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CN101107122A - 多层板 - Google Patents

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Publication number
CN101107122A
CN101107122A CNA2006800031041A CN200680003104A CN101107122A CN 101107122 A CN101107122 A CN 101107122A CN A2006800031041 A CNA2006800031041 A CN A2006800031041A CN 200680003104 A CN200680003104 A CN 200680003104A CN 101107122 A CN101107122 A CN 101107122A
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paper
board
layer
resin
paper layer
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CN101107122B (zh
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H·鲁多费尔
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Kaindl Flooring GmbH
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    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2607/00—Walls, panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/269—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension including synthetic resin or polymer layer or component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
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  • Paper (AREA)

Abstract

多层板(100)，包括一材料板(20)，它在其可见表面上涂覆有至少一个用树脂浸渍的纸层(10)；其特征在于，在所述至少一个纸层(10)或最上面的纸层(10)的远离材料板(20)的侧面上存在一树脂层(18)，其平均层厚(d)为至少5μm。

Description

多层板
技术领域
本发明涉及一种多层板，包括一材料板，它在其可见表面上涂覆有至少一个用树脂浸渍的纸层。
背景技术
已知，将木材如刨花板、纤维板例如MDF板(中密度纤维板)或HDF板(高密纤维板)，或OSB板(取向的结构板)涂覆装饰纸层，其优选用氨基塑料树脂浸渍。此外已知，将通过多个纸层相叠构成的层压材料(连续的层压材料-CPL)涂覆有装饰纸层，其优选用氨基塑料树脂浸渍。为此采用的装饰纸一般具有45至140g/m2的单位面积重量。通常用于纸幅浸渍的树脂是包括三聚氰胺和甲醛的缩聚产物。当然也使用由尿素或/和三聚氰胺与甲醛的混合缩聚的缩聚产物。
在用树脂浸渍的纸的制造中，将原纸在特别的浸渍装置中用上述的树脂浸渍。紧接着将这样浸渍的并按尺寸剪裁的装饰纸在一面或两面铺在材料板上并且在多级压机、短周期压机或连续工作的压机(连续压机)中压成装饰产品，其然后例如作为装饰板、工作板或地板元件销售。
为了得到装饰产品或装饰纸的要求的表面结构，大多在压机中使用镀铬的压板，其构成有相应的表面结构。在这里所谓“结构”不仅应该被理解为浮雕结构例如木结构或石结构，而且应该被理解为光泽结构例如高光泽、珠光泽或无光泽。
其中光学高光泽的表面按照标准DIN 67530、ISO 2813、ASTM D523和BS 3900部分D5确定成，使其在相对于表面平面成20°的入射角时具有多于60个光泽单位的值。在相对于表面平面成60°的入射角具有10至70个光泽单位的值的表面称为中等光泽的表面，而无光泽的表面在成60°的入射角时具有少于10个光泽单位。
虽然利用全部上述压机型式可以得到光学无光泽的表面，但至今光学高光泽的表面的制造只在多级压机通过紧接着的再冷却是可能的。
但多级压机用于制造具有高光泽表面的多层板，由于需要再冷却阶段而具有大的能量消耗和长的生产期间的缺点，因为整个的压制周期为15至25分钟。相反，在一短周期压制方法中压制周期只为10至30秒，并且在连续的生产方法中压制周期甚至只延续5至10秒。
发明内容
因此本发明的目的是，提供一种多层板，其即使在短周期设备上和在连续工作的设备中也可以制造有高光泽的表面。
为了达到该目的本发明提供一种此类的多层板，其中在至少一个纸层或最上面的纸层的远离材料板的侧面上存在一树脂层，其平均层厚为至少5μm。通过按要求的树脂层，在短周期方法中和在连续压机上也可以按以上的限定制造高光泽的表面，因为至少5μm的平均层厚阻止纸纤维凸出到装饰纸的表面上并从而恶化表面的反射特性。
在这种情况下优选树脂层是一基本上连续构成的层，其层厚在任何点为至少2μm、优选至少3μm。借此确保，树脂层不在任何点处薄成以致虽然平均层厚为至少5μm，但局部仍有各个纸纤维可以凸出到纸层的表面上。
层厚可以例如至多为100μm、优选至多为50μm、仍优选至多为20μm，因为由于仍较大的层厚只带来提高的树脂消耗，而并不达到表面特性、特别是表面光泽的进一步改善。
在本发明的多层板中，所述至少一个纸层也可以包括一可见纸层、优选一装饰纸层。
在多层板制造中应用的可见纸层优选具有一按Bekk测量的至少20秒、优选至少25秒的原纸光滑性。通过这样高的原纸光滑性可以达到，涂敷的树脂量比在不如此光滑的纸中明显较少地沉没入纸中。因此可以利用较少的树脂量达到本发明的树脂层。可见纸层可以例如具有在约45g/m2至约140g/m2之间的单位面积重量。
此外在材料板与可见纸层之间可以设置至少一个衬垫纸层，其用作为另一阻挡层以防树脂沉入。按选择或附加可以在可见纸层的远离材料板的侧面上设置一贴面纸层，其主要用于提高多层板的耐磨性。该贴面纸层优选具有在约10g/m2与约80g/m2之间的单位面积重量。由于用树脂浸渍，贴面纸层变成基本上透明的，从而其实际上并不妨碍对优选构成为装饰纸层的可见纸层的可见度。
所应用的树脂优选是一种由三聚氰胺或/和尿素与甲醛的缩聚产物。
材料板优选是一种木材板例如刨花板，或纤维板优选MDF板或HDF板，或OSB板。或者，材料板是一种通过多个纸层的相叠构成的层压材料板(CPL板)。
附图说明
本发明的其他的特性、特征和优点由以下连同附图的详述是显而易见的，其只示范性地更详细说明本发明的一个实施形式。其中：
图1  大致简化的剖视图，用以说明本发明的多层板的基本结构；
图2  一用于传统的多层板的用树脂浸渍的可见纸层的表面区域的简化横剖面图，没有贴面纸层；以及
图3  一用于本发明的多层板的可见纸层的表面区域的简化横剖面图，没有贴面纸层。
具体实施方式
图1中简示出一多层板100的结构。其中利用一用树脂浸渍的可见纸层10涂覆一材料板20，其包括或者一木材板例如刨花板或纤维板、优选MDF板或HDF板，或者一OSB板，或者一通过多个纸层相叠构成的层压材料板。
此外在材料板20与可见纸层10之间可以设置一衬垫纸层30，其阻止树脂从可见纸层10中沉入。此外为了提高多层板100的耐磨性，可以在可见纸层10的远离材料板20的侧面上设置一贴面纸层40。贴面纸层40可以具有一较小的、在10与80g/m2之间的单位面积重量并因此如果其用树脂浸渍，则基本上是透明的。本发明的多层板100的这种基本结构符合传统的多层板的那种结构。
图2示出一传统的用树脂浸渍的可见纸层10，在图1中所示的结构中(没有贴面纸层40)利用该可见纸层涂覆一材料板20，并且该可见纸层包括一纸纤维12与包围该纸纤维12的浸渍树脂14的混合物。在此可看出，一些纸纤维12一直达到纸层10的可见表面16，从而这些凸出的纸纤维12可以在纸层的可见表面16上形成表面粗糙度，其散射入射光并因此恶化可见表面16的光泽特性。
图3中所示的本发明的可见纸层10与此不同具有一在纸纤维12上方凸出的树脂层18，其理想地具有一均匀的至少5μm的厚度d。通过该在纸纤维12上方凸出的树脂层18，阻止各个纸纤维12凸出直到用树脂浸渍的纸层10的可见表面16，从而在这种用树脂浸渍的纸层10中可以提供一光滑的、良好反射的并从而高光泽的可见表面16。
为了达到这样的凸出的树脂层18，根据所应用的纸的单位面积重量和所采用的压机的工作参数可以或者涂敷足够的树脂，或其可以确保，所涂敷的树脂尽可能少地沉入纸10中或甚至进一步沉入位于其下面的材料板20中，因为或者通过提高原纸光滑性而接近可见表面16地压缩纸纤维12，或者通过在材料板20与装饰纸层10之间采用至少一个衬垫纸层30，其阻止树脂沉入材料板20中。
以下提供多个实例用以提高本发明的多层板100的装饰纸表面的光泽特性：
实例1：提高原纸光滑性
在一具有白色装饰的装饰纸中，将按Bekk测量的原纸光滑性从17s提高到28s。将一如此处理的装饰纸和一没有实施附加平滑的装饰纸用同一树脂液浸渍，此时分别按照平方米涂敷相同的三聚氰胺树脂量。由于通过提高纸表面光滑性使树脂明显较少地沉入纸中，在紧接着的两个不同浸渍的装饰纸的短周期高光泽压制时导致具有提高到28s的原纸光滑性的装饰纸的明显改善的光泽度，其中在相对于纸表面成20°的入射角时，对其没有实施附加平滑的装饰纸具有28个光泽单位(GE)的值，而对其实施了附加平滑的装饰纸具有79GE的值。
实例2：提高树脂量
在一白色的装饰纸中，将涂敷的树脂量比按标准的树脂量相对于原纸重量增加30％。因此在紧接着的在一连续工作的压机上的压制时提供更多的树脂供使用，并因此在纸纤维的上方形成一凸出的树脂层。
具有按标准的树脂涂层的装饰纸此时在20°的入射角下测量光泽度时达到28GE的值，而用与此相对提高30％的树脂量涂敷的装饰纸达到62GE的值。
实例3：不同的树脂量
将不同的装饰纸(白色的、象牙色的和木质的装饰)用同一树脂配方、但不同的树脂量浸渍。在这种情况下按标准浸渍象牙色装饰纸，将木质装饰纸浸渍成使得部分地已可看到凸出的纯浸渍树脂，而将白色装饰纸浸渍成使得在压制之前连续存在一具有至少5μm的平均层厚的凸出的浸渍树脂层。将这些浸渍的装饰纸在一短周期压机中和在一连续工作的压机中分别压成高光泽板或高光泽带。光泽测量的结果如下：
短周期压机 连续工作的压机
  象牙色装饰纸(按标准)     26GE     22GE
  木质装饰纸(稍微提高的树脂涂层)     58GE     48GE
  白色装饰纸(连续的浸渍树脂层)     84GE     74GE
如在以上各实例中表明的，在用于涂覆材料板20的装饰纸10中的高光泽表面16因此可以或这样达到，即在浸渍之前提高待浸渍的纸的原纸光滑性，或这样达到，即比标准参量提高涂敷的树脂量。该两种措施导致在可见纸层10的纸纤维12的上方形成一凸出的树脂层18。

Claims (12)

1.多层板(100)，包括一材料板(20)，它在其可见表面上涂覆有至少一个用树脂浸渍的纸层(10)；其特征在于，在所述至少一个纸层(10)或最上面的纸层(10)的远离材料板(20)的侧面上存在一树脂层(18)，其平均层厚(d)为至少5μm。
2.按照权利要求1所述的多层板(100)，其特征在于，树脂层(18)是一基本上连续构成的层，其层厚(d)在任何点为至少2μm、优选至少3μm。
3.按照权利要求1或2所述的多层板(100)，其特征在于，层厚(d)至多为100μm、优选至多为50μm、仍优选至多为20μm。
4.按照权利要求1至3之一项所述的多层板(100)，其特征在于，所述至少一个纸层(10)包括一可见纸层(10)、优选一装饰纸层(10)。
5.按照权利要求4所述的多层板(100)，其特征在于，在多层板制造中应用的可见纸层(10)具有一按Bekk测量的至少20s、优选至少25s的原纸光滑性。
6.按照权利要求4或5所述的多层板(100)，其特征在于，在材料板(20)与可见纸层(10)之间设置至少一个衬垫纸层(30)，
7.按照权利要求4至6之一项所述的多层板(100)，其特征在于，在可见纸层(10)的远离材料板(20)的侧面上设置一贴面纸层(40)。
8.按照权利要求7所述的多层板(100)，其特征在于，贴面纸层(40)具有在约10g/m2与约80g/m2之间的单位面积重量。
9.按照权利要求4至8之一项所述的多层板(100)，其特征在于，可见纸层(10)具有在约45g/m2与约140g/m2之间的单位面积重量。
10.按照权利要求1至9之一项所述的多层板(100)，其特征在于，所述树脂是一种由三聚氰胺或/和尿素与甲醛的缩聚物。
11.按照权利要求1至10之一项所述的多层板(100)，其特征在于，所述材料板(20)是木材板，例如刨花板，或纤维板优选MDF板或HDF板，或OSB板。
12.按照权利要求1至10之一项所述的多层板(100)，其特征在于，所述材料板(20)是一种通过多个纸层的相叠构成的层压材料板。
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