Method for manufacturing shaving board and shaving board

Abstract

The invention relates to a method for coating a waterproof shaving board (1) in order to be used better and more variously, said shaving board having chips made of wood with a length of 0.5 mm to 50 mm, a width of 0.1 mm to 20 mm and a thickness of 0.05 mm to 2 mm and having at least one adhesive with an adhesive fraction of at least 12% by weight of dry wood, the method comprises the following steps: providing a shaving board (1) which has an upper side (1a) and a lower side (1b) and side surfaces, applying a coating (3), installing decorative parts, optionally structuring the coating (3) on at least one section of the upper side, the lower side or the side surfaces, and optionally hardening the coating. The invention also relates to a coated waterproof shaving board.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a particle board and a particle board, in particular a waterproof particle board. Background Art

[0002] A particle board that is dimensionally stable in the presence of moisture and has an adhesive share of at least 12% is called a waterproof particle board. Such a particle board has a relatively rough and aesthetically poor surface. Summary of the Invention

[0003] The object of the present invention is to improve the properties of such a waterproof particle board and to have a more diverse range of applications.

[0004] This object is solved by the method according to claim 1 and the particle board according to claim 10. The dependent claims relate to advantageous refinements of the present invention.

[0005] The particle board has an adhesive share of at least 12% by weight relative to dry wood. Based on the share of wood or chips, preferably an adhesive share of at least 15% by weight relative to dry wood, preferably at least 17% by weight of dry wood, particularly preferably at least 20% by weight of dry wood, and most preferably at least 25% by weight of dry wood is applied to the chip material. As long as the moisture content of the layers of the particle mat and / or the individual layers does not exceed the upper limit value after the application of the adhesive, any desired adhesive content can be applied to the chip material. Preferably, the upper limit value of the moisture content is between 1% by weight of the glued wood and 20% by weight of the glued wood, preferably between 3% by weight of the glued wood and 18% by weight of the glued wood, particularly preferably between 5% by weight of the glued wood and 15% by weight of the glued wood.

[0006] The adhesive share is expressed relative to the chip material, that is, the share of the adhesive is expressed with respect to the weight of the chips used. For chips that can absorb moisture (such as wood chip material), the adhesive share is referenced to the wood dried to constant weight. The chip material is dried to constant weight at 103 ± 2 °C and is called absolutely dry wood (dry wood: absolutely dry wood). The share of the adhesive is expressed as 100% solids content, i.e., without any added liquid.

[0007] To provide chips, lignocellulosic materials are used, such as wood, such as round wood, fresh wood, old wood or residual wood, or annual plants, usually straw or bagasse. These chip materials have a length of 0.5 mm to 50 mm, a width of 0.1 mm to 20 mm and a thickness of 0.05 mm to 2 mm. Here, a distinction is made between coarse chips having a length of 5 mm to 50 mm, a width of 1 to 20 mm and a thickness of 0.2 to 2 mm and fine chips having a length of 0.5 mm to 25 mm, a width of 0.1 to 5 mm and a thickness of 0.05 to 1 mm.

[0008] A high binder proportion during gluing of the chips allows the production of water-resistant and thus moisture-resistant particle boards which, moreover, have a high strength. Furthermore, it has surprisingly been found that, by virtue of the high binder proportion, the swelling of the particle board, for example by immersion in water for 24 hours, becomes reversible. The determination of the swelling properties is preferably carried out in accordance with DIN EN 317. After a drying-back of 24 hours, for example at room temperature, the particle board has again reached its initial dimensions, such as the starting length, starting width and starting thickness before immersion in water for 24 hours. It can thus be inferred that the binder joints remain substantially undamaged during the action of water. This swelling and shrinking property has not been observed in existing particle boards; on the contrary, existing particle boards usually have a partially irreversible residual swelling. The field of application of the particle board is thus expanded as a result of the ability to completely restore the deformation caused by swelling.

[0009] Particularly preferably, a binder having a first thermosetting component and a second thermoplastic component is used for the production of the particle board. The binder is present in an amount of at least 12% by weight, relative to the dry wood, to 60% by weight, relative to the dry wood, preferably 15% by weight, relative to the dry wood, to 45% by weight, relative to the dry wood, particularly preferably 18% by weight, relative to the dry wood, to 35% by weight, relative to the dry wood, in particular 20% by weight, relative to the dry wood, to 33% by weight, relative to the dry wood, advantageously 24% by weight, relative to the dry wood, to 31% by weight, relative to the dry wood.

[0010] According to an advantageous embodiment of the invention, condensation resins, in particular aminoplastics, such as melamine formaldehyde resins, urea formaldehyde resins (UF resins) or benzoguanamine resins, and phenolic plastics, such as phenolic resins (PF resins), are used as the thermosetting component, either alone or in admixture. The aminoplastics are used in aqueous solution, for example as melamine resins, usually as melamine formaldehyde resins (MF resins), where the solids content of the aminoplastics is preferably at least 45% by weight, relative to the aqueous solution; advantageously, the solids content exceeds 50% by weight. The upper limit of the solids content is predefined by the solubility and, if necessary, the processability of the aminoplastics during the manufacturing process, for example in a nozzle or in a high-pressure gluing process.

[0011] Preferably, the binder has at least melamine resin, such as MF resin (melamine formaldehyde resin), as the first component. Melamine resin is preferred because it has low expansibility and low hygroscopicity and is hydrolysis-resistant. Alternatives are phenolic resin, urea resin, or a mixture or combination of multiple components of these thermosetting first components. Although urea resin is not water-resistant, it can surprisingly be used, especially in combination with melamine resin and / or phenolic resin, to manufacture the particleboard according to the present invention. In particular, melamine resin can be used either alone as the first component or in combination with one or more other thermosetting components. The share of UF resin is preferably at most 50% by weight of MF or PF resin without impairing the water resistance or water stability of the particleboard.

[0012] In the context of the present invention, a combination means a mixture of resins that can be used as the first component, where a mixture of two or more first-component resins is simultaneously applied to the chip material. Alternatively, multiple different resins of the first component are used sequentially, for example because these resins cannot be used as a mixture, or because separately applying different resins of the first component or a single resin of the first component of the binder (e.g., for subsequent product characteristics and / or application characteristics) has an advantageous effect.

[0013] Preferably, the thermoplastic second component of the binder, technically diphenylmethane diisocyanate (PMDI), is applied to the chip material. Alternatively or additionally, other substances can be used as the second component, such as diphenyl isocyanate (MDI) (also used in emulsified form as eMDI), but polyurethane can also be used as the second component. The share of the second component is preferably greater than 1% by weight, especially 3% by weight or more, and advantageously 5% by weight or more, all relative to dry wood. Thus, the share of the second component, such as PMDI, in the particleboard according to the present invention is significantly higher than that in a normal particleboard. Advantageously, for example, the second component of the binder, such as PMDI, is also used in the same way or especially in the cover layer of the particleboard according to the present invention in a multi-layer structure board. The second component is preferably used in the same amount in the intermediate layer and the cover layer. Here, multiple substances that are equally suitable as the second component can be applied to the chips either simultaneously in a mixed manner or individually sequentially.

[0014] Preferably, at least one third component, such as a polyol or a polyether, can preferably be added as a solid to the first and second components of the binder respectively. The third component can be added in a share of at most 15% by weight, preferably at most 10% by weight, and particularly preferably 2 to 5% by weight, relative to the total amount of the binder.

[0015] According to an advantageous embodiment, the elastic properties of the particle board can be modified, in particular improved, by adding an elastomer or a thermoplastic (which serves as an elastic additive), for example by adding polyvinyl acetate (PVAc) or ethylene vinyl acetate (EVA). Acrylates, styrene acrylates or polyurethanes (PU) are particularly preferably used in the form of liquid additives (such as dispersions or emulsions) for elastifying the particle board according to the invention, since they are waterproof. Acrylates, styrene acrylates or PU with a glass transition temperature TG of less than 0 °C are preferably used. However, monoethylene glycol or diethylene glycol are also suitable for elastifying the particle board. The above-mentioned elastifying additives can be used alone or in combination. The addition of the elastomer or thermoplastic reduces the brittleness of the particle board and improves its elastic properties, such as the modulus of elasticity. In addition, the addition of the elastifying additive can also improve the flatness of the particle board according to the invention. The elastifying additive is calculated as a solid and is used in an amount of 1% to 5% by weight, advantageously 2% to 4% by weight, based on the total amount of the particle board (dry). The elastifying additive is added, for example, to the binder, such as melamine resin, before being applied to the chip material and is applied to the chip material together with the binder. Preferably, the medium for elastification is applied to the chip material before or more preferably after the binder.

[0016] As described above, the first component and the second component, and optionally more components, are used in combination as the binder. Preferably, the binder mainly has the first component, especially melamine resin. More preferably, the first component accounts for more than 15% by weight, especially 20% by weight, of the total amount of the binder used. According to the specific requirements of the particle board, the ratio of the first component to the second component of the binder can be continuously adjusted within a wide range. This preferably relates not only to the intermediate layer but also to the other layers in a multi-layer board structure. The ratio of the first component to the second component applied to the chip material is 2:1, more preferably 3:1, particularly preferably 4:1 or 5:1, or a ratio between these values. If the particle board according to the invention has a covering layer, a higher proportion of the first component of the binder is preferably used in the covering layer compared to the intermediate layer.

[0017] Particularly preferably, these chips or chip mats are pressed into particle boards having an odd number of layers, wherein the layers are distinguished in particular by different chip sizes. For example, the particle board has three or five stacked layers. In a particle board having three layers, for example, an intermediate layer is arranged between two covering layers. The intermediate layer typically consists of at least 30% by weight, preferably at least 45% by weight, particularly preferably at least 60% by weight of the share of the pressed particle board and usually has coarse chips. The covering layers are dispersed symmetrically or asymmetrically with respect to their weight shares and usually have fine chips. If the particle board according to the invention consists of a single-layer structure, different chip portions consisting of coarse chips and fine chips are aggregated in one layer.

[0018] For manufacturing the particle board according to the invention, one or more additives can also be used, for example. Antioxidants, light stabilizers, antistatic agents, colorants, fungicides, flame retardants, agents for setting the thermal conductivity or electrical conductivity of a medium or one or more fillers are used. As fillers, for example, mineral particles can be used, but ceramic, synthetic or particles made of glass or plastic can also be used. The additives or fillers can be applied to the chip material individually or in a mixed form. The fillers and / or additives can also be arranged in admixture with the binder, in particular applied after mixing.

[0019] According to an advantageous embodiment of the invention, a water-repellent agent is arranged on the chips before pressing the chips, in particular after gluing the chips. As the water-repellent agent, for example, paraffin or wax is provided, which is typically used in an amount of at most 5% by weight of the dry wood, mostly in an amount of at most 2% by weight of the dry wood, often in an amount of 0.1% by weight to 1% by weight of the dry wood, optionally up to 1.5% by weight of the dry wood. The use of the hydrophobizing agent helps to reduce the swelling tendency of the clamping plate and to improve the moisture resistance of the particle board.

[0020] According to an advantageous refinement of the invention, the particle board is ground after pressing. For this purpose, a grinding device having a grinding medium (for example, sandpaper and / or preferably a grinding belt) can be provided. Grinding is usually carried out in two grinding processes, wherein a grinding medium having a particle size of 50 - 60 is used in the first grinding process and a grinding medium having a particle size of 80 - 100 is used in the second grinding process. The particle board according to the invention has a harder surface than the known particle boards according to DIN EN 312, wherein it is preferred to use a grinding medium having a coarser particle size. Preferably, the particle size in the two grinding processes is at most 60, preferably at most 50, particularly preferably at most 40.

[0021] The particle board manufactured by the above method can be adapted to different requirements by different combinations of chips, binders, fillers and optionally other additives (such as wax). Therefore, it is expressly stated that the features described in connection with the invention can be freely combined with each other respectively.

[0022] The particle board according to the invention is preferably waterproof and thus also moisture-proof. The particle board preferably has outstanding and unusual expansion and shrinkage characteristics, wherein the already small expansion additionally causes a large degree of recovery of the expansion during subsequent drying.

[0023] The particle board according to the invention is typically formed in a plate shape, that is to say, the particle board usually has two main surfaces, which are also referred to hereinafter as the upper side and the lower side. The upper side and the lower side are spaced from each other by the thickness of the particle board. The narrow sides of the particle board meet the upper side and the lower side at the edges and extend between the upper side and the lower side. The thickness of the finished particle board can be from 2 mm to 80 mm, typically between 3 mm and 50 mm, mostly between 3 mm and 32 mm. Typical applications may require the particle board to have a thickness of 6 mm to 32 mm. The particle board can have flat main surfaces; however, the upper side and / or the lower side can also be stamped or milled or otherwise processed so that a variable thickness of the particle board is achieved relative to the surface of the particle board.

[0024] The narrow sides of the particle board according to the invention can be processed using common tools. These tools can be sawed, cut or milled. The maximum length and width of the particle board can be cut according to requirements, for example, during subsequent processing. Smaller dimensions can be produced, for example, by cutting the particle board initially manufactured in a press. Typical dimensions of the particle board can be 6700 mm (length) × 2500 mm (width) (after pressing), 1380 mm × 195 mm (after being divided into floor panels, wall panels or ceiling panels), or 3048 × 2800 mm. Since the width of the board corresponds to the usual floor height, the latter specification is particularly suitable for use in construction.

[0025] Advantageously, the particle board according to the invention has only minimal thickness swelling, in particular thickness swelling measured according to the test method described in DIN EN 317, which is less than 5%, advantageously less than 4%, preferably less than 3%, particularly preferably less than 2.5% relative to the original board thickness. It is also advantageous that the uncoated particle board has an edge swelling of less than 6%, preferably less than 5%, according to the test method described in EN-13329, and the coated particle board particularly preferably has an edge swelling of less than 4%. This swelling can be reduced by more than 90% relative to a standard particle board of the same thickness made from the same chip material but with less binder use and other binder types. The value of less than 5% for the edge swelling of the uncoated particle board and the value of less than 4% for the edge swelling of the coated particle board are thus particular improvements relative to the known particle boards according to DIN EN 312.

[0026] The average density of the particle board according to the invention is preferably 800 kg / m 3 to 1000 kg / m 3 and preferably 830 kg / m 3 to 970 kg / m 3 and particularly preferably 850 kg / m 3 to 950 kg / m 3 . Thus, this average density is about 100 kg / m 3 to 300 kg / m 3 higher than that of the known particle board of type P2 according to DIN EN 312.

[0027] The particle board according to the invention has very good strength properties, especially a high transverse tensile strength, which is at least 2.5 N / mm 2 and preferably at most 3 N / mm 2 and especially at most 4 N / mm 2 . Preferably, the particle board has a modulus of elasticity of 3000 N / mm 2 to 5000 N / mm 2 , advantageously from 3500 to 5000 N / mm 2 and particularly preferably 4000 to 5000 N / mm 2 . Due to the good strength properties, the fixing effect of individual fastening devices in the board is better, and the particle board according to the invention requires fewer fastening devices (such as screws) during fixing. In addition, the higher transverse tensile strength allows for higher-strength processing of the particle board according to the invention, such as milling simple profiles in the side edges of the board. For example, at least one simple profile, such as a tongue-and-groove profile, can be processed on the narrow face of the particle board, which enables two mutually interlocking boards to be oriented with each other not only in the vertical direction but also in the horizontal direction. The high flexural strength of at least 35 N / mm 2 and preferably at least 40 N / mm 2 of this particle board allows it to be used as a structural element, such as for use as a wall reinforcement.

[0028] The invention also relates to the use of the above-mentioned particle board for structural purposes in indoor and outdoor areas. The particle board according to the invention is characterized in that it can be used in a variety of ways due to minimal swelling, especially reduced thickness swelling in the area of the narrow face. During indoor extensions, the particle board can be used, for example, as a floor or as a floor covering, with or without a coating respectively. Here, different from, for example, non-waterproof floors or floor coverings, the particle board according to the invention can also be used in damp and wet spaces, especially because in its narrow face area, even if optionally provided with edge profiles and freely exposed to moisture, it will not swell significantly in water or high-humidity environments or will almost completely return to its original size after drying.

[0029] This means that, for example, on existing devices for manufacturing wood-based panels, it is possible to produce a particle board that is substantially non-swelling, dimensionally stable, high-strength, water- and moisture-resistant, and not limited to narrow dimensions.

[0030] Of course, the particle board according to the invention can also be used as wall panels or ceilings, as furniture boards, and as structural boards, especially when expanding damp and wet spaces, or laboratory spaces, technical spaces, or workshops, but not limited thereto. In outdoor structures, the particle board according to the invention is equally suitable as a structural board, typically, for example, as an exterior wall panel, for outdoor window sills, claddings (including roof coverings), and wall elements.

[0031] The coated particle board according to the invention can be used, for example, for indoor and outdoor floors. In this way, the same floor or floor covering can be used for the interior area and the adjacent exterior area (terrace, balcony, exterior wall, passage). The particle board according to the invention is preferably suitable for structures, especially furniture, in both indoor and outdoor areas. For example, it is possible to expand workshops, production plants, or livestock houses without any problems using the particle board coated according to the invention. Here, not only vertical surfaces can be manufactured, but especially also horizontal surfaces that must be waterproof or moisture-proof. In addition, the coated particle board according to the invention can also be used, due to its water resistance, for example, for fire protection elements and structural elements in shipbuilding, especially when it is provided with or coated with a fire protection substance and is thus designed, for example, to be difficult to ignite, more precisely, not only in technical areas but also in areas used by passengers, because decorative surfaces can be designed.

[0032] The coated particle board can optionally be designed as a panel, i.e., when needed, profiles are provided on at least one, usually two or four edges. This profile is preferably used to fix two panels to each other usually without an adhesive. Two panels arranged side by side can also be butt-connected alternatively. These panels can be fixed, for example, by a double-sided tape that is arranged in the lateral area of the joint between directly adjacent panels. It is also possible to bond directly adjacent panels or boards, and preferably a water-resistant adhesive is used.

[0033] The surface of the uncoated particle board is rough and, for example, not suitable for decorative purposes, but also not suitable for certain non-decorative purposes, for example, due to the surface roughness. Maintenance and hygienic upkeep of the rough surface are almost impossible. There is no information in the prior art regarding the coatability of waterproof particle boards. It has surprisingly been found that the waterproof particle board can be coated in various ways:

[0034] The waterproof particle board may be provided with a single or multi-layer coating applied at least sectionally. The coating is applied to at least one section of the surface of the waterproof particle board, typically on one side and / or the edge. Preferably, the coating is arranged on the upper side and / or the lower side of the particle board.

[0035] The coating may have one layer or multiple layers, and the layers may have, for example, synthetic resin, paint, paper (especially synthetic resin-impregnated paper), veneer, film (especially metal film or plastic film), cork, felt, and / or laminate. If paper, especially synthetic resin-impregnated paper, is used, the paper may be, for example, a covering layer without a decorative part, decorative paper, liner, or backing paper. The synthetic resin-impregnated paper is characterized in that the synthetic resin used to impregnate the paper is dry but still chemically reactive, that is, it has not hardened. It is preferred to use a combination of at least one decorative paper and a covering layer. Typically, melamine formaldehyde resin and / or urea resin may be used as the synthetic resin. However, alternatively, the synthetic resin may also be a laminate made from multiple synthetic resin-impregnated papers pressed against each other, where the synthetic resin, usually melamine and / or urea, has been hardened, so the laminate is also listed separately in the coating.

[0036] The coating may have multiple layers made of the same material. However, the coating may also include multiple layers composed of two or more of the above materials. Typical combinations of layers include, for example, synthetic resin, paper, and paint, laminate and paint, veneer and paint, paper or veneer and paint. The coating may be applied in a solid or liquid form. For example, in the case of synthetic resin or paint, the coating may be arranged in a solid or liquid form. The coating may be applied to the surface to be coated of the waterproof particle board, for example, by spraying, pouring, rolling, scraping, or nozzle installation. A planar coating such as paper, laminate, film, or veneer is placed on the surface to be coated of the waterproof particle board.

[0037] The coating may be designed to have a decorative part. As an addition to or an alternative to the decorative part, the coating may have a structure, that is, a three-dimensionally designed surface. Preferably, the structure is adapted to the decorative part (patterned embossing).

[0038] The coating may be fixed to the waterproof particle board with an adhesive. Hot melt adhesives are often used as adhesives, and the hot melt adhesives are also called hot melts. Typical hot melt adhesives are, for example, polyvinyl acetate (PVAc), polyamide resin, saturated polyester, ethylene-vinyl acetate copolymer (EVA), polyolefin, block copolymer (such as styrene-butadiene-styrene or styrene-isoprene-styrene), and polyimide. Polyvinyl acetate, ethylene-vinyl acetate copolymer, and polyolefin are particularly suitable for fixing the coating. The adhesive used to arrange the coating or used as the coating, such as the hot melt, is different from the adhesive used to manufacture the waterproof particle board.

[0039] Alternatively, the coating can be directly applied to the waterproof particle board, especially when applying synthetic resin or paint. The coating is preferably applied to the waterproof particle board by pressing (optionally at high temperature). Alternatively, the coating can be hardened by drying or heating (e.g., using infrared or ultraviolet radiation or using an electron beam). The particle board provided with the applied but not yet fixed coating can be directly pressed or subjected to radiation. If a planar coating is applied, it is advantageous to produce a stack of pressings, in which the coating and the waterproof particle board are stacked on top of each other, so as to be subsequently pressed, for example.

[0040] The coating can be supplemented by additional layers which are not usually arranged on the outside. Such additional layers can be: a primer, a base coat, or one or more layers containing corundum, glass particles, plastic particles and / or metal particles. Description of the Drawings

[0041] Embodiments of the present invention will be explained in more detail below with the aid of the drawings. Shown herein are:

[0042] Figure 1 A schematic cross-section of a coated waterproof particle board having a coating made of paper impregnated with synthetic resin on the upper side;

[0043] Figure 2 A schematic cross-section of a coated waterproof particle board having coatings made of paper impregnated with synthetic resin on the upper side and the lower side;

[0044] Figure 3 A schematic cross-section of a coated waterproof particle board having a laminated coating made of laminate. Detailed Description of the Invention

[0045] For all the following embodiments, a three-layer waterproof particle board is used, having an adhesive content of more than 12% by weight, preferably 25% by weight in the two outer cover layers and 30% by weight in the intermediate layer between the outer cover layers. The waterproof particle board, in addition to having a relatively high original density of about 880 kg / m 3 compared to a conventional particle board (about 720 kg / m 3 ), also has a significantly lower swelling of 2% to 3% compared to 28% swelling in a standard particle board classified as P2 according to DIN EN 312:2010, for example. Such a standard particle board P2 is used as a furniture board, for example. Swelling is measured according to DIN EN 317.

[0046] The edge swelling measured here on the coated board according to DIN EN 13329 cannot be detected technically in the measurement of standard particle boards with an adhesive share of less than 12% by weight of the dry particle board; this edge swelling is too high. Differently, in the waterproof particle board according to the invention with an adhesive share greater than 12% by weight of the dry particle board, the edge swelling is only 3% to 4%. Waterproof particle boards of different sizes are used. In the following examples, usually the upper side and optionally the lower side are provided with a coating, and the edges of the waterproof particle board are optionally also provided with a coating. As long as the adhesive is used in connection with the coating of the waterproof particle board, this adhesive is also referred to as "synthetic resin", especially in connection with the examples.

[0047] Example 1:

[0048] A load-bearing board with a paper laminate structure is pressed as Figure 1 described. On the upper side 1a of the waterproof particle board 1 (specification: (length × width × thickness) 2800 × 2070 × 22 mm), a decorative paper 2 and a covering layer 3 thereon are placed. The optionally used backing layer 4 is optionally placed under the lower side 1b of the particle board 1, and this stack of pressings consisting of three or four layers is pressed in a short-cycle press. The covering layer 3, the decorative paper 1, and the optionally used backing layer 4 are each used as synthetic resin-impregnated papers, which will be described in more detail below. This produces a coated waterproof particle board 1, which has a higher impact resistance than, for example, the same coated standard particle board P2 used as a furniture board. The waterproof particle board coated according to this example can be used in areas with high mechanical loads (horizontal application). The impact resistance test according to section 5.13 of DIN EN 14323-07 / 2017 using large spheres gives a value of 1600 mm. The test of the standard particle board P2 with the same coating gives a value of 1200 mm. According to DIN EN 14322 (February 2022 edition), both boards (not only the waterproof particle board used according to the invention but also the standard particle board P2) reach grade 4 (> 350 revolutions) in terms of abrasion resistance.

[0049] For Example 1, a decorative paper with a total weight of 110 to 200 g / m 2 is used, that is, a synthetic resin-impregnated paper, having

[0050] - a decorative base paper with a weight of 50 to 90 g / m 2 weight, having

[0051] - Impregnation carried out before or after printing with a synthetic resin based, for example, on urea resin or melamine resin or a mixture of these two resins, where the synthetic resin is provided in liquid form or as a solid, in particular in powder form. Subsequently, the synthetic resin is dried but not yet hardened. The synthetic resin has thus not yet chemically reacted or polymerized until the end. However, it is no longer sticky after drying. The synthetic resin is used in an amount of 60 g / m 2 to 110 g / m 2 . The total weight of the paper impregnated with the synthetic resin is obtained here and also in the further description of this specification from the weight of the paper and the weight of the synthetic resin used, and is measured after drying and before the synthetic resin hardens.

[0052] In addition, a covering layer with a total weight of 120 to 400 g / m 2 , also known as synthetic resin-impregnated paper, is used, based on

[0053] - a base paper with a weight of 25 g / m 2 to 50 g / m 2

[0054] - impregnated with a synthetic resin based on melamine resin, which is provided in aqueous form or as a solid, in particular in powder form, and which is present in a weight of 85 g / m 2 to 320 g / m 2 after drying.

[0055] Finally, optionally, a backing layer is used as synthetic resin-impregnated paper with a total weight of 150 g / m 2 to 240 g / m 2 , based on

[0056] - a base paper with a weight of 70 g / m 2 to 120 g / m 2

[0057] - impregnated with a synthetic resin which is here, for example, based on urea and / or melamine resin or a mixture consisting of these two resins, and which is provided in aqueous form or as a solid, in particular in powder form. The synthetic resin is used in an amount of 80 g / m 2 to 120 g / m 2 measured after drying but before hardening.

[0058] The paper is impregnated with synthetic resin by pulling the paper through an impregnation bath with liquid synthetic resin, wherein the paper is infiltrated with synthetic resin or a mixture of synthetic resins and the excess synthetic resin is removed, for example peeled off, after passing through the bath. Then the paper impregnated in this way is dried, taking care to avoid the final reaction of the synthetic resin, i.e., hardening. Usually, after drying, the impregnating agent has a residual humidity of 5% to 6% of VC (VC = volatile compounds). Alternatively or optionally, after infiltrating the paper with liquid synthetic resin, powdered synthetic resin is applied to the paper, typically in a sprinkling manner. When synthetic resin-impregnated paper is mentioned in the present invention, this refers to paper that has been infiltrated with synthetic resin, for example as described above.

[0059] The further manufacture of the coating on the waterproof particle board 1 is carried out by producing a stack of pressings, which stack has, from top to bottom, a cover layer 3 as synthetic resin-impregnated paper, a decorative paper 2 as synthetic resin-impregnated paper, a waterproof particle board 1 and optionally a backing layer 4 as synthetic resin-impregnated paper. Then the stack of pressings is pressed into a laminate in a short-cycle hot press, wherein the short-cycle press has an upper pressing plate acting on the cover layer 3, and wherein,

[0060] - under the action of an increased pressure of at least 25 kg / cm 2 and at an elevated temperature of, for example, 200 °C,

[0061] - and a pressing time from 6 seconds to 30 seconds

[0062] - a laminated structure is produced, the surface of which optionally has a surface structure (so-called "pattern pressing") optionally adapted to the decoration.

[0063] The stack of pressings is heated in the press to first liquefy the synthetic resin and then chemically harden it, where it solidifies upon cooling after the press. The structure is pressed into the liquefied synthetic resin in Example 1 and fixed by the hardening of the synthetic resin. When using synthetic resin-impregnated paper, lacquer, veneer or film, especially a metal film or a plastic film, surface embossing is a common treatment.

[0064] Furthermore, optionally, after pressing, a single-layer or multi-layer lacquer layer can be provided on the cover layer 3, especially in order to set surface properties such as gloss, high gloss or surface roughness, or in order to provide fingerprint resistance. The lacquer is preferably provided as a UV lacquer, for example as an acrylic lacquer or as a polyurethane lacquer, typically provided as a UV-cured or radiation-cured lacquer, usually provided in two to three layers, where, preferably when applying multiple lacquer layers, the already applied layer is dried after each lacquer layer is applied. After the last lacquer layer is applied, complete hardening of the lacquer layer is carried out. The adhesion of the lacquer layer to the cover layer 3 can optionally be improved by applying a primer to the cover layer 3 before applying the lacquer.

[0065] Example 1 thus describes a waterproof particle board 1 on which a double coating, each consisting of a layer of synthetic resin-impregnated paper, is provided on the upper side 1a of the particle board 1. Optionally, synthetic resin-impregnated paper may also be provided on the lower side 1b. According to a further variant of this embodiment, optionally after applying a primer that improves the adhesion of the paint to the synthetic resin-impregnated paper, one or more paint layers may also be provided on the upper side 1a on the synthetic resin-impregnated paper.

[0066] The usability of the waterproof particle board 1 is improved by this surface coating. Apart from the optionally provided structure, the coating provides a smooth and high-strength surface. Thus, the surface of the upper side 1a can be better cared for and better protected against external influences. In addition, the edge swelling is minimal.

[0067] Example 2:

[0068] A load-bearing board with a paper laminate structure is pressed, such as Figure 2 described, on the upper side 1a and the lower side 1b of the waterproof particle board 1 (dimensions: 2800×2070×25 mm), decorative paper 2 and a covering layer 2 are respectively laid on both sides, and such a stack of five-layer pressings is pressed in a short-cycle press. The covering layer 3 and the decorative paper 2 are each used as synthetic resin-impregnated paper. This produces a coated waterproof particle board 1 that has a higher impact resistance and lower swelling than the same structure with a standard particle board P2. The two-sided coated waterproof particle board 1 manufactured according to the invention can be used in areas with high mechanical loads and high water absorption loads (vertical applications). Here, for example, it may relate to the construction of bathroom furniture or kitchen furniture, or to the expansion of kitchens, bathrooms, and dressing rooms in humid areas or the interior expansion of ships, especially when the waterproof particle board is additionally equipped to be non-flammable. The impact resistance test according to section 5.13 of DIN EN 14323-07 / 2017 using large spheres gives a value of 1600 mm. The test of the standard particle board P2 with the same coating gives a value of 1200 mm. Both boards reach grade 4 in terms of abrasion resistance (> 350 revolutions)

[0069] For Example 2, decorative paper 2 for the upper and lower parts with a total weight of 110 to 200 g / m 2 is used as synthetic resin-impregnated paper, based on

[0070] - decorative base paper with a weight of 50 to 90 g / m 2 weight, having

[0071] - Impregnation carried out before or after printing using a synthetic resin such as based on urea resin or melamine resin or a mixture of these two resins, wherein the synthetic resin is provided in liquid form or as a solid, in particular in powder form. Subsequently, the synthetic resin is dried but not yet hardened until it is present in a weight of 60 g / m 2 to 110 g / m 2 .

[0072] Furthermore, an upper covering layer and a lower covering layer are each used as papers impregnated with a synthetic resin with a total weight of 120 to 400 g / m 2 based on a base paper with a weight of 25 g / m 2 to 50 g / m 2 impregnated with a synthetic resin such as based on melamine resin, which is provided in aqueous form or as a solid, in particular in powder form, and which is present in a weight of 85 g / m 2 to 320 g / m 2 after drying.

[0073] The further manufacture of the coating on the waterproof particle board 1 is carried out by producing a stack of pressings, which stack has, from above and below, an upper covering layer 3 as a paper impregnated with a synthetic resin, an upper decorative paper 2 as a paper impregnated with a synthetic resin, and the waterproof particle board 1, as well as a lower decorative paper 2 and a lower covering layer 3. In a short-cycle hot press, the stack of pressings consisting of five layers is pressed into a laminate, wherein the short-cycle press has an upper pressing plate acting on the upper covering layer 3, and wherein,

[0074] - under the action of an increased pressure of at least 25 kg / cm 2 and at an elevated temperature of, for example, 200 °C,

[0075] - and a pressing time from 6 seconds to 30 seconds

[0076] - a laminated structure is produced, the surface of which optionally has a surface structure optionally adapted to the decoration (so-called "pattern embossing").

[0077] The waterproof particle board 1 coated on both sides produced in this way can be used, for example, especially in vertical applications, such as as partition elements or cabinet wall panels. It has particular strength and can (unlike standard particle board P2) be used in damp and wet spaces, or also in difficult climatic conditions, such as areas with high air humidity, such as bathrooms or saunas, laundries or laundrettes.

[0078] Example 3:

[0079] Laminating CPL / HPL

[0080] As Figure 3As described, the coated waterproof particle board 1 (specification: 2800×600×28 / 38 mm) has a profile 5 milled on the edge, which is exemplarily implemented as a rounded portion facing the lower side 1b. Such a particle board 1 is also called a slat and is used, for example, as a working board in kitchens, workshops or laboratories.

[0081] A thin laminate (continuous pressure laminate CPL or high-pressure laminate HPL) with a thickness of, for example, 0.5 mm here is pasted on the upper side 1a, and a backing layer 4 is pasted on the lower side 1b with an adhesive 6, here for example a hot melt. The thin laminate 7 consists of a cover layer, a decorative paper and a plurality of base papers arranged below the decorative paper. The decorative paper and the cover layer are respectively impregnated with melamine resin. The lower papers are impregnated either with a melamine / phenol mixed resin (when using CPL) or with phenolic resin (when using HPL). These thin laminates 7 are manufactured either on a continuous press (CPL) or on a multi-layer press (HPL). The application amount of the hot melt is about 100 g / m 2 .

[0082] As the backing layer 4, either a thin laminate 7, optionally a plastic film or a paper, is used on the lower side 1b of the waterproof particle board 1, and the paper is bonded to the particle board 1 with the same amount of adhesive as the thin laminate 7.

[0083] Pressing is carried out in a laminator at about 120 °C under a pressure of 300 N / cm 2 and a pressing duration of about 1 second. In the first pressing process, the backing layer 4 is first pasted onto the lower side 1b of the particle board 1, and in the second pressing process, the thin laminate 7 is then pasted onto the upper side 1a of the particle board 1 respectively.

[0084] After the adhesive has cooled, the thin laminate 7 pasted onto the upper side 1a of the particle board 1 is fixed on the milled edge in the following way: on a post-forming mechanism, PVAc adhesive is applied to the formed edge, and the thin laminate 7 is formed around the milled profile 5 and fixed on the edge with PVAc adhesive. Therefore, in this embodiment, the upper side 1a, the lower side 1b and the edge of the waterproof particle board 1 are all coated.

[0085] On the waterproof particle board 1 and in the comparative sample of the standard particle board P2 coated with a laminate with a thickness of 0.8 mm, the impact resistance was tested according to DIN EN 438-2019-03, Tl.2 test 20. Here, the laminated laminate 7 on the waterproof particle board 1, although having a significantly smaller thickness (0.5 mm compared to 0.8 mm), also reaches an impact resistance value of 22 N. In addition, the surface stability in the post-formed area of the waterproof particle board 1 is significantly better due to the higher original density. In addition, it is obvious that a narrower post-formed radius can also be achieved with a thinner laminate. The design flexibility and the scope of application of the waterproof particle board 1 coated by lamination have been significantly expanded compared to the standard particle board P2 with the same coating method.

[0086] Example 4:

[0087] Pressed bearing plate floor with a paper laminate structure On the upper side 1a of the waterproof particle board 1 (specification: 2800×2070×10 mm), there are placed a decorative paper 2 and a covering layer 3 (for example, a covering layer of usage class 34 according to DIN EN 13329); an optional backing layer 4 is placed below the lower side 1a of the particle board 1. This structure corresponds to Figure 1 the schematic diagram in. This four-layer stack of pressings is pressed in a short-cycle press. The covering layer 3, the decorative paper 2, and the optional backing layer 4 are each used as synthetic resin-impregnated papers.

[0088] This produces the coated waterproof particle board 1, which has a higher impact strength than the same structure of the standard particle board P2 with the same coating. The impact resistance test according to section 5.13 of DIN EN 14323-07 / 2017 using a large sphere gives a value of 1800 mm. The test of the standard particle board P2 with the same coating gives a value of 1200 mm. Both boards reach usage class 34 in terms of abrasion resistance (DIN EN 13329: "Laminated floors - Elements with a surface layer based on aminoplastic thermosetting resins", August 2016 edition).

[0089] For Example 4, a decorative paper 2 with a total weight of 110 to 200 g / m 2 was used as the synthetic resin-impregnated paper, based on

[0090] - a decorative base paper with a weight of 50 to 90 g / m 2 weight, having

[0091] - Impregnation carried out before or after printing using a synthetic resin such as based on urea resin or melamine resin or a mixture of these two resins, wherein the synthetic resin is provided in liquid form or as a solid, especially in powder form. Subsequently, the synthetic resin is dried but not yet hardened until it is present in a weight of 60 g / m 2 to 110 g / m 2 and exists.

[0092] In addition, a cover layer 3 is used as paper impregnated with a synthetic resin having a total weight of 120 to 400 g / m 2 based on

[0093] - Base paper with a weight of 25 g / m 2 to 50 g / m 2

[0094] - Impregnated with a synthetic resin such as based on melamine resin, the synthetic resin being provided in a water-containing form or as a solid, especially in powder form, and after drying, it is present in a weight of 85 g / m 2 to 320 g / m 2 and exists, and

[0095] - Optionally, a corundum content of about 30 g / m 2 is introduced, which is either added to the synthetic resin for impregnation or sprinkled onto the synthetic resin provided on the paper during or after the impregnation process. When grade 34 of use is to be achieved, corundum must be used.

[0096] Finally, optionally, a backing layer 4 is used as paper impregnated with a synthetic resin having a total weight of 150 g / m 2 to 240 g / m 2 based on

[0097] - Base paper with a weight of 70 g / m 2 to 120 g / m 2

[0098] - Impregnated with a synthetic resin such as based on urea resin and / or melamine resin or a mixture of the two resins, which is water-containing or provided as a solid, especially in powder form and subsequently, optionally, after drying, it is present in a weight of 80 to 120 g / m 2 and exists.

[0099] ​​The coating on the waterproof particleboard 1 is further produced by producing a press stack which, from top to bottom, has a cover layer 3 as a synthetic resin-impregnated paper with an optional addition of corundum, a decorative paper 2 as a synthetic resin-impregnated paper, a waterproof particleboard 1 and an optional backing layer 4 as a synthetic resin-impregnated paper. The press stack is pressed into a laminate in a short-cycle hot press, wherein the short-cycle press has an upper pressing plate acting on the cover layer and wherein,

[0100] - At least 25kg / cm 2 Under the effect of increased pressure and at an elevated temperature of, for example, 200°C,

[0101] - And the pressing time from 6 seconds to 30 seconds

[0102] - A laminate structure is produced, the surface of which optionally has a surface structure which is optionally adapted to the decoration (so-called "embossing").

[0103] Optionally, one or more lacquer layers can also be applied to the cover layer 3, in which structures are optionally embossed, in particular in order to set the surface properties, for example the gloss, high gloss or matte of the surface or to provide anti-fingerprint properties. The lacquer is preferably applied as a UV lacquer or radiation-curing lacquer, for example as a lacquer based on acrylates and / or methacrylates, usually in two to three layers, wherein preferably when applying multiple layers of lacquer, the already applied layers are dried after each lacquer layer is applied. After the last lacquer layer has been applied, complete curing of the lacquer layer takes place. The adhesion of the lacquer layer to the cover layer can optionally be improved by applying a primer to the cover layer before applying the lacquer.

[0104] After coating, the waterproof particleboard 1 is cut by a multi-blade saw to produce smaller boards, so-called raw sizes, which are then provided with profiles on the edges that can be connected without adhesive, so that these boards can be used as floor elements or wall elements or ceiling elements. Compared with standard particleboards P2, the laminate floor produced according to this embodiment using waterproof particleboards 1 has a significantly better milling effect.

[0105] Floor panels produced in this way from the waterproof particleboard 1 coated, in contrast to floor panels produced from standard particleboards P2, can also be used in wet environments due to the dimensional stability resulting from the greatly reduced expansion properties.

[0106] Embodiment 5:

[0107] Carrier sheet with liquid cover layer including direct printing of decoration

[0108] Manufacture floor panels (DIN EN 15668: Laminated floors - Direct printed elements with synthetic resin surface layer, November 2021 edition) with a liquid-applied coating made of synthetic resin using thin waterproof particle board 1 (specification: 2800×2070×10 mm). Coat the waterproof particle board 1 with liquid synthetic resin, where a primer layer is installed on the particle board in advance and then a decorative part is installed on the primer layer by direct printing. Subsequently, at least two layers of liquid synthetic resin layers are applied on the direct printing, where optionally, for example, by sprinkling or nozzle, corundum is added to the non-outer layer made of synthetic resin. Corundum can also be mixed into the liquid synthetic resin.

[0109] The waterproof particle board 1 coated in this way is hardened in a short-cycle press (KT press). Specifically, the coating of Example 5 is applied in the following steps:

[0110] · Prime the upper side of the waterproof particle board with a synthetic resin, such as melamine resin, urea resin, or a mixture of these two synthetic resins, applied in liquid form as a primer layer in an amount of about 20 g / m 2 to 30 g / m 2 (solid content: melamine resin: about 65 wt%, urea resin: about 50 wt%). This application is carried out by roll coating.

[0111] · Dry the resin to a moisture content of about 20% of the primer layer with a drying device, such as a circulating air dryer or an infrared radiator.

[0112] · Optionally: Apply a colored primer in liquid form in an amount of 5 g / m 2 to 10 g / m 2 multiple times (for example, a mixture composed of pigments and binders, such as casein or zein) (solid content: about 50 wt%), where intermediate drying is carried out with a drying device, such as by circulating air or an infrared radiator. Usually, two to six layers of colored primer are applied. The application of the colored primer is also achieved by roll coating. Here, white pigments (titanium dioxide, calcium carbonate, barium sulfate) are preferably used.

[0113] · Optionally: Apply a liquid primer, such as an isocyanate primer in an amount of about 10 g / m 2 to 20 g / m 2 to improve the adhesion of the subsequently applied layers. The primer is dried with a circulating air dryer or an infrared radiator. It also works with roll coating for application.

[0114] · Print on the upper side of the waterproof particle board, optionally improving the adhesion of the upper side with a primer. The printing method can be analog printing (such as roll printing) or digital printing (such as inkjet printing using water-based ink). Then, if necessary, dry the ink using a drying device, such as a circulating air dryer.

[0115] · Install a sealing layer by means of roll pressing. The liquid sealing layer consists of a synthetic resin, preferably a melamine resin (solid content approximately 65% by weight), and optionally glass beads (glass bead diameter: 70 μm to 90 μm) mixed therein. The application amount of the synthetic resin is 20 g / m 2 -30 g / m 2 . The glass bead content accounts for 10% to 20% of the weight of the liquid synthetic resin. Subsequently,

[0116] · Dry but do not harden the synthetic resin using a circulating air dryer or by means of an infrared radiator, followed by cooling and temporary storage.

[0117] · Apply the liquid synthetic resin, such as melamine resin, in the roll pressing application at a rate of approximately 60 g / m 2 to 80 g / m 2 (solid content approximately 65% by weight) to the side of the printed and already sealed board with a layer of synthetic resin.

[0118] · Optionally: Sprinkle corundum onto the undried liquid melamine resin using a spreading device. The corundum has a particle size of F180 to F240 according to the FEPA standard. Depending on the desired abrasion resistance, the amount is usually 20 g / m 2 and 50 g / m 2 of corundum.

[0119] · Apply the synthetic resin, such as melamine resin, on the upper side of the board in an amount of 20 g / m 2 to 40 g / m 2 multiple times (preferably up to 5 layers). The melamine resin has the above-mentioned solid content. When applying the last layer, optionally add glass beads (diameter: 70 to 90 μm) to the synthetic resin in an amount of 10% to 20% of the amount of the liquid synthetic resin. Conduct intermediate drying using a drying device, such as a circulating air dryer or an infrared radiator, after each application.

[0120] · Corresponding to the coating on the upper side, it is also possible to optionally apply a liquid synthetic resin, such as melamine resin, on the back side of the particle board. This can also be achieved using a roll pressing application device, and the application of the liquid synthetic resin can reach, for example, 100 g / m 2 to 140 g / m 2The total amount. The melamine resin has the above-mentioned common solid content. In addition, dyes or pigments can also be included in the synthetic resin. Here, intermediate drying needs to be carried out either with the help of a circulating air dryer or with the help of an infrared radiator.

[0121] · Finally, in a short-cycle hot press, as already described for Example 1, a waterproof particle board coated with a dry but not yet hardened coating on one or both sides is pressed into a laminated structure with a hardened synthetic resin.

[0122] - Under the action of an increased pressure of at least 25 kg / cm 2 and at an elevated temperature of 200 °C,

[0123] - And a pressing time of 6 to 30 seconds

[0124] - Optionally, in the case of constructing a surface structure above the decorative element; optionally adapted to each other, as a so-called "matched embossing".

[0125] The impact resistance (large ball) determined on the coated waterproof particle board of this embodiment is 1400 mm. The test on the comparative product with the standard particle board P2 only obtained an impact resistance of 900 mm. Therefore, the product with the waterproof particle board reaches usage grade 33, while the comparative product with the standard particle board P2 only reaches usage grade 32.

[0126] If it is desired to further process the coated waterproof particle board, for example, into a board with profiled edges, this further processing can be carried out in the same manner as described in Example 4. The coated waterproof particle board or a board made from the coated particle board can also be used in the same manner. The characteristics of the bearing board coated according to Example 5 are comparable to those of the coated particle board according to Example 1.

[0127] Example 6

[0128] Carrier flooring with pressed paper laminate (elastic laminate) Decorative paper 2 and cover layer 2 are placed on the upper side 1a of a waterproof particle board 1 (format: 2800×2070×10 mm); an optional backing layer 4 is placed under the lower side 1b of the particle board 1 and the three- or four-layer pressed stack is pressed in a short-cycle press. The cover layer 3, the decorative paper 2 and the optional backing layer 4 are each used as synthetic resin-impregnated paper. In this case, a polyurethane dispersion is used as the synthetic resin, either PUR CHEM WB-420 or PUR CHEM LC-380 as a softer-touch variant, each with a crosslinker PUR-CHEM AD-200R and optionally with a release agent such as WB-475; all of the above products are produced by the manufacturer PurChem Systems Inc. This results in a coated waterproof particle board 1 that has a higher impact resistance than the same structure with a standard particle board P2.

[0129] The impact resistance test according to DIN EN 14354: 2017-11, Appendix C, states that the EC3 class is achieved if the test object achieves an impact stress (elasticity) of more than 1400 mm. Section 5.13 of DIN EN 14323-07 / 2017 using a large ball yields a value of 1500 mm for the waterproof particleboard 1 according to the invention. The test of the standard particleboard P2 with the same coating yields a value of 1200 mm.

[0130] For Example 6, a total weight of 110 to 200 g / m 2 Decorative paper as synthetic resin impregnated paper, based on

[0131] -With 50 to 90 g / m 2 Weight of decorative base paper, with

[0132] - Impregnation with a synthetic resin based on the above-mentioned polyurethane dispersion (solids content: about 50% by weight), carried out before or after printing. The synthetic resin is then dried, but not yet hardened, until it has a density of 60 g / m 2 Up to 110g / m 2 The weight exists.

[0133] In addition, the cover layer is used as a total weight of 103 to 400 g / m 2 Synthetic resin impregnated paper, based on

[0134] -Weight: 18g / m 2 Up to 50g / m 2 The base paper

[0135] - Impregnation is applied using a synthetic resin based on the above-mentioned PU dispersion (solid content: approximately 55% by weight),

[0136] and after drying but before hardening, it is present in a weight of 85 g / m 2 to 320 g / m 2 and optionally, there is a corundum content of approximately 30 g / m2, which is introduced by adding to the dispersion or by spreading during or after the impregnation of the base paper. Alternatively, the corundum may already be included in the base paper.

[0137] Finally, optionally, a backing layer is used as a paper impregnated with a synthetic resin with a total weight of 80 g / m 2 to 240 g / m 2 based on

[0138] - a base paper with a weight of 70 g / m 2 to 120 g / m 2

[0139] - impregnated with a synthetic resin based on the above-mentioned PU dispersion (solid content: approximately 55% by weight), which is installed in a liquid state and which is present in a weight of 80 g / m 2 to 120 g / m 2 after drying but before hardening.

[0140] The further preparation of the coating on the workpiece is completed by preparing a press stack, which successively includes from top to bottom: a cover layer as an impregnated synthetic resin paper, a decorative paper as an impregnated synthetic resin paper, a waterproof particleboard, and optionally a backing layer as an impregnated synthetic resin paper. The press stack is pressed into a laminated structure in a short-cycle hot press, where the short-cycle press has an upper pressing plate acting on the cover layer, and where,

[0141] - under the action of an increased pressure of at least 25 kg / cm 2 and at an elevated temperature of, for example, 200 °C,

[0142] - and a pressing time from 6 seconds to 30 seconds, and

[0143] - a laminated structure is manufactured, the surface of which optionally has a surface structure (so-called "pattern embossing") optionally adapted to the decoration.

[0144] Optionally, one or more paint layers can be installed on the cover layer, and structures are embossed in the cover layer as described in Example 1.

[0145] This embodiment of the coated and waterproof particle board also has a very low edge swelling, where the board also shrinks back to its original thickness after drying. After applying the coating, smaller panels, so-called original fixed sizes, are produced from the waterproof particle board on a multi-blade saw, and these panels can then be further processed into floor elements with glue-free profiles. Compared to the standard particle board P2, the laminated floor made of waterproof particle board has significantly better milling results.

[0146] Example 7:

[0147] Waterproof particle board with a veneer surface:

[0148] The starting materials will be explained below. As an alternative to the backing layer made of paper (Alternative I), a backing layer made of veneer (Alternative II) can also be used. The veneer used for the backing layer can have the same or different, especially simpler quality, as the veneer used for the upper side.

[0149] Veneer on the upper side:

[0150] Thickness: 0.6 mm

[0151] Species: Oak

[0152] Paper: Synthetic resin-impregnated kraft paper

[0153] Paper weight: 25 g / m 2

[0154] Resin application amount: 600%

[0155] Synthetic resin: Melamine resin

[0156] Waterproof particle board: Thickness 7.8 mm

[0157] Backing layer:

[0158] I Paper: Synthetic resin-impregnated kraft paper

[0159] Paper weight: 25 g / m 2

[0160] Resin application amount: 600%

[0161] Synthetic resin: Melamine resin

[0162] II Veneer thickness 0.6 mm

[0163] Species: Poplar

[0164] The above data are exemplary and can vary depending on the veneer used, such as veneer thickness, veneer humidity, or veneer density, or the type of wood of the veneer.

[0165] Manufacture of synthetic resin-impregnated paper

[0166] The paper is guided through a bath having a liquid synthetic resin, here a melamine resin. In this bath, the paper is impregnated or infiltrated with the liquid synthetic resin. After impregnation or infiltration, the excess synthetic resin is removed by a doctor blade, so that there is only a layer of synthetic resin on the upper side of the paper now infiltrated with the synthetic resin. The upper side of the synthetic resin-infiltrated paper consists of resin, here melamine resin. The amount of synthetic resin used can vary. However, the amount is preferably determined in such a way that, upon subsequent pressing, the veneer to be installed is penetrated by the synthetic resin liquefied in the press to at least 2 / 3 of the veneer thickness. Further preferably, the veneer is compressed in the press. Thus, according to a particularly preferred embodiment, at least 2 / 3, advantageously completely, of the veneer is impregnated with synthetic resin at the end of the pressing process. Thereby, the swelling and shrinkage of the veneer are largely reduced.

[0167] The paper thus infiltrated is dried to a residual humidity of, for example, 5% to 6%. 25 g / m 2 The resin application of the heavy paper is 600% relative to the paper weight. Drying is carried out, for example, in a tunnel dryer, where the paper is passed over by hot air nozzles from the upper and lower sides and thus dried, wherein, however, the synthetic resin does not harden. The dried synthetic resin-infiltrated paper can now be stored until it is used.

[0168] The synthetic resin-infiltrated paper for the backing layer can be manufactured in the same way as described above. The synthetic resin-infiltrated paper for the counterpart is also dried until, for example, a VC value of 6%. The veneer for the backing layer can be prepared and subsequently processed in the same way as the veneer for the upper side.

[0169] Manufacture of veneer sheet

[0170] The backing layer, the carrier plate, the synthetic resin-infiltrated paper, and the veneer are laminated into a stack of pressings, wherein the synthetic resin-infiltrated paper has its upper side with the synthetic resin facing the upper side of the waterproof particleboard and its lower side facing the veneer. The stack of pressings is placed in a KT press (short-cycle press) and pressed there at a temperature of 180 °C and a pressure p = 30 N / mm 2 during a pressing time of 60 seconds.

[0171] Pressing can be carried out with a simple smooth pressing plate. However, in this embodiment, alternatively, a structured pressing plate can also be used as a structure-imparting member. For example, a pressing plate having a wood structure can be used. The wood structure of the pressing plate can be seen in the veneer, which may be different from the wood structure of the veneer. There is no visible melamine resin layer constructed on the upper side of the veneer. Then the coated waterproof particleboard is optionally coated with 50 g / m 2 to 100 g / m 2of UV paint with an application amount or 20 g / m 2 to 40 g / m 2 of UV oil is used for surface finishing. Here, the application amount conforms to the desired usage level. Especially when a higher usage level with improved abrasion resistance is to be achieved, corundum can optionally be introduced into the UV paint.

[0172] In the above manner, the veneer surface of the upper surface can be prominently presented or designed in a way that was not achievable before. The back of the waterproof particle board can remain as it is, especially in the case where veneer is applied according to Scheme II; or, an impact sound insulation layer can also be subsequently superimposed on the back.

[0173] The method according to the present invention provides Veneer sheet better design possibilities and thus better usage characteristics.

[0174] Example 8

[0175] A coating with hot melt

[0176] Another alternative for coating the surface of the particle board according to the present invention is to apply a hot melt, such as polyurethane hot melt (PU hot melt), polyester hot melt, polyamide hot melt, polyolefin hot melt or polyacetal hot melt, such as vinyl acetate hot melt. Generally, thermoplastics, especially post-crosslinked thermoplastics, can be used as hot melts. The hot melt can be applied in a single layer or multiple layers, and preferably in multiple layers. The hot melt can have the same additives as those used for installing plastics mentioned above. The hot melt can be used uncolored or colored, where the share of pigments can be at most 30% by weight. The hot melt can be transparent or opaque. The hot melt can be applied over the entire surface or in sections on the surface of the workpiece according to the present invention. The hot melt is applied in an amount of 10 g / m 2 to 300 g / m 2 preferably in an amount of 50 g / m 2 to 200 g / m 2 After the hot melt is applied at a temperature of 80°C to 160°C, usually 100°C to 130°C, it is fixed by cooling. The hot melt can be roll-coated, knife-coated or spray-coated. The layer of the already applied and preferably already cooled hot melt can be printed especially with water-based or UV-curable printing inks or inks. The hot melt coating is often combined with a paint layer, usually with the final outer paint layer forming the outer side of the coated board-shaped workpiece. In addition, the hot melt is also often used to fix other coating materials, especially in combination with laminates, such as continuous pressure laminates (CPL) or high-pressure laminates (HPL). However, in this case, the hot melt should not be regarded as a surface coating, but as an adhesive for other coating materials.

[0177] Specifically, such a coating can be implemented as follows, for example:

[0178] · Place a white-colored polyurethane hot melt (PU hot melt) on a carrier plate

[0179] · (Application amount: approximately 60 g / m 2 to 120 g / m 2 ), which is applied in a liquid state at a temperature of 120 °C to the surface or upper side of the carrier plate by means of a roller application device. The carrier plate serves as the workpiece here, and if necessary, the still liquid hot melt is smoothed in a second application device. The share of the pigment in the PU formulation is approximately 20% by weight.

[0180] · Cool the surface

[0181] · Print a white liquid ink layer with a digital printing press (application amount: 10 g / m 2 to 20 g / m 2 ), and then optionally dry the ink layer, for example, by a circulating air dryer.

[0182] · Use a digital printing press to directly print a decorative part on the surface with water-based ink or UV ink, and then optionally dry the ink, for example, by a circulating air dryer.

[0183] · Place another uncolored PU hot melt layer by means of a roller application device (application amount: 50 g / m 2 ).

[0184] · Sprinkle corundum grains into the hot melt by means of a spreading device (particle size: F180 to F240, according to the FEPA standard) (application amount: between 10 g / m 2 and 50 g / m 2 ), depending on the required abrasion resistance.

[0185] · Apply another PU layer by means of a roller application device (application amount: approximately 30 g / m 2 ).

[0186] · Cool the surface

[0187] · Paint the surface with a UV paint containing approximately 30 g / m2 of corundum-based nanoparticles to improve scratch resistance (paint application amount: 10 g / m2 to 40 g / m2), and then perform UV curing.

[0188] The coated particle board can also be cut into boards and provided with edge profiles as described for Example 1. The application of the particle board coated according to Example 3 and optionally the panels manufactured therefrom is also as described in Example 1.

[0189] List of reference numerals

[0190] 1 Waterproof particle board

[0191] 1a Upper side

[0192] 1b Lower side

[0193] 2 Decorative paper

[0194] 3 Overlay

[0195] 4 Backing layer

[0196] 5 Profile

[0197] 6 Adhesive

[0198] 7 Thin laminate.

Claims

1. A method for coating a waterproof particle board, wherein, the particle board has chips made of wood with a length of 0.5 mm to 50 mm, a width of 0.1 mm to 20 mm and a thickness of 0.05 mm to 2 mm, and has at least one binder with a binder share of at least 12% by weight relative to the dry wood. The method has the steps: - providing a particle board having an upper side, a lower side and side faces, - applying a coating, - installing a decorative element, - optionally structuring the coating on at least one section of the upper side, the lower side or the side faces respectively, and - optionally hardening the coating.

2. The method according to claim 1, characterized in that, the coating is selected from the group of thermosetting synthetic resins, such as melamine resins, polyurethane resins, paints, such as UV-curable paints or hot melts.

3. The method according to claim 1 or 2, characterized in that, the coating is applied in the form of a liquid coating, a granular coating, paper and / or film, veneer, laminate and / or felt.

4. The method according to any one of the preceding claims, characterized in that, the coating is single-layer or multi-layer.

5. The method according to any one of the preceding claims, characterized in that, the coating is hardened under the action of pressure and / or temperature.

6. The method according to any one of claims 1 to 4, characterized in that, the coating is cured by radiation, especially by electron-curing radiation or UV radiation.

7. The method according to any one of claims 1 to 4, characterized in that, the coating is fixed to the waterproof particle board by an adhesive.

8. The method according to any one of the preceding claims, characterized in that, the structuring is produced by mechanical means or chemical means.

9. The method according to any one of the preceding claims, characterized in that, the coating is provided with fillers, especially corundum or glass beads.

10. A particle board, manufactured from the following materials, which have wood cellulose chips with a length of 0.5 mm to 50 mm, a width of 0.1 mm to 20 mm and a thickness of 0.05 mm to 2 mm and a binder of more than 12% by weight, wherein, the plate-shaped workpiece has an upper side, a lower side and side faces, characterized in that the upper side, the lower side or at least one side face is at least sectionally provided with a coating, which has a decorative part and optionally has a structure.

11. The particle board according to claim 9, characterized in that, a primer is applied between the workpiece and the coating or on the coating.

12. The particle board according to claim 9 or 10, characterized in that, an adhesive is applied between the workpiece and the coating.

13. The particle board according to any one of claims 9 to 11, characterized in that, at least two opposite side faces have profiles.

14. An application of a particle board with a coating according to claims 10 to 13 as a floor covering, a wall covering, a ceiling covering.

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