Plate produced by the direct lamination

FIELD: construction materials industry; other industries; production of the plates produced by the direct lamination.

SUBSTANCE: the invention presents the plate of the direct lamination. The purpose of the invention is creation of the plate of the direct lamination, so that in it the graphics image of the relief shall correspond to the relief reconstruction of its surface. At that it is possible to use the hot pressure moderate for the decorative layer. The plate is manufactured by the method of the hot pressing of the core with the resin-saturated absorbing layers including the surface with one decorative layer containing the graphics image of the surface of the imitated material. The plate also contains the deposited on the decorative layer transparent covering layer with the relief reconstitution of the surface structure of the imitated material. Between the decorative layer and the core there is the intermediate resin-containing layer made in the form of the prefabricated separate adhesive layer with the saturating resin. The given version has the technological advantages at manufacture of the plates of the big dimensions, and also allows to manufacture the plates having the structured surfaces, at that the structure precisely coincides with the graphics image of the below located decorative layer.

EFFECT: the invention ensures creation of the plate of the direct lamination, which graphics image of the relief precisely corresponds to the relief reconstruction of its surface and the given version has the technological advantages at manufacture of the plates of the big dimensions.

3 cl, 2 dwg

 

The invention relates to a plate for direct lamination manufactured by hot pressing of the core with resin-impregnated absorbent layers including at least a surface with one decorative layer containing a graphic image of the surface of the simulated material and printed on the decorative layer of resin-impregnated transparent cover layer.

To simulate materials include, for example, such construction materials as wood, ceramics, natural or artificial stone. Artistic depiction of such material may pass details, for example, the surface of the material in the treated condition, as varnished wood, or in a worn condition with traces of wear, etc. For such plates, obtained by direct lamination used in further reduction of DPL, derived from the English name of the direct-pressure-laminate. Plate DPL are produced in the so-called press with a given quantum. When this individual layers overlay one another and are aligned in such a way that the graphic image and structured the pressing plate before pressing exactly overlap. This is a feature of the plates of the proposed type. This is an attempt to conform to the user a visual impression of the graphic print with tactile impression atplay. On close examination, plate embossed surface structure corresponds more or less to the graphic image.

The objective of the invention is to provide a plate for direct lamination so that it a graphic image of the simulated material corresponded relief reproduction of its surface, with sparing of the decorative layer by hot pressing.

In accordance with the invention the task is solved in that the decorative layer is formed dry before hot pressing paper without impregnating resin that between the decorative layer and the core is provided intermediate smilacaceae layer is performed before the hot pressing in the form of pre-fabricated separate adhesive layer with an impregnating resin, while the adhesive layer contains a matrix in which you have entered an impregnating resin, and that a transparent cover layer is provided with an embossed reproduction of the surface structure of the simulated material.

Soft when pressed smilacaceae intermediate layer with the matrix serves as a buffer into which is pressed decorative paper. Decorative paper is no longer pressed and not razravnivaetsya solid core surface. Ready-made decorative paper can be wavy. In this case, in places stamping on ocnovnom layer she pressed a little deeper in the intermediate layer, than before and after the place of stamping. So there is no crushing of the paper fibers.

Since the intermediate layer before the hot pressing is performed in the form of pre-fabricated separate adhesive layer with an impregnating resin, this version has a technological advantage in the manufacture of plates of large dimensions. The adhesive layer may be impregnated with the same known manner that the covering layer and the decorative paper, while the coating on the core of MDF, HDF or chipboard additional means of production and technical costs.

To the amount of impregnating resin in the adhesive layer was sufficient for bonding to the core, the adhesive layer is provided, the excess resin. This excess is consistent with the specific value of the absorbent capacity of the core material. The smaller the seal material of the core, the greater must include the excess resin. Therefore, a relatively large excess of resin is required for the core material of the chipboard, krupnomolotoy structure which absorbed a large amount of resin during hot pressing.

Due to the fact that the adhesive layer contains a matrix in which you have entered an impregnating resin, depending on the nature of the matrix it can be snabjeniaya resin below its degree of saturation or to have the excess impregnating resin, which adheres to the surface of the saturated matrix.

The preferred manner of a matrix made of paper, so the impregnating resin is well absorbed by the paper.

The decorative layer is preferably from cellulosic material. In particular, the decorative layer can serve as a paper, the graphical image of the simulated material applied to the paper, for example, by a method of color printing. A significant aspect of the invention is that before the hot pressing of the layers on a cellulose material of the decorative layer impregnating resin is not applied. According to the prior art of decorative paper impregnated with excess resin. This means that absorption of cellulose material reaches the degree of saturation at 100% of their absorbency, however, at least on one side of the layer provided with an additional quantity of impregnating resin. It is not embedded, and sticks in the form of a layer of material on the cellulosic material. Strong impregnation of the molten resin leads to swelling of the cellulosic material. This is reflected in the increase in paper size in length and width. According to the prior art for the production of plates direct lamination in which a graphic image coincides with an embossed surface structure, permanently applied then impregnate coratina paper.

Known types of decorative paper supplied in a print shop graphic image of the simulated material. Then a print shop supplies decorative paper to the company, which carries out the impregnation sealed paper, resin. Finally, the paper gets out to the manufacturer of the laminate, which method DPL repressive it on the stove.

In the manufacture of printing device image is expressly required to take into account the expected increase in the size of the pulp material arising from the application of the molten resin. The aim is obtain after drying tar paper, which is enlarged in size and pattern coincides with the pressing plate press DPL, so between the graphical representation and the structure was not offset.

Because of the different orientation of the pulp fibers decorative paper increase the paper size in length and width should not be uniform. When printing a graphic image is taken, for example, an increase in width of 1.6% and an increase in length of 0.6%. Therefore, an imprint of the graphic image is reduced so that the paper enlarged reached theoretical nominal size matching the size of the pressing plate.

Increase the paper size in the application due to a the m number of factors, such as the quality of the pulp fibers of the paper, the nature of processing in the paper machine, the humidity during manufacturing and storage, various so-called dye bath for printing graphic images, as an impregnating resin, in particular its composition, and the conditions of mixing water and hardeners, dosage impregnating mass in a machine for impregnating used additives, such as fly ash, etc.

When processing the printing ink should be noted the following trends: paint with less covering power, such as paint, printing light maple surface, helps increase size and dark printing ink with greater opacity, for example, for printing a dark surface mahogany reduces the size increase. The latter is due to the fact that the paint with greater opacity covers the cellulose surface to a greater extent, and therefore, the molten resin with the sealed side of the paper gets worse in the cellulose material.

Due to many factors increase the size of the paper it is easy to understand that taken by the printer decrease graphics can be only an approximation to the given size, allowing the paper size enlarged to conform with the size of the pressing plates is.

To reduce the effect of increasing the size of paper, the invention refuses impregnation of the decorative layer of excess resin. Instead, the amount of impregnating resin is 0%. Since the objective is to limit the size of the paper, we do not envisage the use of an impregnating resin. Due to this pulp material remains dry, so the paper is increased to a lesser extent than impregnated paper. On top of the decorative layer as a covering layer, impregnated with resin top layer and under the decorative layer is placed smilacaceae intermediate layer. During hot pressing, respectively, at the boundary surfaces between the layers should be sufficient amount of resin to firmly and permanently glue them together.

Especially important for the present invention is the above measure providing for the creation of a decorative layer of dry prior to hot pressing of paper, which has no resin impregnation. This eliminates the effect of increasing moisture due to the molten resin. The paper does not have to be transported to the plant by impregnation, she immediately entered from the printer, can be processed on the press DPL in the laminated plate. This eliminates the problem of increasing the size of the paper is ri the manufacture of a decorative layer. Printing henceforth there is no need to consider due to the resin to increase size. A graphic image of the simulated material can be produced directly with the ratio 1:1. Become unnecessary additional costs to reduce graphic image.

The advantage of processing the decorative layers with little or no increase in humidity is particularly evident in the industrial production of slabs direct lamination. This is due to the large size of the presses used for lamination of the layers. When using very small presses, such as the length and width of one meter, and increase the size of paper 1.6% deviation from the predetermined amount of increase is insignificant and is still valid. However, in the case of using a larger press increase the paper size 1.6% causes a much greater error in the specified value. It leads to marriage, large portions of the plate, obtained by direct lamination. Defects of this type cause the greater harm that further processing may be, as a rule, only whole plate.

Plate direct lamination for further processing are cut, for example, a large number of panels, which are further processed in decorative finishes for walls, floor or ceiling.

In addition to the nternet pressing layers in the press with a given quantum known bonding method of continuous extrusion. When this is applied to the core layers wrapped and served with rolls.

The solution according to the invention for fixing the size of the paper can be manufactured by the method of continuous extrusion plate having a structured surface, the structure is exactly the same as the graph below the decorative layer. The structure should be applied by a rotary method from the roll. Even a minimal increase in the size of the paper will be harmful, because the error in the overlay graphic image and surface structure continues and is enhanced by the infinite unwinding from the roll.

Below the invention on the example of implementation clearly illustrated by drawings, where

figure 1 - cut plate direct lamination cross-section according to the prior art;

figure 2 - cut plate direct lamination cross-section according to the invention.

Shown in figure 1, the plate 1 is a plate according to the prior art. On the upper side 2 of the core 3 of the fibrous plates of high density (high density fibre board - HDF) printed decorative layer 4. There is a graphic image 5 simulated material. In turn, on top of the decorative layer 4 is provided with a top layer 6 of the PR is impregnated with resin of the upper layer. In the upper layer is embossed embossed surface structure, which reproduces the surface of the simulated material. It is advisable to achieve precise alignment of the graphic image 5 decorative layer 4 with an embossed surface structure 7 a cover layer 6. Due to this, the optical impression of the graphic image 5 should correspond with the tactile impression of the embossed surface structure 7.

The decorative layer 4 according to the prior art is made of sealed paper, which before hot pressing is also impregnated with resin. Decorative paper lies directly on the core 3 plates. On the bottom, opposite the decorative layer 4, the side plate 8 on the core 3 is provided so-called layer 9 reciprocal tension, also called compensatory paper. This layer 9 reciprocal tension also usually consists of resin-impregnated paper. The thickness of the compensation of paper corresponds approximately to the total thickness of the decorative layer 4 and top layer 6. Without the layer 9 reciprocal tension laminated plate when cooled deformed under the influence of various stresses in the core 3 and in a layered structure (4, 5).

According to the shown figure 1 is a prior art embossing coating layer 6 causes almost offset him replusive is their decorative paper 4, in particular sealed at its side.

Cellulose fiber decorative paper 4 razduplyayutsya and take damage. The quality of the graphic image 5 first flat printing surface decorative paper suffers from the strain.

Further, according to the prior art it is difficult to achieve alignment of the graphic image 5 simulated material with an embossed surface structure 7. We are talking here not about the problem of orientation, and about the problem of dimensionality, as the increased size of the impregnated decorative paper is different from a single sheet of paper to another.

If the plate is obtained by direct lamination between the decorative layer 4 and the core 3 is not provided additional smilacaceae layer itself decorative paper should be impregnated with resin. The impregnated resin decorative layer is required, as for hot pressing a certain amount of resin serves as an adhesive between the decorative paper and the core 3 to ensure a durable and long lasting joints.

Figure 2 shows the plate according to the invention, obtained by direct lamination, with a decorative layer 4 is sealed in paper. Graphic image 5 on the decorative paper is consistent with the surface structure of 7 created by embossing on u is defined on top of the decorative layer 4 covering layer 6. Graphic image 5 as the roughness of the surface structure 7 are an imitation of the surface of a material, such as wood, ceramics, natural or artificial stone, etc.

To ensure gentle treatment of hot pressing the decorative layer 4, between the decorative paper 4 and the core 3 of the laminated plate is smilacaceae intermediate layer 10. In the proposed example, the intermediate layer 10 before hot pressing is a pre-manufactured separate adhesive layer 10, impregnated with resin.

The adhesive layer 10 contains a matrix in which you have entered an impregnating resin. The matrix also consists of paper. The content of resin in the paper corresponds to the degree of saturation of the paper, including the excess that sticks to the surface of the paper. Thus obtained adhesive layer 10 forms a reserve sufficient resin for gluing paper with the core 3. HDF-core material 3 absorb part of the excess resin 10. This also applies to the reverse side of the adhesive layer 10, United with decorative paper 4, which also forms a supply of resin, in particular for gluing paper adhesive layer with a decorative paper 4.

Decorative paper 4 according to figure 2 represents a dry paper without resin impregnation, with the high absorbing capacity for the resin of the adhesive layer 10. Excess resin adhesive layer 10 corresponds to the absorbency of the core 3 and the dry decorative paper 4 and provides a strong and durable bonding of the layers 3, 4, 6, and 10.

According to figure 2 we can see that the generated embossed in the surface coating layer 5 structure 7 leads to significantly less significant strain on the sealed side of the decorative paper 4 than in the prior art according to figure 1, due to the softness and pliability located under the decorative paper 4 of the adhesive layer 10. In places deep embossing on the cover layer 6 decorative paper 4 can be immersed in the adhesive layer 10, and not replusive on the solid surface of the core 3. Thus, it is gentle treatment of decorative paper 4 during hot pressing. Saved stability decorative paper 4 equally as quality graphic image 5.

Due to the use according to the invention not impregnated decorative paper 4 there is no difficulty associated with applying decorative paper with 4 color printing, with reduced dimensions, which only magnified reach approximately the size of the corresponding pressing plate.

For manufacturing a plate according to the invention, obtained by direct lamination, apply decorative paper 4 which sizes without reducing the Ekati are playing 1:1 the surface of the simulated material. This exactly matches the dimensions of the corresponding pressing plate press DPL. Thus disappear all of the above in the description of the invention the factors affecting the increase of the size of the impregnated paper. However, the invention simplifies the manufacture of such plates direct lamination, because they allow you to match graphics 5 with surface structure 7.

Plate according to figure 2 at its opposite decorative layer bottom side 8 of the core 3 includes the layer 9 reciprocal tension of the resin-impregnated paper, the thickness of which corresponds approximately to the total thickness of the layers 4, 6 and 10, located on the upper side of the core 3, allowing thus on both sides of the core 3 to balance the stresses generated during cooling of the fresh plate.

The reference list of items

1. Stove

2. The upper side

3. Core

4. The decorative layer / Decorative paper

5. Graphic

6. The covering layer

7. The surface structure

8. Bottom

9. Layer reciprocal tension

10. Intermediate layer / Adhesive layer

1. Plate (1) direct lamination manufactured by hot pressing of the core (3) with resin-impregnated absorbent layers (4, 6), including, at least, is Ernest with one decorative layer (4), containing a graphic image (5) the surface of the simulated material and applied on the decorative layer (4) resin-impregnated transparent covering layer (6), characterized in that the decorative layer (4) formed dry before hot pressing paper without impregnating resin, between the decorative layer (4) and the core (3) is provided intermediate smilacaceae layer (10)made prior to hot pressing in the form of pre-fabricated separate adhesive layer (10) with an impregnating resin, while the adhesive layer (10) contains a matrix in which you have entered an impregnating resin, and a transparent cover layer (6) is provided with a raised playing surface structure (7) of the simulated material.

2. Stove direct lamination according to claim 1, characterized in that the impregnation of the adhesive layer (10) contains an excess of resin.

3. Stove direct lamination according to claim 1 or 2, characterized in that the matrix is formed of paper.



 

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