ES2406358T3 - Construction element of wood-derived material with special haptic properties and procedure for manufacturing such construction element - Google Patents

Abstract

Construction element, in particular a panel, of wood-derived material, in particular for use as a furniture building element or as a wall, ceiling or floor panel (3.1, 3.2), with a surface layer (1) and a material covering (2) that partially covers the surface layer and forms a microstructure that has a depth of roughness RZ according to DIN 4768 in the range of 2 μm to 30 μm, characterized in that the coating of material (2) covers from 10% to 50% of the surface layer surface (1) and because areas defined by the coating of material (2) are arranged irregularly and irregularly distributed over the surface layer (1).

Description

Construction element of wood-derived material with special haptic properties and procedure for manufacturing such construction element

The invention relates to a construction element, in particular a panel, of wood-derived material, in particular for use as a furniture construction element or as a wall, ceiling or floor panel, with a surface layer and a coating of material which partially covers the surface layer. The invention further relates to a process for the manufacture of such a constructive element, in which a surface layer is applied on a support plate of wood-derived material or on a support profile of wood-derived material and in the that a coating of varnish type material is printed on the surface layer.

Plates of wood-derived material with decorative coating are used multiple times as floor panels, as wall and ceiling cladding or as furniture building elements. In most cases, this type of panels has a rectangular shape and is usually provided, at least in its longitudinal edges, with profiles that allow the adjacent panels to be coupled in order to create a large surface covering. In this sense, the use of wood fiber plates is very widespread, preferably the so-called MDF (medium density fiberboard) or HDF (high density fiberboard) plates manufactured according to The dry procedure. In addition to direct printing it is also possible to press sheets of paper, impregnated with synthetic resin and pre-dried, under conditions of high temperature and pressure directly on the plate surfaces to apply the desired decorative element. Since these impregnated materials tend to contract during pressing, they generate a tension and, therefore, it is always necessary to provide both sides of these plates with impregnated paper to prevent the curvature of the plates as a result of the tension.

In addition to the laminated wood fiber plates, recently directly coated plates have also begun to be used on panels of the mentioned type. Such panels are known, for example, from EP1645339A1. In this case, the fiber plates are provided with a liquid coating means, a decorative element is printed on a dyed base layer, for example, a decorative element with a wood effect, and finally applying one or more transparent sealing layers. EP1645339A1 describes the manufacture of a structured surface by applying a first coating and a second coating with an application amount that can vary spatially.

From EP1892352A2 a floor panel is known which has a base plate (support plate) printed on its upper side with a decorative layer, a first layer of varnish and a second layer of varnish being applied on the decorative layer. Therefore, the first layer of varnish applied on the decorative layer is harder and less elastic than the second layer of varnish located below. The first layer of varnish contains wear-resistant particles, in particular corundum, while the second layer of softer and more elastic varnish clearly contains a smaller amount of wear-resistant particles or, generally, none. In this way favorable conditions must be achieved with respect to the wear properties of such floor panels.

From EP1351821B1 a process is known for the manufacture of laminated floor panels, in which an elastomer damping film is arranged between a bearing core and a layer of duroplastic, decorative and wear-resistant laminate. The damping film and the layer of duroplastic, decorative and wear-resistant laminate are joined together and with the bearing core by pressing. Floor panels manufactured in this way must have improved properties in relation to the isolation of step noise.

The present invention has the objective of providing a construction element, in particular a panel, of material derived from wood for use as a construction element of furniture or wall, ceiling or floor panel, which from the haptic point of view has a surface Soft appearance and can be manufactured economically. The invention has in particular the objective of providing a process for the manufacture of such a constructive element or panel.

This objective is achieved by a constructive element with the characteristics of claim 1 or by a method with the characteristics of claim 12.

In the secondary claims, preferred and advantageous configurations of the constructive element or of the process according to the invention appear.

The construction element according to the invention has a support element, in particular in the form of a plate or a profile of material derived from wood, which is provided with a surface layer and a coating of layer-like material that is arranged above, not covering the material lining completely, but only partially the surface layer and forming a microstructure that has a roughness in the range of 2 μm to 30 μm, covering the material lining from 10 to 50% of the surface of the surface layer, and areas, defined by the coating of material, being arranged in an irregularly limited manner and unevenly distributed over the surface layer.

Accordingly, the process according to the invention provides that a surface layer is applied on a support plate of wood-derived material or on a support profile of wood-derived material and that a material coating be printed on the surface layer of varnish type so that it covers from 10% to 50% of the surface of the surface layer and that after hardening forms a microstructure that has a depth of roughness in the range of 2 μm to 30 μm and is arranged irregularly and unevenly distributed over the surface layer.

In the case of the construction elements or panels of the type mentioned at the beginning, haptic properties of the varnished surfaces have been surprisingly achieved, not achieved so far, by printing or applying a closure layer with the gravure process.

The construction elements of wood-derived material, which have been manufactured according to the invention, have a soft-looking surface. The appearance of a soft surface is produced or simulated essentially or fundamentally by the special microstructure. Since the microstructure is produced by printing a coating of varnish type material, comparatively favorable manufacturing costs are generated for the construction elements according to the printing. For this purpose, continuous operation cylinder printing machines that are known per se and have high performance can be used. For carrying out the process according to the invention, the machines must be equipped with at least one printing cylinder configured according to the invention.

A particularly preferred configuration of the process according to the invention is that the coating of material is printed so as to cover 20 to 40%, particularly preferably 25 to 35% of the surface of the surface layer, and after hardening it forms areas that they are arranged irregularly and irregularly distributed over the surface layer. The construction elements or panels manufactured in this way have a surface that from the haptic point of view has an appearance that corresponds to a smooth and oiled solid wood surface. This appearance is obtained in particular if the coating of material is printed according to a preferred configuration of the process such that the microstructure has a depth of roughness in the range of 5 μm to 20 μm, preferably in the range of 6.5 μm at 15 μm.

The material coating is preferably printed so that the microstructure, formed by it, comprises a plurality of separate zones, whose respective surface extension is in the range of 0.01 mm2 to 0.1 mm2. The process according to the invention provides in particular in a preferred configuration that the coating of material is printed so that in an area of 1 cm 2 of the surface layer at least 200, preferably at least 400 microstructure zones are arranged separately.

Another preferred configuration of the process according to the invention is characterized in that a transparent sealing layer is applied or printed as a surface layer, because before the sealing layer a decorative element with wood effect is printed on the support plate or the support profile and because on the coating of material, which forms the microstructure, a porous structure formed from a varnish is applied. In this way a wooden surface is imitated, in particular also from the optical point of view. The three-dimensional porous structure is preferably printed here in accordance with the wood grain represented by the two-dimensional decorative element with wood effect, thus largely imitating the appearance of authentic wood.

The invention is explained in detail below by means of a drawing that represents several embodiments. In the drawing they show:

Fig. 1A, 1B and 1C three scanning electron microscope images of a surface section of a panel, manufactured according to the invention, according to a first embodiment;

Fig. 2A, 2B and 2C three scanning electron microscope images of a surface section of a panel,

manufactured according to the invention, in accordance with a second embodiment;

Fig. 3

a schematic representation of a device for direct printing of constructs of wood-derived material in the form of a plate; elements

Fig. 4

a schematic representation of two panels linked together, in perspective view ; Y

Fig. 5

a detailed representation on an enlarged scale of the junction area of the panels in front side view.  figure 4,

Scanning electron microscope images (REM images), shown in Figures 1 and 2, were taken on four samples of construction elements or panels manufactured according to the invention. For this purpose, the samples were cut from panels in the form of a plate by means of a block cutter, ensuring in this case that the surfaces, which were to be measured optically, were kept free of scratches and dirt. Next, the surface of the respective disc-shaped sample was cleaned with a cleaning product, glued on a sample holder, metallized with gold and analyzed to determine the depth of roughness in a microscope

Scanning electronic The gold coating layer here was approximately 2 atoms thick.

The three REM samples of the respective figures 1 or 2 were taken with different degrees of magnification. The REM image identified with the letter A shows in each case a 50-fold magnification and the REM image identified with the letter B shows in each case a 100-fold magnification and the REM image identified with the letter C shows in each case an enlargement 1000 times, the respective image being provided on the lower edge, to the right, of a scale (200 μm, 100 μm or 10 μm).

The panels or samples according to the invention respectively have a support plate of wood-derived material, preferably an MDF or HDF plate. The respective support plate is provided with a surface layer 1 of one or more layers, which is itself essentially essentially smooth. A coating of material 2 is printed on the surface layer 1 as a type of closure layer.

The coating of material 2 covers the surface layer 1 only partially and forms a microstructure. The term "microstructure" means in this context a structure that has a roughness depth RZ according to DIN 4768 in the range of 2 μm to 30 μm, preferably 5 μm to 20 μm, especially 6.5 μm at 15 μm. The coating of material 2 does not occupy the entire surface, but is limited locally. That is, the material lining, which closes, or the closing layer 2 has not been applied over the entire surface. However, the coating of material 2 is distributed so that at first glance it cannot or can hardly be determined where it was applied or not.

The zones, which are defined by the coating of material and which form the microstructure, comprise a plurality of zones separately, whose respective surface extension is in the range of 0.01 mm2 to 0.1 mm2. The zones, which form the microstructure, comprise a plurality of zones separately, being arranged in an area of 1 cm 2 of the surface layer 1 at least 200, preferably at least 400 microstructure zones separately.

Figures 1 and 2 show surfaces of construction elements or panels according to the invention, in which the coating of material 2 covers from 10 to 50%, preferably from 20 to 40%, especially preferably 25 to 35% of the surface of the surface layer 1 applied before, preferably printed, and in which the areas defined by the coating of material 2 are arranged in an irregularly limited manner, as well as irregularly distributed over the surface layer 1. The coating of material 2 has size elevations irregular, in particular of different height (microelevations). The elevations are arranged unevenly. The surface layer 1, located under the coating of material 2, is in this case a transparent, essentially smooth sealing layer. A decorative element, for example, a decorative element with a wood, tile or natural stone effect, is arranged under the transparent sealing layer. The surfaces shown in Figures 1 and 2 produce a very smooth effect from the haptic point of view and are perceived as oiled surfaces of genuine wood.

The coating of material 2, which forms the microstructure, contains particles that increase resistance to wear and / or scratches and abrasion. The grain 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 identified as nanoparticles.

A device for direct printing of wood-derived plates is represented schematically in Figure 3. Several plates 3 are arranged on a conveyor belt 4 and are fed individually, one behind the other, to the different machining stations 5, 6, 7, 8. The transport direction is indicated in Figure 3 by an arrow and runs from left to right. Instead of several separate plates 3, in the device according to figure 3, a plate of wood-derived material with a larger size or a plate of wood-derived material with continuous manufacturing, which is divided into, can also be machined individual plates after machining described below.

In the machining stations 5 and 6, a multicolored decorative element, for example, bicolor, is printed on the plates 3 by means of the gravure process. However, this decorative element could also be printed in three or four colors or digitally. In the present example, the machining stations 5 and 6 have in this regard application rollers 5.1, 6.1 comprising at least one engraved roller.

In figure 3 it is further shown that the surface of the plates 3 is provided with a transparent sealing layer in another machining station 7 after the decorative element is printed. In the sealing station 7 a surface layer (sealing layer) of essentially continuous varnish is applied. For this purpose, the machining station 7 has an application roller 7.1 that applies a uniform, essentially smooth, varnish layer on the surface of the plates 3. The applied layer is dried or hardened at least partially by a machining device further 7.2 which is connected below. The further machining device 7.2 can cause drying and hardening, for example, by means of a hot air stream or electromagnetic radiation, in particular UV radiation.

The machining station 7 is followed by another machining station 8. In the machining station 8, a coating of varnish-like material that is partially covered is applied or printed by means of an application roller 8.1

the surface layer applied before (sealing layer), the coating of material forming on the surface layer a microstructure corresponding, for example, to one of the microstructured surfaces shown in Figures 1 to 4. To produce the coating of material 2 of Varnish type is preferably used a particle that increases resistance to wear and / or scratches and abrasion, for example, a varnish containing corundum particles and / or quartz particles. The microstructure of this coating of material 2 is produced here essentially by means of an engraved roller (printing cylinder) 8.1, on whose envelope surface a corresponding microstructure is configured.

In the further machining device 8.2, then connected, the last applied layer is hardened at least partially, that is, the microstructured closure layer, so that the microstructure is solidified and sufficiently fixed, and does not flatten due to a shift. In this hardening stage, hardening can also occur, if not yet complete, of the layer or layers arranged below and applied in one of the machining stations 5, 6 and / or 7 connected in front.

It is also naturally possible to add other machining stations (not shown) to the machining stations described 5, 6, 7, 8. Thus, for example, according to a preferred variant of the process according to the invention it can be printed on the layer of closure, which forms the microstructure, a porous lacquer structure to mimic, for example, the wood pores (depressions) of a wooden surface (wood grain). This porous lacquer structure is preferably configured as a negative porous structure, that is, the depressions (pores) of a wooden surface are not configured as depressions, but as small lacquer elevations.

In relation to the optical and haptic properties it has been especially advantageous to apply the microstructure according to the invention on a porous lacquer structure.

On the back side (bottom side) of the support plate 3, a back layer of varnish can be applied if necessary. The application of the varnish backing, preferably in color, is carried out, for example, by application rollers. To dry the varnish back layer, for example, nozzle dryers are used.

After the decorative layer, the sealing layer 1, the material lining (closing layer) 2, which closes and forms the microstructure according to the invention have been sufficiently hardened, and, if necessary, the back layer of varnish, the plate is divided of large format support 3, coated in this way, on a plurality of panels by means of a saw or the like. Then, on the sides of the longitudinal joint and, if necessary, on the sides of the transverse joint of the respective panel, profiles 9, 10 are made by milling to drag the panel with a corresponding panel. The profiles are designed here as slot 9 and tab 10 (see figure 5).

In figure 4 two panels 3.1, 3.2 are shown, which are joined together and respectively have on their upper side a decorative element with wood effect, a sealing layer 1 and a coating of material that closes, forming the coating of material 2 , indicated with small dots, a microstructure according to the invention. Panels 3.1, 3.2 are configured as floor panels. Also, these can also be used for wall or ceiling cladding.

The embodiment of the invention is not limited to the embodiments described above. Rather, a plurality of variants is possible which, in the case also of a different configuration, make use of the invention indicated in the appended claims. Thus, for example, the invention can also be implemented particularly advantageously in construction elements of wood-derived material in the form of profiles, for example, in directly printed skirting boards.

Claims (20)

one.

 Construction element, in particular a panel, of wood-derived material, in particular for use as a furniture construction element or as a wall, ceiling or floor panel (3.1, 3.2), with a surface layer (1) and a cladding of material (2) that partially covers the surface layer and forms a microstructure that has a roughness depth RZ according to DIN 4768 in the range of 2 μm to 30 μm, characterized in that the coating of material (2) covers 10% 50% of the surface of the surface layer (1) and because areas defined by the coating of material (2) are arranged irregularly and irregularly distributed over the surface layer (1).

2.

 Constructive element according to claim 1, characterized in that the microstructure has a depth of roughness in the range of 5 μm to 20 μm, preferably in the range of 6.5 μm to 15 μm.

3.

 Construction element according to claim 1 or 2, characterized in that the zones that are defined by the coating of material (2) and form the microstructure comprise a plurality of zones separately, whose respective surface extension is in the range of 0.01 mm2 at 0.1 mm2.

Four.

 Construction element according to one of claims 1 to 3, characterized in that the areas that are defined by the coating of material (2) and form the microstructure comprise a plurality of areas separately, being arranged in an area of 1 cm2 of the surface layer (1) at least 200, preferably at least 400 microstructure zones separately.

5.

 Constructive element according to one of claims 1 to 4, characterized in that the surface layer (1) is a transparent sealing layer, a decorative element, preferably a decorative element with a wood, tile or tile effect being arranged under the sealing layer. natural stone.

6.

 Construction element according to one of claims 1 to 5, characterized in that the material coating

(2) covers 20% to 40%, preferably 25% to 35% of the surface layer surface (1).

7.

 Construction element according to one of claims 1 to 6, characterized in that the surface layer (1) is a transparent sealing layer, a wooden decorative element being arranged under the sealing layer and being arranged on the material lining (2) , which forms the microstructure, a porous structure formed by a varnish.

8.

 Constructive element according to one of claims 1 to 7, characterized in that the surface layer (1) is a transparent sealing layer, configured in a smooth manner.

9.

 Construction element according to one of claims 1 to 8, characterized in that the construction element is composed of a panel (3.1, 3.2) having a support plate, the support plate being provided with the surface layer (1) and the coating of material (2) partially covering the surface layer, and presenting the longitudinal joint sides and / or the transverse joint sides of the support plate profiles (9, 10) for dragging the panel (3.1) into a corresponding panel (3.2).

10.

 Constructive element according to one of claims 1 to 9, characterized in that the coating of material (2) forming the microstructure contains particles that increase resistance to wear and / or scratches and abrasion, preferably corundum particles and / or particles of quartz.

eleven.

 Constructive element according to claim 10, characterized in that the particles that increase resistance to wear and / or scratches and abrasion have a grain size of less than 20 μm, preferably less than 15 μm.

12.

 Procedure for manufacturing a construction element, in particular for use as a furniture construction element or as a wall, ceiling or floor panel (3.1, 3.2), in which a surface layer (1) is applied on a plate of support of material derived from wood or on a support profile of material derived from wood and on which a coating of varnish-type material (2) is printed on the surface layer that has a roughness depth RZ according to the standard DIN 4768 in the range of 2 μm to 30 μm, characterized in that the coating of material (2) is printed so that it covers 10 to 50% of the surface of the surface layer (1) and after hardening forms a microstructure, and is arranged irregularly and irregularly distributed over the surface layer.

13.

 Method according to claim 12, characterized in that the coating of material (2) is printed so that the microstructure has a depth of roughness in the range of 5 μm to 20 μm, preferably in the range of 6.5 μm to 15 μm.

14.

 Method according to claim 12 or 13, characterized in that the coating of material (2) is printed so that the microstructure formed by it comprises a plurality of areas separately, whose respective surface extension is in the range of 0.01 mm2 to 0.1 mm2.

fifteen.

 Method according to one of claims 12 to 14, characterized in that the coating of material (2) is printed so that at least 1 200 of the surface layer (1) is arranged, preferably at least 400 microstructure zones separately.

16.

 Method according to one of claims 12 to 15, characterized in that the surface layer (1) is

5 apply or print a transparent sealing layer and because before the sealing layer a decorative element, preferably a decorative element with a wood, tile or natural stone effect is printed on the support plate or on the support profile. 17. Method according to one of claims 12 to 16, characterized in that the coating of material (2) is printed so as to cover 20 to 40%, preferably 25 to 35% of the surface of the layer 10 (1) and after hardening it forms areas that are arranged irregularly and irregularly distributed over the surface layer. 18. Method according to one of claims 12 to 17, characterized in that a transparent sealing layer is applied or printed as surface layer (1), because a wooden decorative element is printed on the support plate before the sealing layer or on the support profile and because on the lining of The material (2) that forms the microstructure prints a porous structure formed by a varnish.

19.

 Method according to one of claims 12 to 18, characterized in that as a surface layer (1) a transparent sealing layer is applied or printed in a smooth manner.

twenty.

 Method according to one of claims 12 to 19, characterized in that to produce the coating of

Varnish type material (2) is used varnish containing particles that increase resistance to wear and / or scratches and abrasion, preferably corundum particles and / or quartz particles.