Method for producing a colour-fast and weather resistant plate

Abstract

The invention relates to a method for producing a colour-fast and weather resistant plate. In order to provide a colour-fast and weather resistant plate with a simple coating, a waterproof carrier plate is provided, on which a first layer of a coating is applied, which is chosen from a group comprising decorative paper, finish film, veneer, paint, continuous pressure laminate (CPL) or high pressure laminate (HPL), and on which a second layer of a coating is applied, which is a paint layer, a layer made from an oil, a wax or a glaze. The invention further comprises a colour-fast and weather resistant plate.

Description

[0001] Description

[0002] Process for producing a color- and weather-resistant board

[0003] The invention relates to a method for producing a color- and weather-resistant board.

[0004] Weather-resistant panels for outdoor applications are known, e.g., from WO 2020 / 211989 Ai. The panel disclosed therein is provided with complex, multi-layer coatings that allow for use in outdoor applications.

[0005] The object of the invention is to propose a method for producing a panel with a simpler coating that is weather-resistant and, in addition, as colorfast as possible.

[0006] This object is achieved by a method for producing a color- and weather-resistant plate according to claim 1 and by a color- and weather-resistant plate according to claim 13.

[0007] The method according to the invention for producing a color- and weather-resistant plate provides a waterproof carrier plate to which a maximum three-layer coating is applied directly or with a fixing agent.

[0008] A waterproof carrier plate is known, for example, from WO 2020 / 211988 Ai or WO 2020 / 211989 Ai. Alternatively, a waterproof carrier plate is used, which is manufactured as follows:

[0009] Providing fibers,

[0010] Providing the binding agent,

[0011] Providing an elasticizing additive

[0012] Application of the binder and the elasticizing additive,

[0013] Forming the fibre cake from the fibres provided with binder and elasticising agent,

[0014] Pressing the fiber cake in a press while curing the binder to produce a carrier board, wherein 15 wt.% to 35 wt.% melamine resin or phenolic resin and 5 wt.% to 20 wt.% urea resin and 0.1 wt.% to 7 wt.% of the elasticizing additive, each based on the total weight of the carrier board (atro), are used as binder.

[0015] To produce the waterproof carrier plate, fibers are first prepared. Organic or inorganic fibers can be used. Natural fibers, e.g., lignocellulosic fibers, cotton or linen fibers, or synthetic fibers such as fibers made of thermoplastic materials such as polyethylene or polypropylene, but also polycarbonate, polyacrylate, polymethacrylate, or polyurethane can be used to produce the waterproof carrier plate. Inorganic fibers such as carbon fibers or fibers made of mineral or ceramic raw materials or glass fibers are particularly suitable for producing the waterproof carrier plate when mixed with other fibers. In particular, mixtures of fibers, in particular mixtures of the aforementioned fibers, can be used to produce the waterproof material. Mixtures of fibers enable the properties of the waterproof material to be adjusted, e.g.,the elasticity or flexural properties, dimensional stability, strength, but also the manufacturing properties and processability. Fibers within the meaning of this invention also include fiber bundles; smaller chips are also included, provided their fibers can still be largely coated with a binder. According to the invention, it is preferred if the fiber content of the carrier board is less than 50 wt.% of the total weight of the carrier board. It is further preferred if the proportion of lignocellulosic fibers is less than 45 wt.% of the total fiber content.

[0016] A binder is provided for the production of the waterproof carrier board. Melamine or phenolic resin, on the one hand, and urea resin, on the other, are used. The binder used preferably comprises melamine resin, typically melamine-formaldehyde resin. Phenolic resin can be used as an alternative to melamine resin or in a mixture with melamine resin. Although phenolic resin is waterproof, it is dark in color and, due to its alkali content, slightly hygroscopic. However, the inventors have recognized that, despite its hygroscopic properties, phenolic resin can be used to produce waterproof boards. The individual resins mentioned above, in particular melamine, urea, and phenolic resins, can be used both in mixtures with one another and as mixed condensates. Particularly suitable resins include guanamine resin, melamine-formaldehyde resin, melamine-urea-formaldehyde resin (MUF resin), and also melamine-urea-phenol-formaldehyde resin (MUPF).A guanamine resin is used, for example, in the.

[0017] EP 0 011 049 Ai discloses. Melamine resin and / or phenolic resin are used according to the invention in combination with urea resin. According to the invention, the proportion of melamine resin in the binder is 15 wt.% to 35 wt.%, based on the total weight of the carrier board (dry), in particular 20 wt.% to 30 wt.%, advantageously 20 wt.% to 25 wt.%, particularly preferably 15 wt.% to 25 wt.%. The melamine resin can be replaced entirely or partially by phenolic resin. The proportion of urea resin according to the invention is 5 wt.% to 20 wt.%, advantageously 5 to 18 wt.%, preferably 10 wt.% to 18 wt.%, particularly preferably 10 wt.% to 15 wt.%, in each case based on the total weight of the carrier board (dry). The total amount of binder used to produce the waterproof carrier plate is preferably up to 48% by weight, particularly preferably up to 45% by weight, advantageously up to 43% by weight, particularly advantageously 25% to 40% by weight.-%, each based on the total weight of the carrier board (dry). Melamine resin or phenolic resin on the one hand and urea resin on the other hand are advantageously used in a ratio of 3.5:1 to 1:1, advantageously between 3:1 and 1:1, in particular 2.5:1, preferably 2.5 - 1.5:1. Within the aforementioned limits, the ratio between melamine resin or phenolic resin on the one hand and urea resin on the other hand can be continuously adjusted.

[0018] Thermoplastic binders are advantageously avoided or excluded, in particular the use of thermoplastic binders exceeding 7% by weight is avoided or excluded. The carrier plate according to the invention is preferably free of halogens (e.g., fluorine, chlorine), but also of terephthalates.

[0019] According to an advantageous embodiment, the elastic properties of the waterproof carrier plate can be modified, in particular improved, by adding an elastomer or thermoplastic as an elasticizing additive, e.g., by adding polyvinyl acetate (PVAc) or ethyl vinyl acetate (EVA), but also a modified isocyanate compound. Acrylate or styrene acrylate are preferred for elasticizing the waterproof carrier plate, particularly in the form of a liquid additive such as a dispersion or emulsion because they are waterproof. Glycol, e.g., mono- or diethylene glycol, are also suitable for elasticizing the waterproof carrier plate, as are caprolactam, longer-chain diols or triols, e.g., glycerol, and also polyols, sugars, sugar alcohols, or guanamine compounds.The aforementioned elasticizing additives can be used individually or in a mixture of two or more of the aforementioned components. The addition of elastomers or thermoplastics reduces the brittleness of the waterproof substrate and improves its elastic properties, e.g., the modulus of elasticity. Furthermore, the addition of elasticizing additives improves the flatness of the waterproof substrate. The elasticizing additive is used as a solid, calculated proportionally to the total amount of waterproof substrate (dry), in an amount of 0.1 wt.% to 7 wt.%, preferably from 1 wt.% to 5 wt.%, advantageously 2 wt.% to 4 wt.%.

[0020] According to an advantageous embodiment of the invention, up to 1 wt.% of a hardener is added to the binder, which accelerates the curing of the binder, usually a chemical reaction such as a condensation reaction or an addition reaction. A typical example of a hardener is ammonium sulfate.

[0021] The use of a hydrophobicizing agent for producing the waterproof carrier plate according to the invention has also proven advantageous. Examples of such agents include paraffin or wax, which are typically used in amounts of up to 4% by weight, based on the weight of the plate-shaped material, usually as an emulsion.

[0022] The waterproof core board optionally contains additives. Fillers can be used as a possible additive to optimize the weight of the board material, usually to minimize it, but in individual cases also to increase it, or they can contribute to further improving the matrix structure of binder and fibers. An additive or a combination of additives can serve alternatively or additionally to optimize certain properties of the boards, e.g., electrical or thermal conductivity, insulating properties, or strength properties. An additive usually replaces fibers in the waterproof core board. Since the waterproof core board should exhibit minimal swelling in the presence of water, especially minimized thickness swelling, non-hygroscopic or non-swelling additives or fillers, as well as additives or fillers that are resistant to hydrolysis, are preferred.Such aggregates or fillers can be mineral particles, but also ceramic, synthetic particles, or particles made of glass or metal. For example, calcium carbonate (CaCO3) and / or barite (BaSO4) can be used as fillers, metal particles can be used to improve thermal and / or electrical conductivity, or expanded plastic particles can be used to reduce weight. The size of the particles is preferably no larger than one millimeter, preferably between 10 pm and 800 pm. The particles can have any shape, e.g. granular or powdery, but also thread-like. Mixtures of different particles can also be used, e.g. mixtures of different materials, shapes, or sizes. Up to 30 wt.% aggregate, based on the total weight of the waterproof carrier plate (dry), is used, particularly preferably up to 20 wt.%, advantageously up to 15 wt.%.The lower limit of the amount used is determined by the detectability of an aggregate or filler. The aggregate or filler can be applied to the fibers before or after the binder is applied, preferably by spraying or scattering.

[0023] Hot presses are preferably used to produce the waterproof carrier plate, with press plates or circulating metal belts heated to a predetermined temperature. Suitable press temperatures can be selected from 110 °C to 250 °C, preferably from 110 °C to 180 °C, advantageously from 140 °C to 160 °C (temperature of the press plate or belt). The thinner the plate, the lower the press temperature can be selected. Alternatively, the press speed can be increased, i.e., the press time can be shortened. Suitable press pressures are, for example, in the range of 0.3 N / mm 2 up to 5.5 N / mm 2 , in particular 1 N / mm 2 up to 3 N / mm2 The pressing time is advantageously between 6 seconds / mm of plate thickness (hereinafter: s / mm) and 60 s / mm, usually between 10 s / mm and 30 s / mm, preferably between 20 s / mm and 25 s / mm. To minimize the pressing time, the temperature can be increased within the aforementioned range. In continuous presses, the feed rate of the circulating metal belts, between which the waterproof carrier plate is produced by pressing, is usually between 250 mm / second and 400 mm / second, preferably between 300 mm / second and 350 mm / second, depending on the length of the press.

[0024] A waterproof board, the surface of which may be painted, oiled, waxed or varnished, can be used in outdoor applications, but is generally not weather-resistant and colorfast according to DIN EN 4892-2 n'2021, method A or ISO 105 A02, A03, A04 and A05 and therefore usually does not meet the requirements of tenders.

[0025] According to the invention, a coating is applied to this waterproof carrier board, which contains, for example, fibers and up to 35% by weight of melamine resin or phenolic resin and up to 20% by weight of urea resin, in each case based on the total weight of the carrier board (dry as dry matter) as a binder. The coating has a first layer selected from the group comprising decorative paper, finish foil, varnish, continuous pressure laminate (CPL) or high pressure laminate (HPL) and a second layer which is a varnish layer. The varnish layer can be applied in several layers, e.g. in order to achieve a greater layer thickness. When applying a varnish layer in several layers, it can be applied either wet-on-wet, with the individual layers being applied directly one after the other. Alternatively, the previously applied varnish layer can be gelled, i.e. it can be at least partially cured using, for example, UV light or electron beam curing.

[0026] The coating, in particular its first layer, can advantageously be applied directly to the waterproof carrier board or with the aid of a fixing agent. Typical examples of direct application include pressing a synthetic resin-containing coating, e.g., a paper or veneer impregnated with melamine resin, phenolic resin, or another synthetic resin, in particular a synthetic resin-impregnated decorative paper, onto a surface of the carrier board. A coating that is attached to the surface of the carrier board with a fixing agent, e.g., a first layer of veneer, CPL or HPL, or film, is often fixed with an adhesive, in particular a hotmelt adhesive.

[0027] Until now, panels, especially wood-based panels for outdoor applications, had to be as water-resistant as possible to largely rule out dimensional changes during their service life. The panel produced according to the invention must also be color-stable and weather-resistant. Color fastness is particularly important for outdoor applications because the panel is typically exposed to the elements for years, e.g., as a facade panel or as an exterior window sill, for exterior structures such as fences, pergolas, or stables, or when used for outdoor furniture, e.g., as a tabletop for outdoor tables. Even if the panel itself is weather-resistant, the decor must also remain color-stable over the long term to ensure the aesthetic appearance of the panel remains as consistent as possible.To test the weather resistance and color fastness of the panel, the weathering behavior of the coated panel is tested for 3000 hours in a test device according to DIN EN ISO 4892-2 11 / 2021, using method A. In the context of this invention, color fastness is tested according to ISO 105 A02, A03, A04, and A05, respectively. In particular, the color fastness test according to ISO 105 uses a gray scale to assess color bleeding (A02) and a gray scale to assess color change (A03).

[0028] The application of the coating, in particular the second layer of the coating, a primer, or even a fixative, can be achieved by pressing, rolling, doctoring, spraying, and / or pouring. Pressing is preferably suitable for resin-impregnated paper or films, especially for lacquer-coated paper or lacquer-coated finish foil. Oil, wax, or a glaze can be applied by rolling, doctoring, spraying, and / or pouring.

[0029] To better bond the first or second coat of lacquer to the substrate, a primer is preferably applied that adheres well to the substrate—here, the surface of the carrier board, the decorative paper, the finish foil, the continuous pressure laminate (CPL), or the high pressure laminate (HPL)—and also establishes a good bond with the lacquer of the first or, in particular, the second coat. Acrylate compounds, which are preferably UV-curing, are used as primers. The primer is preferably applied in a quantity of up to 25 g / m 2 applied to the respective substrate and at least partially cured. The primer is usually applied in liquid form. The primer helps ensure a well-adhering first and second coat of the coating. This is promoted by the preferred wet-on-wet application of primer and paint; therefore, there is no drying after the primer is applied.

[0030] A particularly simple and, with regard to color fastness, effective coating of a carrier board involves applying a primer to the surface of the carrier board, which improves the adhesion of the paint to the surface of the carrier board. The primer preferably has no influence on the color and / or weather resistance of the board according to the invention. A first layer of paint and a second layer of paint, in particular a UV-curing or electron-beam-curing paint (an EBC paint), can then be applied to the primer. A total of up to 150 g / m 2Lacquer is applied to the surface of the carrier plate. The first layer and the second layer can contain the same or different lacquers or lacquer compositions. Curing of the lacquer, i.e., the polymerization of the lacquer molecules, as well as curing of the primer, preferably occurs at least partially after the application of the primer or each lacquer layer. Complete curing is particularly preferred after each layer has been applied.

[0031] In particular, the application of two coats of lacquer allows for economical coating of the waterproof panel, while still opening up numerous variations in visual and technical design by optimally utilizing pigments and additives that significantly influence the lacquer properties. For example, a colored lower lacquer layer can be covered by an upper lacquer layer containing metal particles to create special aesthetic effects, or a lower lacquer layer containing antifungal agents can be covered by an upper lacquer layer containing conductive particles to meet technical requirements such as color and / or weather resistance, abrasion resistance, and conductivity.

[0032] According to an alternative embodiment of the method according to the invention, a resin-impregnated paper, in particular a decorative paper, is applied to the carrier board, wherein the resin-impregnated decorative paper is optionally provided with a primer as the first layer of the coating and, according to the invention, with a second layer of varnish. The paper, for example, with a paper weight of 15 g / m 2 up to 250 g / m 2 , can be a neutral or a decorative paper. It is impregnated with a synthetic resin, usually a melamine resin, so that a typical paper weight of 150 g / m 2 up to 400 g / m 2for the paper impregnated with synthetic resin. After impregnation, which usually takes place in an impregnation bath, excess synthetic resin is wiped off and the paper impregnated with the specified amount of synthetic resin is dried so that the synthetic resin is no longer sticky but is still reactive, i.e. the synthetic resin has not yet fully formed the polymer framework. The synthetic resin can partially penetrate the paper. However, it can also protrude on one or both sides of the paper if an excess of synthetic resin is applied to the paper. Optionally, a layer of primer is applied to the dried, resin-impregnated paper. The primer serves to optimally bond the subsequent layer of varnish to the resin-impregnated paper. After application, the primer is advantageously allowed to dry at least partially.This coating is well-known and proven for indoor applications; however, it is surprising that it is also sufficiently color- and weather-resistant for outdoor applications.

[0033] A layer of varnish, particularly a UV-curing or electron-beam-curing varnish, is preferably applied to the resin-impregnated and primed paper. A maximum of 50 g / m 2 varnish applied.

[0034] The resin-impregnated paper is placed on the carrier plate, with the side with the varnish layer facing away from the carrier plate. The resin-impregnated paper is then pressed directly onto the carrier plate. The individual resin layers are preferably dried, for example, using hot air or IR radiation, to a moisture content of 5% to 25%, preferably 4% to 10%. They then reach the so-called B-stage, in which the resins are usually no longer tacky but still reactive. The fully applied resin coating is then cured in a press, e.g., a short-cycle press, under the influence of pressure and elevated temperature. Typical pressing conditions include a temperature of 160°C to 220°C, preferably 180°C to 200°C, and a pressure of 20 kg / cm³. 2 up to 50 kg / cm 2 , preferably 22 kg / cm 2 up to 40 kg / cm 2and a pressing time of 5 seconds to 60 seconds, preferably 5 seconds to 30 seconds.

[0035] This version of the invention is easy to manufacture in existing facilities and is particularly resistant to weathering. The color, which is applied, for example, with decorative paper or varnish, remains stable even when the panel is exposed to the elements.

[0036] A further embodiment of the invention provides that, instead of the resin-impregnated paper, a finish film is used, which is coated with a layer of primer and then with a layer of varnish before being applied to the carrier plate. The primer and varnish are applied and dried as described above. Unlike the resin-impregnated paper, the finish film is usually applied to the carrier plate using a fixing agent. The fixing agent, preferably a hot melt adhesive, is applied to the carrier plate or the finish film, and the carrier film and finish film are permanently bonded together under the influence of pressure in a press, e.g., a vacuum press.

[0037] Finally, the usability of the surface of the workpiece according to the invention can be improved by applying a lamination. The lamination has a coating with a mostly ready-to-use outer side, which is generally adhered to the material according to the invention, e.g., as described above, using a hotmelt or another adhesive. A typical version of a lamination is a CPL or HPL, which consists, for example, of a plurality of synthetic resin-impregnated papers, wherein the synthetic resin-impregnated papers or films are pressed together while the synthetic resin is fully curing. However, PVC films can also be laminated on. The CPL or HPL or other coatings with a ready-to-use surface, such as PVC film, are typically applied to the surface of the plate-shaped workpiece using a hotmelt as an adhesive. The lamination is pressed on, for example,at 8o °C to 200 °C in a laminating press at a pressure of up to 300 N / cm. 2 The pressing time is short, usually a maximum of 1 second. Laminating systems are usually designed as calender systems.

[0038] Even if the surface of a lamination is already ready for use, this does not preclude the application of a further coating or sealant, be it for aesthetic reasons or to further improve usability. A typical example is the application of a varnish as a second layer, for example to achieve special optical effects or because at least one varnish layer contains corundum to improve abrasion resistance or Aerosils to further improve scratch resistance. The second layer can be made up of several layers of varnish, applied one after the other, during lamination, or on top of the other first layers of the coating mentioned above. The individual layers of varnish can each be fully cured before the subsequent layer of varnish is applied, or they can be uncured or partially cured.The individual layers can be made of the same varnish or of different varnishes or varnish compositions.

[0039] A veneer can be used as the first layer. It can either be coated with adhesive and laminated in a veneer or laminating press, or it can be bonded to the substrate using synthetic resin by pressing it in a synthetic resin press (KT press). A primer can be used, for example, to improve the bonding of the adhesive or synthetic resin. Veneer, paper, varnish, oil, wax, or a glaze can be used as a second layer, each applied in one or more layers, preferably in a quantity of up to 250 g / m². 2 , preferably up to 200 g / m 2 , especially 100 g / m 2 , at least 25 g / m 2Advantageously, the second layer of the coating can first be applied to the first layer and cured if necessary, before the interconnected first and second layers can be applied to the carrier board. Thus, a coating is applied to the carrier board in which a decorative paper, a finish film, or CPL or HPL is already coated with a layer of varnish.

[0040] Optionally, a texture can be embossed into the second layer of the coating, preferably before or during curing. The texture can particularly mimic natural wood or stone textures, but it can also mimic signs of wear or manufacturing defects, for example, of wood or stone structures.

[0041] The features of the first and second layers explained above can be combined as desired.

[0042] In the context of this invention, all percentages refer to weight percent (wt%) unless otherwise stated. All quantities, e.g., "g / m 2 ", especially for paint or primer, refer, unless otherwise stated, to 100% solids. In fact, liquid-applied paints or primers, in particular, are processed according to the manufacturer's specifications at significantly lower solids contents of typically 40 to 60% by weight. The "absolute dry" term refers to fibers dried to constant weight at 105 °C.

[0043] Details of the invention are explained below using exemplary embodiments:

[0044] The carrier board is a waterproof board, which can be composed, for example, of the components mentioned above (fibers, binder or adhesive, elasticizing additive, hardener, hydrophobizing agent and / or filler). For the following examples, a Corepel board is used as the waterproof carrier board, which has the following composition: 30 wt.% melamine resin, 15 wt.% urea resin, 4 wt.% diethylene glycol as elasticizing additive, 0.5 wt.% ammonium sulfate as hardener, 15 wt.% calcium carbonate as filler and 33 wt.% dry fibers. The Corepel board is pressed at a pressing temperature of 180 °C and a pressure of 4 N / mm 2 Pressed at a pressure of 6 s / mm plate thickness, the plate is pressed into an 8 mm plate for examples 1 to 3 and into a 10 mm plate for example 4. The plate is then sanded and coated according to the following examples.

[0045] Example 1:

[0046] A waterproof board, here a sanded 8 mm Corepel board (format: 2800 x 1000 mm), is first coated on a painting line operating at a speed of 30 m / min with a UV primer, e.g. an acrylate primer that is curable with UV light, in a quantity of 1 - 20 g / m 2 coated with a paint roller. It is lit with a gallium lamp with 80 watts / cm 2 gelled, i.e., at least partially cured. In an alternative version, the primer can be omitted. A pigmented EBC (electron beam curing) coating, in this case a urethane acrylate coating, is then applied using a coating machine in a quantity of approximately 100 g / m 2applied. The varnish contained approximately 15% pigment (white) and, in this exemplary embodiment, was preferably adjusted with reactive thinner to a viscosity of 70-80 see (4 mm DIN cup). Hexanediol diacrylate and trimethylolpropane triacrylate are preferably used as reactive thinners. The varnish is gelled with an electron beam (225 V, 100 kGray). All varnish curing processes using electron beams discussed in connection with this invention are preferably carried out under an inert gas atmosphere, e.g., a nitrogen atmosphere. Alternatively, a UV-curing varnish can be used.

[0047] A roller unit is then used to apply a topcoat containing nanoparticles, e.g., an acrylate coating containing fumed silica. The coating is applied in a quantity of approximately 10-20 g / m 2The entire structure is then cured again with an electron beam curing unit (225 V, 250 kGray). Alternatively, a UV-curing polyurethane coating can be used. After cooling, the coated panels are cut to size in a profile line. A sample from this production is then tested according to DIN EN ISO 4892-2, 11 / 2021, method A for 3000 h. After testing, no color deviations or other defects were detectable (gray scale rating: 4-5, ISO 105 A2, A3). This makes the coating described above ideal for outdoor use, e.g., as a facade panel. The waterproof panel coated according to the invention also proves to be acid-resistant and scratch-resistant.

[0048] Example 2:

[0049] A decorative paper (80 g / m 2 , width of the roll: 2070) is impregnated in an impregnation channel with approx. 80 g melamine resin / m 2(calculated as 100 wt.% solids). The impregnation channel operates at a speed of 30 m / min. The paper is impregnated with resin in the impregnation tank, and preferably the top surface is sharply removed with a knife blade before entering the flotation dryer. In the drying channel, the impregnated material is dried to a residual moisture content of 5 wt.% to 10 wt.%, typically approximately 6 wt.% to 8 wt.%. After leaving the flotation dryer, the paper is first coated with a varnish roller with a UV primer in an amount of 15-20 g / m 2 It is operated with a gallium lamp with 80 watts / cm 2 Then, an ESH varnish is applied to the top of the decorative paper using a varnish roller (varnish from Example 1). The amount was 40-50 g / m 2 The varnish can also be applied in two layers of 20 - 25 g / m 2The coating can be applied either wet-on-wet or by curing the first layer. The complete coating is then cured with an EBH lamp (225 V, 100 kGray). The coating cures under an inert gas, e.g., nitrogen. The impregnated materials are then cut to size (2800 x 2070 mm). They are then pressed onto both sides of a waterproof board, in this case, an 8 mm Corepel board, in a short-cycle press. The pressing parameters were: a pressing temperature of 180°C, a pressure of 40 N / cm 2 and a pressing time of 20 seconds.

[0050] A sample is cut from the coated, large-format panel for weathering testing and tested in the same way as the sample from Example 1. No color changes or other defects are detected (gray scale rating: 4-5, ISO 105 A2, A3). Example 3:

[0051] A decorative paper with a paper weight of 80 g / m 2and a roll width of 2070 mm is impregnated in an impregnation channel with approx. 80 g melamine resin / m 2 (based on 100% solids by weight). The impregnation channel operates at a speed of 30 m / min. The paper is impregnated with resin in the impregnation tank, and the top surface is sharply removed with a knife blade, preferably before the flotation dryer. In the drying channel, the impregnated paper is dried to a residual moisture content of approximately 6%.

[0052] After the flotation dryer, the paper is first coated with a varnish roller with a UV-curing primer in a quantity of 15 - 20 g / m 2 It is operated with a gallium lamp with 80 watts / cm 2 gelled, but not fully cured. A UV varnish, preferably an acrylic varnish, is then applied to the top of the decorative paper using a roller. The amount was 20-30 g / m 2The coating system (primer and coating) is then cured with a UV lamp (Hg, 120 watts / cm). The coating cures under an inert gas, e.g., nitrogen. The coating is preferably mixed with photoinitiators to promote color stability.

[0053] The impregnated sheets are then cut to size (2800 x 2070 mm). They are then pressed onto both sides of a waterproof board, e.g., an 8 mm Corepel board, in a short-cycle press. The pressing parameters are identical to the pressing conditions of Example 2.

[0054] A sample for weathering testing is cut from a large-format panel coated as described above and tested analogously to the sample from Example 1. No color changes or other defects are detected (gray scale rating: 4-5, ISO 105 A2, A3).

[0055] Example 4:

[0056] A finish foil, i.e., a paper impregnated with synthetic resin, in which the synthetic resin is cured, unlike decorative paper, is used to coat a waterproof board, typically the waterproof board described above. The finish foil (width: 1300 mm) has a paper weight of 80 g / m². 2 and is 100 g / m 2 up to 120 g / m 2 Impregnated with synthetic resin. Typically, urea resin or a mixture of urea resin and acrylic resin is used, but another, preferably thermosetting synthetic resin or a mixture of synthetic resins can also be used. The finish film in a solid-color decor, here in gray, which was impregnated in a first step with a mixture of an acrylate and urea resin, is first coated on the top side with a paint roller in a coating line with a UV primer in a quantity of 15-20 g / m². 2The coating line operates at 30 m / min. The primer is applied with a gallium lamp with 80 watts / cm 2 Then, an ESH varnish is applied to the top of the finish foil using a varnish roller. The varnish from Example 1 is used for this purpose. The amount used is 40-50 g / m 2 It can be applied in one or more layers, as described in Example 1. The coating system consisting of primer and coating is then cured with an EBC lamp (225 V, 100 kGray). Curing with the help of the electron beam takes place in a protective gas atmosphere, e.g., nitrogen.

[0057] The varnished finish foil is then applied using a PU hotmelt (application quantity: 100 g / m 2) a 10 mm thick Corepel board is laminated to the top surface in a laminating line. The same lacquered finish film is laminated to the back of the Corepel board. A sample is cut from a large-format board for weathering testing and tested in the same way as the sample from Example 1. No color changes or other defects are detected (gray scale rating: 4-5, ISO 105 A2, A3).

[0058] Example 5

[0059] A waterproof board, e.g., as described above, is, according to a first alternative, either varnished or coated with a primer. Suitable options include UV-curing primers or varnishes, for example, acrylate-based, or electron-beam-curing primers or varnishes. A decoration is printed at least in sections onto this first varnish layer or primer. The decoration is preferably applied digitally, e.g., using an inkjet printer. According to a second alternative, a decoration is printed at least in sections directly onto the, for example, sanded and dust-free surface of the waterproof board. If printed with a UV-curing ink, this is cured immediately after the decoration is applied. A second varnish layer is applied to the first varnish layer, which has been provided with a decoration at least in sections according to the first or second alternative. The applied coating weight is, for example, 8 g / m 2 up to 150 g / m 2, typically 15 g / m 2 an acrylate varnish. The preferred varnish is a UV- or electron beam-curing varnish, typically in a quantity of up to 150g / m 2 . Advantageously, the first lacquer layer is at least partially dried or cured, typically gelled, before applying the decoration to enable the application of a precise decoration. After applying the second lacquer layer, which, for example, in a quantity of 8 g / m 2 is applied, the lacquer layers are cured. The first and / or second lacquer layer can be applied in one or more layers, either wet-on-wet or after the previously applied layer has cured. Optionally, a structure can be embossed into the lacquer, particularly into the second lacquer layer, preferably before or during curing.

[0060] A sample for weathering testing is cut from the panel coated with two coats of paint and tested analogously to the sample from Example 1. No color changes or other defects are detected (gray scale rating: 4-5, ISO 105 A2, A3).

[0061] Example 6

[0062] A paper, veneer, or plastic film is laminated onto a waterproof board, such as an 8 mm Corepel board. The paper, for example, has a sheet weight between 6 oz / m 2 and 100 g / m 2or the plastic film, e.g. made of polyethylene, is optionally provided with a decoration, in particular with a digital decoration, e.g. applied by means of an inkjet printer. The paper, veneer, or plastic film is glued or laminated to the waterproof board, e.g. with a hot-melt adhesive. Before or after application to the waterproof board, the paper or plastic film is coated with a layer of varnish, preferably a UV- or electron-beam-curing varnish, e.g. an acrylic varnish. The varnish is advantageously applied in an amount of up to 150 g / m 2 applied in one or more layers and cured. Optionally, a structure can be embossed into the lacquer, preferably before or while the lacquer is curing. The veneer and paper can alternatively be coated with a layer of oil, wax, or glaze, preferably in a quantity of up to 200 g / m². 2 , advantageously up to 150 g / m 2, applied in one or more layers.

[0063] A sample is cut from each of the panels coated as described above for a weathering test and tested analogously to the sample from Example 1. Here, too, no color changes or other defects are detected (gray scale rating: 4-5, ISO 105 A2, A3).

Claims

AMENDED CLAIMS received by the International Bureau on 15 July 2024 (15.07.2024) 1. A method for producing a board which is colour- and weather-resistant according to DIN EN ISO 4892-2 11 / 2021 and ISO 105 A2, A3, with a water-resistant carrier board comprising lignocellulosic fibres, with a coating, wherein the coating is applied as a first layer selected from the group comprising decorative paper, finish foil, lacquer, veneer, continuous pressure laminate (CPL) or high pressure laminate (HPL), and as a second layer, wherein the second layer is a lacquer layer, a layer of oil, wax or a glaze.

2. Method according to claim 1, characterized in that the coating is applied by pressing, rolling, doctoring, spraying and / or pouring.

3. Method according to one of claims 1 or 2, characterized in that a primer is applied to the carrier board, the decorative paper, the finish film, the CPL or the HPL before the application of varnish.

4. Method according to claim 1 or one of claims 1 to 3, characterized in that the second layer is constructed from two or more layers of varnish, oil, wax or glaze.

5. Method according to claim 4, characterized in that a UV-curing or an electron beam-curing lacquer is selected as the lacquer.

6. A method according to claim 4 or 5, characterized in that a maximum of 150 g / m 2 Varnish, oil, wax or glaze can be applied.

7. Method according to one of claims 1 to 3, characterized in that a synthetic resin-impregnated paper, in particular a synthetic resin-impregnated decorative paper, is applied to the carrier plate.

8. Method according to claim 7, characterized in that the lacquer-coated AMENDED SHEET (ARTICLE 19) layered, resin-impregnated paper is applied directly to the carrier plate, in particular pressed onto the carrier plate.

9. Method according to claim 7 or 8, characterized in that a maximum of 50 g / m 2 Varnish, oil, wax or glaze can be used for the second layer.

10. Method according to claim 1, characterized in that a finish film, a CPL or an HPL, which is already coated with a second layer of lacquer, is applied to the carrier plate.

11. Method according to claim 10, characterized in that the finish film, the CPL or the HPL is each applied to the carrier plate with a fixing agent.

12. The method according to claim 10, characterized in that a hot melt adhesive or a hot melt adhesive is used as the fixing agent.

13. Board which is colour- and weather-resistant according to DIN EN ISO 4892-2 11 / 2021 and ISO 105 A2, A3, comprising a water-resistant carrier board to which a coating is applied, wherein the coating comprises a first layer selected from the group comprising decorative paper, finish foil, veneer, lacquer, continuous pressure laminate (CPL) or high pressure laminate (HPL), and a second layer, wherein the second layer is a lacquer layer, a layer of oil, wax or a glaze.

14. Board according to claim 13, characterized in that a primer is applied to the carrier board, the decorative paper, the finish film, the lacquer, the veneer, the continuous pressure laminate (CPL) or the high pressure laminate (HPL).

15. Board according to claim 13 or 14, characterized in that the carrier board and finish film, veneer, continuous pressure laminate (CPL) or high pressure laminate (HPL) are connected to one another by a fixing agent. AMENDED SHEET (ARTICLE 19)

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