Composition for sealing and coating square and / or bevelled edges of wood material panels

Abstract

The present invention relates to a composition for sealing and coating square and / or bevelled edges of wood material panels, comprising a) at least one edge stain coating material and b) at least one additive composed of at least one compound of general formula (I) R1 aSiX1 (4-a), where X1 is alkoxy, aryloxy, acyloxy, and R1 is an organic moiety selected from the group comprising alkyl, aryl, cycloalkyl, which can be interrupted by -O- or -NH-, and where R1 comprises at least one functional group Q1, which is selected from a group containing an acryl group, an acryloxy group, a methacryl group, a methacryloxy group, a cyano group, an isocyano group and an epoxide group, and a is 0, 1, 2, 3, in particular is 0 or 1, at least one compound of general formula (II) R2 bSiX2 (4-b), where X2 is H or alkoxy, aryloxy, acyloxy, R2 is a non-hydrolyzable organic moiety R2 selected from the group comprising alkyl and aryl, and b is 1, 2, 3, or 4, and at least one aqueous polymer dispersion, characterized by a viscosity (measured according to EN ISO 2431:2011, 21°C) with a flow time between 20 and 100 seconds, preferably between 30 and 80 seconds, particularly preferably between 35 and 60 seconds over a time period of at least 30 minutes, preferably at least 60 minutes, particularly preferably at least 120 minutes.

Description

[0001] Composition for sealing and coating edges and / or bevels of wood-based panels

[0002] The present invention relates to a composition for coating and sealing edges and / or bevels of wood-based panels, the use of this composition and wood-based panels with this composition.

[0003] Description

[0004] Floor panels with tongue-and-groove profiles on the side edges for installation in panel assemblies, such as laminate flooring, are widely used and conventionally known. The tongue-and-groove profiles enable easy installation of floor panels into floor coverings. Such floor coverings can be made of wood fiberboard or plastic panels, for example. The floor panels are usually provided with a decorative layer and an abrasion-resistant surface layer.

[0005] Laminate flooring with so-called V-joints has proven very popular. These V-joints are created when installing floorboards with bevels. The bevels are angled milled grooves on the side edges of the floorboards, which are then painted with colored varnishes and give the laminate flooring a visual appearance similar to parquet.

[0006] It is well known that laminate flooring, especially after switching from tongue-and-groove glued elements to glueless installation, has a weak zone at the transition between the elements when it comes to moisture attack or the occurrence of moisture damage. This damage can occur due to direct exposure to moisture, over-care, etc. However, this problem is offset by the very simple and quick installation of this flooring with so-called click profiles. It can be assumed that well over 90% of laminate flooring today is manufactured with a click profile.

[0007] To mitigate moisture damage, various strategies have been used individually or in combination. The simplest way to prevent moisture penetration into the profile is to use the tightest possible fit in the tongue and groove joint. However, this can make it difficult to join the elements or lead to damage. This method also has the disadvantage that if water penetrates the tongue and groove area, the wood-based substrate will swell normally.

[0008] This effect can be enhanced by creating a compaction at the transition between the elements during direct coating using a special press plate. This is described in WO 2017 / 072657 A1. However, this only delays swelling and does not completely prevent it.

[0009] Another option is sealing the profile with hydrophobic agents. WO 2006 / 038867 describes the use of waxes to coat the edges, with at least partial penetration of the wax into the wood-based material being observed. EP 903451 A2 describes the use of diisocyanate diphenylmethane to treat the edges, which readily penetrates the wood-based material. WO 2008 / 078181 A1, in turn, uses a fluorinated polymer, e.g., perfluoroalkyl methacrylic copolymer, as the coating agent, with the layer-forming material being solid at room temperature.

[0010] The disadvantage of these known sealants is that they often migrate into the wood substrate during application, thus minimizing the waterproofing effect. However, this can also occur afterward, so the effect is gradually lost during use.

[0011] Another option is the use of swell-modified wood-based panels, which use higher-quality glues (melamine-reinforced UF glues, PMDI, etc.) during production. Swelling can also be reduced by increasing the amount of glue. However, these options are the least cost-effective, as increased glue quantities and / or higher-quality glues lead to a significant increase in the cost of the panels. They are also considered rather disadvantageous from a recycling perspective.

[0012] Of the measures described, only the use of higher-quality adhesives leads to a reduction in the swelling of the boards. The others merely delay the penetration of water into the profile area.

[0013] Accordingly, the known measures have various disadvantages. For example, the improvement in source protection is too small, some of the proposed measures cannot withstand real-world conditions, and the resulting effects are temporary.

[0014] The present invention was therefore based on the object of overcoming the aforementioned disadvantages. In particular, the technical object of the invention was to produce a laminate flooring that, by sealing the bevel area, creates a watertight profile.

[0015] The aim is to make it possible to utilize existing system technology. In particular, this should enable the system to pass the so-called NALFA test (24-hour water immersion test, ISO 4760). This test aims to prevent water penetration into the profile through appropriate measures.

[0016] This approach has the advantage that it eliminates the need to use wood fiberboard (MDF / HDF = fiberboard / fiberboard with increased bulk density) with increased adhesive quantities or higher-quality adhesive systems as the substrate, as ideally, water does not penetrate the board. The system used should, if possible, not require solvents. Furthermore, no chemicals that are chemically aggressive or highly polluting should be used. Reactive systems (e.g., isocyanates), which can come into contact with the product surface through overspray and react with it, should also be avoided.

[0017] This object is achieved according to the invention by a composition having the features of claim 1.

[0018] Accordingly, a composition for sealing and coating edges and / or bevels of wood-based panels is provided, the composition comprising the following: a) At least one bevel paint, and b) At least one additive comprising at least one compound of the general formula (I)

[0019] R 1 aSiX 1 (4 -a) (I), where

[0020] - X 1 Alkoxy, aryloxy, acyloxy, and

[0021] - R 1 an organic radical is selected from the group comprising alkyl, aryl, cycloalkyl, which may be interrupted by -O- or -NH-, and

[0022] - where R 1 has at least one functional group Qi selected from a group containing an acrylic, acryloxy, methacrylic, methacryloxy, cyano, isocyano and epoxy group, and

[0023] - a = 0, 1, 2, 3, in particular 0 or 1,

[0024] - at least one compound of general formula (II)

[0025] R 2 bSiX 2 (4 -b) (II), where

[0026] - X 2 H or alkoxy, aryloxy, acyloxy,

[0027] - R 2 a non-hydrolyzable organic residue R 2 is selected from the group comprising alkyl and aryl, and

[0028] - b = 1 , 2, 3, or 4, and

[0029] - at least one aqueous polymer dispersion.

[0030] The composition according to the invention has a viscosity (measured according to EN ISO 2431:2011, Paints and varnishes - Determination of flow time using flow cups, 21 °C) with a flow time between 20 and 100 see, preferably between 30 and 80 see, particularly preferably between 35 and 60 see over a period of at least 30 minutes, preferably of at least 60 minutes, particularly preferably of at least 120 minutes.

[0031] The composition according to the invention is defined by its specific viscosity. The measurement method used here to determine viscosity according to EN ISO 2431:2011 requires the use of a measuring cup, with the viscosity being determined indirectly by the flow time of the composition from this measuring cup.

[0032] In further preferred embodiments, the viscosity can have the stated flow times of up to at least 24 h, 36 h, or 72 h. A significant advantage of the present composition is that it is stable over a longer period (at least up to 72 h) and does not gel. This enables reliable reproducibility and usability of the composition according to the invention.

[0033] Although a composition for edge sealing comprising silanes and a polymer dispersion is known from EP 3 597 706 B1, it is unstable and gels after a short time. The differences in viscosity and stability arise from the manufacturing process.

[0034] A bevel paint and a sealant are combined after the floor panels have been profiled. This mixture or composition is applied to the panel edges and / or the milled bevel using the existing application unit (application wheel or vacuum cleaner). Once dry, this mixture effectively seals the profile and bevel areas against water penetration. A particular advantage is that it is applied in a combined application, thus avoiding the installation of an additional application unit and additional drying. The components can be mixed immediately before application to the edge and / or bevel. This also allows for easy changes to the components during ongoing production. This also applies to color changes.

[0035] The additive used in the present composition comprises a crosslinking component, the compound of general formula (I), and a hydrophobic component, the compound of general formula (II). The crosslinking, hydrophilic component of formula (I) enables, on the one hand, a bonding of the compound to the wood fibers, particularly via the free -OH groups (present or formed by hydrolysis of, for example, alkoxy groups), and, on the other hand, the formation of a network. The hydrophobic component of formula (II) - formed, for example, from the alkyl groups of the radical R 2 - forms a water-repellent barrier. This prevents water from diffusing through the network of the formed coating.

[0036] The additive used in this composition fills the pores present in the wood fiberboard and envelops the wood fibers, thereby "sealing" them. On the other hand, the use of hydrophobic modifications creates a "hydrophobic effect" on the remaining pores and the still uncoated wood fibers. To achieve the highest possible flexibility of the coating, the silane compounds are mixed with a suitable aqueous polymer dispersion. The polymers used have functional groups that are compatible with the inorganic silane matrix. Therefore, a coating with a high degree of crosslinking can be produced even at low temperatures.

[0037] This composition can be used for any board and adhesive system. The composition reduces swelling in wood fiberboards, regardless of the adhesive system used, varying porosity, or board thickness. The swelling-reducing effect of this composition has been demonstrated for HDF boards and particleboards with urea-formaldehyde glue (UF glue), melamine-urea-formaldehyde glue (MUF glue), or polyurethane-based glue (PMDI glue), as well as for boards made of wood-plastic composites (WPC).

[0038] The composition according to the invention thus offers several advantages. For example, it significantly reduces swelling of the edges, the composition does not penetrate or migrate into the boards, the composition can be used with any board and adhesive system, and only relatively small application quantities are required. In particular, the composition according to the invention prevents moisture penetration into the V-joints formed after the installation of floor panels.

[0039] In one embodiment, the amount of additive in the present composition is between 20 and 80 wt%, preferably between 25 and 50 wt%.

[0040] In a further embodiment, the at least one bevel color used in the present composition comprises color pigments and at least one solvent or suspending agent, in particular an aqueous solvent or suspending agent. Carbon black, iron oxides, titanium dioxide, and / or organic pigments are used as color pigments. Suitable solvents or suspending agents are melamine resin-formaldehyde resins or acrylates, with aqueous mixtures thereof being preferred. In one embodiment, the bevel color comprises color pigment, acrylate, and water.

[0041] The rest X 1 is advantageously selected from a group containing C 1-6 -alkoxy, in particular methoxy, ethoxy, n-propoxy and butoxy, C 1- -aryloxy, in particular phenoxy, C 2-7 -acyloxy, in particular acetoxy or propionoxy, and the radical X 2is advantageously selected from a group containing H, Ci-6-alkoxy, in particular methoxy, ethoxy, n-propoxy and butoxy, Ce- -aryloxy, in particular phenoxy, C2-7-acyloxy, in particular

[0042] Acetoxy or propionoxy,

[0043] The organic residue R 1 is preferably selected from a group comprising C1-C10-alkyl, in particular C5-C25-alkyl, C2-C8-alkenyl, C5-C8-cycloalkyl and C5-C8-cycloalkenyl. In one embodiment, the organic R 1 selected from the group containing methyl, ethyl, n-propyl, isopropyl, n-butyl, s-butyl, t-butyl, pentyl, hexyl, cyclohexyl, vinyl, 1-propenyl, 2-propenyl, butenyl, acetylenyl, propargyl, butadienyl or cyclohexadienyl, preferably methyl, ethyl, propyl or vinyl.

[0044] In one embodiment of the present composition, the at least one functional group Q 1selected from a group containing epoxy, methacrylic, methacryloxy, cyano and / or isocyano groups. The functional group Q 1 can therefore advantageously have a residue with a double bond or an epoxy group, which can be activated and polymerized by means of UV radiation.

[0045] In a variant of the present composition, compounds of the general formula (I) according to R 1 a Six 1 (4-a), in particular R 1 Six 1 3, with a functional group Q 1 be selected from methacryloxypropyltrimethoxysilane (MPTS), aminoethylaminopropyltrimethoxysilane, silanes with an epoxy functionalization such as glycidyloxypropyltriethoxysilane, or silanes with a vinyl functionalization such as vinyltrimethoxysilane.

[0046] As described, the residue R 1 at least one functional group Q 1 In addition, the remainder R1 also substituted with other residues

[0047] The term “substituted” refers to the substitution of one or more atoms, usually H atoms, by one or more of the following substituents, preferably by one or two of the following substituents: halogen, hydroxy, protected hydroxy, oxo, protected oxo, C8-cycloalkyl, bicyclic alkyl, phenyl, naphthyl, amino, protected amino, monosubstituted amino, protected monosubstituted amino, disubstituted amino, guanidino, protected guanidino, a heterocyclic ring, a substituted heterocyclic ring, imidazolyl, indolyl, pyrrolidinyl, C1-C12-alkoxy, C1-C12-acyl, C1-C12-acyloxy, acryloyloxy, nitro, carboxy, protected carboxy, carbamoyl, cyano, methylsulfonylamino, thiol, C1-C12-alkylthio and C1-C12-alkylthio. -Alkylsulfonyl. The substituted alkyl, aryl, and alkenyl groups can be substituted once or twice, preferably with the same or different substituents.

[0048] The term "aryl," as used herein, refers to aromatic hydrocarbons, for example, phenyl, benzyl, naphthyl, or anthryl. Substituted aryl groups are aryl groups that are substituted, as defined above, with one or more substituents as defined above.

[0049] The term “cycloalkyl” includes the groups cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and cycloheptyl.

[0050] In a particularly preferred variant of the present composition, the compound of general formula (I) corresponds to the formula SiX 1 4, where the remainder X 1 Alkoxy, especially methoxy, ethoxy, n-propoxy, or i-propoxy. Tetramethoxysilane and tetraethoxysilane are particularly preferred crosslinkers.

[0051] In a further embodiment of the present composition, the non-hydrolyzable organic radical R 2the compound according to formula (II) selected from a group comprising Ci-Cis-alkyl, in particular Ci-Cw-alkyl, and Ce-Cw-aryl. These may be unsubstituted or substituted with another hydrophobic group.

[0052] It is preferred if the non-hydrolyzable organic radical R 2 is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, s-butyl, t-butyl, pentyl, hexyl, heptyl, octyl, nonyl, cyclohexyl, phenyl, and naphthyl. Methyl, ethyl, propyl, octyl, or phenyl radicals are particularly preferred.

[0053] In the context of the present invention, the term “non-hydrolyzable organic residue” is understood to mean an organic residue which, in the presence of water, does not lead to the formation of an OH group or NH2 group linked to the Si atom.

[0054] The compound of formula (II) may in particular comprise one of the following formulas:

[0055] - R 2Six 2 3 with R 2 as a C1-C10 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, or as a C6-C10 aryl group, preferably phenyl and with X 2 as alkoxy, in particular methoxy, ethoxy, n-propoxy, or i-propoxy, such as octyltriethoxysilane, phenyltriethoxysilane. In one variant of the present composition, one compound of general formula (I) and one compound of general formula (II) are used as additives.

[0056] In a further variant of the present composition, however, at least one compound of general formula (I) and at least two, preferably at least three, compounds of general formula (II) may also be present in the additive. Any combination is conceivable here.

[0057] The additive used in this composition may contain the following combinations:

[0058] - at least one SiX 14, where the remainder X 1 Alkoxy, especially methoxy, ethoxy, n-propoxy or i-propoxy, and at least one R 2 Six 2 3 with R 2 as a C1-C10 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, or as a C6-C10 aryl group, preferably phenyl and with X 2 as alkoxy, in particular methoxy, ethoxy, n-propoxy or i-propoxy, such as methyltriethoxysilane, octyltriethoxysilane, phenyltriethoxysilane; or

[0059] - at least one SiX 1 4, where the remainder X 1 Alkoxy, especially methoxy, ethoxy, n-propoxy or i-propoxy, and at least one R 2 Six 2 3 with R 2 as a C1-C10 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, such as methyltriethoxysilane, octyltriethoxysilane and at least one R 2 Six 2 3 with R 2 as a C6-C10 aryl group, preferably phenyl and with X 2as alkoxy, especially methoxy, ethoxy, n-propoxy or i-propoxy, such as phenyltriethoxysilane. or

[0060] - at least one SiX 1 4, where the remainder X 1 Alkoxy, especially methoxy, ethoxy, n-propoxy or i-propoxy, and at least two R 2 Six 2 3 with R 2 as a C1 -C10 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, such as methyltriethoxysilane, octyltriethoxysilane and at least one R 2 Six 2 3 with R 2 as a C6-C10 aryl group, preferably phenyl and with X 2 as alkoxy, in particular methoxy, ethoxy, n-propoxy or i-propoxy, such as phenyltriethoxysilane.

[0061] Furthermore, in one variant, the composition may contain tetraethoxysilane as a compound of formula (I) and methyltriethoxysilane and phenyltriethoxysilane as compounds of formula (II). In another variant, the composition may contain tetraethoxysilane as a compound of formula (I) and methyltriethoxysilane, phenyltriethoxysilane, and octyltriethoxysilane as compounds of formula (II).

[0062] In a further embodiment, the compound of general formula (I) is contained in the composition in a molar amount between 0.08 - 0.2 mol, preferably 0.1 - 0.15 mol, particularly preferably 0.1-0.12 mol and the compound of general formula (II) is contained in a molar amount between 0.05 and 0.1 mol, preferably between 0.06 and 0.09 mol, particularly preferably between 0.07 and 0.08 mol.

[0063] The range of the molar amount given for the compound of the general compound (II) can refer to one compound or to the sum of two compounds or three compounds of the general formula (II)

[0064] Thus, in the variant of the composition of tetraethoxysilane as a compound of formula (I) and methyltriethoxysilane and phenyltriethoxysilane as compounds of formula (II), 0.15 mol of tetraethoxysilane and 0.04 mol of methyltriethoxysilane / 0.033 mol of phenyltriethoxysilane may be contained.

[0065] In the other variant of the composition of tetraethoxysilane as a compound of formula (I) and methyltriethoxysilane, phenyltriethoxysilane and octyltriethoxysilane as compounds of formula (II), 0.1 mol of tetraethoxysilane and 0.03 mol of methyltriethoxysilane, / 0.025 mol of phenyltriethoxysilane and 0.043 mol of octyltriethoxysilane may be contained.

[0066] The ratio of the silane compound of formula (I) to the silane compounds of formula (II) is preferably between 1:0.5 and 1:2, particularly preferably between 1:0.75 and 1:1.5, most preferably between 1:1 and 1:1.2.

[0067] In a further embodiment of the present composition, the at least one polymer is selected from the group comprising polyurethanes, epoxy resins; melamine resins, such as melamine-formaldehyde resin, and polyacrylates.

[0068] In the present case, the use of a polyurethane polymer is preferred, wherein the polyurethane polymer is based on aromatic polyisocyanates, in particular polydiphenylmethane diisocyanate (PMDI), toluene diisocyanate (TDI) and / or

[0069] Diphenylmethane diisocyanate (MDI), with PMDI being particularly preferred.

[0070] The polymer is incorporated into the network formed from the silane compounds and gives the composition flexible properties that facilitate application.

[0071] The type of polymer used is preferably matched to the silane compounds used. For example, it is advantageous to use epoxy-modified silanes together with epoxy polymers, and methacrylate-modified silanes together with acrylate polymers.

[0072] In a further embodiment of the present composition, it is also possible to use more than one polymer.

[0073] In a further embodiment, the polymer content in the presently used composition is at least 30 wt%, preferably at least 20 wt%, particularly preferably at least 10 wt%. In one embodiment, the ratio of sol-gel to polymer is between 1:0.1 and 1:0.5, preferably between 1:0.2 and 1:0.4 (based on the solids).

[0074] The solvent content, which is essentially determined by the use of silanes, is between 1 and 15 wt.%, preferably 2 to 13 wt.%, particularly preferably between 4 and 10 wt.%. However, these figures do not initially take into account the solvent content of the polymer used. Solvents are, in particular, water and / or alcohols, preferably ethanol here. The alcohol content can be, for example, < 1%. It is also possible for the present composition to contain exclusively alcohol and little or no water, i.e., the silane compounds and also the polymer dispersion can be used in an alcoholic form.

[0075] In a further embodiment, the present composition can contain inorganic particles, in particular SiO2, Al2O3, ZrO2, TiO2 particles. The particles preferably used here have a size between 2 and 400 nm, preferably between 2 and 100 nm, particularly preferably between 2 and 50 nm. The addition of the inorganic particles increases the solids content of the composition, thereby improving the application behavior of the composition. The addition of inorganic particles also prevents shrinkage and cracking. The inorganic particles can be used in an amount range of 0.1 to 25 wt.%, preferably 5 to 20 wt.%, based on the solids content of the silane material (sol-gel material).

[0076] The additive used in this composition may contain the following combinations:

[0077] - at least one SiX 1 4, where the remainder X 1Alkoxy, especially methoxy, ethoxy, n-propoxy or i-propoxy, and at least one R 2 Six 2 3 with R 2 as an 01-010 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, or as an 06-010 aryl group, preferably phenyl and with X 2 as alkoxy, in particular methoxy, ethoxy, n-propoxy or i-propoxy, such as methyltriethoxysilane, octyltriethoxysilane, phenyltriethoxysilane, polyurethane and optionally SiO2 particles; or

[0078] - at least one SiX 1 4, where the remainder X 1 Alkoxy, especially methoxy, ethoxy, n-propoxy or i-propoxy, and at least one R 2 Six 2 3 with R 2 as 01-010 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, such as methyltriethoxysilane, octyltriethoxysilane and at least one R 2 Six 2 3 with R 2 as 06-010-aryl group, preferably phenyl and with X 2as alkoxy, in particular methoxy, ethoxy, n-propoxy or i-propoxy, such as phenyltriethoxysilane, polyurethane and optionally SiO2 particles, or

[0079] - at least one SiX 1 4, where the remainder X 1 Alkoxy, especially methoxy, ethoxy, n-propoxy or i-propoxy, and at least two R 2 Six 2 3 with R 2 as 01-010 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, such as methyltriethoxysilane, octyltriethoxysilane and at least one R 2 Six 2 3 with R 2 as 06-010-aryl group, preferably phenyl and with X 2 as alkoxy, in particular methoxy, ethoxy, n-propoxy or i-propoxy, such as phenyltriethoxysilane, polyurethane and optionally SiO2 particles.

[0080] A particularly preferred variant of the present composition comprises tetraethoxysilane, methyltriethoxysilane, phenyltriethoxysilane, octyltriethoxysilane and polyurethanes and optionally SiO2 particles.A very particularly preferred variant of the present composition comprises tetraethoxysilane, methyltriethoxysilane, phenyltriethoxysilane, octyltriethoxysilane, polyurethane and SiO2 particles.

[0081] According to a first embodiment, the present composition can be prepared in a process comprising the following steps:

[0082] Providing at least one dispersion A) comprising

[0083] Polymer dispersion and optionally a dispersion of inorganic particles, - providing a solution B) comprising a mixture of at least one compound of the general formula (I), at least one compound of the general formula (II) and at least one catalyst, in particular an acid,

[0084] - Addition of solution B) to dispersion A) and neutralization of the additive mixture (e.g. by addition of a basic compound);

[0085] - separating the aqueous phase of the additive from polymer dispersion, at least one compound of formula (I) and at least one compound of formula (II), and

[0086] Addition of the additive to at least one bevel color.

[0087] The present composition can also be prepared according to a second embodiment in a process comprising the following steps:

[0088] - Providing a solution C) comprising a mixture of at least one compound of the general formula (I), at least one compound of the general formula (II) and at least one polymer dispersion (an ion exchanger);

[0089] - Providing a solution D) comprising at least one compound of the general formula (II) and at least one catalyst, in particular an acid,

[0090] - Stir solution D) into solution C);

[0091] - separating the aqueous phase of the additive from at least one compound of formula (I), at least two compounds of formula (II) and polymer dispersion; and

[0092] Addition of the additive to at least one bevel color.

[0093] Inorganic and / or organic acids suitable as catalysts are selected from a group consisting of phosphoric acid, acetic acid, p-toluenesulfonic acid, hydrochloric acid, formic acid, or sulfuric acid. Ammonium salts such as ammonium sulfate, which react as weak acids, are also suitable. p-toluenesulfonic acid is particularly preferred.

[0094] For subsequent neutralization of the reaction mixture, a basic compound such as ammonia or NaOH is preferably added. This leads to a separation of the aqueous phase containing the binder component from the alcoholic phase (ethanolic phase). The aqueous phase can then be easily separated from the alcoholic phase. If inorganic particles are added to the binder composition, the inorganic particles are preferably used in an amount between 0.1 and 15 wt.%, preferably 0.5 to 10 wt.%, particularly preferably between 1 and 5 wt.%.

[0095] As already mentioned above, the present composition can be used for coating or sealing edges and / or bevels of wood-based panels, in particular WPG, chipboard, HDF or MDF boards.

[0096] The object of the present invention is also achieved by a wood-based panel with the present composition.

[0097] Accordingly, at least one wood-based panel, such as HDF or MDF panel or chipboard, comprises at least one composition according to the invention, with which in particular the edges and / or bevels of the wood-based panel are coated for the purpose of sealing.

[0098] The composition can be applied to the edges and / or bevels of the wood-based panel, e.g. by spraying, rolling or using a vacuum.

[0099] The layer thickness of the composition on the plate edge and / or bevel can be in a range between 10 and 50 pm, preferably between 20 and 40 pm.

[0100] The composition can be applied in liquid form with a quantity between 100 and 200 silane fl. g / m 2 , preferably between 120 and 150 silane fl. g / m 2applied to the board edges and / or bevels. This results in a solids content on the board edge of between 5 and 25 mg / cm 2 , preferably between 10 and 20 mg / cm 2 .

[0101] Wood-based panels, such as particle boards and fiberboards such as MDF and HDF boards, are made from wood chips or wood fibers that are obtained by chipping the wood chips in a chipper or by defibrating the wood chips in a refiner. The wood fibers used in wood fiber boards have a length of between 1.5 mm and 20 mm and a thickness of between 0.05 mm and 1 mm. The size of the wood chips used in wood chipboards depends on whether they are used in the top layer or middle layer. In the middle layer, the chips start at a mesh size of > 0.125 mm, while in the top layer they start at > 0.8 - 1.0 mm. These wood-based panels can have various binder systems that are mixed and pressed with the wood fibers as a binding agent.Preferred binder systems are: formaldehyde resins, such as urea-formaldehyde resins, melamine-formaldehyde resins, melamine-urea-formaldehyde resins; polyurethanes, preferably based on polydiphenylmethane diisocyanate (PMDI), epoxy resin, or polyester resins.

[0102] These wood-based panels can also be coated on the top surface with foils, e.g., foils made of thermoplastic materials such as PVC or PP, or paper impregnates, such as impregnated with decorative paper layers or overlay papers. Overlay, decorative, counterweight, and kraft paper impregnates are based on thin paper layers that are fully or partially saturated (impregnated) with a resin, preferably melamine-formaldehyde resin.

[0103] Impregnations can be applied, for example, in an impregnation bath, by rolling, anilox rollers, by doctor blades, or by spraying. In one variant, the paper layers are treated as follows: First, the back of the paper layer is impregnated (e.g., in an impregnation tank) with a resin with a solids content between 50 and 70 wt%, preferably 60 wt%. After passing through an air gap, immersion impregnation with a resin follows. Excess resin is removed in a doctor blade system / pair of squeeze rollers, and optionally (in the case of an overlay paper layer), abrasion-resistant particles are sprinkled onto the impregnated paper layer. A drying step follows to a residual moisture content of approximately 6%.

[0104] In the case of coated wood-based panels, these papers (decorative, overlay) are applied to the wood-based panels and pressed together. Typically, the impregnated decorative paper is first applied to the top side of the wood-based panel. The decorative impregnated paper is then followed by at least one overlay impregnated paper. The counter-layer impregnated paper is pressed onto the underside of the wood-based panel. A typical structure of a coated HDF panel, from top to bottom, is: overlay impregnated paper, decorative impregnated paper, HDF core, counter-layer impregnated paper.

[0105] In one embodiment, it is also provided to apply a veneer to a wood-based panel. Such veneers typically have a surface finish based on UV or ESH varnishes. The veneers are glued onto the wood-based panel (HDF, particleboard, OSB, etc.). Urea or PVAc glues with hardeners are usually used to bond the veneers to the substrate.

[0106] It is also possible to press the veneer onto the wood-based panel in a short-cycle press using paper impregnated with melamine resin (e.g., an overlay). The pressing parameters are approximately T > 150°C, p > 30 bar, and t > 30 see. This technology can also be used to produce veneer flooring with veneers that are approximately 0.5 mm thick. It is crucial that the melamine resin penetrates as far as possible into the veneer during the pressing process. This not only reinforces the veneer with the synthetic resin, but also fixes the veneer compressed by the pressing. However, the melamine resin should not ooze out of the veneer, as this would lead to discoloration of the surface and adhesion problems during subsequent painting or oiling.

[0107] In a preferred embodiment, a particle board pressed with a veneer is used. For this purpose, in a first step, a resin-impregnated paper (preferably a resin-impregnated kraft paper) with a veneer is applied to a particle board (e.g., on the top side) and pressed together. In a more advanced variant, a resin-impregnated paper and / or a veneer are used as the counterlayer.

[0108] It is also possible for the wood-based panel to be coated with liquid resin layers (liquid coating) and pressed. In this process, a primer layer is first applied to the wood-based panel, followed by a layer of primer, which is then printed to form a decorative layer. Additional resin layers are then applied to the decorative layer as protective and wear-resistant layers. The wood-based panel can accordingly have at least one decorative layer on the top surface and a multi-layer resin structure containing abrasion-resistant particles, cellulose fibers, and glass beads.The following layer structure is possible (from bottom to top): Backing layer consisting of six resin layers - wood-based panel - primer layer - printed decorative layer - protective layer, in particular a protective layer made of a not yet fully cured resin - first resin layer with cellulose fibers - layer of abrasion-resistant particles - second resin layer - third resin layer with glass beads - fourth resin layer with glass beads - fifth resin layer with glass beads - sixth resin layer (without glass beads). The protective layer serves to cover the decorative layer and protect it during intermediate storage (stacking, storage, transport). The additional resin layers on the top side together form an overlay that protects the finished laminate against abrasion and enables structuring in synchronization with the decorative layer.

[0109] When using the described wood-based panels as floor panels, the wood-based panels are provided with a tongue-and-groove interlock and used for floating installation. A corresponding installation method involves laying a first floor panel and attaching a second floor panel to the first floor panel, with the tongue of the second floor panel being inserted into the groove of the first floor panel.

[0110] After installation, the beveled floor panels form V-shaped joints that are sealed by the applied composition of bevel paint and additive and protected against moisture penetration.

[0111] The invention is explained in more detail below with reference to exemplary embodiments.

[0112] Embodiment 1: Production of a sealing composition according to a first process variant

[0113] Preparation of dispersion A)

[0114] 28.8 g of an aqueous SiO2 dispersion (Köstrosol 3550) and 20 g of an aqueous polyurethane solution Alberdingk U 3215 are introduced.

[0115] Preparation of solution B)

[0116] In parallel, 12.3 g of octyltriethoxysilane, 2.4 g of methyltriethoxysilane, 6.1 g of phenyltriethoxysilane, 20.8 g of tetraethoxysilane, and 28.8 g of water are heated to 50 °C and stirred. 2.8 g of sulfuric acid are then added while stirring for 120 minutes. This solution is then stirred into the above suspension while still warm and stirred at room temperature for a further 60 minutes. A 0.1 molar NaOH solution is added until a pH of 7.5 is reached.

[0117] After 24 hours of standing, the alcoholic phase is separated using a separating funnel.

[0118] The additive can now be added up to 50 wt.% to a commercially available bevel paint, which remains stable for several weeks. Curing after application occurs thermally (e.g., 100 °C, 5 minutes). Example 2: Production of a sealing composition according to a second process variant

[0119] Preparation of solution C)

[0120] After initial charging of 6.1 g of phenyltriethoxysilane and 20.8 g of tetraethoxysilane, 7.2 g of demineralized water and 0.8 g of Lewatit 2629 ion exchanger, the mixture is stirred for 3 hours at 60 °C. The ion exchanger is then removed by filtration, and in a further step, 12 g of water and 17 g of an aqueous polyurethane solution, Alberdingk U 3215, are added.

[0121] Preparation of solution D)

[0122] In parallel, 12.3 g of octyltriethoxysilane and 2.4 g of methyltriethoxysilane are added, and 2.4 g of sulfuric acid (1 molar) and 20 g of water are added. The mixture is hydrolyzed at 55 °C for 4 hours. After cooling to room temperature, solution B is stirred into solution A and stored for 8 hours without stirring. Two phases form, which are then separated using a separating funnel.

[0123] The additive can now be added up to 50% by weight to a commercially available bevel paint, which remains stable for several weeks. After application, curing occurs thermally (e.g., 100 °C, 5 minutes).

[0124] Embodiment 3: Comparison of the composition according to Embodiment 1 and a composition according to EP 3 597 706 B1

[0125] Composition according to EP 3 597 706 B1

[0126] The chamfered paint used has a flow time (4 mm nozzle) of 36 seconds at 21 °C (measured according to EN ISO 2431:2011 "Paints and varnishes - Determination of flow time using flow cups"). Additive "A" according to the application example in EP 3 597 706 B1 has a flow time of 11 seconds.

[0127] Adding 25 wt.% of "A" to the chamfer varnish resulted in a flow time of 60 seconds. After a 60-minute waiting time, this increased to 140 to 150 seconds. After a further 60 minutes of waiting time, no further measurements were possible because the mixture had gelled. Adding 50 wt.% of "A" to the chamfer varnish resulted in a flow time of 120 seconds. After a 60-minute waiting time, the mixture had gelled.

[0128] Composition according to Example 1

[0129] The used bevel paint still has a flow time (4 mm nozzle) of 36 seconds at 21 °C. Additive "B" according to Example 1 has a flow time of 13 seconds.

[0130] The addition of 25 wt. % of "B" to the chamfer varnish resulted in a flow time of 40 seconds. After a waiting time of 60 minutes, the flow time remained at 40 seconds. After a further 60 minutes, there was no increase, nor after 72 hours.

[0131] Adding 50 wt.% of "B" to the chamfer varnish resulted in a flow time of 40 seconds. After a 60-minute waiting period, the flow time remained at 40 seconds. After another 60 minutes of waiting, there was no increase, nor after 72 hours.

[0132] Example 4:

[0133] A 7.4 mm HDF with a density of approx. 850 kg / m 3, which had been produced using a urea-formaldehyde glue in a conventional amount, was coated on the top side with an overlay (AC4) and a decorative impregnate and on the underside with a counter-coat impregnate in a short-cycle press under pressure and temperature (p=40 bar, T=200°C, t=15 see). The boards are transferred to a maturing store to cool and after three days are cut into raw planks on a flooring line. They were then provided with a glueless profile (see image), which produced a negative result in the NALFA test in approximately 80% of the tests. This was a glueless profile without additional plastic locking agents. The bevel was provided with a mixture of bevel paint and silane additive according to example 1 (application quantity: 1.0 g fl. / linear meter, solids content: approximately 42%). The mixture applied to the bevel was dried using an IR lamp. For comparison, planks were produced with only the bevel paint.

[0134] Example 5:

[0135] A 7.4 mm HDF with a density of approx. 850 kg / m 3 , which had been produced with a urea-formaldehyde glue in a usual amount, was provided with the following material applications on the top in a production line, with an intermediate drying after each application:

[0136] Melamine primer (20 g melamine resin fl. / m 2 (Solid content: 55 wt%) with drying primer white (multiple application total:

[0137] 25 g white primer fl. / m 2 (Solid content: approx. 50 wt%) with intermediate drying primer (10 - 20 g fl. / m 2 ) with drying

[0138] Printing (indirect gravure or digital printing)

[0139] Melamine cover (approx. 20 - 30 g melamine resin fl. / m 2 , solids content: approx. 65 wt% with approx. 10 - 20% glass beads based on liquid resin)

[0140] The pre-coated HDF were then coated with the following material in another production line:

[0141] Melamine resin application above (approx. 60 - 80 g melamine resin fl. / m 2 , Solids content:

[0142] 55% by weight)

[0143] Spreading application of corundum (20 -30 g corundum / m 2 , F220 according to FEPA standard)

[0144] Multiple melamine resin application on top with drying (5 applications: total application: 60 - 80 g melamine resin fl. / m 2 , Solids content: approx. 55 wt%,

[0145] 3. Application with 10 - 20 wt% glass beads)

[0146] Multiple melamine resin application below with intermediate drying (3 applications: total application: 140 -160 g melamine resin fl. / m 2 m solids content; approx. 55 wt%)

[0147] The recipes contain the necessary auxiliary materials such as hardeners, wetting agents and release agents. This structure is then coated in a short-cycle press under pressure and temperature (p=40 bar, T=200°C, t=15 see). The boards are transferred to a maturing store to cool and after three days they are cut into raw planks on a flooring line. They were then provided with a glueless profile (see image), which produced a negative result in around 80% of the NALFA tests. This was a glueless profile with no additional plastic locking agents. The bevel was coated with a mixture of bevel paint and according to example 1 (application quantity: 1.0 g fl. / linear meter, solids content: approx. 42%). The mixture applied to the bevel was dried using an IR radiator. For comparison, planks were produced with bevel paint only. Example 6: NALFA test (ISO 4760)

[0148] Test surfaces (10 per variant) were created from the planks produced in Examples 4 and 5 in accordance with ISO 4760. 100 ml of colored water was poured into the ring glued to the surface. The water remained on the surface for 24 hours. An assessment was then carried out according to the standard. This included not only determining the residual amount of water in the ring but also determining the swelling of the test specimens in the test area. The results are summarized in the following table.

[0149] The same procedure was applied to other glueless profiles (with and without plastic locking devices) that had failed the NALFA test. In all cases, a significant improvement in the NALFA test was observed. The test pass rate was greater than 90% for all variants.

[0150] Example 7: Waterproof chipboard with veneer surface and sealant

[0151] The raw materials are explained below. As an alternative to the paper backing (Alternative I), a veneer backing (Alternative II) can also be used. The veneer for the backing can be of the same or different, particularly simpler, quality as the veneer for the top surface.

[0152] Veneer for the top:

[0153] Thickness: 0.6 mm

[0154] Type: Oak

[0155] Paper: Resin-impregnated kraft paper

[0156] Paper weight: 25 g / m 2 Resin application: 600%

[0157] Synthetic resin: Melamine resin waterproof chipboard: Thickness 7.8 mm

[0158] Countermove:

[0159] I Paper: Resin-impregnated kraft paper

[0160] Paper weight: 25 g / m 2

[0161] Resin application: 600%

[0162] Synthetic resin: melamine resin

[0163] II Veneer thickness 0.6 mm

[0164] Species: Poplar

[0165] Production of resin-impregnated paper:

[0166] The paper is passed through a bath of liquid synthetic resin, in this case melamine resin. In the bath, the paper is impregnated or soaked with liquid synthetic resin. After impregnation or soaking, excess synthetic resin is removed by a scraper, so that a layer of synthetic resin is only present on the top side of the now resin-impregnated paper. The top side of the resin-impregnated paper consists of synthetic resin, in this case melamine resin. The amount of synthetic resin used can be varied. However, it is preferably calculated such that the applied veneer penetrates the applied veneer to at least 2 / 3 of its thickness during the subsequent pressing process due to the synthetic resin liquefied in the press. More preferably, the veneer is compressed in the press. According to a particularly preferred embodiment, after the pressing process is complete, the veneer is at least 2 / 3, advantageously completely, impregnated with synthetic resin.Swelling and shrinkage of the veneer is thus largely reduced.

[0167] The soaked paper is dried to a residual moisture content of, for example, 5% to 6%. The resin application of the 25 g / m 2 The drying rate of heavy paper was 600% based on the paper's weight. Drying takes place, for example, in a continuous dryer, where hot air jets blow onto the paper from the top and bottom, thereby drying it without curing the resin. The dried, resin-impregnated paper can then be stored until it is ready for use.

[0168] The resin-impregnated paper for the backing can be produced in the same way as described above. The resin-impregnated paper for the backing is also dried to a VC value of, for example, 6%. The veneer for the backing can be prepared and subsequently processed in the same way as the veneer for the face.

[0169] Making the veneered panel:

[0170] The backing sheet, core board, resin-impregnated paper, and veneer are stacked to form a press stack, with the resin-impregnated paper facing the waterproof particleboard with its upper side, which contains the resin, and the underside facing the veneer. The press stack is placed in a short-cycle press (KT press) and pressed at a temperature of 180°C and a pressure of p = 30 N / mm 2 pressed during a pressing time of 60 seconds.

[0171] It can be pressed using a simple, smooth press plate. In this example, structured press plates can also be used as an alternative to create structure. For example, a press plate with a wood texture can be used. The wood texture of the press plate is then visible in the veneer, which may differ from the wood texture of the veneer. No discernible melamine resin layer had formed on the upper side of the veneer. The coated, waterproof chipboard was then optionally coated with a UV varnish with an application rate of 50 g / m². 2 up to 100 g / m 2 or with a UV oil with an application quantity of 20 g / m 2 up to 40 g / m 2 The surface is refined. The application quantities are based on the desired service class. Corundum can optionally be incorporated into the UV coating, especially when higher service classes with improved abrasion resistance are to be achieved.

[0172] The veneer surface on the top side is thus accentuated or designed in a way that was previously impossible. The back of the waterproof chipboard can be left as it is, especially if a veneer was applied according to Alternative II, or alternatively, impact sound insulation can be subsequently laminated on.

[0173] The large format is then first cut into raw, fixed pieces on a flooring line and then milled into profiled planks. These planks can be beveled or unbeveled.

[0174] The bevel or the straight veneer edge is coated with a mixture of bevel paint and silane additive according to Example 1 (application quantity: 1.0 g fl. / linear meter, solids content: approx. 42%). The coating is dried using an IR lamp.

Claims

Claims 1. Composition for sealing and coating edges and / or bevels of wood-based panels, comprising c) at least one bevel paint comprising color pigments and at least one aqueous solvent, and d) at least one additive comprising at least one compound of the general formula (I) R 1 aSiX 1 (4 -a) (I), where - X 1 Alkoxy, aryloxy, acyloxy, and - R 1 an organic radical is selected from the group comprising alkyl, aryl, cycloalkyl, which may be interrupted by -O- or -NH-, and - where R 1 has at least one functional group Qi selected from a group containing an acrylic, acryloxy, methacrylic, methacryloxy, cyano, isocyano and epoxy group, and - a = 0, 1, 2, 3, in particular 0 or 1, - at least one compound of general formula (II) R2 bSiX 2 (4 -b) (II), where - X 2 H or alkoxy, aryloxy, acyloxy, - R 2 a non-hydrolyzable organic residue R 2 is selected from the group comprising alkyl and aryl, and - b = 1 , 2, 3, or 4, and - at least one aqueous polymer dispersion, characterized by a viscosity (measured according to EN ISO 2431:2011, 21 °C) with a flow time between 20 and 100 see, preferably between 30 and 80 see, particularly preferably between 35 and 60 see over a period of at least 30 minutes, preferably at least 60 minutes, particularly preferably at least 120 minutes.

2. Composition according to claim 1, characterized in that the additive is contained in an amount between 20 and 80% by weight, preferably between 25 and 50% by weight.

3. Composition according to one of the preceding claims, characterized in that the at least one bevel color comprises color pigments and an aqueous melamine resin formaldehyde suspension.

4. Composition according to one of the preceding claims, characterized in that at least one compound of the general formula (I) and at least two, preferably at least three compounds of the general formula (II) are contained.

5. Composition according to one of the preceding claims, characterized in that X 1 is selected from a group containing C1-6-alkoxy, in particular methoxy, ethoxy, n-propoxy and butoxy, C1-w-aryloxy, in particular phenoxy, C2-7-acyloxy, in particular acetoxy or propionoxy, and X 2 is selected from a group containing H, C1-6-alkoxy, in particular methoxy, ethoxy, n-propoxy and butoxy, C1-w-aryloxy, in particular phenoxy, C2-7-acyloxy, in particular acetoxy or propionoxy, 6. Composition according to one of the preceding claims, characterized in that the compound of general formula (I) of the formula SiX 1 4, especially withX 1 Alkoxy, in particular methoxy, ethoxy, n-propoxy or i-propoxy.

7. Composition according to one of the preceding claims, characterized in that the non-hydrolyzable organic R 2 is selected from a group comprising Ci-Cw-alkyl, in particular Ci-Cw-alkyl, and Ce-Cw-aryl. Composition according to one of the preceding claims, characterized in that non-hydrolyzable organic R 2is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, s-butyl, t-butyl, pentyl, hexyl, heptyl, octyl, nonyl, cyclohexyl, vinyl, 1-propenyl, 2-propenyl, butenyl, acetylenyl, propargyl, phenyl, and naphthyl. A composition according to any one of the preceding claims, characterized in that the compound of formula (II) comprises one of the following formulas: - R 2 4Si with R 2 as a C1-C5 alkyl group, preferably methyl or ethyl; - R 2 aSiX 2 with R 2 as a C1-C5 alkyl group, preferably methyl or ethyl and with X 2 as H, - R 2 SiX2a with R 2 as a C1-C10 alkyl group, preferably methyl, ethyl, propyl, pentyl, hexyl, heptyl, octyl, or as a C6-C10 aryl group, preferably phenyl and with X 2as alkoxy, in particular methoxy, ethoxy, n-propoxy, or i-propoxy. Composition according to one of the preceding claims, characterized in that the at least one polymer of the polymer dispersion is selected from the group comprising polyurethanes, in particular polydiphenylmethane diisocyanate (PMDI), epoxy resins, melamine resins, and polyacrylates. Composition according to one of the preceding claims, characterized in that inorganic particles, in particular SiO2, AlO3, ZrO2, or TiO2 particles, may be present. Composition according to one of the preceding claims, producible in a process comprising the following steps: Providing at least one dispersion A) comprising polymer dispersion and optionally a dispersion of inorganic particles, - Providing a solution B) comprising a mixture of at least one compound of the general formula (I), at least one compound of the general formula (II) and at least one catalyst, in particular an acid, - Addition of solution B) to dispersion A) and neutralization of the additive mixture (addition of a basic compound); - separating the aqueous phase of the additive from polymer dispersion, at least one compound of formula (I) and at least one compound of formula (II), and Addition of the additive to the at least one bevel color. Composition according to any one of claims 1-12, producible in a process comprising the following steps: - Providing a solution C) comprising a mixture of at least one compound of the general formula (I), at least one compound of the general formula (II) and at least one polymer dispersion (an ion exchanger); - Providing a solution D) comprising at least one compound of the general formula (II) and at least one catalyst, in particular an acid, - Stir solution D) into solution C); - separating the aqueous phase of the additive from at least one compound of formula (I), at least two compounds of formula (II) and polymer dispersion; and Addition of the additive to the at least one bevel color. Use of a composition according to one of the preceding claims for coating / sealing edges and / or bevels of wood-based panels, in particular chipboard, HDF, or MDF boards. Wood-based panel comprising at least one composition according to one of claims 1 to 13 applied to an edge and / or bevel.

Images