The method for producing building panelIt is on March 14th, 2013 that the application, which is the applying date, application No. is 201380012808.5, entitled " productionThe divisional application of the Chinese patent application of the method for building panel ".
Invention field
Embodiment of the present invention is related to a kind of side for producing building panel such as floor, wallboard, ceiling, furniture assembly etc.Method.
Technical background
Wood-fibred base direct pressing laminate flooring generally includes the top dress of 6-12mm fiber plate core, 0.2mm thick laminated plateDecorations property superficial layer and 0.1-0.2mm thick laminated plate, plastics, paper or similar material lower balancing layer.
Laminate surface generally includes two scraps of paper, i.e., 0.1mm thickness printing ornament paper and is applied on the facing paper and anticipatesIt is intended to the thick transparent decorative paper of 0.05-0.1mm for protecting the facing paper to prevent abrasion.Stamp on the opaque facing paper is only about0.01mm is thick.Usually the transparent dressing bread made of extra-milled fibre (such as alpha-cellulose fiber) is for example hard and transparent containing abrasion resistant particlesSmall particles of alumina.Extra-milled fibre is considerably long, about 0.5-5mm, this gives intensity required by the decorative paper.In order to obtainBright property, all natural resins being present in virgin fibers have been removed and alumina particle are applied to dress with very thin layerIt adorns on paper.The superficial layer of laminate flooring is characterized in that decoration and polishing machine are usually obtained with two separates layers stacked on top of each otherIt arrives.
Printing ornament paper and veneer melamine/formaldehyde resin dipping are simultaneously laminated to wood-fibred base core or plane under heat and pressureCard core.
The size range that alumina particle can have is 20-100 microns.Particle can mix superficial layer in several waysIn.Such as they can be mixed in paper pulp in the manufacturing process of decorative paper.They can also be in the impregnating process process of veneerIn the paint film that middle spray is on wet paint film or incorporation is for impregnating veneer.
The wearing course can also produce under no cellulose veneer.At this time with above-mentioned similar approach by melamine/formaldehyde treeRouge and alumina particle are applied directly on facing paper as upper paint layer.The wearing course is commonly referred to as liquid veneer.
Using the available extremely abrasive surface of the production method and such surface is mainly used for laminate flooring, but can alsoTo be used for furniture assembly and similar application.The wearability that high quality laminate flooring has turns for 4000-6000, this corresponds to basisThe wear rating AC4 and AC5 that iso standard Taber Abraser is measured.
It it is known that the wearability of japanning wood surface can cover the transparent paint film of wood surface by mixing alumina particleIn and significantly improve.
Most common core material used in laminate flooring is the fiberboard with high density and good stability, commonly referred to asHDF-high density fiberboard.Sometimes MDF-medium density fibre board (MDF)-is also used as core.Also use other core materials such as particieboard.
Developed new " no paper " floor type recently, wherein obtained using powder technology comprising it is processed or not plusThe solid laminating surface of the substantially uniform mixture of the wooden particle, adhesive and abrasion resistant particles that work is crossed.The floor type is referred to hereinafter asFor " solid lamination " floor.Abrasion resistant particles are preferably alumina particle and adhesive is preferably thermosetting resin such as melamine/formaldehydeResin.Other suitable materials are, for example, silica or silicon carbide.The generally preferably conduct in a dry form of all these materialsMixed-powder is applied on HDF core and is solidified into the solid laminate layers of 0.2-1.0mm under heat and pressure.In solid laminate flooringSolid layer provides impact and wearability.
Powder technology is also used for the floor that production has the surface for being combined with paper technology and powder technology.The floor typeHereinafter referred to as " wood powder laminate flooring ".Facing paper is applied to the sublayer comprising wood powder and adhesive.Facing paper passes through normalAdvise veneer protection.The major advantage on such floor is can to obtain deep embossing and improved impact resilience.
Powder technology can be used for the floor that production has the powder veneer being arranged in decorative layer.Powder veneer includesThe wooden particle, adhesive and abrasion resistant particles such as aluminium oxide.Powder veneer substitutes conventional veneer and provides improvement compared with conventional veneerWear-resisting property.
Powder of the manufacture for the decorative surface of such as floor, operating surface, wallboard, furniture and other application fields is mixedThe standard production for closing object is based on dry blend process.
Melamine/formaldehyde resin, abrasion resistant particles and the pigment by the wooden particle, spray drying mix in a dry form in a mixerMerge fine dispersion.Because mixture of powders produces in a dry form, the distribution of adhesive is limited on the outside of the wooden particle upper and viscousMixture is not distributed across on the surface of abrasion resistant particles and pigment.In addition, in the dry blend process, additive is in the mixtureDistribution is restricted.Even if being added, since the non-uniform Distribution of additive can not obtain the required effect of additive.
The depth of the wooden particle impregnates and the wetting of pigment and the abrasion resistant particles for improve wearability is in drawing methodIt carries out at high temperature under high pressure.Step in pressing process should include wood including complete hot-melt adhesive, by adhesive distributionIn the matrix of grain, pigment and abrasion resistant particles and impregnate and soak the surface of solids.These steps should reach the solidifying of adhesive compositionImplement and occur after this final solidification of adhesive before glue point.
Being unsatisfactory for these conditions will lead to the surface with limited pollution resistance and/or the fuzzy table with high opacityFace.
Cavity and channel of the adhesive in such as wooden particle of open section it is incomplete impregnate cause higher opacity withAnd the pollution resistance risk of difference.In practice it is verified be difficult to be made with low opacity based on bleaching particle, adhesive andThe powder veneer of abrasion resistant particles.
The incomplete wetting on abrasion resistant particles surface will cause the poor adhesion between resin matrix and abrasion resistant particles, this is on boundaryMicropore is generated in face.These micropores generate open surfaces, and wherein capillarity causes to pollute, this is difficult to remove, thus is difficult toCleaning.
Although foregoing description is related to flooring material, the foregoing description of technology and its problem is also applied for other application, such asLaminate for other purposes, such as wallboard, ceiling, furniture etc..
The foregoing description of various known aspects is characterization of the applicant to this, without be to recognize that it is any of above be described as it is existingTechnology.
It summarizes
The purpose of embodiment of the present invention is to provide for the improvement to above-mentioned technology and known technology.
The another object of at least some embodiments of the present invention will improve the pollution resistance of building panel.
At least some embodiments of the present invention another object is that improve the transparency and/or translucence of building panel.
The another object of at least some embodiments of the present invention is to provide for a kind of producing under the dipping for improving the wooden particleThe method of building panel.
The another object of at least some embodiments of the present invention is to provide for a kind of producing point of additive in the mixtureDissipate the method for improved building panel.
At least some embodiments of the present invention another object is that prevent each component of the mixture during transportationSeparation.
At least some of these and other purposes being illustrated by the description and advantage have passed through a kind of production buildingThe method realization of plate, this method comprises:
Formation includes the mixture of the wooden particle, solvent, adhesive and at least one additive, wherein the adhesive and instituteIt states at least one additive and is evenly distributed on the mixture and wherein the adhesive-dipping wood particle by the solvent,
The dry mixture,
The mixture is applied on substrate, and
Forming layer and to mixture application heat and pressure.
Building panel can be floor, wallboard, ceiling, furniture assembly etc..
If using thermosetting resin as adhesive, the layer is by applying heat and pressure to solidify the mixture shapeAt.
Solvent refers to the substance for being capable of forming solution, suspension or colloid.The solvent can be liquid such as water.
The advantages of at least some of embodiment of the present invention is to improve adhesive to the dipping of the wooden particle.In addition, also changingIt has been apt to wetting of the adhesive at least one additive and other particles described in the mixture.When in a dry form mixing woodWhen grain and adhesive, adhesive is limited to be arranged in extra-granular and is therefore being arranged between the wooden particle in resin matrix.SoAnd by the way that the wooden particle is mixed with adhesive by solvent in liquid form, be at least partly dissolved in the solvent and is therefore inThe adhesive-dipping wood particle of liquid form.When mixing the wooden particle, solvent and adhesive, wherein adhesive is in first stepIt is at least partly dissolved in the solvent or is added in the wooden particle in a dry form and solvent is then added, adhesive is at least partlyDipping and/or the surface for applying the wooden particle.In addition, with by the wooden particle, mixed phase ratio, adhesive exist in a dry form with adhesiveDistribution in the mixture is improved.In addition, improving the adherency between resin matrix and the wooden particle, thus result in micro-The risk of crackle or micropore reduces.As a result layer more easy to clean and more insensitive to pollution is obtained.
Another advantage is to obtain the layer with improved pollutant performance.By the way that the wooden particle and adhesive are mixed by solventIt closes, adhesive penetrates into any cavity or channel in the wooden particle.Such any cavity or channel are at least partly filled shouldAdhesive.Therefore the pollution resistance of this layer is improved, enters in the wooden particle because dirt is impermeable and the layer is made permanently to change colour.KnotFruit can remove crude removal from the layer.
Further, since adhesive penetrates into any cavity in the wooden particle or channel, improve this layer transparency and/orTranslucence.Cavity or channel in the wooden particle usually lead to high opacity in this layer, because they are filled with air.It is logicalIt crosses and is filled by adhesive or at least partly any cavity in filling timber particle or channel, provide more transparent layer.
Another advantage is that at least one addition is added in the embodiment permission of the method for the present invention in a manner of easily and effectivelyAgent.In addition, the embodiment of the method for the present invention provides the improvement distribution of additive in the mixture.By the way that additive is addedEnter in the mixture including solvent, which promotes the distribution of the additive in the mixture.Therefore the effect of the additiveBecause of improving due to being uniformly distributed in the mixture.Extraly, since the improvement of additive is distributed, knot needed for acquisition can be reducedAdditive capacity required by fruit.
Since the wooden particle, adhesive and at least one additive mix in liquid form by solvent, reduces andIt is thus more environmental-friendly and be more amenable for use in following production stage from the dust of the mixture.
Extraly, after forming the mixture, point of each component of the mixture for example during transportation is reducedFrom risk, because adhesive adheres to the wooden particle and the wooden particle is made, without solidifying, particulate matter to be consequently formed in conjunction with additive.ThisGrain object is formed by the wooden particle, adhesive and at least one additive.
Substrate can be core, decorative layer or another powder bed.
The step of forming the mixture may include that solvent is added to the wooden particle, adhesive and at least one additiveMixture in.According to the program, the preferably wooden particle, adhesive and additive are in dried forms and form dried powder mixingObject.The solvent is added to form wet powder or paste in the dry powder mixture comprising the wooden particle, adhesive and additive, thisDepending on the quantity of solvent being added in the mixture of powders.
The step of forming the mixture may include by the wooden particle and comprising adhesive and at least one additiveSolvent mixing.According to the alternative, the wooden particle is mixed with the solvent comprising adhesive and additive.It will in first stepAdhesive and additive are added in the solvent.Therefore adhesive and preferable additives are at least partly dissolved in the solvent, i.e.,Therefore adhesive is formed in liquid form.Depending on the quantity of solvent being added in the mixture of powders, which forms wet powderOr paste.
The mixture can for example further include abrasion resistant particles, and preferably aluminium oxide such as corundum is as additive.Wear-resistingGrain improves the wearability of this layer.
The mixture can for example further include at least one pigment as additive.The pigment can be colored pigmentOr effect pigment.Include in the mixture of solvent or being directly added into solvent by the way that pigment to be added, improves pigment at thisDistribution in mixture.As a result amount of pigment required by required effect can be reduced.
Substrate can be core.Therefore it can provide comprising core and by mixed comprising the wooden particle, adhesive, solvent and additiveClose the building panel for the superficial layer that object is formed.In replacement embodiment, the building panel that can be provided includes core, by including woodThe sublayer that the mixture of grain, adhesive and additive is formed and the decorative layer being arranged in the sublayer.
The core can be wood based core, preferably be made of MDF, HDF, OSB, WPC or particieboard.
Substrate can be decorative layer.According to the embodiment, which is formed in the veneer arranged in the decorative layer.ByThis can provide the building comprising decorative layer and veneer formed by the mixture comprising the wooden particle, adhesive, solvent and additiveBuild plate.The decorative layer is preferably disposed on core.The decorative layer can be calico paper, glued board, solid wood, stamp plastic layer, wood powder baseLayer, wood powder base including stamp etc..
It may include that the mixture is applied to by the wooden particle and dry adhesives in the step of applying the mixture on substrateOn the additional layer of formation.It is possible thereby to provide the building panel comprising first layer and the second layer, wherein first layer by the wooden particle and is doneThe dry-blend of the adhesive of dry form is formed, and the second layer is by the mixing of the wooden particle, solvent, at least one additive and adhesiveObject is formed.
This method may further include forms additional layer on said layer, so that layer formation sublayer layer canTo form sublayer.The sublayer, which can be, has for example antistatic or sound absorbing performance functional layer.The required performance of the sublayer can be withIt is obtained by certain additives in the mixture.
The additional layer can be formed on the mixture before the step of forming this layer.
This method may further include the printing in dry mixture, preferably by digital printing.Due to byThe transparency for the layer that the method for the present invention is formed improves, and improves the eye impressions for the stamp printed in the mixture.Due to thisThe transparency of layer, the clearer three dimensional impression of available stamp.
The step of formation and/or the dry mixture, can carry out under vacuum.As a result further improve adhesive to woodThe dipping of particle and wetting.
It is described at least one additive can be wetting agent, release agent, catalyst, antistatic agent, curing agent, defoaming agent,Coupling agent, plasticizer or compatilizer.
The adhesive can be thermosetting resin, preferably melamine/formaldehyde resin.
The adhesive can be thermoplastic resin.
Binder content can be the 30-80 weight % of the mixture.The wooden granule content can be the 1-50 of the mixtureWeight %.The wooden particle can be recycling, primary or finished.
Solvent can be water, glycol, polyalcohol or alcohol.
Building panel can be floor.Floor can be provided with mechanical locking system.
According to the second aspect of the invention, embodiment of the present invention is real by the building panel produced according to the method for the present inventionIt is existing.Building panel according to a second aspect of the present invention can combine some or all of advantages of this method already discussed above, becauseAnd the discussion of front is also applied for the building panel.
According to the third aspect of the invention we, a kind of method for producing building panel is provided.This method includes being formed comprising woodParticle, solvent, adhesive and at least one additive mixture, wherein the adhesive and at least one additive byThe solvent is uniformly distributed the in the mixture and wherein adhesive-dipping wood particle, and the dry mixture applies the mixtureIt is added in decorative layer and by applying heat and forming layer and pressure to the mixture.
If the layer is formed by applying heat and pressure with solidifying the mixture using resinoid.
The third aspect of the present invention is also applied for reference to the above-mentioned advantage of first aspect present invention.This aspect according to the present inventionEmbodiment, which forms veneer in decorative layer.
The decorative layer can be arranged in core, preferably in wood based core.The decorative layer can be calico paper, glued board, solid wood, printFlower plastic layer, wood powder base, wood powder base including stamp etc..
Brief description
The present invention such as reference shows the accompanying schematic figure more detailed description of embodiment of the present invention.
Fig. 1 shows the method for production building panel.
Fig. 2 shows the method for production building panel.
Fig. 3 a shows the first embodiment of building panel.
Embodiment shown in Fig. 3 a is shown in more detail in Fig. 3 b.
Fig. 4 shows the second embodiment of building panel.
Fig. 5 shows the third embodiment of building panel.
Fig. 6 shows the 4th embodiment of building panel.
Fig. 7 a-d shows the method that floor and production are provided with the marginal portion of mechanical locking system.
Fig. 8 shows the floor for being provided with mechanical locking system.
Detailed description
The method for illustrating to produce building panel 1 such as floor, wallboard, ceiling, furniture assembly referring now to Fig. 1.
This method include to be formed comprising the wooden particle 14, solvent, adhesive 19 and at least one additive 15 mixture 2.The mixture can mix in a mixer.
The wooden particle 14 refers to the wooden particle of macroscopic scale.The wooden particle 14 can be by wood fiber bundle or part wood fiber bundle shapeAt.The wooden particle 14 can be unprocessed, recycling, primary, finished or culled wood.Finished wood particle refers toThe wooden particle through mechanically and/or chemically handling.Finished wood particle, which further refers to, have been bleached, sieved and/or has groundThe wooden particle.The example of such finished wooden particle is Jelu-Werk productionHM 150.The wooden particle 14 can be withWith less than 300 μm, preferably smaller than 100 μm of length.
As described above, the wooden particle 14 can be fine grinding or not refine.Depending on application, the lignin content of the wooden particle 14 canWith variation.Both low lignin content, the preferably smaller than 10% wooden particle 14 can be used, and high lignin content can be used such as larger thanThe 20% wooden particle 14, this depends on the application of layer to be formed.In certain embodiments, using alpha-cellulose particle.IfThe mixture will form veneer, and in the embodiment as described in reference Fig. 4 and 6, then the wooden particle 14 used is preferably essenceThe wooden particle grind and bleach and preferably primary.
As the substituted or supplemented of the wooden particle, plant granule such as jute, flax, flax, cotton, hemp, bamboo, sweet can be usedBagasse and sisal hemp.Mineral fibres such as glass fibre can also be thought of as substituted or supplemented.
The wooden particle 14 can be in the wooden granular powder form.
Adhesive 19 can be thermoplasticity or thermosetting resin.The example of thermosetting resin be melamine/formaldehyde resin (MF),Other examples of urea-formaldehyde resins (UF), phenol-formaldehyde resin (PF) or amino resins, or mixtures thereof epoxy resin.HeatThe example of plastic resin be polyvinyl chloride (PVC), polyethylene (PE), polyurethane (PU), polypropylene (PP), polystyrene (PS),Polyamide (PA) etc..
Binder content can be the 30-80 weight % of the mixture.The wooden granule content can be the 1-50 of the mixtureWeight %.
Solvent is preferably liquid.Solvent can be water, glycol, polyalcohol or alcohol.Another example is acetone.Select solvent withSo that adhesive 19 is at least partially soluble in the solvent.However, adhesive 19 need not be preferably solved in the solvent, suspension orColloid is also acceptable and including in the meaning of dissolution.
At least one additive 15 can be for example wetting agent, release agent, catalyst, antistatic agent, curing agent, disappearInfusion, coupling agent, plasticizer or compatilizer.Those skilled in the art are it is generally understood that combination more than one is different types ofAdditive 15.Additive refers to the required performance or improvement being added in the mixture to improve plate to be produced or promotes plate shapeAt any substance.Additive 15 can be among solidification or before the additive that consumes and be still in this after solidificationBoth additives 15 in layer.
In some embodiments, other particles or additive can be added in the mixture.For example, in order to increase thisAbrasion resistant particles 12 such as aluminium oxide or silica can be added in the wearability of plate into the mixture.Pigment can also be addedIn the mixture.Pigment can be both colored pigment and effect pigment.
According to an alternative, by the wooden particle 14 of the above-mentioned type, the adhesive 19 of the above-mentioned type and described at least oneThe additive 15 of kind the above-mentioned type is mixed in a dry form to form dry powder mixture 2.Then by the above-mentioned typeSolvent be added in the dry powder mixture comprising the wooden particle 14, adhesive 19 and at least one additive 15.BondingThus agent 19 is at least partly dissolved in the solvent.Therefore, after solvent is added, adhesive 19 is in liquid form and is formed wetMixture 2.It is preferred that at least one additive 15 is also at least partly dissolved in the solvent.
According to another alternative, adhesive 19 is at least partly dissolved in the solvent before being added in the wooden particle 14.Then adhesive 19 is added in liquid form in the dry wooden particle 14.Adhesive 19 is dissolved in solvent therein, the wooden particle is addedSo that forming wet mixture 2 in 14.Adhesive 19, the wooden particle 14 and solvent are the above-mentioned type.
The additive 15 of at least one the above-mentioned type can be added in the solvent before mixing with the wooden particle 14Or it can be mixed in a dry form with the wooden particle 14 before the solvent is added.
The combination of above-mentioned alternative is also possible.In a dry form by a part of wooden particle 14 and adhesive 19 at this timeIt mixes and solvent is added in the drying composite 2 comprising the wooden particle 14, adhesive 19 and at least one additive 15.By the wooden particle 14 of second part and the adhesive 19 being at least partly dissolved in the solvent, i.e. liquid adhesive mixes.
Regardless of which kind of alternative used, the result is that obtaining adding comprising the wooden particle 14, adhesive 19, solvent and at least oneAdd the mixture 2 of agent 15.Gained mixture 2 is wet mixture.Depending on the amount of solvent, mixture 2 can be in wet powder or pasteForm.
The dipping of adhesive 19 and/or the surface at least partly applying the wooden particle 14.Adhesive soaks abrasion resistant particles 12, describedThe particle in the mixture is added with any other at least one additive 15.Adhesive 19 is also penetrated into the wooden particle 14 and is formedAny air cavity or channel in.By using the adhesive 19 being at least partly dissolved in the solvent, improve compared with dry-blendDistribution of the adhesive 19 in mixture 2.
Further, since adhesive 19 and at least one additive 15 are at least partly dissolved in the solvent, therefore shouldLiquid solvent is conducive to the distribution of adhesive 19 and at least one additive in mixture 2.The liquid solvent is equablyAdhesive 19 and at least one additive 15 are distributed in mixture 2.19 He of adhesive is obtained compared with dry mixtureThe more evenly distribution of at least one additive 15.
Drying composite 2 in a subsequent step, such as by heating mixture 2, being heated by IR, by conditioning etc..Drying composite 2 is so that mixture 2 obtains certain water content, such as 0.5-10%.The water content depends on solvent.AsExample, mixture 2 can be dried 24 hours at 60 DEG C.Drying composite 2 is so that form the mixture of powders of substantially dry.
Depending on solvent for use, which can at least partly evaporate in the drying process, if such as water is used as solventIf.If the solvent is may remain in after drying in the mixture using another type of solvent.If needing,It can grind and/or sieve mixture 2.The wooden particle 14 can be ground to less than 300 μm, preferably smaller than 100 μm of size.
In order to further improve the wooden particle 14 dipping and at least one additive 15 and any other particle such asThe wetting of abrasion resistant particles 12, mixing can carry out under vacuum.Drying can also carry out under vacuum, to improve the wooden particle 14Dipping.It, can drying composite 2 in a mixer by using vacuum and heat in mixed process.
The mixture 2 of the wooden particle 14, adhesive 19, solvent and at least one additive 15 is applied to Fig. 1 and 2 instituteOn the substrate 3 shown.Mixture 2 is applied on substrate 3 as powder.Mixture 2 can be dispersed in substrate by dissemination apparatus 60On.Then mixture 2 is formed as into layer by applying heat and pressure.If using thermosetting resin, by applying heat and pressureMixture 2 is solidified.Mixture 2 can be suppressed 10-55 seconds under 150-210 DEG C and 30-100 bars.It, can as specific exampleMixture 2 to be suppressed 35 seconds under 170 DEG C and 40 bars.Pressure can pass through roller 21, press belt 23 in continuous pressing equipmentOr compacting matrix applies.Or interrupted press device can also be used.
When mixture 2 has been cured, forming layer 5.
By the way that mixture is pressed to the embossing available embossed surfaces of pressure matrix.
Intermediate pressing step can be suppressed in a step or can be introduced before final pressing step to mixture 2.?In intermediate pressing step, mixture 2 is partially compressed with roller 21.Continuously or intermittently press device can be used.It is suppressed among thisIn step process, mixture 2 does not preferably solidify, or at least not fully cured.
In an embodiment shown in Fig. 3 a and 3b, mixture 2 is applied to core 6.Core 6 can be wood based core such asMDF, HDF, OSB, WPC (wood polymers complex) or particieboard.In other embodiments, core 6 can be mineral board, modelingFlitch or the like.Core 6 may include thermoplastic resin or thermosetting resin.
When applying heat and pressure to the mixture 2 being arranged on core, which is adhered to the core simultaneously.
In the embodiment shown in Fig. 3 a and 3b, mixture 2 forms the superficial layer 5 being arranged on the upper surface of core 6.SolidThe additive 15 not consumed during changing is uniformly distributed in whole table surface layer 5.If by other particles such as abrasion resistant particles 12 and/Or pigment is added in mixture 2, then these particles are also uniformly distributed in whole table surface layer 5.It the upper surface of core 6 can be with additionAgent 15 contacts.If these particles can also be contacted with the upper surface of core 6 including abrasion resistant particles 12 and/or pigment.Mixture 2A part of adhesive 19 can also penetrate into core 6.
Superficial layer 5 can be decorative surface layer.As set forth above, it is possible to by pigment be added mixture 2 in coloured/Nonferrous layer obtains the layer with certain performance by the way that effect pigment is added.As an alternative or supplement, mixture 2 can be appliedIt is added on the core 6 with coloured upper surface.By that with suitable color, can reduce and be wanted in mixture 2 upper surface of core 6The amount of pigment asked.It can upper surface japanning to core 6.
Form the 30-60 weight % that binder content in the mixture of the decorative surface layer can be the mixture.ShapeIt can be the 20-50 weight % of the mixture at granule content wooden in the mixture of the decorative surface layer.
Mixture 2 can also be applied on the core 6 of the direct printing in the upper surface of core 6.The stamp can for example be borrowedIt helps digital printing or is formed by directly printing.
Furthermore, it is possible to the printing in mixture 2.The stamp can preferably pass through ink-jet by digital printing technologyPrinting machine 22 is printed.Printed layer is consequently formed in the mixture.The stamp is before applying heat and pressure to mixture 2 in mixtureIt is printed in 2.If stamp can carry out after the pre-stamped step but before final compacting using pre-stamped step.ShapeIt can be the 50-80 weight % of the mixture at binder content in the mixture of printed layer.It is formed in the mixture of printed layerThe wooden granule content can be the 10-35 weight % of the mixture.
In replacement embodiment, the substrate 3 for applying the mixture thereon is temporary substrate such as press belt shown in Fig. 220, pressing plate or barrier foil.Layer 5 that can be isolated with substrate 3 is consequently formed.Layer 5 can in separate steps with core 6 or anotherLayer connection.
In another embodiment, mixture 2 forms veneer 9.In the embodiment shown in Fig. 4, mixture 2 is appliedIt is added on decorative layer 8.Decorative layer 8 can be decorative paper layer, decorative plastic layer such as PVC or PU, powder base printed layer, institute as aboveStamp core, outer surface of wood surface layer, face veneer layer or any other decorative layer stated.It is preferred that the facing paper or plastic layer are calico paperOr plastic layer, such as printed by digital printing, direct printing or Rotogravure stamp.
Decorative layer 8 can be arranged on the core 6 of the above-mentioned type with reference to Fig. 3 a and 3b, or can be formed and be stayed in then and coreThe separated decorative layer 8 of 6 connections.
In this embodiment, mixture 2 is applied to decorative layer 8.Mixture 2 is formed as by applying heat and pressureOverlay coating 9.If using resinoid, solidification mixture 2 and form overlay coating 9.When to mixture 2 apply heat and pressureWhen, mixture 2 is adhered to decorative layer 8 simultaneously.The embodiment of the method for the present invention is outstanding due to its transparency and pollution resistance increaseIt suitably forms the veneer 9.Required wearability is provided by the way that abrasion resistant particles 12 such as aluminium oxide, veneer 9 are added into the mixtureEnergy.
Form the 50-80 weight % that binder content in the mixture of overlay coating can be the mixture.Form overlay coatingMixture in the wooden granule content can be the mixture 10-35 weight %.
The method of the present invention can be also used for forming sublayer 10.In the embodiment shown in Fig. 5, mixture 2 is appliedIn substrate 3, such as in the form of the core 6 of the type above with reference to described in Fig. 3 a and 3b.Then by applying heat and pressure as previously describedMixture 2 is formed as into layer.If using thermosetting resin, by applying heat and pressure-cure mixture 2.Additional layer is as joinedIt is arranged in sublayer 10 according to the decorative layer 8 of Fig. 4 type as described above so that sublayer 10 is arranged between core 6 and additional layer 8.
Alternatively, additional layer such as decorative layer 8 can be arranged in front of application heat forms sublayer 10 with pressure wants shapeAt on the mixture 2 of sublayer 10.When applying heat and pressure, additional layer 8 is due to mixture forms and/or be solidified into sublayer 10It is adhered to sublayer 10 simultaneously.Form the 30-60 weight % that binder content in the mixture of sublayer 10 can be the mixture.ShapeIt can be the 20-50 weight % of the mixture at granule content wooden in the mixture of sublayer 10.
It is also contemplated that can include the layer row of the wooden particle 14, at least one additive 15 and adhesive 19 by more than oneIt is listed on substrate 3.In an embodiment shown in Fig. 6, substrate 3 will be arranged in by a kind of first layer that mixture is formed 11As the above-mentioned type core 6 on, which is formed by the adhesive 19 of the wooden particle 14 and dried forms.It will be according to the method for the present inventionEmbodiment formed the second layer 5 be arranged on first layer 11.Therefore the second layer 5 is by including the wooden particle 14, adhesive 19, moltenThe formation of the mixture 2 of agent and at least one additive 15.First and second layer 11,5 by common step apply heat andPressure and formed, such as by solidifying the adhesive.Alternatively, the shape in the back before applying the second layer 5 of first layer 11At, and the second layer 5 is formed in latter step.
The adhesive of sublayer 10 can be phenol/formaldehyde resins, urea/formaldehyde resin or PVAc.
It is also contemplated that both the top layers for arranging sublayer on base material and being arranged in sublayer can be by the method for the present inventionProduction.The binder content for forming the mixture of sublayer 10 can be the 30-60 weight % of the mixture.Form the mixed of sublayer 10Close the 20-50 weight % that the wooden granule content in object can be the mixture.Form in the mixture of top layer that binder content can be withFor the 50-80 weight % of the mixture.Forming the wooden granule content in the mixture of top layer can be the 1-30 weight of the mixtureMeasure %.
It is also contemplated that above-mentioned top layer can be arranged in any kind of decorative layer.
Mixture 2 can form functional layer, such as antistatic layer, absorbent treatment and/or sound insulating layer, moisture blocking layer.The functionLayer can be used as sublayer arrangement.
Because mixture 2 does not have restricted movement in the horizontal or vertical directions, mixture 2 is for forming embossing portionDivide and is advantageous.Coin segment can be as forming such as referred to Fig. 4 above with reference to as described in Fig. 3 a and 3b or when forming veneer 9It is formed in the layer that the mixture 2 of the superficial layer 5 is formed.When the mixture forms sublayer 10, can be extended intoDeep embossing in sublayer shown in Fig. 5.In Fig. 5, essentially by molding sublayer 10 to decorative layer 8 provide upper part 8a andCoin segment 8b lower than upper part 8a.
The building panel 1 formed by the embodiment of the method for the present invention is particularly suitable as floor.Example can be provided to floorSuch as the mechanical locking system 4 of the type as described in WO 2006/043893, WO 2007/015669, WO 2009/116926.
Fig. 7 a shows the building panel 1 that floor is formed according to the embodiment of the disclosure.Building panel 1 includes according to this public affairsThe superficial layer 5 that the embodiment opened is produced and is arranged on core 6.Apply balance layer 7 in back side as shown in Figure 7b.Fig. 7 c is shownIt is cut into the building panel of several pieces of floor units 2.Fig. 7 d, which is shown, is formed as floor 1 in long side mechanical locking system 4,4 'Floor unit.Mechanical locking system is generally also formed on short side.Can be used all allow with inclination, horizontal and vertical takesLock, bending, side such as push away at the known locking system of lockings.However, floor also can have fairly simple locking system or only haveThere is the straight flange for being similar to masonry and they may be glued to the sublayer floor.
Fig. 8 shows such floor 1,1 ' with mechanical locking system 4.Mechanical locking system 4 includes having locking singleThe bolt 30 of member 31, the lock cell 31 match with lock slots 32 and merge lockplate 1,1 ' on D2 in the horizontal direction.Mechanical caging systemSystem 4 further comprises the tongue 33 cooperated with glossal canal 34 and lockplate 1,1 ' on vertical direction D1.The long side and short side of floor are equalMechanical locking system can be provided with.Alternatively, the long side of floor can be provided with mechanical locking system with horizontal and vertical locking,And short side can be provided with mechanical locking system and be only used for horizontal lock.It is also contemplated that other locking systems are possible.
Balance layer 7 can be connected in the above-described embodiment core 6 or substrate back side or.Balance layer 7 can also be byThe embodiment of the method for the present invention is formed.The binder content for forming the mixture of balance layer 7 can be the 50-80 of the mixtureWeight %.The wooden granule content for forming the mixture of balance layer 7 can be the 15-45 weight % of the mixture.
Embodiment of the present invention is particularly suitable in floating floor.However, embodiment of the present invention is not excluded for glueClose the floor on sublayer floor.
It is emphasized that embodiment of the present invention may be used as plate or for example be glued to core upper surface layer.The disclosure may be used alsoIn application for such as wallboard, smallpox and furniture assembly and the like.It can be also used for the surfacing for having optionalAs in the floor of cork or timber, to improve abrasion and design performance.
Embodiment of the present invention illustrates referring now to following non-limiting examples.
Embodiment 1: the powder base veneer formed by dry blend process
By melamine/formaldehyde resin (MF) (64 weight %) of spray drying, bleach the wooden particle (27 weight %), in interleaving agentAdditive (0.5 weight %), the wetting agent PAT959/F (0.5 weight %), catalyst PATHS710 (0.5 weight of PAT523W formAmount %) and aluminium oxide (9 weight %) mix 15 minutes in the dry state, then as powder base on black powder base is decoratedVeneer.
The aggregate is suppressed 35 seconds under 170 DEG C and 40 bars.
As a result fuzzy graying surface is obtained, pollution resistance is weak.
Embodiment 2: the powder base veneer formed by the wet and dry-mixing method of combination
By the dry wooden particle of 424g and 100g aluminium oxide and the additive (0.5 weight %) of interleaving agent PAT523W form,Wetting agent PAT959/F (0.5 weight %), catalyst PATHS710 (0.5 weight %) are mixed to form dry-blend.1200g is wetMelamine/formaldehyde resin (50 weight %MF) is added in the dry-blend and mixes 10 minutes.Final mixture is still in powder, is containedThe water being additionally added.
The powder is 24 hours dry at 60 DEG C, size is then ground to less than 300 μm.
The dry group of the gained of powder produced becomes 55 weight % melamines/formaldehyde resin (MF), 36 weight % bleaching woodGrain and 9 weight % aluminium oxide.
The powder is used as powder veneer on black and white powder base decoration, by aggregate under 170 DEG C and 40 barsCompacting 35 seconds.
Black cosmetic shows good transparency, and white in finish shows perfect pollution resistance.White in finish is shownIt is out the surface contamination of 5 (5) according to the EN438 based on the test for using permanent indicia pen.
Embodiment 3: the powder base veneer formed by the wet and dry-mixing method of combination
By the dry wooden particle of 318g and 100g aluminium oxide and the additive (0.5 weight %) of interleaving agent PAT523W form, profitHumectant PAT959/F (0.5 weight %), catalyst PATHS710 (0.5 weight %) are mixed to form dry-blend.By the wet honey of 1400gAmine/formaldehyde resin (50 weight %MF) is added in the dry-blend and mixes 10 minutes.Final mixture is in paste form.
It is under amblent air temperature that the paste is 3 days dry, it is then 24 hours dry at 60 DEG C.Then the mixture is ground toSize less than 300 μm.
The dry group of the gained of powder produced becomes 64 weight % melamines/formaldehyde resin (MF), 27 weight % bleaching woodGrain and 9 weight % aluminium oxide.
The powder is used as powder veneer on black and white powder base decoration, by aggregate under 170 DEG C and 40 barsCompacting 35 seconds.
Black cosmetic shows excellent transparency, and white in finish shows perfect pollution resistance.White in finish is shownIt is out the surface contamination of 5 (5) according to the EN438 based on the test for using permanent indicia pen.
Embodiment 4: it adds water in complete mixture of powders
Method described in above-described embodiment indicates how the transparency and pollution resistance that improve product by the second layer.This firstLayer provides design, and the second layer assigns pollution resistance.
A kind of method for generating the surface comprising powder bed is described in WO 2009/065769, which both hadDecoration functions also have wear-resisting and functions.The powder has identical described in dry powder veneer mixture in embodiment 1Weakness.
The pollution resistance of single layer powder can be by being added powder described in WO 2009/065769 for water and/or additive(1 part of water is to 1 part of powder) is significantly improved in mixture.The water and powder are thoroughly mixed into homogeneous paste.Then the paste is existedDry 72 hours and drying 24 hours at 60 DEG C in amblent air temperature ,if needed grinding and screening.The pollution resistance of the product is goodIt is good.
Instead of using dry adhesive and water is added, fluid binder (mixing, optional vacuum impregnation) can be used, such asThe upper further processing.The pollution resistance of the product is significant, shows according to the EN438 based on the test for using permanent indicia penFor the surface contamination of 5 (5).The color of these powder is stronger than corresponding dry mixed powders.Therefore amount of pigment can be reduced.
Embodiment 5: printed layer
Decalcomania on powder base veneer as described in Example 3 has more than the powder produced as described in Example 1Clear and strong color.
What is considered is there are many changes to embodiment described herein, these change still by appended claimsIn the scope of the invention defined in book.For example, what is considered is that the mixture can be used for being formed more than one layer, for example, sublayer andBoth veneers or arrangement stacked on top of each other it is several layers of.These layers can be by applying heat and pressure in a step or individually walkingHeat and pressure are applied to each layer in rapid and formed.It is also considered that other can also be added other than above-mentioned particle and additiveAgent and/or particle is added to be added in the mixture.It is also considered that including both thermoplastic adhesives and resinoidAdhesive can be used in the mixture.