EP1690603B1 - Fiberboard comprising a coating deposited on at least a section of its surface - Google Patents

Fiberboard comprising a coating deposited on at least a section of its surface Download PDF

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Publication number
EP1690603B1
EP1690603B1 EP20060002044 EP06002044A EP1690603B1 EP 1690603 B1 EP1690603 B1 EP 1690603B1 EP 20060002044 EP20060002044 EP 20060002044 EP 06002044 A EP06002044 A EP 06002044A EP 1690603 B1 EP1690603 B1 EP 1690603B1
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EP
European Patent Office
Prior art keywords
synthetic resin
particles
fibers
cellulose
timber board
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.)
Active
Application number
EP20060002044
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German (de)
French (fr)
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EP1690603A1 (en
Inventor
Ralf Sczepan
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Kronotec AG
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Kronotec AG
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Publication date
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Priority to PL06002044T priority Critical patent/PL1690603T3/en
Publication of EP1690603A1 publication Critical patent/EP1690603A1/en
Application granted granted Critical
Publication of EP1690603B1 publication Critical patent/EP1690603B1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/06—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2203/00—Other substrates
    • B05D2203/20—Wood or similar material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00—Sheets
    • B05D2252/10—Applying the material on both sides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2601/00—Inorganic fillers
    • B05D2601/20—Inorganic fillers used for non-pigmentation effect
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2602/00—Organic fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0254—After-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31942—Of aldehyde or ketone condensation product
    • Y10T428/31949—Next to cellulosic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31942—Of aldehyde or ketone condensation product
    • Y10T428/31949—Next to cellulosic
    • Y10T428/31957—Wood
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31942—Of aldehyde or ketone condensation product
    • Y10T428/31949—Next to cellulosic
    • Y10T428/31964—Paper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y10T428/31982—Wood or paper
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31975—Of cellulosic next to another carbohydrate
    • Y10T428/31978—Cellulosic next to another cellulosic
    • Y10T428/31986—Regenerated or modified
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31989—Of wood

Definitions

  • the invention relates to a wood-based panel having an at least partially applied surface coating and a method for applying the coating.
  • Wood-based panels with a surface coating which is usually applied to the top, possibly also the underside and the side surfaces, are known for many purposes. Increasingly important floor panels made of wood materials, but also ceiling and wall panels, wood-based panels for room dividers and the like. In order to obtain a durable surface coating which is also abrasion-resistant in the case of floors, the use of impregnates is customary.
  • Impregnates are special papers impregnated with synthetic resin.
  • the resins incorporated in the paper are cured to such an extent that the papers are dry and storable.
  • the impregnates are cured under the action of pressure and temperature. Pressure and temperature are usually applied in presses.
  • the softening prior to the final curing resin flows through the paper framework through to a layer which, where the impregnate is applied, the surface of the wood-based panel coated.
  • the impregnate may include, as required, a paper printed with a decor. It may be incorporated corundum as a means against the abrasion in the impregnate.
  • Typical examples are the DE 27 18 705 A1 , the US2001 / 0006704 and the GB1 579 661 in which the application of melamine resin is described on a wood-based panel.
  • the melamine resin may be provided with pigments or fillers.
  • thermosetting synthetic resins especially in the processing of the well-suited and inexpensive aminoplasts.
  • the synthetic resin e.g. a melamine resin
  • the special paper has undergone this change in shape.
  • the synthetic resin When the synthetic resin is applied directly to a wood-based material surface, the synthetic resin itself can be applied sparingly depending on the desired layer thickness. With a relatively thin, direct application, however, it is disadvantageous that the synthetic resins do not always form the desired, uniform layer on the surface of the wood-based material board.
  • the surface coating has an uneven layer thickness.
  • thermosetting resins exert a strong tensile force in the plane of the coated surface of the wood-based panel due to the large shrinkage stress arising on emergence, which in part lead to deformations which make further processing of the coated panel impossible.
  • the high shrinkage stress in conjunction with the relatively low adhesive force of the thermosetting synthetic resins on the plate also causes flaking occur.
  • the invention is therefore based on the object to propose a directly applied surface coating for a wood-based panel, which avoids the disadvantages described above.
  • the object is achieved with a wood-based panel according to claim 1.
  • the liquid-applied synthetic resin layer is cured under the action of elevated temperature and / or elevated pressure.
  • cellulose fibers, viscose fibers, synthetic fibers or fibers of glass or a mixture of at least two of the aforementioned fibers causes the shrinkage of the resin during curing greatly reduces the stresses occurring in the surface of the coated wood material and especially the deformations caused thereby .
  • a so-called balance of the same resin or a material with comparable properties in order to equalize the stresses occurring can be applied to the opposite surface of the wood-based panel, in the position of use usually the bottom, a so-called balance of the same resin or a material with comparable properties in order to equalize the stresses occurring.
  • Such a synthetic resin layer mixed with cellulose fibers, viscose fibers, synthetic fibers or fibers made of glass or a mixture of at least two of the aforementioned fibers does not require paper as a carrier material and is therefore much less expensive and less energy-consuming to produce than known coatings.
  • fibers improves the cohesion and in particular the adhesion of layers of synthetic resin, which are applied to wood-based surfaces, in particular thermosetting resins.
  • Particularly suitable is the addition of fibers has proven in aminoplasts, especially in melamine resins.
  • the invention comprises both typical fibers whose diameter is small in relation to the length, and particles which are cuboidal or spherical, so have approximately the same dimensions in length, height and width, for example crystalline cellulose particles.
  • Suitable cellulose fibers whether in the form of natural cotton fibers such.
  • As linters as particles of crystalline cellulose or in the form of synthetically produced fibers such as viscose, Tencel or the like ..
  • synthetic fibers or fibers made of glass are suitable, provided that they are compatible with the selected resin. Mixtures of at least two of the aforementioned fibers, which are added to a synthetic resin for coating the surface of a wood-based panel, have proved to be particularly advantageous.
  • the diameter of the fibers may typically be between 10 ⁇ m and 150 ⁇ m, preferably between 15 ⁇ m and 40 ⁇ m.
  • the length of the fibers may be 10 .mu.m to 100 .mu.m, preferably 10 .mu.m to 80 .mu.m.
  • the fibers used according to the invention need not have a large degree of slimming, they can also be used as cubic fibers with approximately the same edge length or as roundish particles.
  • fibers are sufficient to achieve the purpose desired according to the invention.
  • 5 percent by weight (% by weight) of fibers based on the weight of the synthetic resin used are sufficient for the film formation z.
  • % by weight As a melamine resin on a wood-based material surface significantly, in particular to improve uniform and at the same time the adhesion of the resin to the wood-based panel.
  • 1 to 40% by weight of fibers are based on the weight of the synthetic resin used used, more preferably 5 to 20% by weight.
  • the fibers are transparent after curing of the synthetic resin layer on the wood-based panel. As a result, the visibility of a decoration already applied to the surface of the wood-based material remains unimpaired.
  • corundum to the fiber-reinforced synthetic resin layer according to the invention on the surface of the wood material is readily possible. If the corundum is applied homogeneously with the fiber-reinforced synthetic resin, it is not effectively shielded by the fibers, which can lead to increased wear of the press plates. To remedy this problem, it may prove useful, above the existing, fiber-reinforced synthetic resin layer according to the invention at least one further layer of a synthetic resin or a synthetic resin mixture, for. B. a further layer of synthetic resin, which is optionally mixed with fibers to apply.
  • the fiber-added layer of synthetic resin which is at least partially applied to the surface of a wood-based panel, part of a multi-layer surface coating.
  • a wood-based panel part of a multi-layer surface coating.
  • these layers are all applied directly to the surface, for example by spraying, rolling or knife coating. If corundum is used, it can be applied by a litter device. It can be sprinkled directly into the fiber-reinforced resin layer.
  • the layer of liquid synthetic resin provided with fibers can readily be arranged as one of several layers at any point of the multilayer surface structure.
  • a medium-density fiberboard 65 g / m 2 of a melamine resin On the top and bottom of a medium-density fiberboard 65 g / m 2 of a melamine resin are applied, which has a solids content of about 58%.
  • the melamine resin 20 wt% crystalline cellulose particles are mixed.
  • the cellulose particles have a diameter of 100 ⁇ m. The job is done by means of rollers.
  • the thus applied melamine resin layer is precondensed in a hot air oven to a residual moisture content of the melamine resin of 6 wt .-%.
  • the final curing of the melamine resin is carried out in a short-cycle press at 165 ° C for 20 seconds.
  • the both sides equally coated wood-based panel is evenly coated after curing of the melamine resin coating without defects and unchanged flat.
  • 80 g / m 2 of a mixture of melamine resin, which has a solids content of about 58%, are applied to the top of a medium-density fibreboard (MDF) previously printed with decor.
  • MDF medium-density fibreboard
  • the melamine resin is blended with 20 g / m 2 of cellulose particles with a diameter of 80 to 100 microns.
  • 20 g / m 2 of corundum in the form of cubic particles with 40 to 60 ⁇ m edge length are mixed into the melamine resin.
  • the term "g / m 2 " refers in each case to the amount that is applied to one square meter surface of the wood-based panel.
  • melamine resin is applied in an amount of 30 g / m 2
  • the cellulose blended in the melamine resin in an amount of 10 g / m 2 .
  • the cellulose particles in this layer have a diameter of 10 .mu.m to 20 .mu.m.
  • a balance bar of 50 g / m 2 melamine resin and 10 g / m 2 cellulose particles is applied.
  • These fiber-reinforced melamine resin layers are pre-dried in the hot air stream to a residual moisture content of 6% water content in the synthetic resin layer.
  • the final processing of the fiber-reinforced melamine resin coated MDF boards is carried out in short-cycle presses at 165 ° C for 20 sec to plates which have on the decor-printed top highly abrasive properties, and which are used as floor laminate panels.

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)
  • Protection Of Plants (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

One or more layers of liquid plastic resin blended with fibers, is coated onto the wooden panel. The resin is a thermoset, especially an aminoplastic, particularly melamine resin. The fibers are cellulose, viscose, other synthetics, glass, ceramic or their mixtures. Preferably 5-20 wt% of fibers are employed, based on the weight of resin used. Once the composite is hardened, the fibers are transparent. Corundum is included in the layer. An independent claim is included for the corresponding coating method.

Description

Die Erfindung betrifft eine Holzwerkstoffplatte mit einer mindestens abschnittsweise aufgetragenen Oberflächenbeschichtung und ein Verfahren zum Aufbringen der Beschichtung.The invention relates to a wood-based panel having an at least partially applied surface coating and a method for applying the coating.

Holzwerkstoffplatten mit einer Oberflächenbeschichtung, die üblicherweise auf die Oberseite, ggf. auch die Unterseite und die Seitenflächen aufgetragen ist, sind für viele Einsatzzwecke bekannt. Zunehmend Bedeutung haben Fußbodenpaneele aus Holzwerkstoffen, aber auch Decken- und Wandpaneele, Holzwerkstoffplatten für Raumteiler und dergleichen. Um eine widerstandsfähige, bei Fußböden zudem abriebfeste Oberflächenbeschichtung zu erhalten, ist der Einsatz von Imprägnaten üblich.Wood-based panels with a surface coating, which is usually applied to the top, possibly also the underside and the side surfaces, are known for many purposes. Increasingly important floor panels made of wood materials, but also ceiling and wall panels, wood-based panels for room dividers and the like. In order to obtain a durable surface coating which is also abrasion-resistant in the case of floors, the use of impregnates is customary.

Imprägnate sind Spezialpapiere, die mit Kunstharz getränkt sind. Die in das Papier eingebrachten Kunstharze werden so weit gehärtet, dass die Papiere trocken und lagerfähig sind. Nach dem Aufbringen auf die Holzwerkstoffplatten werden die Imprägnate unter Einwirkung von Druck und Temperatur ausgehärtet. Druck und Temperatur werden in der Regel in Pressen aufgebracht. Das vor dem endgültigen Aushärten erweichende Kunstharz verfließt dabei durch das Papiergerüst hindurch zu einer Schicht, die dort, wo das Imprägnat aufgetragen ist, die Oberfläche der Holzwerkstoffplatte beschichtet.Impregnates are special papers impregnated with synthetic resin. The resins incorporated in the paper are cured to such an extent that the papers are dry and storable. After application to the wood-based panels, the impregnates are cured under the action of pressure and temperature. Pressure and temperature are usually applied in presses. The softening prior to the final curing resin flows through the paper framework through to a layer which, where the impregnate is applied, the surface of the wood-based panel coated.

Das Imprägnat kann, je nach Anforderung, ein mit einem Dekor bedrucktes Papier umfassen. Es kann Korund als Mittel gegen den Abrieb in das Imprägnat eingearbeitet sein.The impregnate may include, as required, a paper printed with a decor. It may be incorporated corundum as a means against the abrasion in the impregnate.

Die Herstellung von Imprägnaten ist aufwändig und kostenintensiv, insbesondere wegen der teuren Spezialpapiere, die als Trägermaterial für Kunstharz, Dekor und ggf. Korund dienen.The production of impregnates is complex and expensive, especially because of the expensive special papers that serve as a carrier material for synthetic resin, decor and corundum if necessary.

Es wurden daher Techniken entwickelt, Dekore ohne Trägerpapier unmittelbar auf die Oberfläche von Holzwerkstoffe aufzubringen und auch Kunstharze sowie ggf. Korund. Typisches Beispiel hierfür sind die DE 27 18 705 A1 , die US2001/0006704 und die GB1 579 661 in denen das Aufbringen von Melaminharz auf eine Holzwerkstoffplatte beschrieben ist. Das Melaminharz ist ggf. mit Pigmenten oder Füllstoffen versehen.Therefore, techniques have been developed to apply decors without backing paper directly to the surface of wood-based materials, as well as synthetic resins and possibly corundum. Typical examples are the DE 27 18 705 A1 , the US2001 / 0006704 and the GB1 579 661 in which the application of melamine resin is described on a wood-based panel. The melamine resin may be provided with pigments or fillers.

Im Detail traten beim Auftragen der meist duroplastischen Kunstharze, insbesondere bei der Verarbeitung der gut geeigneten und kostengünstigen Aminoplaste, aber Schwierigkeiten auf. Bisher wurde das Kunstharz, z.B. ein Melaminharz, auf das Spezialpapier aufgetragen und vorkondensiert. Das Trocknen des Imprägnats führte zum Schwinden, bedingt durch eine Reaktion des Kunstharzes. Das Spezialpapier hat diese Formänderung mitgemacht. Beim Aufpressen des Imprägnats auf die Holzwerkstoffplatte waren keine signifikanten Formänderungen mehr zu beobachten.In detail, however, difficulties arose when applying the most thermosetting synthetic resins, especially in the processing of the well-suited and inexpensive aminoplasts. Heretofore, the synthetic resin, e.g. a melamine resin, applied to the special paper and precondensed. Drying of the impregnate resulted in shrinkage due to a reaction of the synthetic resin. The special paper has undergone this change in shape. When the impregnate was pressed onto the wood-based panel, no significant changes in shape were observed.

Beim direkten Auftragen des Kunstharzes auf eine Holzwerkstoff-Oberfläche kann das Kunstharz an sich sparsam je nach der gewünschten Schichtdicke aufgetragen werden. Bei einem verhältnismäßig dünnen, direkten Auftrag ergibt sich jedoch nachteilig, dass die Kunstharze nicht stets die gewünschte, gleichmäßige Schicht auf der Oberfläche der Holzwerkstoffplatte ausbilden. Die Oberflächenbeschichtung weist eine ungleichmäßige Schichtdicke auf.When the synthetic resin is applied directly to a wood-based material surface, the synthetic resin itself can be applied sparingly depending on the desired layer thickness. With a relatively thin, direct application, however, it is disadvantageous that the synthetic resins do not always form the desired, uniform layer on the surface of the wood-based material board. The surface coating has an uneven layer thickness.

Außerdem erweist sich das Schwinden der Kunstharze beim Aushärten als problematisch. Die aushärtenden Kunstharze üben durch die beim Austreten entstehende, große Schrumpfspannung eine starke Zugkraft in der Ebene der beschichteten Oberfläche der Holzwerkstoffplatte aus, die zum Teil zu Verformungen führen, die eine weitere Verarbeitung der beschichteten Platte unmöglich machen. Die große Schrumpfspannung führt in Verbindung mit der verhältnismäßig geringen Haftkraft der duroplastischen Kunstharze an der Platte zudem dazu, dass Abplatzungen auftreten. Die mangelnde Filmbildung, die insbesondere bei Melaminharzen beobachtet wird, führt beim unmittelbaren Auftrag auf die Oberfläche einer Holzwerkstoffplatte dazu, dass sich beim Aushärten Teile des Kunstharzes von der Holzwerkstoffplatte lösen.In addition, the shrinkage of synthetic resins proves to be problematic during curing. The thermosetting resins exert a strong tensile force in the plane of the coated surface of the wood-based panel due to the large shrinkage stress arising on emergence, which in part lead to deformations which make further processing of the coated panel impossible. The high shrinkage stress, in conjunction with the relatively low adhesive force of the thermosetting synthetic resins on the plate also causes flaking occur. The lack of film formation, which is particularly observed in melamine resins, leads to the immediate Application to the surface of a wood-based panel to allow parts of the resin to dissolve from the wood-based panel during curing.

Der Erfindung liegt daher die Aufgabe zugrunde, eine direkt aufzutragende Oberflächenbeschichtung für eine Holzwerkstoffplatte vorzuschlagen, die die vorstehend beschriebenen Nachteile vermeidet.The invention is therefore based on the object to propose a directly applied surface coating for a wood-based panel, which avoids the disadvantages described above.

Die Aufgabe wird gelöst mit einer Holzwerkstoffplatte gemäß Anspruch 1.The object is achieved with a wood-based panel according to claim 1.

Die flüssig aufgetragene Kunstharz-Schicht wird unter Einwirkung von erhöhter Temperatur und/oder erhöhtem Druck ausgehärtet.The liquid-applied synthetic resin layer is cured under the action of elevated temperature and / or elevated pressure.

Der Zusatz von Cellulosefasern, Viskosefasern, synthetischen Fasern oder Fasern aus Glas oder einer Mischung von mindestens zwei der vorgenannten Fasern beim unmittelbaren Auftragen des Kunstharzes auf eine Holzwerkstoffbberfläche hat sich unerwartet als sehr geeignet erwiesen, um eine gleichmäßige Schichtstärke des Kunstharzes auf der Oberfläche der Holzwerkstoffplatte zu gewährleisten.The addition of cellulose fibers, viscose fibers, synthetic fibers or fibers of glass or a mixture of at least two of the aforementioned fibers in the direct application of the resin to a Holzwerkstoffbberfläche has unexpectedly proved to be very suitable to a uniform layer thickness of the resin on the surface of the wood-based panel guarantee.

Weiter bewirkt der Zusatz von Cellulosefasern, Viskosefasern, synthetischen Fasern oder Fasern aus Glas oder einer Mischung von mindestens zwei der vorgenannten Fasern, dass das Schwinden des Kunstharzes beim Aushärten die in der Oberfläche des beschichteten Holzwerkstoffs auftretenden Spannungen und vor allem die dadurch hervorgerufenen Verformungen stark verringert. Um zu gewährleisten, dass keine unerwünschten Verformungen der Holzwerkstoffplatte auftreten, kann auf der gegenüberliegenden Oberfläche der Holzwerkstoffplatte, in der Gebrauchslage meist der Unterseite, ein sogenannter Ausgleichsstrich desselben Kunstharzes oder eines Materials mit vergleichbaren Eigenschaften aufgetragen werden, um die auftretenden Spannungen zu vergleichmäßigen.Furthermore, the addition of cellulose fibers, viscose fibers, synthetic fibers or fibers of glass or a mixture of at least two of the aforementioned fibers causes the shrinkage of the resin during curing greatly reduces the stresses occurring in the surface of the coated wood material and especially the deformations caused thereby , In order to ensure that no undesirable deformations of the wood-based panel occur, can be applied to the opposite surface of the wood-based panel, in the position of use usually the bottom, a so-called balance of the same resin or a material with comparable properties in order to equalize the stresses occurring.

Eine solche mit Cellulosefasern, Viskosefasern, synthetischen Fasern oder Fasern aus Glas oder einer Mischung von mindestens zwei der vorgenannten Fasern versetzte Kunstharz-Schicht kommt ohne ein Papier als Trägermaterial aus und ist damit weitaus preisgünstiger und mit weniger Energieaufwand herzustellen als bekannte Beschichtungen.Such a synthetic resin layer mixed with cellulose fibers, viscose fibers, synthetic fibers or fibers made of glass or a mixture of at least two of the aforementioned fibers does not require paper as a carrier material and is therefore much less expensive and less energy-consuming to produce than known coatings.

Der Zusatz solcher Fasern verbessert den Zusammenhalt und insbesondere auch die Haftung von Schichten aus Kunstharz, die auf Holzwerkstoff-Oberflächen aufgetragen sind, insbesondere duroplastische Kunstharze. Als besonders geeignet hat sich der Zusatz von Fasern bei Aminoplasten, vor allem bei Melaminharzen erwiesen.The addition of such fibers improves the cohesion and in particular the adhesion of layers of synthetic resin, which are applied to wood-based surfaces, in particular thermosetting resins. Particularly suitable is the addition of fibers has proven in aminoplasts, especially in melamine resins.

Die Erfindung umfasst sowohl typische Fasern, deren Durchmesser gering ist im Verhältnis zur Länge, als auch Partikel, die quader- oder kugelförmig sind, also annähernd gleiche Abmessungen in Länge, Höhe und Breite aufweisen, beispielsweise kristalline Cellulosepartikel. Geeignet sind Cellulosefasern, sei es in Form natürlicher Baumwollfasern wie z. B. Linters, als Partikel kristalliner Cellulose oder in Form synthetisch hergestellter Fasern wie Viskose, Tencel oder dergl.. Aber auch synthetische Fasern oder Fasern aus Glas sind geeignet, sofern sie mit dem jeweils ausgewählten Kunstharz kompatibel sind. Als besonders vorteilhaft haben sich Mischungen aus mindestens zwei der vorgenannten Fasern erwiesen, die einem Kunstharz zur Beschichtung der Oberfläche einer Holzwerkstoffplatte zugesetzt werden.The invention comprises both typical fibers whose diameter is small in relation to the length, and particles which are cuboidal or spherical, so have approximately the same dimensions in length, height and width, for example crystalline cellulose particles. Suitable cellulose fibers, whether in the form of natural cotton fibers such. As linters, as particles of crystalline cellulose or in the form of synthetically produced fibers such as viscose, Tencel or the like .. But also synthetic fibers or fibers made of glass are suitable, provided that they are compatible with the selected resin. Mixtures of at least two of the aforementioned fibers, which are added to a synthetic resin for coating the surface of a wood-based panel, have proved to be particularly advantageous.

Der Durchmesser der Fasern kann typischerweise zwischen 10 µm und 150 µm betragen, vorzugsweise zwischen 15 µm und 40 µm. Die Länge der Fasern kann 10 µm bis 100 µm betragen, vorzugsweise 10 µm bis 80 µm. Die erfindungsgemäß eingesetzten Fasern müssen keinen großen Schlankheitsgrad aufweisen, sie können auch als kubische Fasern mit annähernd gleicher Kantenlänge oder als rundliche Partikel eingesetzt werden.The diameter of the fibers may typically be between 10 μm and 150 μm, preferably between 15 μm and 40 μm. The length of the fibers may be 10 .mu.m to 100 .mu.m, preferably 10 .mu.m to 80 .mu.m. The fibers used according to the invention need not have a large degree of slimming, they can also be used as cubic fibers with approximately the same edge length or as roundish particles.

Schon geringe Mengen an Fasern genügen, um den erfindungsgemäß gewünschten Zweck zu erreichen. Bereits 5 Gewichtsprozent (Gewichts-%) Fasern bezogen auf das Gewicht des eingesetzten Kunstharzes reichen aus, um die Schichtbildung z. B. eines Melaminharzes auf einer Holzwerkstoff-Oberfläche signifikant zu verbessern, insbesondere zu vergleichmäßigen und gleichzeitig die Haftung des Kunstharzes auf der Holzwerkstoffplatte zu verbessern. Nach einer bevorzugten Ausführung der Erfindung werden 1 bis 40 Gewichts-% Fasern bezogen auf das Gewicht des eingesetzten Kunstharzes eingesetzt, besonders bevorzugt 5 bis 20 Gewichts-%.Even small amounts of fibers are sufficient to achieve the purpose desired according to the invention. Already 5 percent by weight (% by weight) of fibers based on the weight of the synthetic resin used are sufficient for the film formation z. As a melamine resin on a wood-based material surface significantly, in particular to improve uniform and at the same time the adhesion of the resin to the wood-based panel. According to a preferred embodiment of the invention, 1 to 40% by weight of fibers are based on the weight of the synthetic resin used used, more preferably 5 to 20% by weight.

Die Zugabe von Fasern zu dem aufzutragenden Kunstharz ist technisch ohne weitere Schwierigkeiten möglich. Mit steigendem Anteil der Fasern an dem aufzutragenden Kunstharz und/oder steigender Länge bzw. Größe der Fasern kann es zu einem Anstieg der Viskosität des aufzutragenden Kunstharzes kommen. Dies ist jedoch in weiten Bereichen akzeptabel.The addition of fibers to the applied resin is technically possible without further difficulties. As the proportion of fibers in the synthetic resin to be applied increases and / or as the length or size of the fibers increases, the viscosity of the synthetic resin to be applied may increase. However, this is acceptable in many areas.

Nach einer weiter bevorzugten Ausführungsform der Erfindung sind die Fasern nach dem Aushärten der Kunstharz-Schicht auf der Holzwerkstoffplatte transparent. Dadurch bleibt die Sichtbarkeit eines auf der Oberfläche des Holzwerkstoffs bereits aufgetragenen Dekors unbeeinträchtigt.According to a further preferred embodiment of the invention, the fibers are transparent after curing of the synthetic resin layer on the wood-based panel. As a result, the visibility of a decoration already applied to the surface of the wood-based material remains unimpaired.

Die Zugabe von Korund zu der erfindungsgemäß faserverstärkten Kunstharz-Schicht auf der Oberfläche des Holzwerkstoffs ist ohne weiteres möglich. Wird der Korund homogen mit dem faserverstärkten Kunstharz aufgetragen, so ist er durch die Fasern nicht wirksam abgeschirmt, was zu erhöhtem Verschleiß der Pressbleche führen kann. Um diesem Problem abzuhelfen, kann es sich als sinnvoll erweisen, über der vorhandenen, erfindungsgemäß faserverstärkten Kunstharz-Schicht mindestens eine weitere Schicht aus einem Kunstharz oder einer Kunstharz-Mischung, z. B. einer weiteren Schicht aus Kunstharz, die ggf. auch mit Fasern versetzt ist, aufzutragen.The addition of corundum to the fiber-reinforced synthetic resin layer according to the invention on the surface of the wood material is readily possible. If the corundum is applied homogeneously with the fiber-reinforced synthetic resin, it is not effectively shielded by the fibers, which can lead to increased wear of the press plates. To remedy this problem, it may prove useful, above the existing, fiber-reinforced synthetic resin layer according to the invention at least one further layer of a synthetic resin or a synthetic resin mixture, for. B. a further layer of synthetic resin, which is optionally mixed with fibers to apply.

Nach einer vorteilhaften Ausführungsform ist die mit Fasern versetzte Schicht aus Kunstharz, die mindestens abschnittsweise auf die Oberfläche einer Holzwerkstoffplatte aufgetragen ist, Bestandteil einer mehrschichtigen Oberflächenbeschichtung. So können z. B. dekorgebende Farbschichten, Verschleißschichten mit Korund-Anteilen, elastisch verformbare, weiche Schichten oder Decklackschichten aufeinander folgen, um die Oberfläche einer Holzwerkstoffplatte, die begangen werden soll, verschleißfest zu beschichten. Nach einer bevorzugten Ausführungsform der Erfindung werden diese Schichten sämtlich direkt auf die Oberfläche aufgetragen, beispielsweise durch Sprühen, Walzen oder Rakeln. Wird Korund eingesetzt, so kann es durch eine Streu-Einrichtung aufgetragen werden. Es kann unmittelbar in die faserverstärkte Kunstharz-Schicht eingestreut werden.According to an advantageous embodiment, the fiber-added layer of synthetic resin, which is at least partially applied to the surface of a wood-based panel, part of a multi-layer surface coating. So z. As decorative color layers, wear layers with corundum portions, elastically deformable, soft layers or topcoat layers follow each other to wear the surface of a wood-based panel to be committed wear-resistant. According to a preferred embodiment of the invention, these layers are all applied directly to the surface, for example by spraying, rolling or knife coating. If corundum is used, it can be applied by a litter device. It can be sprinkled directly into the fiber-reinforced resin layer.

Die Erfindung betrifft weiter ein Verfahren zum Auftragen eines flüssigen Kunstharz-Faser-Gemisches auf eine Holzwerkstoffplatte gemäß Anspruch 8. Das Verfahren hat die Schritte

  • Einmischen von Fasern oder Partikeln in ein flüssiges Kunstharz
  • Aufstreichen, Aufwalzen, Aufgießen, Aufrakeln oder Aufsprühen des Kunstharz-Fasergemisches auf die Holzwerkstoffplatte
  • Trocknen des Kunstharz-Fasergemisches.
The invention further relates to a method for applying a liquid resin-fiber mixture to a wood-based panel according to claim 8. The method has the steps
  • Mixing of fibers or particles in a liquid synthetic resin
  • Brushing, rolling, pouring, knife coating or spraying the resin-fiber mixture on the wood-based panel
  • Drying of the synthetic resin-fiber mixture.

Wird erfindungsgemäß eine Oberflächenbeschichtung aus mehreren Schichten aufgebracht, so kann die Schicht aus flüssigem, mit Fasern versehenen Kunstharz ohne weiteres als eine von mehreren Schichten an beliebiger Stelle des mehrschichtigen Oberflächenaufbaus angeordnet sein.If, according to the invention, a surface coating of a plurality of layers is applied, the layer of liquid synthetic resin provided with fibers can readily be arranged as one of several layers at any point of the multilayer surface structure.

Soweit es sich um Schichten handelt, deren Material trocknen oder aushärten muss, ist es nach einer vorteilhaften Weiterbildung der Erfindung möglich, die soeben aufgetragene Schicht soweit anzutrocknen oder anzuhärten, dass der Auftrag der nächsten Schicht möglich ist. Erst wenn sämtliche Schichten aufgetragen sind, erfolgt das gleichzeitige und vollständige Aushärten sämtlicher Schichten. Dieses Trocknen in mehreren Abschnitten ist hinsichtlich der Kosten und hinsichtlich der Verbindung der verschiedenen Schichten untereinander sinnvoll.As far as it concerns layers whose material must dry or harden, it is possible according to an advantageous development of the invention to dry or harden the layer just applied so far that the application of the next layer is possible. Only when all layers are applied, the simultaneous and complete curing of all layers takes place. This multi-section drying makes sense in terms of cost and interconnection of the various layers.

Details der Erfindung werden an Hand der nachfolgenden Ausführungsbeispiele näher erläutert:Details of the invention will be explained in more detail with reference to the following exemplary embodiments:

Beispiel 1example 1

Auf die Oberseite und die Unterseite einer mitteldichten Faserplatte werden 65 g/m2 eines Melaminharzes aufgetragen, das einen Festkörper von ca. 58% aufweist. In das Melaminharz sind 20 Gewichts-% kristalline Cellulosepartikel eingemischt. Die Cellulosepartikel weisen einen Durchmesser von 100 µm auf. Der Auftrag erfolgt mittels Walzen.On the top and bottom of a medium-density fiberboard 65 g / m 2 of a melamine resin are applied, which has a solids content of about 58%. In the melamine resin 20 wt% crystalline cellulose particles are mixed. The cellulose particles have a diameter of 100 μm. The job is done by means of rollers.

Die so aufgetragene Melaminharz-Schicht wird in einem Warmluftofen vorkondensiert bis auf eine Restfeuchte des Melaminharzes von 6 Gew.-%. Das abschließende Aushärten des Melaminharzes erfolgt in einer Kurztakt-Presse bei 165 °C für 20 Sekunden. Die beidseits gleich beschichtete Holzwerkstoffplatte ist nach dem Aushärten der Melaminharz-Beschichtung gleichmäßig ohne Fehlstellen beschichtet und unverändert eben.The thus applied melamine resin layer is precondensed in a hot air oven to a residual moisture content of the melamine resin of 6 wt .-%. The final curing of the melamine resin is carried out in a short-cycle press at 165 ° C for 20 seconds. The both sides equally coated wood-based panel is evenly coated after curing of the melamine resin coating without defects and unchanged flat.

Beispiel 2Example 2

Auf die Oberseite einer zuvor mit Dekor bedruckten mitteldichten Faserplatte (MDF) werden 80 g/m2 einer Abmischung von Melaminharz, das einen Festkörpergehalt von ca. 58 % aufweist aufgetragen. Das Melaminharz ist abgemischt mit 20 g/m2 Cellulosepartikeln mit einem Durchmesser von 80 bis 100 µm. Weiter sind in das Melaminharz 20 g/m2 Korund in Form kubischer Partikel mit 40 bis 60 µm Kantenlänge eingemischt. Die Angabe "g/m2" bezieht sich jeweils auf die Menge, die auf einen Quadratmeter Oberfläche der Holzwerkstoffplatte aufgebracht wird.80 g / m 2 of a mixture of melamine resin, which has a solids content of about 58%, are applied to the top of a medium-density fibreboard (MDF) previously printed with decor. The melamine resin is blended with 20 g / m 2 of cellulose particles with a diameter of 80 to 100 microns. Furthermore, 20 g / m 2 of corundum in the form of cubic particles with 40 to 60 μm edge length are mixed into the melamine resin. The term "g / m 2 " refers in each case to the amount that is applied to one square meter surface of the wood-based panel.

Nach der Zwischentrocknung der korundhaltigen Schicht wird eine weitere Schicht aus Melaminharz und Cellulose aufgebracht. Das Melaminharz wird in einer Menge von 30 g/m2 aufgetragen, die in das Melaminharz eingemischte Cellulose in einer Menge von 10 g/m2. Die Cellulosepartikel in dieser Schicht haben einen Durchmesser von 10 µm bis 20 µm.After the intermediate drying of the corundum-containing layer, another layer of melamine resin and cellulose is applied. The melamine resin is applied in an amount of 30 g / m 2 , and the cellulose blended in the melamine resin in an amount of 10 g / m 2 . The cellulose particles in this layer have a diameter of 10 .mu.m to 20 .mu.m.

Auf der Unterseite der MDF-Platte wird ein Balance-Strich aus 50 g/m2 Melaminharz und 10 g/m2 Cellulosepartikeln aufgetragen.On the underside of the MDF board, a balance bar of 50 g / m 2 melamine resin and 10 g / m 2 cellulose particles is applied.

Diese faserverstärkten Melaminharz-Schichten werden im Warmluftstrom auf eine Restfeuchte von 6% Wassergehalt in der Kunstharzschicht vorgetrocknet.These fiber-reinforced melamine resin layers are pre-dried in the hot air stream to a residual moisture content of 6% water content in the synthetic resin layer.

Die abschließende Verarbeitung der mit faserverstärktem Melaminharz beschichteten MDF-Platten erfolgt in Kurztakt-Pressen bei 165 °C für 20 sec zu Platten, welche auf der dekor-bedruckten Oberseite hoch abrasive Eigenschaften aufweisen, und die als Fussboden-Laminatplatten Verwendung finden.The final processing of the fiber-reinforced melamine resin coated MDF boards is carried out in short-cycle presses at 165 ° C for 20 sec to plates which have on the decor-printed top highly abrasive properties, and which are used as floor laminate panels.

Claims (11)

  1. A derived timber board with a surface coating applied at least in parts with at least one coating of a synthetic resin applied in a liquid state, characterized in that the at least one coating of a synthetic resin applied in a liquid state is reinforced with particles of cellulose.
  2. The derived timber board according to claim 1, characterized in that the particles of cellulose are present in the form of natural cotton fibres, such as linters, as particles of crystalline cellulose or in the form of synthetically manufactured cellulose as viscose, TENCEL.
  3. The derived timber board according to claims 1 or 2, characterized in that the particles of cellulose are cellulose fibres with a diameter between 10 µm and 150 µm, preferably between 15 µm and 40 µm and that the length of these fibres is between 10 µm and 100 µm, preferably 10 µm to 80 µm.
  4. The derived timber board according to claim 1, 2 or 3, characterized in that the particle-reinforced synthetic resin coating comprises a thermosetting synthetic resin, in particular an aminoplastic, specifically a melamine resin.
  5. The derived timber board according to at least one of the preceding claims, characterized in that the concentration of particles amounts to at least 5 weight percent, preferably 5 to 40 weight percent, particularly preferably 5 to 20 weight percent with reference to the weight of the synthetic resin used.
  6. The derived timber board according to at least one of the preceding claims, characterized in that the particles added to the synthetic resin are transparent after the synthetic resin has cured.
  7. The derived timber board according to at least one of the preceding claims, characterized in that the synthetic resin coating reinforced with particles contains corundum.
  8. The derived timber board according to at least one of the preceding claims, characterized in that the particle-reinforced synthetic resin coating is a component of a multi-layered surface coating.
  9. A method for applying a liquid synthetic resin-particle mixture to a derived timber board, comprising the steps of:
    - mixing particles of cellulose into a liquid synthetic resin
    - painting, rolling, pouring, application by squeegee or spraying the synthetic resin-particle mixture to the derived timber board
    - drying the synthetic resin-particle mixture.
  10. The method according to claim 9, characterized in that the particles of up to 40 weight percent with reference to the weight of the synthetic resin used are mixed into the synthetic resin.
  11. The method according to claim 10, characterized in that the synthetic resin-particle mixture is dried in a plurality of stages.
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EP1753818A1 (en) * 2004-05-27 2007-02-21 Basf Aktiengesellschaft Method for producing coated substrates

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DE102005006599B4 (en) 2011-11-24
DE102005006599A1 (en) 2006-08-17
EP1690603A1 (en) 2006-08-16
ATE440676T1 (en) 2009-09-15
PL1690603T3 (en) 2010-01-29
DE502006004624D1 (en) 2009-10-08
US20060183853A1 (en) 2006-08-17
US7771837B2 (en) 2010-08-10
ES2332188T3 (en) 2010-01-28

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