Decorative paper, containing electrically charged fibres

FIELD: textiles, paper.

SUBSTANCE: wear proof particles are treated with adhesion promoter based on silane or sylon and then deposited on paper, impregnated with resin, thereby obtaining coating. Fibre is electrically charged and put onto the coating. Drying is then carried out. The device for implementing the given method has a equipment for depositing wear proof particles on paper, equipment for charging fibre and putting the charged fibre onto the paper. The latter consists of a roller with depressions, made with provision for rotating, and a brush mounted near the roller for cleaning the depressions. The device also has apparatus for electrically charging the roller and/or the brush and the roller, which is made with provision for rotation and passing paper sheets under the roller with depressions. Paper, made using this technique, has a wear proof coating and electrically charged fibres on the wear proof coating. The charged fibres used can be made from polyester and/or cotton, and/or cotton linter.

EFFECT: obtaining wear proof paper with improved properties.

14 cl, 3 dwg

 

The technical field

The invention relates to a method and apparatus for manufacturing paper with a wear resistant surface, and the paper made according to this method.

Prior art

In the patent US 4940503 disclosed method, according to which the wear-resistant particles are distributed in the outer layer, impregnowana melamine resin, or a decorative paper impregnated with melamine resin. The outer layer and the decorative paper is then pressed together and get a decorative paper with a wear resistant surface. However, wear resistance, which can be achieved in this way is relatively low compared with other methods. In addition, the outer layer refers to a paper, it is necessary to produce separately.

In the publication WO 00/44984 A1 disclosed a method, according to which the decorative paper sprayed with a special dispersion containing wear-resistant particles, such as corundum or silicon carbide. Decorative paper in turn used in the manufacture of panels for laminate flooring. It should be recognized that using this method can achieve good performance wear. However, the necessary technical equipment is quite complex compared to the simple spray snooty is their particles. Specialists know that the wear-resistant particles deposited on decorative paper, should be covered with an outer layer to protect the press in the process of pressing the decorative paper with a stove in the manufacture of, for example, panels for laminate flooring or countertops with a wear resistant surface.

In the publication WO 00/44984 A1 disclosed a method, according to which the wear-resistant particles, such as corundum, distribute impregnated decorative paper. After that put the fibers with the resin, and a layered system is pressed. In this way, you can avoid the separate manufacture of decorative paper. However, with this method, it is problematic to create a protective layer, which would ensure a positive quality of the top layer of paper.

Disclosure of inventions

Thus, a task that should be solved by the invention is to create a wear-resistant paper with improved properties.

The task is solved through the method, according to which the paper is applied wear-resistant particles. Then electrostatically charged fibers. Fibers in an electrically charged state put on paper. Thus relatively easy to apply the fibers to the paper in a controlled manner. All or at least a large part of the fibers subsequently is raised vertically relative to the paper. So it is possible to achieve uniform distribution of fibers. The result is a paper containing wear-resistant particles, deposited on the surface. In addition, on the surface of the paper containing wear-resistant particles are provided vertically spaced fibers.

For making paper with a wear resistant surface according to the invention using the device containing means for applying wear-resistant particles on the paper and means for charging the fibers and for applying the charged fibers on the paper, including the roller with grooves made with the possibility of rotation, and a brush mounted adjacent roller are made with the possibility of cleaning the grooves, and means for electrical charging roller and/or brush, rollers, made with the possibility of rotation and passing the paper web under the roller with grooves.

Means for applying wear-resistant particles on the paper includes an additional roller with grooves made with the possibility of rotation, and an additional brush set next to a roller made with the possibility of cleaning the grooves, also contains tools made with the possibility of passing the paper web extra cushion.

For application to the paper fibers in an electrically charged state is used, for example the EP, causing the roller to which is supplied an electric charge. The surface causing the roller is provided with recesses or notches for receiving fibers. Preferably, the recess was irregularly shaped and irregularly distributed over the surface of the roller. Fiber is applied to cause the platen top. Preferably, causing the roller was made of insulating material such as plastic or rubber, in order to transfer electric charge from the roller on the fiber. During the rotation of the platen fiber eventually fall off from him. Paper containing wear-resistant particles, pressed the lower part of the roller. In this way, the fibers fall onto the paper and placed in a vertical position.

When the compression of the paper in the press upright fibers lie in the folded state over the wear-resistant particles. Thus, the press is protected from damage.

As the press, in particular, using such media, working with a rotating belts or rollers. In this case, the paper together with tape moves in a press with one hand. Standing upright fibers are then uniformly lean in the same direction. In this way we obtain a uniformly protected surface. Paper laminated with a stove, comes out of the press in any other places is. Stove with paper, has a wear-resistant surface. Thus obtained product can be used as countertops. If necessary, the plate can be cut into individual elements having a predetermined size. The individual elements on the sides can be provided with connecting elements for receiving panels for flooring.

Usually put on paper decor. To this end, the paper can be printed drawing. Then on the decor, that is printed on the surface, causing wear-resistant particles. Paper together with the plate moves in a press, so that was visible decor. In this case, the material of the fibers is chosen so that the fibers were not practically spoiled the appearance of the decor.

Paper manufactured by the method according to the invention, contains a wear-resistant coating and fiber that are on the wear-resistant coating. The hallmark of the paper is that it contains electrically charged fibers. These fibers can be made of a polyester and/or cotton and/or cotton Linter.

The fibers may consist of polyester. On the one hand, this allows to obtain fibers of electric charge. On the other hand, through such fiber is still visible decor.

Although the polyester has the required properties for the aforementioned purpose, this m is a material predetermined is quite expensive.

Consequently, for greater efficiency, it is preferable to use cotton Linter. Cotton Linter is a very short fibers that accumulate in the manufacture and pulling cotton and which cannot be spun. These waste products can also be electrically charged. In addition, you can create a transparent protective layer, wherein the decoration of the underlying securities remains outstanding. The length of the fibers may be of the order of half-millimetre. However, fiber can be a length of 2-4 mm

To ensure uniform distribution of the fibers with the roller on the paper, it is preferable to clean out the grooves for causing the platen. For this reason, in particular, used the additional roller with bristles (brush), adjacent to causing the platen. This roller with bristles also rotates and, thus, removing the fibers from the recesses to cause the shaft.

According to one of the options for dealing with the platen touches the blade, holding the excess fibers to provide the desired dosage. Preferably, when applying the fibers to the side of the paper were provided by a funnel to receive the excess fibers and bring them back on causing the platen. Due to this recirculation can be reduced.

According to one of the options for ensuring that the Oia required surface properties of electrically charged fibers, put on paper or intended for use on paper treated with resin, in particular melamine resin. As a rule, required resistance to dyes and chemicals. In addition, melamine resin very well protects the surface from moisture.

According to one of embodiments of the invention, the wear-resistant particles are applied on the paper with the resin. This method in General is known from the publication WO 00/44984 A1. First, the paper preferably impregnorium resins, in particular melamine resin, or a mixture of melamine resin and urea resin, to improve the adhesion of the wear-resistant particles to the paper. It is useful to have the excess resin was returned back to the container that contains wear-resistant particles with the resin. By recirculatory resins, on the one hand, effectively reducing costs. But more importantly, thanks to the recycling of the resin in the container creates a fluid motion. This movement helps to maintain the wear-resistant particles in a suspended condition. In this way improves the uniform distribution of the particles in the resin. In addition, this method can be processed relatively large wear particles.

According to one embodiments of the invention after the deposition of wear-resistant particles and resin on paper it is consequently dry. The result is dried molecular escalation, namely the condensation polymerization (polycondensation). Thus, on paper, a first layer. At this point, electrically charged fibers deposited on these layers may not be implemented in this layer. If the fiber into the first layer, the fibers are already not able to exercise the necessary protection of the press. Thus, the preliminary drying contributes to the fact that fiber will be able to provide the necessary protective action.

In a preferred alternative embodiment of the invention, the wear-resistant particles sprayed on impregnated decorative paper. In particular, to achieve a good degree of abrasion resistant particles are protected by the adhesion promoter. After that, the decorative paper is applied electrically charged fibers.

Preferably, the paper was impregnated with resin and, in particular, by means of measuring rollers. Or impregnation can also be performed using a doctor knife. Using resin or by impregnating the wear-resistant particles are fixed on the paper.

Using wear-resistant particles makes it possible to achieve a more uniform distribution compared with the sputtering method, known from the publication WO 00/44984 A1. In addition, decreases if estvo necessary equipment. Protection particles with adhesion promoter is very simple, because the particles only are immersed for some time in the tub. Technically it is, essentially, less difficult in comparison with the equipment necessary according to the publication WO 00/44984 A1.

For more reliable dosing wear-resistant particles treated with adhesion promoter, preferably dried before application. In the dry state and, therefore, the most convenient for dispensing state, the adhesion promoter is fully covered by particles, providing, thus, a particularly good degree of adhesion. With this purpose, the wear-resistant particles are first immersed in a fluid, consisting mainly of adhesion promoter. Or wear-resistant particles are sprayed with an adhesion promoter. It is even less complicated in comparison with the actions required according to the publication WO 00/44984 A1, because this dosing and management are not taken into account. Then the particles are dried, after which they become the most convenient for the application. The dried particles treated with adhesion promoter, put on paper, in particular on decorative paper. Preferably, in order for the application used a roller with grooves, preferably spaced unevenly. The depth of the recesses, however, is essentially the same. Isocost is ikie particles, treated with adhesion promoter, applied to the roller at the top and, therefore, fall within the recess. The excess material, which implies excess wear-resistant particles treated with adhesion promoter, blowin doctor blade. After rotating the roller in contact with the brush that sweeps away from the roller wear-resistant particles treated with adhesion promoter.

For even a crumb particles treated with adhesion promoter, with a rotating roller, it is preferable that the brush was made in the form of a roller made with the possibility of rotation, provided with bristles to sweep particles. In this way, the wear-resistant particles is applied on the decorative paper evenly and, particularly preferably, in the amount of 18 to 25 g/m2depending on the desired degree of abrasion. The preferred grain size is from 50 to 200 microns in diameter, more preferably 90-130 μm. When choosing smaller diameter consumes more wear-resistant particles with adhesion promoter. When choosing the larger diameter of the wear-resistant particles can damage the press despite containing fiber protective layer.

Before applying the wear-resistant particles on the paper, according to a preferred variant of the invention, corresponding to the paper web passes through, such as the er, melamine resin or a mixture containing melamine resin. Using the adhesion promoter wear-resistant particles, for example particles of corundum or silicon carbide, can be combined in a resin matrix. If it is not, between the wear-resistant particles and the resin or the resin matrix may remain visible boundary layers, which will lead to gray mind. If an adhesion promoter is not used, the wear-resistant particles can be removed from the matrix, which will lead to low degrees of abrasion.

When the paper is coated with wear-resistant particles, as well as with electrically charged fibers pressed together with an additional layer, for example with the panel surface temperature during extrusion is preferably lies within 180-185°C. Typically use pressure 20-35 bar. This temperature is preferred when working with resins. This pressure is preferred to keep the water contained in the layered system, in liquid form. Otherwise, water may be released in gaseous form and to produce a rough surface. Due to the high pressure get even more uniform surface.

To reduce costs it is preferable that the decorative paper had a weight per unit area of 10 to 60 g/m2most preferably 20 to 40 g/m2. Decorative panels, the main paper is preferably impregnated with acrylate or galatsaray dispersion, to further reduce the number of expensive melamine resin required for impregnation. The acrylate or dispersion presoviet in the paper, in particular, on both sides, to ensure penetration of the paper. In the publication WO 02/079571 A1 disclosed acceptable compositions, and method of introduction of acrylate or dispersion into the paper in the sense of the present invention. When applying the wear-resistant particles, preferably at the side of the paper were provided by a funnel for receiving excess wear-resistant particles. In this way the possible management of the wear-resistant particles, as they applied to the surface of paper in excess. In particular, particles of corundum or aluminum oxide for the application process amplifiers adhesion, since materials such as, for example, silicon carbide is in any case relatively easy to integrate in a resin matrix. Silicon carbide, however, has the disadvantage compared with corundum or aluminum oxide, as it contains dark particles, in particular, visible light decor. Thus, typically, the silicon carbide is not suitable for optical reasons.

When the application of decorative paper typically use 100 to 120 wt.% resin with respect to the decorative paper. Thus, if the mass of a unit square of decorative paper 100 g/is 2use the amount of resin comprising from 100 to 120, But if there is a paper with a weight per unit area of only 30 g/m2and if the paper shrunk acrylate or galatsaray dispersion, the amount of resin required for impregnation, can be reduced to 45-55 wt.%.

Instead of the melamine resin can also be used mixed resin. Typically, such a mixed resin may contain from 70 to 80 wt.% urea resin and from 20 to 30 wt.% melamine resin, to reduce the cost of resin. Preferably, in order to reduce costs decorative paper was impregnated with the mixed resin.

The result is a decorative paper, while after the application of wear-resistant particles on the paper corundum is located in the same plane. This can be confirmed with a microscope. In addition, can be detected successfully used an adhesion promoter, covering the wear-resistant particles.

As the adhesion promoter are preferred amplifiers silane-based, as these amplifiers adhesion is better suited for connection, on the one hand, to the corundum or aluminum oxide, and on the other hand, to obtain the required adhesion to the resin and, therefore, the required durability.

Generally speaking, and also fit on the other amplifiers adhesion. However, determined that to the greatest extent meet the requirements of the amplifiers adhesion-based aminosilanes.

Brief description of drawings

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

figure 2 presents made paper;

figure 3 shows a panel made of paper.

Information confirming the possibility of carrying out the invention

Wear-resistant particles 1 of corundum with a diameter of 90 to 130 μm coated with adhesion promoter silane-based and then dried. After that, wear-resistant particles become loose, causing the platen 2, as shown in section in figure 1. The platen 2 has on its surface recesses and notches (not shown). Slow counter-clockwise rotation of the roller 2 in the direction of the arrow 3 deposited particles are moved to the doctor knife 4, which is in contact with the platen 2 with the open end. By using the doctor knife 4 provides a more uniform and complete filling of the recesses of the wear-resistant particles 1. After that, wear-resistant particles are moved further to the rapidly rotating brush 5, which in the present example, rotates clockwise in the direction of the arrow 6. Thus, the wear-resistant particles are completely clean of recesses and dosed on the surface of the decorative paper 7. Decorative boom is ha 7 passes under the roller by means of the respective rotating rollers 8 and 9. Immediately after this decorative paper 7 impregnorium mixture prepared from 25 wt.% melamine resin and 74 wt.% urea resin. Decorative paper has a weight per unit area of 30 g/m2and processed with the inner sides of the acrylate. The amount of resin applied when the application is 15 g per square meter of paper.

Thus, it is very uniformly applied to the paper, wear-resistant particles. Wear-resistant particles are touching the surface with printed decoration.

Then on decorative paper in a manner analogous to that described above, for wear-resistant particles 1 cause of fiber 10, which may be impregnated with melamine resin. Use the device that contains the elements shown in figure 1. However, the elements involved at this stage of the method, such as a roller, a brush and a cleaning blade composed in this case of electroconductive materials such as, for example, rubber or plastic. Involved elements such as roller, doctor blade and/or brush, additionally electrically charged. This leads to the fact that the fibers reaching the roller is electrostatically charged. When removed from the platen fiber moves with acceleration in the direction of the paper. Thanks repulsion effect fibers evenly distributed throughout the paper. They are computers who correctly to each other and essentially vertically relative to the paper.

When implementing this method during application of the wear-resistant particles, it is preferable to use a fairly large amount of resin compared with the application of the particles by spraying, especially if applied fiber, unprocessed pre-resin. When spraying a mixture containing the resin and wear resistant particles, usually applied from 100 to 250 wt.% the mixture relative to the mass of a unit area of the paper in the dry (unprocessed) form. In this case, in one of the embodiments of the invention select this amount of resin to dry the paper had a coating weight which is higher in 2-2,5 times or more.

After application to the paper electrically charged fibers 10 paper preferably dried. Thus get the paper, with one side containing wear-resistant particles and, on the other hand, prepared for use in the press. Figure 2 shows a schematic structure of the paper.

Decorative paper 12 containing wear-resistant layer, pressed under a pressure of 30 bar and temperatures up to 180°With plate base 13 made of fiberboard, and protivopravnoy paper 14. Completely or predominantly standing essentially vertically fiber on top of the wear-resistant particles 1. In this way the press can be protected from damage, wear resistant particles.

Afterthis is cut into panels of the desired size, usually 20-40 cm wide and long, as a rule, 80-160 cm and supply them to the side of the connecting elements, such as, for example, the groove 15 or the sheet 16. Preferably, the groove and tongue were provided with an additional locking elements (not shown) to ensure a secure fit between the two panels, to ensure a fixation parallel to the surface of the panels. This recording is known, for example, from the publication WO 02/079571 A1.

Protopopova paper has, in particular, low weight per unit area of 20 to 60 g/m2and, preferably, treated acrylate and impregnated before pressing urea resin or a mixture containing predominantly urea resin. Thus, the costs associated with the use of protivopravnoy paper, minimized, because they use a relatively small amount of resin and, in addition, a relatively inexpensive resin. Protopopova paper protects the panel or working stove, etc. from the strain.

1. A method of manufacturing paper having a wear resistant coating (1, 11) and fiber located on the wear-resistant coating (1, 11), in which wear-resistant particles (1) is applied to the paper with the resin, electrically charged fibers (10) and put them on the floor, consisting of wear-resistant particles and resin.

2. The method according to claim 1, in which, after Nanase the ia fibers (10) the paper is dried.

3. The method according to claim 1 or 2, wherein a mixture of resin and wear resistant particles sprayed on the paper, and the excess resin return from paper into the mixture, after spraying and before applying fiber paper coated with a layer of preferably dried.

4. The method according to claim 1 or 2, in which the paper impregnorium resin, and wear resistant particles (1) is treated with adhesion promoter and put on paper.

5. Device for manufacturing paper with a wear resistant surface, characterized in any of the preceding paragraphs, containing the means for applying wear-resistant particles on the paper and means for charging the fibers and for applying the charged fibers on the paper, including roller (2) with grooves made with the possibility of rotation, and a brush mounted adjacent roller are made with the possibility of cleaning the grooves, and means for electrical charging roller and/or brush, rollers (8, 9), made with the possibility of rotation and passing the paper web (7) under the roller (2) with grooves.

6. The device according to claim 5, where the means for applying wear-resistant particles on the paper includes an additional roller (2) with grooves made with the possibility of rotation, and an additional brush (5)set next to a roller made with the possibility of cleaning the grooves, also containing means(8, 9, 8', 9'), �ispolnenie with the possibility of passing the paper web (7) under the additional roller.

7. Paper manufactured by the method according to any one of claims 1 to 4, containing wear-resistant coating (1, 11) and fiber that are on the wear-resistant coating (1, 11), characterized in that it contains electrically charged fiber (10) of the polyester and/or cotton and/or cotton Linter.

8. Paper according to claim 7, characterized in that the fiber (10), located on the wear-resistant coating (1, 11), are arranged vertically with respect to the paper surface (7).

9. Paper according to claim 7 or 8, characterized in that it contains wear-resistant particles (1), coated with adhesion promoter.

10. Paper according to claim 7 or 8, characterized in that it contains wear-resistant particles (1)having a diameter ranging from 50 to 200 μm, preferably from 90 to 130 μm.

11. Paper according to claim 7 or 8, characterized in that the wear-resistant particles (1) coated with the adhesion promoter silane-based, preferably the adhesion promoter on the basis of aminosilane.

12. Paper according to claim 7 or 8, characterized in that the wear-resistant particles (1) are composed of aluminum oxide, preferably made of corundum.

13. Paper according to claim 7 or 8, characterized in that it has a mass per unit area of from 10 to 60 g/m2, preferably from 20 to 40 g/m2and the inner surface of the paper is preferably impregnated with acrylate or galatsaray dispersion.

14. Paper according to claim 7 or 8, characterized in that it is impregnated CME is using resins, containing amino and additional resins, in particular urea resin, and provided with a decoration, and made with the possibility of placing on the stove, on the lower side of which is Protopopova paper.



 

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