Laminate with synchronous structure

Abstract

The present invention relates to a process for manufacturing laminates, in particular continuously pressed laminates (CPL), which can be used, for example, as surface laminates for manufacturing workbenches or floor panels. The treatment includes providing a facing sheet and a support structure, and pressing the facing sheet and the support structure in a CPL treatment.

Description

[0001] This application is a divisional application of Chinese patent application No. PCT / EP2017 / 084805, Chinese application No. 201780097938.1, filed on December 29, 2017, entitled "Laminated Body with Synchronous Structure". Technical Field

[0002] The present invention relates to a method for manufacturing laminates, particularly continuously pressed laminates, a method for manufacturing panels, and the laminates and panels manufactured accordingly. Background Technology

[0003] Modern technologies have enabled the production of a wide range of materials suitable for panel manufacturing, such as wall, ceiling, and floor panels. To produce such panels, a so-called finish foil can be applied to a substrate made of, for example, MDF or HDF, during a coating process. The finish foil can ultimately form the surface of the resulting panel. The finish foil can be impregnated and / or painted decorative paper. In the prior art, the substrate is typically an MDF (medium-density fiberboard) or HDF (high-density fiberboard) board.

[0004] Generally, panels manufactured in this way are unsuitable for use as workbenches, doors, or furniture panels due to their insufficient surface abrasion resistance. This is particularly disadvantageous for workbenches, for example, those exposed to a certain amount of material stress during daily use. Consequently, doors or workbenches made with such panels exhibit higher surface abrasion when intended for everyday use and therefore wear out more quickly. As a result, using conventional finishing sheets to coat MDF or HDF boards is unsuitable for normal and heavy-duty products such as workbenches.

[0005] Furthermore, the surface of conventional finishing sheets, and especially their optical and / or tactile appearance, cannot be altered during the coating process used to produce panels. As a result, in this respect, panel manufacturers ultimately rely on the manufacturing processes of the finishing sheet suppliers, which have little or no impact on the appearance of the finished product or panel.

[0006] Further negative effects become apparent when veneer sheets are applied to a substrate such as MDF or HDF boards, particularly noticeable in terms of surface unevenness in the resulting product or panel. Typically, conventional veneer sheets are bonded to the substrate using an adhesive dissolved in water. Due to the moisture content of the adhesive, a so-called "orange peel" effect forms on the substrate, caused by partial swelling of fibers or debris from the substrate (e.g., MDF or HDF). Combined with the relatively thin underlayer of the conventional veneer sheet (which is typically less than 0.1 mm), this results in a highly uneven surface on the finished product.

[0007] Therefore, one object of the present invention is to at least partially overcome the aforementioned disadvantages. A particular object of the present invention is to provide a process that enables the production of more robust or wear-resistant laminates or panels (e.g., for use as workbench or floor panels). Furthermore, it provides the possibility of influencing the appearance of the finished product, laminate, or panel.

[0008] These and other objectives, as will be noticed when reading the following description or as may be recognized by those skilled in the art, can be achieved by means of the process for manufacturing a laminate as described in claim 1, the laminate as described in claim 17 or 19, the panel as described in claim 22, and the process for manufacturing a panel as described in claim 26. Summary of the Invention

[0009] This invention relates to methods for producing laminates, particularly continuously pressed laminates. Such continuously pressed laminates are also known as CPLs (continuous pressure laminates). These are laminates produced from two or more layers in a continuous process. The laminate can be produced in the form of panels or as rolled articles, and can then be used, for example, to coat surfaces to manufacture panels. In the following, the terms "CPL," "continuously pressed laminate," and "CPL laminate" are used synonymously. The use of these synonyms does not imply any additional limitations on the terms, such as in terms of the hardness or form of the material.

[0010] The process includes providing a finishing sheet. The finishing sheet can also be referred to as a top layer. The finishing sheet preferably has a thickness of 0.05 mm to 0.5 mm, more preferably between 0.06 mm and 0.3 mm, more preferably between 0.07 mm and 0.2 mm, more preferably between 0.08 mm and 0.15 mm, and most preferably between 0.09 mm and 0.1 mm. In particular, the thickness of the finishing sheet is preferably less than 0.1 mm. In one form of the invention, conventional finishing sheets can be used.

[0011] The method also includes providing a support structure, wherein the support structure is provided with phenolic resin. The support structure may comprise or consist of several individual layers. The support structure particularly may comprise one or more paper layers. The paper layers may be used as paperboard layers. One or all of these layers preferably comprise phenolic resin. The thickness of the support structure preferably has a thickness from 0.1 mm to 2 mm, more preferably from 0.2 mm to 1.5 mm, more preferably from 0.3 mm to 1.2 mm, more preferably from 0.4 mm to 1.0 mm, and more preferably from 0.5 mm to 0.8 mm.

[0012] This process also includes pressing veneer sheets and support structures in the CPL process. For example, in the CPL process, these laminations can be laminated into an endless sheet in a continuous process using, for example, a dual-belt press with double heating on both sides. The dual-belt press may include structured belts (i.e., belts with structured / embossed surfaces). The pressing pressure can be lower than the pressure used to produce so-called HPL sheets (High Pressure Laminate).

[0013] By combining veneer sheets and support structures with phenolic resin, it is advantageous to produce materials or laminates that are far superior to other materials in terms of abrasion resistance. Therefore, the resulting materials or laminates allow for the production of panels, for example, with a very wide range of applications. Compared to conventional veneer sheets, the resulting materials or laminates are characterized by a larger layer thickness, which ultimately leads to increased abrasion resistance. This means that the laminate can be used as a surface material for manufacturing products such as workbenches, where the products therefore show only slight signs of wear and damage even under normal daily use.

[0014] The resulting CPL laminate preferably has a thickness of 0.1 mm to 2 mm, more preferably from 0.2 mm to 1.5 mm, more preferably from 0.3 mm to 1.2 mm, more preferably from 0.4 mm to 1.0 mm, and even more preferably from 0.5 mm to 0.8 mm. Therefore, the resulting laminate is characterized by a thickness that is preferably significantly greater than the thickness of the facing sheet. However, other thicknesses are also possible. Furthermore, in some designs, the laminate may also be provided with a cover film, for example, to improve light resistance, moisture resistance, or heat resistance, thereby preferably arranging the facing sheet between such a cover film and the support structure. The laminate is preferably polished on one side.

[0015] The veneer sheet can be a commercially available veneer sheet with any structure. For example, it can have an ultra-matte surface finish. Preferably, the veneer sheet is provided with a decorative pattern and a three-dimensional structure. Preferably, the veneer sheet is printed with a decorative pattern and coated with a varnish to create a synchronous structure corresponding to the printed pattern. Preferably, the veneer sheet is then hardened by means of electron beam radiation. Thus, the surface of the veneer sheet can be provided with a (tactile) structure spatially related to the printed pattern. This structure is also referred to in the art as synchronous holes. Therefore, the three-dimensional structure is preferably synchronous with the decorative pattern. In particular, the decorative pattern preferably mimics a wood surface. Thus, the three-dimensional structure also mimics a wood surface. Therefore, the surface of the resulting laminate looks and feels like wood. For example, on the printed knot holes, the generated (surface) structure will contain circular or elliptical tactile structures at the location of the printed knot holes. The difference between the optical pattern and the tactile structure on the resulting laminate is preferably less than 3 mm, preferably less than 2 mm, preferably less than 1 mm, preferably less than 0.5 mm, preferably less than 0.2 mm, and preferably less than 0.1 mm. Ideally, there is no deviation. As a result, laminates can be produced without any displacement between the printed image and the embossing or structure. For example, for a true "wood imprint" of the laminate, the surface structure of the finished laminate perfectly matches the printed image or pattern.

[0016] Preferably, the provided embossed structure is pressed during the CPL process. Thus, for example, an embossed structure can be provided, which is pressed together with the facing sheet and the support structure. The embossed structure can be provided in the CPL process using a structured belt of a dual-belt press. In particular, the embossed structure is preferably a textured pressing belt or structured belt, textured paper, or textured pressing plate. For example, the embossed structure can be prepared by an etching process. The embossed structure can be set with a predetermined gloss level. Thus, for example, the gloss level of the resulting laminate can be changed by three gloss levels. By pressing the facing sheet against the support structure against the embossed structure, the gloss level and the appearance of the resulting surface can be significantly affected. Therefore, the laminate manufacturer no longer relies entirely on the supplier of the facing sheet, but can change its appearance during the production of the laminate. This also allows the structure, pattern, and gloss level of the laminate to be adjusted as synchronously as possible, so that there are no or only minor deviations between the structure, pattern, and gloss level.

[0017] The phenolic resin is preferably a phenol-formaldehyde resin. The phenolic resin preferably contains a curing agent, such that the phenolic resin has a turbidity time of 3.0 to 7.0 minutes, more preferably 3.5 to 6.5 minutes, more preferably 4.0 to 5.5 minutes, more preferably 4.45 to 5.20 minutes, and most preferably 4.7 to 4.9 minutes at 100°C. This allows for the corresponding adjustment of the reactivity of the phenolic resin to achieve optimal curing and resistance of the laminate.

[0018] The resin content in the support structure is preferably 70% to 99% by weight, more preferably 80% to 95% by weight, and most preferably 87% to 93% by weight. The weight refers to the total weight of the support structure. This allows for the production of wear-resistant laminates.

[0019] Providing a support structure preferably involves impregnating the support structure with phenolic resin. The support structure is preferably impregnated with phenolic resin. After proper drying, the volatile components of the impregnated material are preferably between 6.5% and 9.0%, more preferably between 7.0% and 8.5%, and most preferably between 7.5% and 8.0%. This allows the laminate to cure optimally.

[0020] Preferably, the compression is performed in the CPL process at a pressure of 10 bar to 100 bar, more preferably from 15 bar to 80 bar, more preferably from 20 bar to 60 bar, more preferably from 25 bar to 45 bar, and most preferably from 30 bar to 35 bar.

[0021] Preferably, the pressing in the CPL process is carried out at a temperature of 120°C to 200°C, more preferably from 140°C to 180°C, more preferably from 150°C to 170°C, and most preferably at about 165°C.

[0022] Furthermore, the present invention relates to a laminate manufactured according to one of the methods described above. The advantage of this laminate is that it has a greater layer thickness than standard commercially available finishing sheets, resulting in high abrasion resistance. Therefore, the laminate preferably has a thickness of 0.1 mm to 2 mm, more preferably from 0.2 mm to 1.5 mm, more preferably from 0.3 mm to 1.2 mm, more preferably from 0.4 mm to 1.0 mm, and more preferably from 0.5 mm to 0.8 mm. Furthermore, the color or pattern, structure, and / or gloss of the laminate should preferably be synchronized as described above.

[0023] Furthermore, the present invention relates to a laminate, and more particularly to a continuously pressed laminate. The laminate has a facing sheet and a support structure, wherein the support structure is provided with phenolic resin. The facing sheet and the support structure are pressed together. The laminate also has the thickness described above and provides high abrasion resistance.

[0024] Furthermore, the present invention relates to a panel, and more particularly to a wall, ceiling, or floor panel. The panel can also be designed as a door or furniture panel, and can be used as a vertical surface, for example, in furniture. The panel can also be designed as a workbench. The panel has a support board and a laminate according to the above embodiments. For example, HDF, MDF, or particleboard can be used as the support board. The resulting panel has high surface resistance and therefore a long service life. In particular, compared to panels where conventional veneer sheets are directly pressed onto a support board, the use of the above-described laminate results in a flat and uniform surface of the panel, avoiding the "orange peel" effect.

[0025] The panel is preferably designed as a floor panel. The panel preferably has a connecting element designed for reliable connection with at least one other panel (similar or identical in design), whereby the connection occurs without adhesive. Due to the improved surface properties, it is advantageous to produce a uniform and durable floor covering.

[0026] Furthermore, the present invention relates to a method for producing panels, particularly panels as described above. The method includes providing a laminate as described above, and providing a support plate, particularly HDF, MDF, or particleboard. The process also includes applying, particularly laminating, the laminate onto the support plate.

[0027] Furthermore, the present invention relates to the use of the aforementioned laminate for manufacturing workbenches or vertical surfaces (such as furniture front panels or doors). Due to its high abrasion resistance, this laminate can be used, for example, on workbenches compared to commercially available finishing sheets that are unsuitable for such applications. Production in the CPL process can also result in a very smooth and uniform surface of the finished material.

[0028] The increased abrasion resistance of one of the above-described laminates or panels, or laminates or panels manufactured according to the above-described treatment, can be characterized according to EN 438. In this case, the laminate preferably exhibits a ball impact value of at least 5 N, more preferably at least 7 N, more preferably at least 8 N, and even more preferably at least 9 N under the action of a ball. Similarly, the laminate can preferably exhibit a ball impact value of up to 15 N, more preferably at least 12 N under the impact load of a ball. Additionally, the laminate can preferably exhibit a ball impact value of up to 15 N, more preferably at least 12 N under the action of a ball. The panel should have a ball impact value of at least 15 N, more preferably at least 17 N, more preferably at least 19 N, more preferably at least 21 N, and even more preferably at least 22 N under the impact load of a ball. Likewise, the laminate can preferably exhibit a ball impact value of up to 30 N, preferably up to 25 N, under the impact load of a ball. Attached Figure Description

[0029] The invention is described in more detail below with reference to the accompanying drawings. Like elements have like reference numerals.

[0030] Figure 1 A method for manufacturing a continuously pressed laminate according to an embodiment of the present invention is illustrated schematically; and Figure 2 The configuration of a panel according to another embodiment of the present invention is illustrated schematically. Detailed Implementation

[0031] Figure 1 A process for producing a continuously pressed laminate 10 according to an embodiment of the invention is illustrated. A dual-belt press is provided having two structured belts 20, 21 arranged opposite to each other. These structured belts 20, 21 guide the individual layers in the CPL process to ultimately form a CPL laminate or laminate 10. The structured belts 20, 21 may comprise structured belts (made of etched and chrome-plated steel) or textured paper (painted and embossed paper) or the like.

[0032] The material or layer fed to the structured strips 20, 21 includes a veneer sheet 11, a support structure 12, and, in the illustrated embodiment, a dry sheet 13 made of sodium kraft paper. The support structure 12 is arranged between the veneer sheet 11 and the dry sheet 13.

[0033] exist Figure 1 In the illustrated embodiment, the support structure 12 comprises four separate paper layers. However, those skilled in the art will understand that in other embodiments, more or fewer paper layers or other materials may be used to form the support structure 12. The paper layers of the support structure 12 contain phenolic resin. For this purpose, each paper layer is impregnated accordingly. A decisive factor is the reactivity of the phenolic resin, which is set to impregnate each hardener within a tolerance range of preferably 4.45 to 5.20 minutes (turbidity time measured at 100°C). Furthermore, the resin content in the impregnated material is set between 87% and 93% (based on paper weight). The volatile components of the impregnated material after drying are maintained within a tolerance of 7.5% to 8.0%.

[0034] The veneer 11 has a printed image that mimics the surface of wood. Furthermore, the veneer 11 has a (tactile) structure synchronized with the printed image. Therefore, this structure matches the printed image, so that in the finished laminate 10, the tactile imprint matches the optical imprint. Alternatively, the veneer 11 may also have different surface finishes, such as an ultra-matte surface.

[0035] In the CPL process, structured strips 20 and 21 are used to press the finishing sheet 11, the support structure 12, and the dry sheet 13. This is carried out at a pressure of 35 to 50 bar and a temperature of 165°C.

[0036] In a particular embodiment of the invention, at least one of the structured strips 20, 21 is provided with a textured surface. This textured surface gives the surface of the resulting laminate a corresponding surface finish, thereby allowing adjustment or alteration of the gloss of the finished laminate. In another embodiment, during the CPL process, the finishing sheet 11 can also be pressed against the structured strip or textured paper to affect the gloss and thus the appearance of the resulting surface. Therefore, it is advantageous to achieve synchronization of the printed image, structure / pores, and gloss of the finished laminate. Summer rings in the printed image can exhibit higher gloss compared to coarser winter rings in the printed image.

[0037] Figure 2 A panel 30 according to another embodiment of the invention is shown. The panel comprises a carrier plate 40 made of MDF or HDF. A CPL laminate or laminate 10 is applied to or laminated onto the carrier plate 40. The laminate 10 is preferably constructed by means of the above reference. Figure 1 The laminate produced by the manufacturing method described above. Therefore, the laminate 10, rather than a standard commercially available veneer sheet, is applied to the support panel 40. Because the laminate 10 has higher abrasion resistance, the surface of the finished panel 30 also has higher abrasion resistance. This means that the panel 30 can be advantageously used not only as a floor, ceiling, or wall panel, but also as a workbench or as a vertical surface such as a furniture front panel or door.

[0038] Furthermore, the surface of panel 30 has a uniform and smooth structure, which is due to the manufacturing process and also due to the increased thickness of the laminate 10 compared to a conventional decorative sheet 11.

[0039] The laminate 10 produced according to the present invention preferably has a ball impact strength of 9N under the impact stress of a small ball, while the correspondingly manufactured panel has a value of 22N.

[0040] In a preferred embodiment, panel 30 can be used as a floor panel. For this purpose, panel 30 includes suitable connecting elements on its sides, which allow this panel 30 to be joined with other panel shapes without the need for adhesive. Due to the advantageous surface quality of panel 30, these panels are very suitable for interconnection.

[0041] List of reference numerals in the attached diagram: 10-layer laminate 11 decorative sheets 12 Support Structure 13 dry tablets 20 and 21 structured zones 30 panels 40 bearing plate.

Claims

1. A method for producing a laminate (10), particularly a continuously pressed laminate (CPL), said laminate (10) to be applied onto a carrier plate (40) to produce a finished panel (30), said laminate (10) having a thickness of 0.1 mm to 2 mm, said method comprising the following steps: A decorative sheet (11) is provided, wherein the decorative sheet (11) is provided with a decorative pattern and a three-dimensional structure, wherein the three-dimensional structure is synchronized with the decorative pattern; A support structure (12) is provided, wherein the support structure (12) comprises one or more individual layers and is provided with phenolic resin by impregnating the one or more individual layers with a phenolic resin impregnating material; and In the CPL process, the support structure (12) and the decorative sheet (11) are pressed together. Wherein, the phenolic resin is phenol-formaldehyde resin; The phenolic resin includes a curing agent, which causes the phenolic resin to have a turbidity time of 3.0 to 7.0 minutes at 100 degrees Celsius. The resin content in the support structure (12) is 87% to 93% by weight; The volatile matter content of the impregnated material after drying is between 6.5% and 9.0%.

2. The method according to claim 1, wherein, The pattern mimics the surface of wood.

3. The method according to claim 1 or 2, wherein, In the CPL process, the material is pressed against the provided embossing structure.

4. The method according to claim 3, characterized in that, The embossing structure is a textured tape, textured paper, or textured plate.

5. The method according to any one of claims 1 to 4, wherein, The phenolic resin includes a curing agent, such that the phenolic resin has a turbidity time of 3.5 to 6.5 minutes, preferably 4.0 to 5.5 minutes, more preferably 4.45 to 5.20 minutes, and most preferably 4.7 to 4.9 minutes at 100 degrees Celsius.

6. The method according to any one of claims 1 to 5, wherein, The support structure (12) comprises one or more layers of paper.

7. The method according to claim 6, wherein, The volatile matter content of the dried impregnated material is between 7.0% and 8.5%, and preferably between 7.5% and 8.0%.

8. The method according to any one of claims 1 to 7, wherein, The compression occurs at a pressure of 10 to 100 bar, preferably from 15 to 80 bar, more preferably from 20 to 60 bar, more preferably from 25 to 45 bar, and most preferably from 30 to 35 bar.

9. The method according to any one of claims 1 to 8, wherein, The pressing is carried out at a temperature of 120 to 200 degrees Celsius, preferably 140 to 180 degrees Celsius, more preferably 150 to 170 degrees Celsius, and most preferably at about 165 degrees Celsius.

10. The method according to any one of claims 1 to 9, characterized in that, The pressing is performed using a dual-belt press, which preferably includes two structured belts (20, 21).

11. The method according to any one of claims 1 to 10, characterized in that, It also includes providing a dry sheet (13), wherein the pressing includes compressing the decorative sheet (11) with the support structure (12) and the dry sheet (13) in the CPL process.

12. A laminate (10) manufactured by the method according to any one of claims 1 to 11.

13. The laminate (10) according to claim 12, wherein the laminate (10) has a thickness of 0.2 to 1.5 mm, preferably 0.3 to 1.2 mm, more preferably 0.4 to 1.0 mm and most preferably 0.5 to 0.8 mm.

14. A laminate (10), particularly a continuously pressed laminate (CPL), said laminate (10) to be applied to a carrier plate (40) to produce a finished panel (30), comprising: Decorative sheet (11); and Support structure (12), wherein the support structure (12) comprises one or more individual layers and is provided with phenolic resin by impregnating the one or more individual layers with a phenolic resin impregnating material; The decorative sheet (11) is provided with a decorative pattern and a three-dimensional structure, wherein the three-dimensional structure is synchronized with the decorative pattern; The decorative sheet (11) is pressed together with the support structure (12) to form the laminate, and The laminate (10) has a thickness of 0.1 to 2.0 mm, more preferably 0.2 to 1.5 mm, more preferably 0.3 to 1.2 mm, more preferably 0.4 to 1.0 mm, and most preferably 0.5 to 0.8 mm. The resin content in the support structure (12) is 87% to 93% by weight.

15. The laminate (10) according to any one of claims 12 to 14, wherein, According to EN 438, the laminate (10) has a ball impact value of at least 5N, more preferably at least 7N, more preferably at least 8N and more preferably at least 9N under the impact load of a small ball.

16. The laminate (10) according to any one of claims 12 to 15, wherein, According to EN 438, the laminate (10) has a ball impact value of not more than 15N, more preferably not more than 12N, under the impact load of a small ball.

17. A panel (30), particularly a wall, ceiling, floor, door or furniture panel or workbench, comprising a support plate (40) and a laminate (10) attached to said support plate according to any one of claims 12 to 16.

18. The panel (30) according to claim 17, wherein the panel (30) is designed as a floor panel, the floor panel including a connecting element adapted to be coupled to another similar panel (30) in shape without adhesive.

19. The panel (30) according to claim 17 or 18, wherein, According to EN 438, the panel (30) has a ball impact value of at least 15N, more preferably at least 17N, more preferably at least 19N, more preferably at least 21N and more preferably at least 22N under the impact load of a small ball.

20. The panel (30) according to any one of claims 17 to 19, wherein, According to EN 438, the panel (30) has a ball impact value of up to 30 N, more preferably up to 25 N, under the impact load of a small ball.

21. A process for manufacturing a panel (30), particularly a panel (30) according to any one of claims 17 to 20: Provide a laminate (10) according to any one of claims 12 to 16; Provide a support board (40), particularly HDF, MDF, or particleboard; and The laminate (10) is applied, in particular, laminated onto the support plate (40).

Images