Method for manufacturing of decorative paper laminate

FIELD: construction.

SUBSTANCE: packet, which is assembled from a layer of barrier paper, layers of power paper impregnated with resin, intermediate layer of paper with high content of resin - 6075%, decorative layer of paper that is not impregnated with resin with decorative pattern and coating from earlier hardened resin is continuously pressed only on one side at the pressure of 1535 bar, temperature of 170200C, speed of pressing 420 m/min. On completion of pressing subsequent completing operations are performed, which include cooling and cutting of edges.

EFFECT: production of object with high characteristics of surface glossiness with higher light refraction, increased resistance to wear, to action of water and chemical reagents.

3 ex

 

The invention relates to the production of laminated composite materials, applies, in particular, the technology of manufacturing decorative paper laminates, which are used in furniture manufacturing, construction, and repair of residential and industrial premises, and finish vehicles.

Decorative paper laminate (DBCP) is a sheet material obtained by the method of extrusion presses on special kinds of paper, impregnated with synthetic thermosetting binder. The prior art method of manufacturing DBCP, including the impregnation of paper alcohol solutions of phenol-formaldehyde resins (CFF), drying the impregnated paper, packaging and pressing packets at an elevated temperature, pressure and pressing speed (Plotkin G., Naughty G.B. Decorative paper-layered plastics. M., 1968, p.87-92). A method of obtaining TBSP comprising a substrate with a decorative top layer formed from impregnated with thermosetting resin sheet of paper with ornaments, and placed on top of a decorative protective layer resistant to abrasion (Liebers]. Layered plastics, decorative surfaces, Saint-Petersburg, Hemostat, 2007). There is also known a method of manufacturing DBCP in accordance with the author's certificate of the USSR No. 5000616. TBSP obtained by impregnation of paper aqueous phenol-formaldehyde binder 4555% concentration, drying of the set of packages from the impregnated sheets of paper and pressing at elevated temperature and pressure.

Analogue containing the maximum number of features in common with the claimed invention, a patent of the Russian Federation No. 1306999, MKI VW 29/00. This patent describes a method of manufacturing a laminate by pressing on floor presses at a given temperature 135140C and a pressure of 100 bar package, recruited from the barrier layer of paper, several layers of the power of paper soaked in an aqueous solution of thermosetting resin content of 3040% binder, decorative paper covering layers of thin transparent paper impregnated with resin. The last layer of paper is intended to protect the decorative layer of the coating from abrasion. Durable plastic is determined by the resistance of the surface to abrasion to remain attractive appearance.

The problem solved by the invention is to obtain a decorative laminate in the process of continuous extrusion with high glossy surface with a high refraction, increased resistance to abrasion, water and chemicals.

The essence of the invention lies in the fact that offered to the persons producing decorative laminate by extrusion package recruited from the barrier layer paper, power layers of paper impregnated with resin, the intermediate layer paper with a high content of resin - 6075%, the decorative layer covered with tar paper with a decorative pattern and a coating of previously utverzhdenii resin on only one side at a pressure of 1535 bar, a temperature of 170200C, pressing speed 420 m/min and the subsequent finishing operations, including cooling and cutting edges.

The prior art finishing material from which the decorative layer is made of covered with tar paper with a decorative pattern and a coating of acrylic resin utverzhdenii previously, for example, electron beam (Liebers. "Laminated plastics, decorative surfaces", str, St. Petersburg, Hemostat, 2007). Such material in the technical literature is called the "Elesgo"acrylic resin hardens under the action of an electron beam of a certain spectrum without heating to high temperatures and pressure. When solidification is no emission of harmful gases into the atmosphere or into the water. "Elesgo provides high surface durability and wear resistance. The optical characteristics of the surface without any losses represent the colors and nuances of the surface, down to the finest branches of the tree structure. Cured acrylic resin shall meet the higher coefficient of refraction of light, than cured under heat and pressure melamine resin. This coating is hygienic, easy to clean, anti-static (does not attract dust), resistant to high temperatures (heat of a burning cigarette)that is impervious to stains and chemicals. The coating is resistant to the action of ultraviolet rays (does not fade in the sun).

However, all existing to date technology "Elesgo" secured, for example, wood-shaving plate with glue and pressing on floor presses. That is decorative and protective material has a thickness of about 0.1 mm and in case of damage (breakthrough) acrylic protective layer properties were lost.

In the proposed method based on the paper "Elesgo" is made of much more durable material - plastic, the surface of which has all the advantages of acrylic films. Even when the violation of the surface of the acrylic film (a breakthrough is impossible, is possible only scratch) due to the strength of the plastic protection of the substrate (particle Board, fiberboard, plywood, etc) continues to be carried out. In order to punch through plastic need much more effort.

To ensure the above decorative plastic surface having acrylic layer, it is necessary to solve two problems:

to build a strong grip is krylovii film with decorative paper;

to ensure the solidity of decorative paper weights and barrier layers, i.e. the integrity of the plastic, not just the connection between the layers of paper.

The complexity lies in the fact that:

- apply acrylic film is already impregnated with melamine-formaldehyde resin is impossible - these resins are too diverse;

is impregnated with an aqueous solution of the resin to the paper already applied acrylic layer is not obtained: first, because of the expansion of paper impregnation solution, and secondly, to ensure complete impregnation (to acrylic).

In this technology this problem is solved by impregnation of paper with already applied on the one hand and utverzhdennym layer of acrylic resin melt melamine-formaldehyde resin in the process of pressing simultaneously with the connection of all layers into a single monolith plastic. According to the claimed method for the first time possible to obtain a solid monolith in the process of continuous pressing on the heated rollers of the package containing the decorative material "Elesgo, and between it and the power layer paper with 6075% resin. When specified in the claims modes (pressure, temperature, speed compression) this quantity of resin is necessary and sufficient to have time to be impregnated with a dry piece of paper "Elesgo" molten resin during presova what I polycondensation in all layers. If the pressing is conducted not in modes as specified in the form, it can happen incomplete impregnation of a dry part of the decorative layer, or not a complete curing of the resin in the compression package. In both cases, the full product is not obtained. When the content of the resin in the intermediate layer is less than 60% not provided impregnation of a dry piece of paper the decorative layer to achieve reliable monolithic connection of the decorative layer with the power layers. If a lot of tar (>75%) - will be too brittle plastic (because the paper gives plasticity, and resin - hardness). It cannot be rolled up (to postformability). It is also possible rejection acrylic film, if through dry paper will be too much resin. The choice of specific values of pressure, temperature and speed of extrusion within the limits specified in the claims is determined by considering the properties and thickness of paper used, properties of the used resin, equipment and other technological factors. Temperature and speed (actual - time pressing) - related parameters governing the amount of heat applied to resin, and, accordingly, provides, on the one hand, the melting and penetration (penetration) resin covered in the paper, on the other curing due to polycondensation. If the speed is greater than 20 m/min and / or low temperature (less than 170C) resin does not have time to melt and flow. If the speed is too small (less than 4 m/min) or high temperature (over 200C) will periuterine resin, the fragility of the plastic and buckling - "twisting"; with a very strong overestimation of the temperature resin polycondensates (cures) before spreading. If the pressure is too low (less than 15 bar) - will not happen of mutual penetration of the resin between the layers will be glued together "layer cake", not a monolith). High pressure - in principle - the more the better, but for continuous pressing is purely structural constraints, and its value may not exceed 35 bar. Obtaining a glossy surface with a high gloss level previously achieved only in the method of storey pressing. In this case we use the method of continuous extrusion.

The order of steps in the production of plastic according to the stated claims following.

1. On unwinding shafts set: roll of decorative paper "Elesgo, roll with the content of the resin 6075%, rolls with power paper impregnated with resin to create the desired thickness of the plastic (if needed), a roll of barrier paper (or other material without impregnation), serving as a barrier layer.

2. Between the tape press preheated to the required temperature, fill all layers of the package in the following the sequence: barrier layer, the layer strength of paper, paper with a resin content of 6075%, decorative paper Elesgo.

3. After pressing, plastic goes through the following operations: cooling (cooling shafts), trimming the edges.

Examples of producing a decorative laminate with decorative paper "Elesgo".

Example 1

intermediate layer with a content of 60% melamine-formaldehyde resin, a pressure of 17 bar, 200C and the pressing speed of 18 m/min

Example 2

intermediate layer with the content of 65% melamine-formaldehyde resin, a pressure of 25 bar, 200C and the pressing speed of 12 m/min

Example 3

intermediate layer with a content of 75% melamine-formaldehyde resin, a pressure of 35 bar, a temperature of 170C and the pressing speed of 6 m/min

A method of manufacturing a decorative laminate by extrusion package recruited from the layer of barrier paper, power layers of paper impregnated with resin, the intermediate layer paper with a high content of resin 6075%, the decorative layer covered with tar paper with a decorative pattern and a coating of utverzhdenii previously resin on only one side at a pressure of 1535 bar, a temperature of 170200C, pressing speed 420 m/min and the subsequent finishing operations, including cooling and cutting edges.



 

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3 ex

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