EP2181860B1 - Construction element made of wood material with special haptic characteristics and method for producing such a construction element - Google Patents

Description

The invention relates to a component, in particular a panel, of wood material, in particular for use as a furniture component or wall, ceiling or floor panel, with a surface layer and a surface layer partially covering the material order. Furthermore, the invention relates to a method for producing such a device in which a surface layer is applied to a carrier plate of wood material or a carrier profile of wood material, and in which a paint-like material order is printed on the surface layer.

Wood-based panels with decorative coating are often used as floor panels and for the cladding of walls and ceilings or as furniture components. Such panels usually have a rectangular shape and are usually provided at least at their longitudinal edges with profiles that allow a coupling of adjacent panels to create a large-scale surface can. Wood fiber boards, preferably so-called dry-process MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard) boards, are widely used for this purpose. In addition to direct printing, papers impregnated with a synthetic resin and predried can also be pressed directly onto the surfaces of the plates under high heat and pressure in order to produce the same to apply desired decor. Since these impregnates tend to shrink during compression, they create a tension, which is why these plates must always be provided on both sides with an impregnated paper in order to prevent a voltage-induced bending of the plates.

In addition to the laminate-coated wood fiber boards also directly coated panels are used for panels of the type mentioned recently. Such panels are, for example, from the EP 1 645 339 A1 known. The fiberboards are provided with liquid coating compositions, wherein a decor, for example a wood decor is printed on a colored base layer and finally one or more transparent sealing layers are applied. The EP 1 645 339 A1 describes the production of a structured surface by applying a first coating and a second coating with spatially varying application amount.

From the EP 1 892 352 A2 a floor panel is known, which has a base plate (carrier plate), which is printed on its upper side with a decorative layer, wherein on the decorative layer, a first lacquer layer and a second lacquer layer are applied. The first coating layer applied to the decorative layer is harder and less elastic than the subsequent second coating layer. The first lacquer layer contains abrasion-resistant particles, in particular corundum, while the second, softer and elastic lacquer layer contains significantly less, as a rule, no abrasion-resistant particles. It should be so favorable conditions in terms of Wear properties of such floor panels can be achieved.

From the EP 1 351 821 B1 For example, there is known a method for producing laminated laminate floor panels, wherein an elastomeric damping sheet is disposed between a support core and a decorative and abrasion resistant thermoset laminate layer. The damping film and the decorative and abrasion-resistant, thermosetting laminate layer are connected to each other and to the support core by means of pressing. The floor panels produced in this way are said to have improved footfall sound properties.

The present invention has for its object to provide a component, in particular panel, wood-based material for use as a furniture component or wall, ceiling or floor panel available, which has a soft-looking surface in haptic terms and can be produced inexpensively. In particular, the invention has for its object to provide a method for producing such a device or panel.

This object is achieved by a component having the features of claim 1 or by a method having the features of claim 12.

Preferred and advantageous embodiments of the device or method according to the invention are specified in the subclaims.

The component according to the invention has a carrier element, in particular in the form of a plate or a profile made of wood material, which is provided with a surface layer and a material layer arranged thereon layer, the material application does not cover the surface layer over the entire surface, but only partially and forms a microstructure, the a roughness depth in the range of 2 microns to 30 microns, wherein the material coverage covers 10 to 50% of the surface of the surface layer, and wherein the material application defined areas are irregularly limited and irregularly distributed on the surface layer.

Accordingly, the method according to the invention provides that a surface layer is applied to a carrier board of wood-based material or a carrier profile of wood-based material, and that a paint-like material application is printed on the surface layer in such a way that it covers 10% to 50% of the surface of the surface layer and after curing forms a microstructure having a surface roughness in the range of 2 microns to 30 microns and irregularly limited and irregularly distributed on the surface layer is arranged.

Surprisingly, it has been possible to achieve haptic properties of the painted surfaces hitherto unattainable in the case of components or panels of the type mentioned at the outset by imprinting or applying a final coating in the gravure printing process.

Components made of wood material produced according to the invention have a soft-seeming surface. The impression a soft surface is caused or simulated essentially or significantly by the special microstructure. Since the microstructure is produced by printing a paint-like material application, comparatively favorable production costs for the components according to the invention result. For this purpose, continuous pressure roller machines can be used, which are known per se and very powerful. For carrying out the method according to the invention, the machines must be equipped with at least one pressure cylinder designed according to the invention.

A particularly preferred embodiment of the method according to the invention is that the material application is printed so that it covers 20-40%, particularly preferably 25-35% of the surface of the surface layer and forms after curing areas that are irregularly limited and irregularly distributed on the Surface layer are arranged. The components or panels produced in this way have a surface which, in terms of haptics, gives an impression which corresponds to that of a smooth, oiled solid wood surface. Such an impression arises in particular when the material application is printed according to a preferred embodiment of the method so that the microstructure has a surface roughness in the range of 5 microns to 20 microns, preferably in the range of 6.5 microns to 15 microns.

Preferably, the material application is printed so that the microstructure formed by it comprises a plurality of separate regions whose respective surface area is in the range of 0.01 mm ² to 0.1 mm ² . In particular, looks the inventive method in a preferred embodiment, that the material application is printed so that in a surface area of 1 cm ^{2 of} the surface layer at least 200, preferably at least 400 separate microstructure regions are arranged.

A further preferred embodiment of the method according to the invention is characterized in that the surface layer is a transparent sealing layer is applied or printed, that before the sealing layer, a wood decor is printed on the carrier plate or the carrier profile, and that on the microstructure forming material one formed from a lacquer Pore structure is printed. In this way, a wooden surface can be imitated, and in particular also in optical terms. The three-dimensional pore structure is preferably printed in concordance with the illustrated wood grain of the two-dimensional wood decor, so that the impression of real wood is very much imitated.

Fig. 1A, 1B und 1C

drei Rasterelektronenmikroskop-Aufnahmen eines Oberflächenabschnitts eines erfindungsgemäß hergestellten Paneels gemäß einer ersten Ausführungsform;

Fig. 2A, 2B und 2C

drei Rasterelektronenmikroskop-Aufnahmen eines Oberflächenabschnitts eines erfindungsgemäß hergestellten Paneels gemäß einer zweiten Ausführungsform;

Fig. 3

eine schematische Darstellung einer Vorrichtung zum Direktbedrucken plattenförmiger Bauelemente aus Holzwerkstoff;

Fig. 4

eine schematische Darstellung zweier miteinander verbundener Paneele, in perspektivischer Ansicht; und

Fig. 5

eine vergrößerte Detaildarstellung des Verbindungsbereichs der Paneele der Fig. 4, in Vorderseitenansicht.

The invention will be explained in more detail with reference to a drawing illustrating several embodiments. In the drawing show:

Figs. 1A, 1B and 1C

three scanning electron micrographs of a surface portion of a panel according to the invention according to a first embodiment;

Figs. 2A, 2B and 2C

three scanning electron micrographs of a surface portion of an inventive manufactured panel according to a second embodiment;

Fig. 3

a schematic representation of an apparatus for direct printing plate-shaped components made of wood material;

Fig. 4

a schematic representation of two interconnected panels, in a perspective view; and

Fig. 5

an enlarged detail of the connecting portion of the panels of Fig. 4 , in front view.

The in Figures 1 and 2 Scanning electron micrographs (SEM images) shown were taken on four samples according to the invention manufactured components or panels. For this purpose, the samples were cut out of plate-shaped panels by means of a dowel cutter, whereby it was ensured that the surfaces to be optically measured remained free of scratches and contaminants. Subsequently, the surface of the respective circular disk-shaped sample was cleaned with a cleaner, adhered to a sample holder, vapor-deposited with gold and examined to determine the surface roughness in a scanning electron microscope. The layer thickness of the gold coating was about 2 atoms.

The three SEM images of the respective FIGS. 1 and 2 were recorded with different degrees of magnification. The SEM image marked A shows a 50-fold each Magnification, the SEM image marked with B shows a 100-fold magnification, and the SEM image marked with C shows a 1000-fold magnification, with the respective image at the lower edge, right with a size scale (200 .mu.m, 100 microns or 10 microns) is provided.

The panels or samples according to the invention each have a carrier plate of wood-based material, preferably an MDF or HDF plate. The respective support plate is provided with a single-layer or multi-layer surface layer 1, which, viewed individually, is substantially smooth. On the surface layer 1, a material application 2 is printed as a kind of finishing layer.

The material application 2 covers the surface layer 1 only partially and forms a microstructure. The term "microstructure" in the present context means a structure having a roughness R _Z according to DIN 4768 in the range of 2 microns to 30 microns, preferably 5 microns to 20 microns, more preferably 6.5 microns to 15 microns. The material application 2 is not present over the entire surface, but is localized. The final material application or the finishing layer 2 is therefore not applied over the entire surface. The material application 2, however, is distributed so that with the naked eye can hardly or hardly be recognized, where it is applied and where not.

The areas defined by the material application, which form the microstructure, comprise a plurality of separate areas whose respective surface area is in the range of 0.01 mm ² to 0.1 mm ² . The areas which the Form microstructure, comprise a plurality of separate regions, wherein in a surface area of 1 cm ^{2 of} the surface layer 1 at least 200, preferably at least 400 separate microstructure regions are arranged.

Figures 1 and 2 show surfaces of inventive components or panels in which the material application 2 10 to 50%, preferably 20 to 40%, particularly preferably 25 to 35% of the surface of the previously applied, preferably printed surface layer 1 covered and the areas defined by the material order 2 irregularly limited and irregularly distributed on the surface layer 1 are arranged. The material order 2 has irregularly large, in particular different height surveys (micro surveys). The surveys are arranged irregularly distributed. The surface layer 1 below the material application 2 is here a transparent, substantially smooth sealing layer. Below the transparent sealing layer is a decor, such as a wood, tile or natural stone decor arranged. The in Figures 1 and 2 The surfaces shown are very haptically smooth and feel like oiled real wood surfaces.

The material layer 2 forming the microstructure contains abrasion-resistant and / or scratch-resistant particles. The particle size of these particles, which are, for example, corundum particles and / or quartz particles, is less than 20 μm, preferably less than 15 μm. Such particles are also referred to as so-called nanoparticles.

In Fig. 3 schematically a device for direct printing of wood-based panels is shown. A plurality of plates 3 are arranged on a conveyor belt 4, which are supplied individually in series to different processing stations 5, 6, 7, 8. The conveying direction is in Fig. 3 indicated by an arrow and runs from left to right. Instead of several separate plates 3, a larger wood-based panel or an endlessly produced wood-based panel in the device according to Fig. 3 which is divided into individual plates according to the processing described below.

By means of the processing stations 5 and 6, a multi-colored, for example, two-tone decor, for example a wood decor printed by gravure printing on the plates 3. But this could also be realized in three- or four-color printing or by a digital printing process. In the present example, the processing stations 5 and 6 for this order applicators 5.1, 6.1, which include at least one gravure roll.

In Fig. 3 is further shown that the surface of the plates 3 is provided after the imprint of the decor by means of another processing station 7 with a transparent sealing layer. In the processing station 7, a substantially full surface layer (sealing layer) is applied from a paint. For this purpose, the processing station 7 on an applicator roller 7.1, which applies a uniform, substantially smooth layer of paint on the surface of the plates 3. through a downstream post-processing device 7.2, the applied coating is at least partially dried or cured. The post-processing device 7.2, for example, by means of a hot air flow or electromagnetic radiation, in particular UV radiation cause the drying and curing.

The processing station 7 is followed by a further processing station 8 by the application station 8 by means of an applicator roller 8.1, the previously applied surface layer (sealing layer) partially covering material applied or printed, the material application forms a microstructure on the surface layer, for example, a corresponds to the microstructured surfaces shown in Figures 1 to 4. To produce the varnish-like material application 2, it is preferred to use an abrasion-resistant and / or scratch-resistance-increasing particle, for example corundum particles and / or quartz particles-containing varnish. The microstructure of this material application 2 is essentially produced by a gravure roll (pressure cylinder roller) 8.1, in whose lateral surface a corresponding microstructure is formed.

In the downstream finishing device 8.2 then the last applied coating, the microstructured finishing layer is at least partially cured, so that the microstructure is sufficiently solidified and fixed, and does not level due to deliquescence. In this curing step, it may also lead to a possibly incomplete curing of the underneath arranged, with one of the upstream processing stations 5, 6 and / or 7 applied coating (s) come.

Of course, further processing stations (not shown) may be added to the described processing stations 5, 6, 7, 8. Thus, for example, according to a preferred variant of the method according to the invention, a pore structure of a lacquer can be printed on the finishing layer forming the microstructure, for example in order to imitate wood pores (depressions) on a wood surface (wood grain). This paint pore structure is preferably formed as a negative pore structure, i. the depressions (pores) of a wooden surface are not formed as depressions, but as small paint elevations.

With regard to the optical and haptic properties, it has proven particularly advantageous to apply the microstructure according to the invention to a paint pore structure.

On the back (underside) of the support plate 3, if necessary, a backslash can be applied. The order of the backslash, which is preferably executed in color, for example, by means of applicator rolls. For drying the backsheet, e.g. Nozzle dryer used.

After the decorative coating, the sealing layer 1 and the final, the microstructure of the invention forming material (finish) 2 - and possibly the backsheet - are sufficiently cured, so coated large-sized support plate 3 by means of a saw or the like divided into a plurality of panels. Afterwards, profiles 9, 10 for the positive connection of the panel with a corresponding panel are milled into the longitudinal sides and optionally also the transverse sides of the respective panel. The profiles are designed as a groove 9 and spring 10 (see. Fig. 5 ).

In Fig. 4 two interconnected panels 3.1, 3.2 are shown, each having on its upper side a wood decor, a sealing layer 1 and a final material application, said indicated by small dots material application 2 forms a microstructure according to the invention. The panels 3.1, 3.2 are designed as floor panels. Likewise, they can also be used to cover walls or ceilings.

The embodiment of the invention is not limited to the embodiments described above. Rather, numerous variants are conceivable, which make use of the invention specified in the appended claims, even with a different design. Thus, the invention can be carried out in particular in components of wood material in the form of profiles, for example, directly printed baseboards advantageous.

Claims (20)

1. Structural element, in particular a panel, made of a wood-based material, in particular for use as a furniture component or a wall, ceiling or floor panel (3.1, 3.2), comprising a surface layer (1) and a material coating (2) which covers the surface layer in part and forms a microstructure which has a surface roughness R_z according to DIN 4768 in the range of from 2 µm to 30 µm, characterised in that the material coating (2) covers 10 % to 50 % of the area of the surface layer (1), and in that regions defined by the material coating (2) being arranged so as to be irregularly delimited and irregularly distributed over the surface layer (1).
2. Structural element according to claim 1, characterised in that the microstructure has a surface roughness in the range of from 5 µm to 20 µm, preferably in the range of from 6.5 µm to 15 µm.
3. Structural element according to claim 1 or claim 2, characterised in that the regions which are defined by the material coating (2) and form the microstructure comprise a plurality of separate regions, the respective square dimensions of which are in the range of from 0.01 mm² to 0.1 mm².
4. Structural element according to any of claims 1 to 3, characterised in that the regions which are defined by the material coating (2) and form the microstructure comprise a plurality of separate regions, at least 200, preferably at least 400, separate microstructure regions being arranged in an area of 1 cm² of the surface layer (1).
5. Structural element according to any of claims 1 to 4, characterised in that the surface layer (1) is a transparent sealing layer, a decorative design, preferably a wooden, tiled or natural stone decorative design, being arranged underneath the sealing layer.
6. Structural element according to any of claims 1 to 5, characterised in that the material coating (2) covers 20 % to 40 %, preferably 25 % to 35 %, of the area of the surface layer (1).
7. Structural element according to any of claims 1 to 6, characterised in that the surface layer (1) is a transparent sealing layer, a wooden decorative design being arranged underneath the sealing layer, and a pore structure, formed from a lacquer, being printed on the material coating (2) forming the microstructure.
8. Structural element according to any of claims 1 to 7, characterised in that the surface layer (1) is a transparent, smooth sealing layer.
9. Structural element according to any of claims 1 to 8, characterised in that the structural element consists of a panel (3.1, 3.2) comprising a carrier plate, the carrier plates being provided with the surface layer (1) and the material coating (2) which covers the surface layer in part, and the longitudinal and/or transverse impact sides of the carrier plate comprising profiles (9, 10) for connecting the panel (3.1) to a corresponding panel (3.2) in an interlocking manner.
10. Structural element according to any of claims 1 to 9, characterised in that the material coating (2) forming the microstructure contains particles which increase abrasion resistance and/or increase scratch resistance and scrub resistance, preferably corundum particles and/or quartz particles.
11. Structural element according to claim 10, characterised in that the particles which increase abrasion resistance and/or increase scratch resistance and scrub resistance have a particle size of less than 20 µm, preferably of less than 15 µm.
12. Method for producing a structural element component, in particular for use as a furniture component or a wall, ceiling or floor panel (3.1, 3.2), in which a surface layer (1) is applied to a carrier plate made of wood-based material or to a carrier profile made of wood-based material, and in which a lacquer-like material coating (2) is printed on the surface layer, which material coating has a surface roughness R_z according to DIN 4768 in the range of from 2 µm to 30 µm, characterised in that the material coating (2) is printed on in such a way that it covers 10 % to 50 % of the area of the surface layer (1), forms a microstructure after curing and is arranged so as to be irregularly delimited and irregularly distributed over the surface layer.
13. Method according to claim 12, characterised in that the material coating (2) is printed on in such a way that the microstructure has a surface roughness in the range of from 5 µm to 20 µm, preferably in the range of from 6.5 µm to 15 µm.
14. Method according to claim 12 or claim 13, characterised in that the material coating (2) is printed on in such a way that the microstructure formed thereby comprises a plurality of separate regions, the respective square dimensions of which are in the range of from 0.01 mm² to 0.1 mm².
15. Method according to any of claims 12 to 14, characterised in that the material coating (2) is printed on in such a way that at least 200, preferably at least 400, separate microstructure regions are arranged in an area of 1 cm² of the surface layer (1).
16. Method according to any of claims 12 to 15, characterised in that a transparent sealing layer is applied or printed on as the surface layer (1), and in that a decorative design, preferably a wooden, tiled or natural stone decorative design, is printed on the carrier plate or the carrier profile before the sealing layer.
17. Method according to any of claims 12 to 16, characterised in that the material coating (2) is printed on in such a way that it covers 20 % to 40 %, preferably 25 % to 35 %, of the area of the surface layer (1) and, after curing, forms regions which are arranged so as to be irregularly delimited and irregularly distributed over the surface layer.
18. Method according to any of claims 12 to 17, characterised in that a transparent sealing layer is applied or printed on as the surface layer (1), in that a wooden decorative design is printed on the carrier plate or the carrier profile before the sealing layer, and in that a pore structure formed from a lacquer is printed on the material coating (2) forming the microstructure.
19. Method according to any of claims 12 to 18, characterised in that a transparent, smooth sealing layer is applied or printed on as the surface layer (1).
20. Method according to any of claims 12 to 19, characterised in that for producing the lacquer-like material coating (2), a lacquer containing particles which increase abrasion resistance and/or increase scratch resistance and scrub resistance, preferably corundum particles and/or quartz particles, is used.

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