Ornamental paper with applied corrundum coated by adhesive

FIELD: technological processes; chemistry.

SUBSTANCE: invention can be used to manufacture attrition-resistant paper in production of laminated panels for floor covering. The paper is impregated by resin and contains attrition-resistant particles, consisting of silicium carbide, aluminium and/or corundum oxide. The particles are covered by silaned adhesion activating agent and are built into the resin matrix. The method of paper manufacturing includes impregnating the paper with resin, spreading attrition-resistant particles along, coated by adhesion activatin agent, along the paper, and then curing the resing by pressurising the paper with other impregnated paper, or with fibers and resin along with heating. The device used to spread the particles along the paper includes rotating shaft with recesses and the brush, located near the shaft, and installed so that to sweep the particles out of the recesses, as well as device to move the paperalong under the shaft. Laminated panel consists of ornamental paper, coated by attrition-resistant layer, applied to base plate, made from wood.

EFFECT: increase of paper attrition resistance and simplificaiton of manufacturing method.

11 cl, 3 dwg

 

The technical field

The invention relates to wear-resistant particles, which are required for the manufacture of decorative paper with a wear resistant surface. The invention relates further to manufactured this way, the decorative paper.

The level of technology

In the patent US 4,940,503 outlined the way in which wear-resistant particles on the choice are either impregnated with melamine resin overlay or impregnated with melamine resin decorative paper. Then overlay and decorative paper are pressed together, so you get a decorative paper with a wear resistant surface. However, wear resistance, which can be achieved in this way is relatively small compared with other methods.

In international publication WO 00/44576 A1 proposes another way in which wear-resistant particles, such as corundum, sprinkle on impregnated decorative paper. Then applied fiber, mixed with resin, and the resulting system is pressed. But with this method, the wear resistance is relatively low.

In international publication WO 00/44984 A1 proposes a method in which the decorative paper is sprayed with a special dispersion containing wear-resistant particles, such as corundum or silicon carbide. This decorative paper, in turn, is used to manufacture the AI layered panels for flooring. This method allows to obtain high wear resistance. However, this method has a drawback consisting in a large number of required equipment. The necessary apparatus for precision spraying, it is necessary to provide continuous mixing of the dispersion, and, finally, there are significant costs for drying.

Disclosure of inventions

The objective of the invention is to provide a simple to manufacture decorative paper with high wear resistance.

According to the invention the wear-resistant particles'm entwined adhesion promoter and dispersed on the surface of the impregnated decorative paper or impregnated overlay. Then decorative paper and overlay are pressed together. If the wear-resistant particles dispersed in decorative paper, instead of the overlay can be applied, for example, the fibers and resin in order to protect the press from damage, wear resistant particles during pressing.

The method of dispersion in contrast to the method of spraying, known from international publication WO 00/44984 A1, provides a more uniform distribution of wear-resistant material. Moreover it requires less equipment. Enveloping particle adhesion promoter is very easy, as it requires only to dip particles at some time in the ACC is stuudy tub. It is technically much more simple compared to the amount of equipment required for WO 00/44984 A1.

To wear particles was particularly well to dose, after encapsulating the adhesion promoter to dry. In dried, and therefore is particularly suitable for dispensing, the state of the adhesion promoter fits wear particle with the highest weight, which allows to obtain a particularly high wear resistance. For this purpose, the wear-resistant particles are first dipped into the fluid, consisting mainly of adhesion promoter. Or wear-resistant particles is sprayed with adhesion promoter. It requires even less compared to the costs required according to WO 00/44984 A1, so as not to have to take into account the dosing and turning. Then the particles are dried and are particularly suitable for use. The dried, coated with adhesion promoter wear-resistant particles are dispersed on the surface of the decorative paper or overlay. For dispersion preferably the platen with unevenly spaced recesses. However, the depth of the grooves should be about the same. Wear-resistant particles coated with the adhesion promoter, sprinkle on top of the platen and are in depressions. The excess material, i.e. excessive wear hour the Itza, coated with adhesion promoter, suscribase scraper. After rotating the roller comes in contact with the brush that sweeps wear-resistant particles coated with the adhesion promoter.

The brush is rotating roller, covered with bristles to evenly fimetaria coated with adhesion promoter particles. This way, the wear-resistant particles are evenly distributed on or decorative overlay paper with a preferred density of from 18 to 25 g/m2depending on the required class durability. The size of the grains ranges from 50 to 200 μm, preferably from 90 to 130 microns in diameter. With a smaller diameter, a relatively large number of wear-resistant particles together with the adhesion promoter is destroyed, and with a large diameter wear-resistant particles can pierce commonly used overlay and corrupt press.

Before you scatter to the paper, i.e. decorative paper or overlay, wear-resistant particles, the respective sheets are passed through the melamine resin or through a mixture containing melamine resin. Due to the adhesion promoter can bind the particles of corundum or silicon carbide with a resin matrix. Otherwise, between the wear-resistant particles and a resin or resin matrix remains visible intermediate layer, which causes the formation of a gray tint If you do not apply adhesion promoter, the wear-resistant particles can be pulled out from the matrix, and this leads to the decrease of wear resistance.

Application of wear-resistant material on the decorative paper is more preferable, because practice has shown that when applying the wear-resistant particles directly on the overlay damage to the press of the wear-resistant particles more likely.

In conclusion, the overlay and decorative paper are joined together and are pressed, so that the wear-resistant particles form the intermediate layer. Preferred surface temperature during crushing 180-185°C. Usually applied pressure 20-35 bar. The specified temperature is preferred, as it resin material hardens. This pressure is preferable because it allows the water contained in the layered system remains liquid. Otherwise, it would have passed in gaseous form and vanished, so that the surface would be rough. In addition, due to the high pressure surface is very smooth.

Especially preferred decorative paper weighing from 20 to 200 g/m2preferably up to 60 g/m2, particularly preferably from 25 to 40 g/m2that allows you to do a small amount of resin. Decorative paper preferably is filled acrylate or containing the th acrylate dispersion, to further reduce the required number of relatively expensive melamine resin. The acrylate or dispersion better press in decorative paper with both parties to ensure their reliable penetration of the paper. In international publication WO 02/079571 A1 describes appropriate formulations and route of administration acrylate or dispersion into the paper in the sense of the present invention.

During the dispersion of the wear-resistant particles, it is desirable to install on the sides of the paper (overlay or decorative paper cones for capture and removal of excess wear-resistant particles. This allows you to reuse the wear-resistant particles, spilled on the sides.

In contrast to the method of spraying, known from WO 00/44984 A1, it does not require the large amount of equipment. When using corundum as wear-resistant material with the invention for the first time managed to get a shiny surface when applying dark decorative paper.

As the wear-resistant particles are preferably used particles of corundum, or aluminum oxide, despite the fact that alternative materials, such as silicon carbide, it is easier embedded in a resin matrix. However, silicon carbide has the disadvantage compared to corundum, or aluminum oxide, the particles of silicon carbide is dark and well-Zam is tiny, especially in light of decorative papers. So reasons the appearance of silicon carbide, as a rule, are less suitable.

When the impregnation resin is usually applied on the decorative paper in the amount of 100 to 120% by weight relative to the weight of the decorative paper. Thus, if the density of the decorative paper is, for example, 100 g/m2is used 100-120 g of resin. If used decorative paper with a density of 30 g/m2and the paper is pressed acrylate or containing acrylate dispersion, the amount of resin required for impregnation, can be reduced to 45-55% by weight.

Instead of the melamine resin may apply mixed resin. Usually such a mixed resin may consist of 70-80% by weight of urea resin, and 20-30% of melamine resin in order to reduce the cost. Decorative paper is preferably impregnated with a mixed resin, since it allows to reduce costs. The overlay is preferably impregnated with melamine resin to provide the desired surface properties. We mean, in particular, insensitivity surface stains and its resistance against chemicals. In addition, the melamine resin is particularly well protects the surface from moisture.

It turns out decorative paper, in which the corundum lies in the same plane. This is the origin Taiwan is the CIO because, that corundum is scattered throughout the paper. This can be set by means of a microscope. In addition, the finished product can detect the adhesion promoter, which envelops the wear-resistant particles.

Preferably apply adhesion promoters silane-based, as these promoters, on the one hand, very well linked to the corundum, or aluminum oxide, and on the other hand, in the desired manner interact with the applied resin, providing the desired coupling, and consequently, the desired wear resistance.

In principle can be applied and other adhesion promoters. But proved to be particularly suitable aminosilanes the adhesion promoter.

A short list of drawings

1 shows a device for dispersion of the wear-resistant particles on the paper;

figure 2 - made paper;

figure 3 - panel made of paper.

The implementation of the invention

Wear-resistant particles 1 of corundum with a diameter of 90 to 130 μm'm entwined celanova adhesion promoter and dried. Wear-resistant particles 1 then become loose and sprinkle on the platen 2, as shown in section in figure 1. The platen 2 has recesses, not shown in the drawing. At slow rotation of the roller 2 counterclockwise in the direction of arrow 3 the scattered particles are fed to the scraper 4, the free end of which is adjacent to valiku. Thanks scraper wear-resistant particles 1 uniformly and completely fill the recess. Hence, the wear-resistant particles are brought to a rapidly rotating brush 5, which in the example is rotated clockwise, as indicated by the arrow 6. When this wear-resistant particles completely fimetausa from the grooves into the surface of the decorative paper 7. Decorative paper using tools 8, 9, 8', 9' of the moving paper web along under the roller, for example a rotating accordingly rollers 8 and 9 is fed under the roller 2. Prior to this decorative paper impregnated with a mixture of 25% by weight of melamine resin and 74% by weight of urea resins. Decorative paper has a density of 30 g/m2and contains within acrylate. When the impregnation per square meter of paper consumed 15 g of resin.

This method can scatter wear-resistant particles on the paper particularly evenly. When this wear-resistant particles 1 are adjacent along the edge to printed on paper with a decorative pattern.

Then on the wear-resistant particles is superimposed impregnated with melamine resin overlay 10, and the resulting system is compressed under the influence of heat input under a pressure of 30 bar at a temperature of 180°C. is Formed is shown schematically in figure 2, the structure in which the wear-resistant part of the s is firmly embedded in the resin matrix 11. Wear-resistant particles 1 are located in one plane.

Now equipped with a wear-resistant layer of decorative paper 12 is pressed with the base plate 13 of the high-density fiberboard (HDF) and a stabilizing substrate 14. Then cut the panel to the desired size, the width is usually from 20 to 40 cm and the length is usually from 80 to 160 cm, with connection elements on the edges in the form of grooves 15 or ridges 16. Preferably, the tongue and groove form is not shown in the drawings, the connecting elements for fastening two panels with geometric circuit, so that the bond is parallel with the surface of the panels. Such fasteners are known, for example, from WO 02/079571 A1.

Stabilizing the substrate usually has a low density of 20 to 60 g/m2supplied preferably acrylate and before pressing impregnated urea resin or a mixture dominated urea resins. This allows to minimize the cost of applying the stabilizing substrate, so as spent relatively little resin, also cheap compared to other resins. Stabilizing the substrate protects the panel from warping.

1. Paper (7) for use with laminate panel, where the paper is impregnated with resin and contains wear-resistant particles (1)comprising silicon carbide, aluminium oxide and/or alumina, distinguish what the lasting themes which wear-resistant particles (1) covered celanova adhesion promoter and embedded in a resin matrix.

2. Paper (7) according to claim 1, characterized in that the wear-resistant particles have a diameter of from 50 to 200 μm, preferably from 90 to 130 μm.

3. Paper (7) according to claim 1 or 2, characterized in that the wear-resistant particles coated with amino-celanova adhesion promoter.

4. Paper according to claim 1, characterized in that it has a density of from 20 to 200 g/m2preferably up to 60 g/m2, particularly preferably from 25 to 40 g/m2and inside the paper-filled acrylate or dispersion containing acrylate.

5. Paper according to claim 1, characterized in that the wear-resistant particles (1) lie in the same plane.

6. Paper (7) according to claim 1, characterized in that the resin contains amine resin and another resin, which is a urea resin, and is provided with a decorative pattern.

7. A method of manufacturing paper with a wear resistant surface, which receive the paper impregnate the paper with resin, characterized in that the paper dissipate the wear-resistant particles coated with the adhesion promoter, and utverjdayut resin by crushing with the other impregnated paper or with the fibers and the resin while applying heat.

8. Laminated panel containing paper, described in any one of claims 1 to 6, which features a wear-resistant layer of decorative paper (12) is Anezina on the base plate (13), made of wood material, such as wood-fiber plate high or medium density.

9. Laminate panel of claim 8, characterized in that it has made with the sides of the connecting elements (15, 16) in the form of tongue and groove, as well as other connecting elements so that the two laminate panels can be interconnected with geometric circuit as perpendicular to the surface of the panel and parallel to the surface of the panel.

10. Laminate panel of claim 8 or 9, characterized in that the stabilizing substrate (14) urea impregnated with resin.

11. Device for dispersion of the wear-resistant particles on the paper, described in any one of claims 1 to 6, characterized in that includes a rotating roller (2) with grooves and the adjacent roller brush (5), which is installed so that it can sweep particles out of the grooves, and means(8, 9, 8', 9') moving paper web along under the platen.



 

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