单板层的均匀着色。
流体压力可不均匀分布。借助不均匀分布的流体压力，亚层的渗透程度可改变单板的表面且可获得不均匀的图案。
所述方法可进一步包括在将单板层施加至亚层之前，在亚层中数字印刷图案。所述方法可进一步包括在压制之前或之后，在单板层上数字印刷图案。
单板层可为单板的连续层或不连续层。单板层可由若干单板件形成。单板层可由若干片单板形成，从而形成单板的拼缝物。亚层可填充单板件之间的间隙。
在施加压力之后，单板层可包含压花部分。与在未压花单板层部分下方相比，在压花部分的下方，一部分亚层受到更大的压缩。
压花部分可在压制之后自然产生。对具有多孔结构的木单板(例如硬材，如被子植物)而言，该单板的多孔部分在压制后形成压花部分，这是因为这些部分在压力释放时不由其压缩状态回弹。在压制期间，这些多孔部分被亚层的粘合剂填充。然后，粘合剂固化和/或硬化，该粘合剂将该多孔部分的位置锁定在压缩状态下。具有高密度(即无孔)的单板部分在压制期间被压缩，然而在压力释放时回弹，由此形成表面层的凸起。该高密度部分不能从亚层吸收足够的粘合剂，以至于在压制后不能被硬化的粘合剂锁定。
对具有无孔结构的木单板(例如软材，例如裸子植物)而言，具有高密度的夏木年轮(也称为晚材年轮)在压制期间不可压缩。相反，夏木年轮被压入亚层中，从而使得亚层被压缩。夏木年轮形成表面层的压花部分。春木年轮(也称为早材年轮)在压制期间可压缩。在压制期间，春木年轮被压缩。然后释放压力，春木年轮回弹且形成凸起。
表面层的压花部分还可通过压花压制设备，例如压花压板压制。
所述方法可进一步包括在与单板层相对的基材表面上施加平衡层。平衡层可为作为粉末施加的粉末基平衡层。粉末基平衡层可包含木颗粒如木素纤维颗粒和/或纤维素颗粒，和粘合剂，优选热固性粘合剂如氨基树脂。平衡层可为树脂浸渍的纸，优选用热固性粘合剂浸渍。
根据本发明的第二方面，本发明由一种带单板构件实现。所述带单板构件包括基材、设置在基材上的亚层，和设置在亚层上的单板层，其中至少一部分亚层渗透通过单板层。
至少一部分亚层可在背对基材的单板表面处可见。
亚层可进一步包含颜料。
亚层可包含填料。填料可为颗粒或纤维，例如木纤维或颗粒，或矿物颗粒或纤维。木颗粒可为木素纤维颗粒和/或纤维素颗粒。木颗粒可为至少部分漂白的。
亚层可包含耐磨颗粒。
基材可为木基板。
所述至少一部分亚层可渗透通过单板层的孔。
单板层可包括木单板、软木单板或石单板。
单板层可包含压花部分。与在未压花单板层部分下方相比，在压花部分下方，一部分亚层受到更大的压缩。
压花部分可在压制之后自然产生。对具有多孔结构的木单板(例如硬材，如被子植物)而言，该单板的多孔部分在压制后形成压花部分，这是因为这些部分在压力释放时不由其压缩状态回弹。在压制期间，这些多孔部分被亚层的粘合剂填充。然后，粘合剂固化和/或硬化，该粘合剂将该多孔部分的位置锁定在压缩状态下。具有高密度(即无孔)的单板部分在压制期间被压缩，然而在压力释放时回弹，由此形成表面层的凸起。该高密度部分不能从亚层吸收足够的粘合剂，以至于在压制后不能被硬化的粘合剂锁定。
对具有无孔结构的木单板(例如软材，例如裸子植物)而言，具有高密度的夏木年轮(也称为晚材年轮)在压制期间不可压缩。相反，夏木年轮被压入亚层中，从而使得亚层被压缩。夏木年轮形成表面层的压花部分。春木年轮(也称为早材年轮)在压制期间可压缩。在压制期间，春木年轮被压缩。然后释放压力，春木年轮回弹且形成凸起。
表面层的压花部分还可通过压花压制设备，例如压花压板压制。
所述方法可进一步包括在与单板层相对的基材表面上施加平衡层。平衡层可为作为粉末施加的粉末基平衡层。粉末基平衡层可包含木颗粒如木素纤维颗粒和/或纤维素颗粒，和粘合剂，优选热固性粘合剂如氨基树脂。平衡层可为树脂浸渍的纸，优选用热固性粘合剂浸渍。
本发明第二方面的带单板构件引入了前文讨论的方法的所有优点，由此前述讨论也可适用于该带单板构件。
根据本发明的第三方面，提供了一种制造构件的方法。所述方法包括：
-提供基材，
-在基材的第一表面上施加亚层，
-在亚层上施加具有多孔结构的表面层，和
-在表面层和/或基材上施加压力，从而使得至少一部分亚层渗透通过表面层的多孔结构。
附图简述
将通过示例并参照所附的示意图更详细地描述本发明，所述示意图显示了本发明的实施方案。
图1a-b示意了根据一个实施方案的制造带单板构件的方法。
图2示意了带单板构件的一个实施方案。
图3示意了带单板构件的横截面。
图4示意了带单板构件的一个实施方案。
图5示意了带单板构件的一个实施方案。
详细描述
图1a-b显示了制造带单板构件10的方法。带单板构件10可为家具组件，建筑板如地板、天花板、墙板、门板、工作台、踢脚板、模塑品、镶边用型材等。所述方法包括提供基材1。基材优选为预制基材，其在制造带单板构件10的方法之前生产。基材1可为板，例如木基板，如图1-3中所示的实施方案中所示。木基板可为木纤维基板，如MDF、HDF、刨花板等，或胶合板。在其他实施方案中，基材可为木塑复合材料(WPC)。基材可为矿物复合板。基材可为纤维水泥板。基材可为氧化镁水泥板。基材可为陶瓷板。基材可为塑料板，例如热塑性塑料板。在另一实施方案中，基材1可为载体，例如纸片或无纺布(如图5所示)，或传送带。
将亚层2施加至基材1的第一表面4上。在图1a所示的实施方案中，亚层2以粉末形式21施加。适于形成亚层2的粉末21通过撒布施加，如图1a所示。亚层还可作为粒子施加。在其他实施方案中，亚层2可作为液体、作为糊、片等施加。亚层2可通过辊涂、喷涂等施加。
在一个实施方案中，亚层2包括浸渍有热固性粘合剂的片。所述片可为纸片。所述片可着色，和/或用于浸渍该片的粘合剂溶液可着色，从而使得该片在浸渍期间着色。
亚层2包含粘合剂。所述粘合剂可为热固性粘合剂、热塑性粘合剂或其组合。所述粘合剂可为木粘合剂(wood mastic)、木填料或任何类型的油灰状糊。热固性粘合剂可为氨基树脂，如蜜胺-甲醛树脂、酚醛树脂、脲醛树脂或其组合。脲醛树脂可单独使用或者与蜜胺-甲醛树脂组合使用，从而与仅使用蜜胺-甲醛树脂相比，降低在固化期间由亚层2形成的张力。热塑性粘合剂可为聚氯乙烯(PVC)、聚乙烯(PE)、聚丙烯(PP)、聚氨酯(PU)、聚乙烯醇(PVOH)、聚乙烯醇缩丁醛(PVB)、聚乙酸乙烯酯(PVAc)，和/或热塑性弹性体(TPE)或其组合。
在施加时，所述粘合剂可呈粉末形式。
亚层2可由包含上述类型的粘合剂和填料的混合物形成。所述混合物可进一步包含颜料。所述混合物可进一步包含添加剂。所述混合物可进一步包含耐磨和/或耐刮擦颗粒。作为混合物的替代方案，可分别在基材1上施加粘合剂、填料、颜料、添加剂和任何其他组分。
填料可为颗粒或纤维，例如木纤维或颗粒，或矿物颗粒或纤维。木颗粒可为木素纤维颗粒和/或纤维素颗粒。木颗粒可为至少部分漂白的。填料可为稻、稻草、玉米、黄麻、亚麻、胡麻、棉、***、竹、甘蔗渣或剑麻颗粒或纤维。亚层可包含淀粉，如玉米淀粉、土豆淀粉等。
填料可为具有吸声性能的填料，例如软木颗粒和/或硫酸钡(BaSO4)。或者，可设置吸声层，例如软木层或软木单板层以作为中间层。将亚层施加在吸声层上。所述吸声层可设置在基材上，或者设置在位于基材上的亚层上。
颜料可比单板层的自然颜色更深，和/或比单板层的自然颜色更浅。颜料可包括白色颜料如TiO2。颜料如TiO2可与至少部分漂白的木颗粒组合，从而因亚层渗透通过单板而获得着白色染色的单板。在一个实施方案中，由白色颜料如TiO2与木颗粒，优选至少部分漂白的木颗粒形成预混物。然后将所述预混物与剩余的木颗粒、粘合剂、添加剂等混合。
添加剂可为润湿剂、抗静电剂如炭黑，和导热颗粒如铝。其他可能的颗粒为磁性物质。
亚层2也可包含箔或片。
亚层中可包含添加剂如发泡剂。发泡剂可为物理发泡剂如EXPANCEL(RTM)，和/或化学发泡剂如AIBN(偶氮异丁腈)或ADC(偶氮二甲酰胺(azodicarbonamide))。
耐磨和/或耐刮擦颗粒可为氧化铝颗粒和/或二氧化硅颗粒。
在一个实施方案中，亚层2基本上由粘合剂和任选的添加剂组成，这意指至少90％的亚层2为粘合剂和任选的添加剂。在一个实施方案中，亚层2不含任何纤维和/或填料。
亚层2可以以200-600g/m2，优选300-500g/m2，例如约400g/m2的量施加。对亚层2所施加的粘合剂的量可为100-300g/m2，优选150-250g/m2，例如约200g/m2。亚层2可包含其量为30-80重量％，优选其量为40-60重量％，例如约50重量％的粘合剂。
在施加单板层3之前，可将亚层2预压制。
将单板层3施加至亚层2上。单板层3可为木单板、软木单板或石单板。单板具有多孔结构，由此可渗透。单板层3可具有约0.2-1mm的厚度。单板层3可为连续或不连续的。单板层3可由若干单板件形成。所述单板件可重叠或不重叠。单板件之间可形成间隙。所述间隙可在压制后被亚层2填充。单板件可随机施加或者形成图案。可形成单板件的拼缝物(patchwork)。单板件可以以图案，例如人字形图案、荷兰图案(Dutchpattern)等排列，其中若干单板件设置在一个基材1上。单板件还可以以使得该单板件或单板件之间的间隙形成模板的方式排列。
亚层2可具有均匀的颜色、不同的色调，或亚层的不同部分可具有不同的颜色。可通过以不同颜色着色亚层2的不同部分而形成多色单板层3。如果单板层3由若干单板件形成，则第一组单板件可具有不同于第二组单板件的颜色。或者，各单板件可被各单板件下方的不同颜色的亚层不同地着色。
在一个实施方案中，可在亚层2中印刷数字印刷物，优选借助喷墨打印机。印刷物的不同颜色渗透通过单板层3，从而使得亚层2的颜色转移至单板层3的表面中。亚层2的颜色和/或图案也可借助粘合剂和印刷技术(BAP)获得，例如如WO2014/017972所述。在一个实施方案中，在单板层3上印刷数字印刷物。
可在芯上设置超过一个单板层3。在一个实施方案中，可在基材1上设置第一单板层，在第一单板层上设置上述类型的亚层2，且在亚层2上设置第二单板层。可在第二单板层和亚层2中形成沟槽，例如在压制后，从而使得第一单板层可见。还可在第二单板层的不同部分之间设置间隙，从而使得亚层和/或第一单板层可见。单板层还可包括交叉设置的单板件。
如图1b所示，当在亚层2上设置单板层3时，在单板层3和/或基材1上施加压力，从而使得在亚层2中形成流体压力。所述压力可由连续挤压30施加或非连续挤压施加(未示出)。优选还施加热。
当施加足够的压力时，亚层2渗透通过单板层3中的孔、裂缝和孔洞。至少一部分亚层2完全渗透通过单板层3，从而使得所述至少一部分亚层2在单板层3上变得可见。所述至少一部分渗透或传输通过单板层3的亚层包含亚层2的至少一种组分。渗透通过单板层3的亚层2的物质可为亚层2的一种或数种组分。例如，亚层2的粘合剂可渗透通过单板层。当在压制期间熔融时，所述粘合剂可将亚层2的任何颜料携带至单板层3的上表面。
在施加时，亚层2可呈流体形式或粉末形式。亚层2的粘合剂(例如热固性或热塑性粘合剂)可作为粉末或以分散体、溶液或悬浮液的流体形式施加。如果在施加时粘合剂以粉末形式施加，则所述粘合剂在所施加的压力下在施加的热超过该粘合剂的熔点时熔融。由此，所述粘合剂呈液体形式。通过施加压力，形成亚层2的流体压力。由此，呈液体形式的粘合剂可渗透单板层3。如果使用热固性粘合剂，则所述热固性粘合剂首先由直至第一温度的熔融过程所主导，随后所述热固性粘合剂由交联过程所主导。
通过控制亚层2渗透通过单板层3的程度，可控制带单板构件10的设计。单板的设计可通过至少部分渗透单板层3且由此在单板层3表面处可见的亚层2而改变。如果单板层3包含裂缝、孔隙和其他不规则物，则完全渗透通过单板层3所需的流体压力降低，从而使得亚层2的部分容易渗透通过单板层3且填充裂缝或孔洞。由此，可避免或至少减少油灰。通过在亚层2中包含颜料，可进一步改变单板的设计。
对一些设计而言，可能希望高渗透程度；而对其他设计而言，可能希望更低或变化的渗透。例如，如果希望单板均匀着色，例如釉化，虹光或染色，则均匀的流体压力是优选的。优选地，单板层3具有均匀的厚度和结构。如果希望变化的渗透，从而导致变化的单板图案，则优选变化的流体压力。单板层3可具有变化的结构，包括裂缝和孔隙。也可控制单板层3的厚度以控制亚层2的渗透，由此控制单板层3的设计。单板层3越薄，则渗透通过单板层3的亚层2的量就越大。
通过控制亚层2的渗透而控制带单板构件10的设计可以以数种方式实施。可控制和调节流体压力。可改变单板层3表面上的流体压力。如果希望亚层2的高程度渗透，则可提高流体压力。如果希望亚层2的较低程度渗透，则可降低流体压力。
流体压力可以以数种方式控制。流体压力可通过控制施加在基材2和/或单板层3上的压力而控制。所施加的温度可影响渗透，例如通过改变亚层2的粘度。
流体压力也可通过在亚层2中产生气体压力而控制。通过在亚层2中产生气体压力，流体压力得以提高。气体压力可通过在亚层中包含化学和/或物理发泡剂而产生。化学和/或物理发泡剂在活化时会提高流体压力。
亚层2的流体压力也可通过调节亚层2中的粘合剂浓度而控制。通过提高亚层2的粘合剂浓度，更多的亚层2物质可渗透通过单板层3。在施加热和压力时流动的亚层2的部分增多，由此更大部分的亚层2可渗透通过单板层3。此外，可调节粘合剂的类型。通过提高亚层2中的热固性粘合剂的量，在施加热和压力时可流动的亚层2的部分增多，由此提高流体压力。
亚层2的流体压力还可通过调节亚层2中的粘合剂类型而控制。通过使用不同类型的粘合剂，可改变亚层2的流体压力，且由此改变渗透。快速固化的粘合剂导致更少的亚层2渗透通过单板层。
流体压力也可通过调节亚层的水分含量而控制。亚层的水分含量越高，则在施加热和压力时形成的蒸汽就越多，由此提高流体压力，且因此提高亚层2通过单板层3的渗透。相反，通过在压制之前降低亚层2的水分含量，例如通过干燥亚层2，则在压制期间形成较少的蒸汽。
亚层2通过单板层3的渗透也可通过在亚层中包含填料而控制。填料通过降低粘合剂的流动而降低亚层的渗透。一些填料，例如木颗粒和其他有机填料会在一定程度上吸收粘合剂，从而降低自由渗透通过单板层3的剩余粘合剂。由此还降低流体压力。
亚层2通过单板层3的渗透也可通过调节亚层2的厚度，例如通过调节所施加的亚层量而控制。如果亚层2作为粉末施加，则可调节施加的粉末量以获得所需的亚层2通过单板层3的渗透。亚层越厚，即所施加的亚层量越大，则渗透通过单板层3的亚层2就越多。
亚层2通过单板层3的渗透也可通过形成贯穿单板层3的孔洞或裂缝而控制。通过形成孔洞和裂缝或者扩大已有的孔洞和裂缝，亚层2容易地渗透通过单板层3。亚层2通过单板层3的渗透也可通过形成孔隙、孔洞和/或裂缝或扩大已有的孔隙、孔洞和/或裂缝，优选通过刷处理而实施。
通过调节和控制这些参数，可控制亚层2通过单板层3的渗透，从而获得所需的单板表面外观，例如如图2-5所示。
在一个实施方案中，在压制后制得的建筑板可为6-25mm厚，优选为8-15mm厚，而芯可为5-22mm厚，优选为7-14mm厚。在压制后，亚层可为0.1-2mm厚。
此外，可在单板层3上施加保护层(未示出)。保护层可为涂层，例如一个或数个漆层。涂层可为丙烯酸酯或甲基丙烯酸酯涂层，例如聚氨酯涂层。涂层可包含耐磨和/或耐刮擦颗粒。保护层可为包含耐磨颗粒的覆盖纸。保护层可为包含作为混合物施加至单板表面上的经处理木纤维、粘合剂和耐磨颗粒的粉末覆盖物，如WO2011/129755所述。如果保护层包含或者为覆盖纸或粉末覆盖物，则保护层优选在施加热和压力的步骤之前施加。由此，保护层在与使单板层与亚层和基材结合相同的步骤中固化且与单板层结合。
带单板构件10可进一步以不同的方式处理，例如刷处理、涂油、涂漆、涂蜡等。
也可在压制前将保护性涂层(未示出)施加至单板层3上。在一个实施方案中，在压制之前，在背对基材1的单板层上表面上施加(例如撒布)蜡粉末。在压制期间，蜡粉末形成带单板构件10的保护性涂层。
在一个实施方案中，在压制之前，在背对基材1的单板层上表面上施加底漆。底漆可为印刷底漆、用于将单板层3准备好以用于涂漆的底漆等。
还可在压制之前或之后，在单板层3上施加保护性箔。保护性箔可为热塑性箔如PU或PVC箔。
在图2的实施方案中，基材1包括木基板如胶合板、HDF、MDF、刨花板等。在该实施方案中，带单板构件10可为建筑板或家具组件。如果带单板构件10为地板或墙板，则该地板或墙板可提供有机械锁定***以与相邻地板或墙板连接。如果带单板构件10为抽屉、架子或其他家具的家具组件，则该家具可提供有机械锁定***以与抽屉、架子或家具组件的其他部分连接。
带单板构件10可提供有装饰性沟槽或斜角。所述装饰性沟槽或斜角可延伸至亚层2中，从而使得亚层2由该带单板构件的上表面可见。所述装饰性沟槽或斜角可设置在提供有机械锁定***的带单板构件的边缘。通过提供延伸至亚层2中的装饰性沟槽，可获得船甲板状的外观。
在图2所示的实施方案中，亚层2已在单板层3的一些单板阻力较低的部分例如单板层的裂缝、孔洞和孔隙中渗透通过单板层3，然而渗透通过单板层3的其他部分的程度较低。如图2所示，亚层2的部分2a在单板层3的表面上可见。亚层2的渗透形成不规则设计的单板。
图3更详细地显示了带单板构件10的横截面。图3更详细地示意了亚层2的部分2a如何渗透通过单板层3以使得亚层2的部分2a由单板层3的暴露表面可见。图3示意亚层2已渗透通过单板层3且填充单板的孔洞6，从而使得亚层2的部分2a通过单板层3可见。如图3中那样，孔洞6可为节。图3还示意亚层2已渗透通过单板层3且填充单板中的裂缝7，从而使得单板层3的部分2a由单板层3的上表面可见。此外，图3显示亚层2的部分2a已渗透通过单板层3的孔8，从而使得亚层2的部分2a在单板层3的上表面上可见。在图3所示的实施方案中，基材1包括木基板，如胶合板、HDF、MDF、刨花板等。带单板构件10还提供有设置在基材1的与亚层2相对的第二表面9上的平衡层5。平衡层5可为作为粉末施加的粉末基平衡层。粉末基平衡层可包含木颗粒如木素纤维颗粒和/或纤维素颗粒，和粘合剂，优选热固性粘合剂如氨基树脂。平衡层可为树脂浸渍的纸，优选用热固性粘合剂浸渍。
图4也显示了上述类型的带单板构件10，其中基材1包括木基板，如胶合板、HDF、MDF、刨花板等。在该实施方案中，带单板构件10也可为建筑板或家具构件，且可提供有机械锁定***。然而，在该实施方案中，与图2所示的实施方案相比，亚层2更均匀地渗透通过单板层3，从而获得更规整的单板层3设计。这可通过施加均匀压力和通过提供具有均匀孔结构和/或均匀厚度的单板层3实现。
图5显示了上述类型的带单板构件10的一个实施方案，其中基材1包括纸或片。基材1形成单板层3和亚层2的载体。该实施方案的带单板构件10可为可弯曲的和/或柔性的。由此，带单板构件10的后成型是可能的。可在随后操作中将带单板构件10与其他构件粘合。带单板构件10可形成例如家具组件的表面。在一个实施方案中，基材为传送带，且在施加热和压力后将带单板构件10从运输带上取下。
可设想本文所述实施方案的许多变型，这些仍落入由所附权利要求所限定的本发明范围之内。
可设想亚层可不与基材直接接触，而是可提供位于基材和亚层之间的中间层。
还可设想建筑板可提供有以与上文所述相同的方式施加的上述类型的第二单板层(未示出)。将上述类型的亚层施加至上述类型基材的第二表面上。芯的第二表面背对上文参照图1-4描述的单板层。在该实施方案中，上文参照图1-4描述的单板层被视为第一单板层，而第二单板层与第一单板层相对地设置。第二单板层的设计如上文参照图1-5描述的那样通过确定亚层渗透通过第二单板层的水平而控制。
实施例
实施例1：
将包含40重量％木纤维、10重量％氧化铝(Alodur ZWSK 180-ST)、49.5重量％蜜胺-甲醛树脂(Kauramin 773)和0.5重量％炭黑(Printex 60)的400g/m2粉末混合物撒布至10.0mm HDF板上以形成亚层。用20g/m2隔离剂(PAT-660)水溶液喷涂所述用于形成亚层的粉末层。将0.6mm橡木单板层置于亚层上，然后在短循环压制中在40巴下使用160℃的压板温度将所述组件压制30秒钟。所得产品为带单板HDF，其在单板层中具有被亚层固化粉末混合物填充的孔和裂缝。
实施例2：
将包含40重量％木纤维、10重量％氧化铝(Alodur ZWSK 180-ST)、49.5重量％蜜胺-甲醛树脂(Kauramin 773)和0.5重量％炭黑(Printex 60)的800g/m2粉末混合物撒布至10.0mm HDF板上以形成亚层。用20g/m2隔离剂(PAT-660)水溶液喷涂所述用于形成亚层的粉末层。将0.6mm橡木单板置于亚层上，然后在短循环压制中在40巴下使用160℃的压板温度将所述组件压制30秒钟。所得产品为带单板HDF，其在单板层中具有与实施例1中产品相比提高量的被亚层固化粉末混合物填充的孔和裂缝。
实施例3：
将包含17.5重量％木纤维、17.5重量％矿物纤维、10重量％氧化铝(Alodur ZWSK 180-ST)、52.5重量％蜜胺-甲醛树脂(Kauramin 773)和0.5重量％炭黑(Printex 60)的400g/m2粉末混合物撒布至10.0mm HDF板上以形成亚层。用20g/m2隔离剂(PAT-660)水溶液喷涂所述形成亚层的粉末层。将0.6mm橡木单板置于亚层上，然后在短循环压制中在40巴下使用160℃的压板温度将所述组件压制30秒钟。所得产品为带单板HDF，其在单板层中具有与实施例1中产品相比提高量的被亚层固化粉末混合物填充的孔和裂缝。
实施例4：
将包含10重量％氧化铝(Alodur ZWSK 180-ST)、89.5重量％蜜胺-甲醛树脂(Kauramin 773)和0.5重量％炭黑(Printex 60)的400g/m2粉末混合物撒布至10.0mm HDF板上以形成亚层。用20g/m2隔离剂(PAT-660)水溶液喷涂所述形成亚层的粉末层。将0.6mm橡木单板置于亚层上，然后在短循环压制中在40巴下使用160℃的压板温度将所述组件压制30秒钟。所得产品为带单板HDF，其在单板层中具有与实施例1中产品相比提高量的被亚层固化粉末混合物填充的孔和裂缝。
实施例5：
将包含40重量％木纤维、10重量％氧化铝(Alodur ZWSK 180-ST)、49.5重量％热塑性粘合剂(Vinnapas 5010N)和0.5重量％炭黑(Printex 60)的400g/m2粉末混合物撒布至10.0mm HDF板上以形成亚层。用20g/m2隔离剂(PAT-660)水溶液喷涂所述形成亚层的粉末层。将0.6mm橡木单板置于亚层上，然后在短循环压制中在40巴下使用160℃的压板温度将所述组件压制30秒钟。所得产品为带单板HDF，其在单板层中具有与实施例1中产品相比降低量的被亚层固化粉末混合物填充的孔和裂缝。
实施例6：
将包含45重量％水、10重量％氧化铝(Alodur ZWSK 180-ST)、44.5重量％蜜胺-甲醛树脂(Kauramin 773)和0.5重量％炭黑(Printex 60)的400g/m2液体混合物施加至10.0mm HDF板上以形成亚层。将0.6mm橡木单板置于所述形成亚层的液体层上，然后在短循环压制中在40巴下使用160℃的压板温度将所述组件压制30秒钟。所得产品为带单板HDF，其在单板层中具有被固化混合物填充的孔和裂缝。

Claims (28)

1.一种制造带单板构件(10)的方法，包括：
-提供基材(1)，
-将亚层(2)施加至基材(1)的表面上，
-将单板层(3)施加至亚层(2)上，
-在单板层(3)和/或基材(1)上施加压力，从而使得亚层(2)的至少一部分(2a)渗透通过单板层(3)，
其中所述方法进一步包括
通过控制亚层(2)通过单板层(3)的渗透而控制单板层的设计。
2.根据权利要求1的方法，其中亚层(2)通过单板层(3)的渗透的控制包括控制亚层(2)的流体压力。
3.根据权利要求2的方法，其中在施加压力时，亚层(2)流体压力的控制包括调节一个或多个如下参数：
-亚层(2)中的粘合剂浓度；
-亚层(2)的水分含量；
-施加在单板层(3)和/或基材(1)上的压力；
-亚层(2)中的气体压力；
-亚层(2)中的填料浓度；和
-单板层(3)的厚度。
4.根据前述权利要求中任一项的方法，其中亚层(2)进一步包含颜料。
5.根据前述权利要求中任一项的方法，其中基材(1)为木基板。
6.根据权利要求2-5中任一项的方法，其中亚层(2)流体压力的控制包括调节亚层(2)中的粘合剂浓度。
7.根据权利要求2-6中任一项的方法，其中流体压力的控制包括调节亚层(2)的水分含量。
8.根据权利要求2-7中任一项的方法，其中流体压力的控制包括调节施加在单板层(3)和/或基材(1)上的压力。
9.根据权利要求2-8中任一项的方法，其中流体压力的控制包括在亚层(2)中产生气体压力。
10.根据权利要求9的方法，其中气体压力的产生包括在亚层(2)中包含化学和/或物理发泡剂。
11.根据前述权利要求中任一项的方法，其中亚层(2)通过单板层(3)的渗透的控制包括在亚层(2)中包含填料。
12.根据前述权利要求中任一项的方法，其中亚层(2)通过单板层(3)的渗透的控制包括在单板层(3)和/或基材(1)上施加压力之前对单板层(3)进行磨削加工。
13.根据权利要求12的方法，其中磨削加工包括在单板层(3)和/或基材(1)上施加压力之前刷处理单板层(3)。
14.根据前述权利要求中任一项的方法，其中亚层(2)通过单板层(3)的渗透的控制包括在单板层(3)中形成孔洞(6)、孔隙(6)和/或裂缝(7)。
15.根据前述权利要求中任一项的方法，其中亚层(2)通过单板层(3)的渗透的控制包括控制单板层(3)的厚度。
16.根据前述权利要求中任一项的方法，其中亚层(2)的所述至少一部分(2a)渗透通过单板层(3)的孔(8)。
17.根据前述权利要求中任一项的方法，其中亚层(2)的所述至少一部分(2a)渗透通过单板层(3)的裂缝(7)和/或孔洞(6)。
18.根据前述权利要求中任一项的方法，其中单板层(3)包括木单板、软木单板或石单板。
19.根据前述权利要求中任一项的方法，其中亚层(2)包含粘合剂。
20.根据权利要求19的方法，其中所述粘合剂为热固性粘合剂或热塑性粘合剂。
21.根据前述权利要求中任一项的方法，其中亚层(2)包含耐磨颗粒。
22.根据前述权利要求中任一项的方法，其中在施加压力后，单板层包含压花部分，与在未压花表面部分下方相比，在压花部分的下方，一部分亚层(2)受到更大的压缩。
23.一种制造带单板构件(10)的方法，包括：
-提供基材(1)，
-将亚层(2)施加至基材(1)的表面上，其中亚层(2)包含颜料，
-将单板层(3)施加至亚层(2)上，
-在单板层(3)和/或基材(1)上施加压力，从而使得亚层(2)的至少一部分(2a)渗透通过单板层(3)，
其中所述方法进一步包括
通过控制亚层(2)通过单板层(3)的渗透而控制单板层的设计。
24.一种带单板构件(10)，包括：
基材(1)，其为木基板，
设置在基材(1)上的亚层(2)，和
设置在亚层(2)上的单板层(3)，
其中亚层(2)的至少一部分(2a)渗透通过单板层(3)，从而使得亚层(2)的至少一部分(2a)在背对基材(1)的单板层(3)表面处可见，和
其中亚层(2)包含颜料。
25.根据权利要求24的带单板构件，其中亚层(2)包含耐磨颗粒。
26.根据权利要求24或25的带单板构件，其中亚层(2)包含填料。
27.根据权利要求24-26中任一项的带单板构件，其中亚层(2)的所述至少一部分(2a)渗透通过单板层(3)的孔(8)。
28.根据权利要求24-27中任一项的带单板构件，其中单板层(3)包含压花部分，其中与在未压花表面部分下方相比，在压花部分的下方，一部分亚层(2)受到更大的压缩。
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Application publication date: 20160817

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