EP2042344A2 - Method for manufacturing coating elements and corresponding manufacturing device - Google Patents

Abstract

The method involves impregnating stretched fiber material or paper web (50) with a resin, particularly with an amino plastic. The stretched fiber material or paper web is also impregnated with heat hardening synthetic resin for e.g. with melamine resin, particularly in an inline method after printing in certain areas. Independent claims are included for the following: (1) a method for producing a laminate; (2) a manufacturing device for producing a coating element; and (3) a device for producing of laminate.

Description

The present invention relates to a method according to the preamble of claim 1.

The present invention further relates to a production device according to the preamble of claim 5.

Laminate is a laminate which is formed by pressing, gluing and / or gluing at least two layers of the same and / or different material.

A laminate which can be used, for example, as a floor, as a wall or ceiling cladding, as a countertop or for the manufacture of furniture, has at least one carrier plate which is coated with at least one coating element, in particular with at least one decorative layer of decorative paper and thermosetting resin.

The support plate is usually a wood-based panel, for example a fiberboard, such as a high-density fiberboard (HDF) or medium-density fiberboard (MDF), or a chipboard or wood-based panel of oriented-scattered microfubers, a so-called O [riented] S [edge] B [oard].

Decisive for the optical appearance of the laminate is the decorative layer which is applied to the top of the carrier plate. The decorative paper of the decorative layer can be printed with color and / or with a pattern or decor, for example with a wood or stone reproduction.

To improve the durability of the laminate decorative paper is usually impregnated with thermosetting resin, such as melamine resin, and / or coated with an abrasion-resistant layer, the so-called overlay.

The overlay has thermosetting synthetic resin, for example melamine resin. For improved resin absorption, the overlay may further comprise fibrous, in particular cellulose-containing, material. This fiber-containing synthetic resin layer may also be provided to improve its abrasion resistance with abrasion-resistant or abrasive substances, for example with corundum particles. For example, the overlay may consist of two transparent melamine resin-impregnated papers, between which a corundum layer is enclosed. Furthermore, corundum filled overlays are common.

On the side of the coating element facing the carrier plate, a core or carrier paper layer of a plurality of papers impregnated with thermosetting synthetic resin, for example phenolic resin, may be arranged. This optional paper layer, which preferably uses kraft paper as the paper, imparts additional hardness and impact resistance to the coating element and improves its staying power.

To improve the dimensional stability of the laminate element, the underside of the carrier plate can be pressed with a so-called counter-pull, for example with a veneer or with another layer impregnated with thermosetting synthetic resin.

In laminate production, a distinction is made between a single-stage and a two-stage production process. In the single-stage production process, the various layers, so the decorative layer of decorative paper and thermosetting resin, the z. B. may be applied in the form of an overlay on the decorative paper, the carrier plate and the optional Backing in a single operation directly to so-called direct pressed laminate (D [irect] P [ressure] L [aminate]) pressed together.

In the two-stage process, however, in a first step from the decorative paper and the thermosetting resin, z. B. may be applied in the form of an overlay on the decor paper, and the optional core or backing paper layer produced a coating element. In a second step, the coating element is then pressed with the carrier plate. These laminate production methods are described in the DIN standards DIN EN 14322, DIN EN 438-2 and DIN EN 13329. With regard to the technical background of the laminate production is further on the document WO 2007/079547 A1 Referenced.

In the known laminate manufacturing process, the decor layer of decorative paper and thermosetting resin is produced in two separate operations on two separate production lines. First, the decorative paper is printed on a first production line, the printing is usually done in the gravure printing process. Following this, the printed decorative paper is rolled up again and transported to a second production facility for impregnation or coating with thermosetting synthetic resin. On the second production line, the printed paper is then impregnated in a second operation or second method with the thermosetting synthetic resin and / or coated with the overlay.

However, the production of the decorative layer on two separate production lines or in two separate production methods is not very efficient, because the raw decorative paper has to be transported to two different production lines and inserted into each of them. It is thus spanned in the first production line for printing the paper, a first paper web of base paper and in the second production line for impregnating or for coating the paper, a second paper web of printed Stretched paper. This production method is time-consuming and thus expensive. Also, two separate manufacturing plants require relatively much space.

A further disadvantage is that the two-time clamping of the paper web can lead to a change in the shape of the decorative paper and thus to a deformation or distortion of the printed pattern and to buckling and / or tearing of the decorative paper.

In the publication DE 600 15 603 T2 In order to avoid fitting inaccuracies of the pattern of a laminate floor, it is proposed to print this pattern by means of a digital printer directly onto the carrier plate, ie, for example, directly onto the wood-based panel. However, this has the disadvantage that the surface of the support plate treated before printing, for example, primed and / or sanded. In addition, in the laminate element according to the document DE 600 15 603 T2 only transparent layers are applied to the carrier plate. It is thus not possible, for example, to apply a core or carrier paper layer of kraft pulp to the carrier plate.

Based on the disadvantages and inadequacies set out above and in acknowledgment of the state of the art outlined above, the object of the present invention is to further develop a method of the type mentioned at the outset and a production device of the type initially mentioned, such that the coating element can be manufactured efficiently, with kinks , Cracks or changes in shape of the printed fiber material or paper can be reliably avoided.

This object is achieved by a method having the features specified in claim 1 and by a manufacturing plant with the features specified in claim 5. Advantageous embodiments and expedient developments of the present invention are characterized in the respective subclaims.

The present invention is fundamentally based on designing a series or inline production device, for example an inline production line, in which the fiber material or paper is printed in a first step and then further processed immediately by means of impregnation and / or coating. According to the present invention, therefore, the delivered fiber material or paper is printed in a production process and then impregnated and / or coated in the same production process.

• mit mindestens einem Harz, insbesondere mit mindestens einem aminoplastischen und/oder wärmehärtbaren Kunstharz, beispielsweise mit Melamin-Harz, imprägniert und/oder
• mit mindestens einer mindestens ein Harz, insbesondere mindestens ein aminoplastisches und/oder wärmehärtbares Kunstharz, beispielsweise Melamin-Harz, aufweisenden Schicht, etwa mit einem so genanten Overlay, beschichtet.

According to the invention, for producing at least one coating element, in particular for producing at least one fibrous material and resin suitable for coating at least one carrier plate, in particular decor paper and aminoplastic and / or thermosetting synthetic resin, first by unwinding raw fiber material or base paper, in particular raw decor paper , Spanned at least one fiber material or paper web. This stretched fiber material or paper web is then at least partially printed with color and / or with at least one pattern or decor. Subsequently, the spanned and printed fiber material or paper web is at least partially

• with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin, impregnated and / or
• coated with at least one at least one resin, in particular at least one aminoplastic and / or thermosetting synthetic resin, for example melamine resin, having layer, such as with a so-called overlay.

The combination of printing and impregnation and / or coating in a production device or in a machine can be realized by arranging at least one impregnating and / or coating device in series or inline with at least one printing device. For example the printing device can be arranged between at least one unwinding device designed for unwinding the fiber material or paper web and a first dip bath or a first coating device of the impregnating and / or coating device. Unwinding device, printing device and impregnating and / or coating device are thus preferably arranged in series, for example on at least one production line or production line, for example on at least one impregnation channel.

According to an advantageous embodiment of the present invention, the manufacturing device comprises the components of a conventional impregnating and / or coating device. However, these components are arranged so that the stretched fiber material or paper web can be both printed as well as impregnated and / or coated.

The printing of the fiber material or paper web can be done by the method of gravure printing or by the method of digital printing. The application of the method of digital printing is particularly advantageous because a digital printing device has a small footprint and thus can be easily integrated into conventional impregnation machines. In addition, a digital printing device or a digital printing unit does not require expensive printing forms. Other advantages of a digital printing device compared to a gravure printing device are lower investment costs and the possibility of simpler and less expensive decor change. In addition, storage costs in the raw materials area can be reduced by means of a digital printing device, since a large number of decors need not be provided.

According to an advantageous embodiment of the present invention, the fiber material or paper web is thus printed by means of at least one digital printing device. This digital printing device fulfills the properties required for printing the fiber material or paper web and is preferably designed to print substantially the entire width of the fiber material or paper web.

Vorteihafterweise the digital printing device is designed to at least partially dry the printed fiber material or paper web. The drying of the fiber material or paper web can take place by means of air and / or by means of ultraviolet radiation and / or by means of the method of near-infrared drying. In addition to pure air drying, therefore, other drying methods such as UV drying and / or NIR drying can be used.

An advantageous embodiment of the printing device, due to a comparatively low printing speed, has a comparatively short, for example a few meters, drying section.

• mindestens ein Harz, insbesondere mindestens ein aminoplastisches und/oder wärmehärtbares Kunstharz, beispielsweise Melamin-Harz, und/oder
• Fasermaterial, insbesondere Zellstoff, und/oder
• mindestens eine abriebfeste Substanz, insbesondere Korund, aufweisenden Schicht versehen werden.

After passing through the printing device or the printing unit, the known impregnation and / or coating process can continue unchanged. For example, the stretched fiber material or paper web can be impregnated or impregnated with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin, and impregnated with at least one after impregnation or impregnation.

• at least one resin, in particular at least one aminoplastic and / or thermosetting synthetic resin, for example melamine resin, and / or
• Fiber material, in particular pulp, and / or
• at least one abrasion-resistant substance, in particular corundum, having layer provided.

Furthermore, the spanned fiber material or paper web, in particular on its side facing away from the resin layer, be coated with at least one core or backing paper layer, wherein the core or backing paper layer at least one impregnated with thermosetting synthetic resin, for example with phenolic resin, fiber material, in particular Paper, such as kraft paper has.

• mindestens ein Beschichtungselement nach einem Verfahren gemäß der vorstehend dargelegten Art hergestellt und
• anschließend auf mindestens eine Trägerplatte aufgebracht, insbesondere aufgeleimt und/oder aufgeklebt und/oder aufgepresst.

The present invention further relates to a method for the production of laminate, for example of at least one laminate floor element, at least one laminate worktop, at least one wall or ceiling cladding element of laminate or at least one laminate furniture element, and a device relating thereto. In this case, the production of laminate according to the invention

• at least one coating element is produced by a process according to the above-described type and
• then applied to at least one support plate, in particular glued and / or glued and / or pressed.

According to an advantageous development of the method according to the invention for the production of a coating element and the production device according to the invention, the spanned fiber material or paper web of the coating element can thus also be applied to the carrier plate, for example to a wooden material plate, such as an MDF, HDF, in the same production process. , OSB or chipboard, or on a plastic plate.

Furthermore, the support plate on its side facing away from the coating element can still be coated in the same production process with at least one counter-pull, for example with at least one veneer and / or with at least one further thermosetting synthetic resin layer. The coating element can be laminated to the carrier plate by means of a single-stage or by means of a two-stage process. From the coating element produced according to the invention, it is thus possible to use both D [irect] P ressure L [aminate] as H [igh] P ressure L [aminate] and C [ontinuous] P ressure L [aminate] as well as L [ow] P [ressure] L [aminate].

• zur Inline-Fertigung bzw. Reihenfertigung von bedrucktem, imprägniertem und/oder beschichtetem Dekorpapier und/oder
• zur Inline-Fertigung bzw. Reihenfertigung von Laminat, insbesondere mittels eines Verfahrens zur Herstellung von Laminat der vorstehend dargelegten Art und/oder mittels mindestens einer Vorrichtung zur Herstellung von Laminat gemäß der vorstehend dargelegten Art.

Finally, the present invention relates to the use of a method for producing at least one coating element according to the type set forth above and / or at least one production device according to the type set forth above

• for in-line production or series production of printed, impregnated and / or coated decorative paper and / or
• for the in-line production or serial production of laminate, in particular by means of a method for the production of laminate of the kind set forth above and / or by means of at least one device for the production of laminate according to the kind set forth above.

As already discussed above, there are various possibilities for embodying and developing the teaching of the present invention in an advantageous manner. For this purpose, reference is made on the one hand to the claims subordinate to claim 1 and claim 5, on the other hand further embodiments, features and advantages of the present invention will be described below with reference to Fig. 1 illustrated embodiment explained in more detail.

Fig. 1 Fig. 1 shows a schematic representation of a first embodiment of a device according to the present invention, which operates according to the method of manufacturing laminate according to the present invention.

• ein Ausführungsbeispiel einer Fertigungseinrichtung 100 zur Herstellung mindestens eines Beschichtungselements gemäß der vorliegenden Erfindung, wobei die Fertigungseinrichtung 100 nach dem Verfahren zur Herstellung mindestens eines Beschichtungselements gemäß der vorliegenden Erfindung arbeitet und
• eine zum Aufbringen des Beschichtungselements, insbesondere der aufgespannten, bedruckten, imprägnierten und/oder beschichteten Fasermaterial- oder Papierbahn 50, auf eine Trägerplatte 60 ausgebildete Laminiereinrichtung 210.

I'm referring Fig. 1 1, a device 200, in particular an inline production line, for the production of laminate, which operates according to the method according to the present invention and has a plurality of functional parts, namely

• an embodiment of a manufacturing device 100 for producing at least one coating element according to the present invention, wherein the manufacturing device 100 according to the method for Producing at least one coating element according to the present invention operates and
• a laminating device 210 formed on a carrier plate 60 for applying the coating element, in particular the spanned, printed, impregnated and / or coated fiber material or paper web 50.

The production device 100 is designed to produce a decorative layer suitable for coating the carrier plate 60, wherein the decorative layer has at least printed decor paper and thermosetting synthetic resin.

• eine zum Aufspannen mindestens einer Fasermaterial- oder Papierbahn 50 mittels Abwickeln von Rohfasermaterial oder von Rohpapier, insbesondere von Rohdekorpapier, ausgebildete Abwickeleinrichtung 10,
• eine zum Bedrucken der aufgespannten Fasermaterial- oder Papierbahn 50 mit Farbe und/oder mindestens einem Muster bzw. Dekor ausgebildete Druckeinrichtung 20 und
• eine in Reihe bzw. inline mit der Druckeinrichtung 20 angeordndete Imprägnier- und/oder Beschichtungseinrichtung 30, nämlich eine Imprägniereinrichtung 30, auf.

For this purpose, the manufacturing device 100

• an unwinding device 10 designed for clamping at least one fibrous material or paper web 50 by unwinding raw fiber material or raw paper, in particular raw decor paper,
• a for printing the clamped fiber material or paper web 50 with color and / or at least one pattern or decor formed printing device 20 and
• an impregnating and / or coating device 30 arranged in series or inline with the printing device 20, namely an impregnation device 30.

This impregnation device 30 is designed to impregnate the clamped fiber material or paper web 50 with aminoplastic and thermosetting synthetic resin, namely with melamine resin. Furthermore, the impregnation device 30 could also be designed to coat the clamped fiber material or paper web 50 with a layer comprising resin, in particular melamine resin, ie with an overlay.

Im in Fig. 1 illustrated embodiment, however, the manufacturing device 100 for coating the clamped fiber material or paper web 50 with the overlay one in series or inline with the Impregnation 30 arranged on coating device 40.

The printing device 20 is arranged between the unwinding device 10 and the impregnation device 30 and designed for printing the fiber material or paper web 50 by the method of digital printing.

For at least partial drying of the printed fiber material or paper web 50, the printing device 20 has a drying device 22. Alternatively (in Fig. 1 not shown), this drying device 22 may also be arranged in series or inline with the printing device 20 and the impregnation device 30, in particular between the printing device 20 and the impregnation device 30.

In contrast to the known from the prior art and practiced methods in which in two separate operations only decorative paper usually printed by gravure printing and then impregnated on another system in a second method, which leads in Fig. 1 Manufacturing device 100 shown in an inline process for printing and impregnation and / or coating of decorative paper. The new is neither the printing itself, nor the impregnation and / or coating, but the fact that this is done inline during a single operation, ie on a manufacturing facility or machine.

LIST OF REFERENCE NUMBERS

10

unwinding

20

Printing device, in particular digital printer or gravure printer

22

drying device

30

Impregnating and / or coating device

40

coater

50

Fiber material or paper web

60

Support plate, in particular wood material or plastic plate

100

Manufacturing facility or manufacturing plant, in particular in-line production line for producing a coating element, in particular for producing a decorative layer suitable for coating a carrier plate 60

200

Device, in particular in-line production line for the production of laminate

210

laminating

Claims (10)

Method for producing at least one coating element, in particular at least one decorative layer suitable for coating at least one carrier plate (60), wherein - Is unwound by unwinding of raw fiber material or raw paper, in particular Rohdekorpapier, at least one fiber material or paper web (50) and the printed fiber material or paper web (50) is printed at least in regions with ink and / or with at least one pattern or decor, characterized,
that the spanned fiber material or paper web (50), in particular in an in-line method, after printing at least partially - Is impregnated with at least one resin, in particular with at least one aminoplastic and / or thermosetting resin, for example with melamine resin, and / or - Is coated with at least one at least one resin, in particular at least one aminoplastic and / or thermosetting resin, such as melamine resin having layer. A method according to claim 1, characterized in that the stretched fiber material or paper web (50) is at least partially dried after printing and prior to impregnation, wherein the drying of the fiber material or paper web (50) in particular - By air and / or - By means of Ultra Violet radiation and / or - By means of the method of near-infrared drying takes place. A method according to claim 1 or 2, characterized in that the printing of the fiber material or paper web (50) by means of the method - of digital printing or - The gravure is done. Process for the production of laminate,
characterized, - That at least one coating element is prepared by a process according to any one of claims 1 to 3, and - That subsequently the coating element, in particular the spanned, printed, impregnated and / or coated fiber material or paper web (50), applied to at least one support plate (60), in particular glued and / or glued and / or pressed. Manufacturing device (100) for producing at least one coating element, in particular at least one decorative layer suitable for coating at least one carrier plate (60), comprising - At least one for clamping at least one fiber material or paper web (50) by unwinding of raw fiber material or raw paper, in particular raw decor paper, trained unwinding device (10) and at least one printing device (20) designed for at least partial printing of the mounted fiber material or paper web (50) with ink and / or at least one pattern or decoration,
marked by
at least one impregnating and / or coating device (30), which is arranged in series with the printing device (20) and - For at least partially impregnating the clamped Fiber material or paper web (50) with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin, and / or - For at least partially coating the clamped fiber material or paper web (50) with at least one resin, in particular with at least one aminoplastic and / or thermosetting synthetic resin, for example with melamine resin is formed. Manufacturing device according to claim 5, characterized in that the printing device (20) - Is arranged between the unwinding device (10) and the impregnating and / or coating device (30) and / or - Is designed to print the fiber material or paper web (50) by the method of digital printing or by the method of gravure printing. Manufacturing device according to claim 5 or 6, characterized by at least one - associated with the printing device (20) or - arranged in series with the printing device (20) and the impregnating and / or coating device (30), in particular between the printing device (20) and the impregnating and / or coating device (30) drying device (22) for at least partially drying the Fiber material or paper web (50) in particular by means of - Air and / or - Ultra violet radiation and / or - the method of near-infrared drying. Manufacturing device according to at least one of claims 5 to 7, characterized in that the resin-containing layer of further - Fiber material, in particular pulp, and / or - At least one abrasion-resistant or abrasive substance, in particular
Corundum,
having. Apparatus (200) for producing laminate,
marked by - At least one manufacturing device (100) according to at least one of claims 5 to 8 and - At least one for applying the coating element, in particular the stretched, printed, impregnated and / or coated fiber material or paper web (50) on at least one support plate (60) formed laminating device (210). Use of a method for producing at least one coating element according to at least one of claims 1 to 3 and / or at least one production device (100) according to at least one of claims 5 to 8 - For in-line production or series production of printed, impregnated and / or coated decor paper and / or for inline production or series production of laminate, in particular by means of a method for producing laminate according to claim 4 and / or at least one apparatus (200) for producing laminate according to claim 9.

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