SE527165C2 - An improved process for making decorative laminate - Google Patents
An improved process for making decorative laminateInfo
- Publication number
- SE527165C2 SE527165C2 SE0400945A SE0400945A SE527165C2 SE 527165 C2 SE527165 C2 SE 527165C2 SE 0400945 A SE0400945 A SE 0400945A SE 0400945 A SE0400945 A SE 0400945A SE 527165 C2 SE527165 C2 SE 527165C2
- Authority
- SE
- Sweden
- Prior art keywords
- layer
- resin
- wear
- process according
- wear layer
- Prior art date
Links
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/08—Impregnating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
- B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/12—Coating on the layer surface on paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/26—Polymeric coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/554—Wear resistance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2386/00—Specific polymers obtained by polycondensation or polyaddition not provided for in a single one of index codes B32B2363/00 - B32B2383/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2451/00—Decorative or ornamental articles
Abstract
Description
527 165 C 769-SE förstärka bindningen mellan dekorskiktet, tryckfärgen och slitskiktet varvid skikten lamineras samman i en laminatpress under förhöjd temperatur och tryck. 527 165 C 769-SE strengthen the bond between the decorative layer, the printing ink and the wear layer, the layers being laminated together in a laminate press under elevated temperature and pressure.
Tryckfärgen är ett lämpligen ett alkydbaserat bläck eller ett polyester-akrylatbaserat bläck. Enligt en utföringsforin av uppfinningen är aminohartset är ett företrat aminoharts eller ett metylolaminoharts.The ink is suitably an alkyd-based ink or a polyester-acrylate-based ink. According to one embodiment of the invention, the amino resin is a etherified amino resin or a methylolamino resin.
Enligt en föredragen utföringsform av uppfinningen innefattar huvuddelen av basskiktet en träbaserad panel vald ur gruppen bestående av en spånskiva, en träfiberskiva och en OSB (Oriented Strand Board) -skiva. Basskiktet kan enligt vissa utfóringsformar av uppfinningen vidare innefatta ett stödjande pappersskikt arrangerat mellan panelen och dekorskiktet.According to a preferred embodiment of the invention, the main part of the base layer comprises a wood-based panel selected from the group consisting of a chipboard, a wood fiber board and an OSB (Oriented Strand Board) board. According to certain embodiments of the invention, the base layer may further comprise a supporting paper layer arranged between the panel and the decorative layer.
Slitskiktet kan enligt en utföringsform av uppfinningen utgöras av ett högvisköst aminoharts applicerat ovanpå det dekorativa skiktet innan lamineringen. Enligt en annan utfóringsform av uppfinningen kan slitskiktet utgöras av en aminoharts/cellulosablandning. Enligt ytterligare en utföringsform av uppfinningen utgörs slitskiktet av ett eller flera aminohartsimpregnerade cellulosaskikt.According to an embodiment of the invention, the wear layer can consist of a highly viscous amino resin applied on top of the decorative layer before the lamination. According to another embodiment of the invention, the wear layer may consist of an amino resin / cellulose mixture. According to a further embodiment of the invention, the wear layer consists of one or more amino resin impregnated cellulose layers.
I ßredragna utföringsformer av uppfinningen innefattar slitskiktet vidare hårda partiklar med en medelpartikelstorlek i området 50nm - 150pm för att ytterligare förbättra motståndskrafter mot slitage. Den övre delen av slitskiktet är lämpligen försedd med hårda partiklar med en medelpartikelstorlek i området 50nm - 30pm medan en inre del av slitskiktet är försedd med hårda partiklar i området 31 um - 150 um. De mindre partiklarna nära ytan kommer att förbättra reptåligheten samtidigt som slitaget på pressutrustning såsom pressplåtar hålls på en rimlig nivå. De hårda partiklarna är företrädesvis valda ur gruppen bestående av kiseloxid, kiselkarbid och aluminiumoxid.In extended embodiments of the invention, the wear layer further comprises hard particles having an average particle size in the range of 50nm - 150pm to further improve abrasion resistance forces. The upper part of the wear layer is suitably provided with hard particles with an average particle size in the range 50 nm - 30 μm while an inner part of the wear layer is provided with hard particles in the range 31 μm - 150 μm. The smaller particles near the surface will improve scratch resistance while keeping the wear on press equipment such as press plates at a reasonable level. The hard particles are preferably selected from the group consisting of silica, silica and alumina.
Slitskiktet är lämpligen försett med en ytstruktur vilken förstärker det realistiska intrycket av dekoren under eller efter lamineringen. Detta åstadkoms lämpligen med någon känd metod för ytstrukturering.The wear layer is suitably provided with a surface structure which reinforces the realistic impression of the decor during or after the lamination. This is conveniently accomplished by any known method of surface structuring.
Enligt en utföringsform av uppfinningen innefattar bindskiktet ett härdplastharts.According to an embodiment of the invention, the bonding layer comprises a thermosetting resin.
Härdplasthartset är lämpligen valt ur gruppen bestående av; 527 165 C 769-SE melaminformaldehydharts, fenolformaldehydharts, ureaformaldehydharts och kombinationer därav.The thermosetting resin is suitably selected from the group consisting of; 527 165 C 769-SE melamine formaldehyde resin, phenol formaldehyde resin, urea formaldehyde resin and combinations thereof.
Enligt en alternativ utföringsform av uppfinningen innefattar bindskiktet ett termoplastharts. Termoplasthartset kan till exempel vara ett polyuretanbaserat smältlim.According to an alternative embodiment of the invention, the bonding layer comprises a thermoplastic resin. The thermoplastic resin can be, for example, a polyurethane-based hot melt adhesive.
Enligt en speciell utföringsform av uppfinningen åstadkoms dekoren genom digitalisering av en verklig förlaga eller genom att helt eller delvis skapas i digitala media. Den digitaliserade dekoren lagras digitalt för att användas som kontrollfunktion och original, tillsammans med möjliga kontrollprogram under tryckning av dekoren.According to a special embodiment of the invention, the decoration is achieved by digitizing a real model or by being created in whole or in part in digital media. The digitized decor is stored digitally for use as a control function and original, along with possible control programs during printing of the decor.
Dekoren kan således erhållas genom att göra en högupplöst eller med vald upplösning, digital bild av den önskade dekoren. Detta utförs lämpligen med hjälp av kamera eller scanner. De vanligaste dekorerena kommer självfallet att vara olika sorters trä eller mineraler såsom marmor, eftersom dessa troligen framgent kommer att vara föredragna dekorer i hem och publika miljöer. Det är emellertid möjligt att avbilda vas som helst som är synligt. Den digitaliserade versionen av dekoren bearbetas sedan för att passa storleken på den stödjande stommen. Det är också möjligt att arrangera dekoren på många olika sätt, såsom att ändra fárgtoner, kontrast, dela upp dekoren i mindre segment och att addera andra dekorativa element. Det är också möjligt att helt och håller skapa dekoren i en dator utrustad för grafisk design.The decor can thus be obtained by making a high-resolution or with the selected resolution, digital image of the desired decor. This is conveniently done using a camera or scanner. The most common decors will of course be different types of wood or minerals such as marble, as these will probably in future be preferred decors in homes and public environments. However, it is possible to image any vase that is visible. The digitized version of the decor is then processed to fit the size of the supporting frame. It is also possible to arrange the decor in many different ways, such as changing color tones, contrast, dividing the decor into smaller segments and adding other decorative elements. It is also possible to completely create the decor in a computer equipped for graphic design.
Det är möjligt att skapa en dekor som är så realistisk att även en professionell har stora problem att visuellt skilja den från verkliga material. Detta gör det möjligt att framställa, till exempel golvpaneler med en närmast perfekt illusion av sällsynta träslag såsom ebenholts eller jakaranda och ändå skydda träslag som hotas av utrotning.It is possible to create a decor that is so realistic that even a professional has great difficulty visually distinguishing it from real materials. This makes it possible to produce, for example, floor panels with an almost perfect illusion of rare woods such as ebony or jacaranda and still protect woods that are threatened with extinction.
Den digitala dekoren används tillsammans med styrprogram för styra en skrivare.The digital decor is used in conjunction with control software to control a printer.
Skrivarn kan vara av elektrostatisk typ eller av typen bläckstråleskrivare. Oftast kommer färgerna gul, magenta, cyan och svart av vara tillräckliga för tryckningsprocessen, men i vissa fall är det fördelaktigt att tillsätta vitt. Vissa färger är svåra att åstadkomma genom att använda färgerna gult, magenta, cyan, svart och vitt varför färgererna ljusmagenta och ljuscyan kan adderas. Det är också möjligt att addera så kallade spotfárger där specifika färgtoner är svåra att återge eller där endast vissa delar av färgspektrat med mellanliggande toner önskas. Den upplösning som C 769-SE krävs beror mycket på den dekor som skall simuleras, men upplösning i området 10 - 1500 punkter per tum (dpi) är det praktiska område där de flesta dekorer kommer att tryckas. Under nonnala omständigheter är en upplösning på 300 - 800 dpi tillräcklig vid simulering av av även mycket komplexa mönster och ändå åstadkomma ett resultat som är mycket svårt att skilja från den verkliga förlagan utan nära och noggrann inspektion.The printer can be of the electrostatic type or of the inkjet printer type. In most cases, the colors yellow, magenta, cyan and black will be sufficient for the printing process, but in some cases it is advantageous to add white. Some colors are difficult to achieve by using the colors yellow, magenta, cyan, black and white, so the colors magenta and light cyan can be added. It is also possible to add so-called spot colors where specific color tones are difficult to reproduce or where only certain parts of the color spectrum with intermediate tones are desired. The resolution required for C 769-SE depends a lot on the decor to be simulated, but the resolution in the range of 10 - 1500 dots per inch (dpi) is the practical range where most decors will be printed. Under normal circumstances, a resolution of 300 - 800 dpi is sufficient when simulating even very complex patterns and still achieve a result that is very difficult to distinguish from the actual model without close and careful inspection.
Såsom nämnt ovan utgörs det genomskinliga Slitskiktet lämpligen av melaminformaldehydharts / cellulosa blandning, högviskös melaminformaldehydharts eller ett eller flera ark av cellulosa vilka är impregnerade med melaminformaldehydharts. Detta slitskikt förenas med stommen och dekoren under värme och tryck varvid hartset härdar. Det är fördelaktigt att addera hårda partiklar i området 50nm - l50um till slitskiktet. Större partiklar, i området 10 mm - 150 mm, företrädesvis 30 mm - 150 mm används främst för att åstadkomma slitstyrka medan de mindre av partiklarna, i området 50 nm - 30 mm, företrädesvis 50 nm - 10 mm används för att åstadkomma reptålighet. De mindre partiklarna används här på eller mycket nära ytan medan de större partiklarna är distribuerade i slitskiktet. Också här består partiklarna med fördel av kiselkarbid, kiseloxid eller aluminiumoxid.As mentioned above, the transparent wear layer is suitably composed of melamine formaldehyde resin / cellulose mixture, highly viscous melamine formaldehyde resin or one or more sheets of cellulose which are impregnated with melamine formaldehyde resin. This wear layer is combined with the frame and the decor under heat and pressure, whereby the resin hardens. It is advantageous to add hard particles in the range 50nm - l50um to the wear layer. Larger particles, in the range 10 mm - 150 mm, preferably 30 mm - 150 mm are mainly used to provide abrasion resistance while the smaller particles, in the range 50 nm - 30 mm, preferably 50 nm - 10 mm are used to provide scratch resistance. The smaller particles are used here on or very close to the surface while the larger particles are distributed in the wear layer. Here, too, the particles advantageously consist of silicon carbide, silicon oxide or alumina.
Slitskiktet pressas lämpligen tillsammans med resten av det dekorativa laminatet i en kontinuerlig bandpress med två pressband. Det är också möjligt att använda en diskontinuerlig process där en eller ett antal ytelement pressas samtidigt.The wear layer is suitably pressed together with the rest of the decorative laminate in a continuous strip press with two press strips. It is also possible to use a discontinuous process where one or a number of surface elements are pressed simultaneously.
Claims (1)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0400945A SE527165C2 (en) | 2004-04-07 | 2004-04-07 | An improved process for making decorative laminate |
PCT/SE2005/000484 WO2005097380A1 (en) | 2004-04-07 | 2005-04-04 | An improved process for the manufacturing of decorative laminate |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0400945A SE527165C2 (en) | 2004-04-07 | 2004-04-07 | An improved process for making decorative laminate |
Publications (3)
Publication Number | Publication Date |
---|---|
SE0400945D0 SE0400945D0 (en) | 2004-04-07 |
SE0400945L SE0400945L (en) | 2005-10-08 |
SE527165C2 true SE527165C2 (en) | 2006-01-10 |
Family
ID=32173715
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
SE0400945A SE527165C2 (en) | 2004-04-07 | 2004-04-07 | An improved process for making decorative laminate |
Country Status (2)
Country | Link |
---|---|
SE (1) | SE527165C2 (en) |
WO (1) | WO2005097380A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090246439A1 (en) * | 2008-03-31 | 2009-10-01 | 3M Innovative Properties Company | Decorative sheet |
DE102009044092A1 (en) * | 2009-09-23 | 2011-03-31 | Theodor Hymmen Holding Gmbh | Method for producing a digitally printed workpiece |
US8591696B2 (en) * | 2010-11-17 | 2013-11-26 | Pergo (Europe) Ab | Method for manufacturing a surface element |
EP3275678B1 (en) * | 2014-01-10 | 2020-12-16 | Agfa Nv | Manufacturing of decorative laminates by inkjet |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
SE516696C2 (en) * | 1999-12-23 | 2002-02-12 | Perstorp Flooring Ab | Process for producing surface elements comprising an upper decorative layer as well as surface elements produced according to the method |
SE523935C2 (en) * | 2002-01-25 | 2004-06-01 | Pergo Ab | Procedure for matching surface panels decor sections |
SE0200945D0 (en) * | 2002-03-27 | 2002-03-27 | Pergo Ab | A process for the manufacture of decorative panels |
-
2004
- 2004-04-07 SE SE0400945A patent/SE527165C2/en not_active IP Right Cessation
-
2005
- 2005-04-04 WO PCT/SE2005/000484 patent/WO2005097380A1/en active Application Filing
Also Published As
Publication number | Publication date |
---|---|
WO2005097380A1 (en) | 2005-10-20 |
SE0400945L (en) | 2005-10-08 |
SE0400945D0 (en) | 2004-04-07 |
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Legal Events
Date | Code | Title | Description |
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NUG | Patent has lapsed |