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CN1468179A - 一种表面元件的制造方法 - Google Patents

一种表面元件的制造方法 Download PDF

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CN1468179A
CN1468179A CNA018167691A CN01816769A CN1468179A CN 1468179 A CN1468179 A CN 1468179A CN A018167691 A CNA018167691 A CN A018167691A CN 01816769 A CN01816769 A CN 01816769A CN 1468179 A CN1468179 A CN 1468179A
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马格努斯·N·尼尔松
拉尔斯·奥尔松
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马德加勒纳·克里斯蒂安松
˹���ء���ɭ
克里斯特·汉森
简·艾里克松
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Abstract

一种装饰用的表面元件的制造方法，其中，该元件包括基础层、装饰层以及UV或电子束固化的漆构成的耐磨层。形成一个或多个滚子或模具的制压纹的表面的一个或多个设有结构形状的表面，可能在使漆固化到所需粘度后，被放置到装饰用的涂漆的表面的表层上，并被连续或不连续地压到其上。漆将被提供有增强装饰层的装饰效果的表面结构形状。之后，耐磨层被完全固化。

Description

一种表面元件的制造方法
本发明涉及一种具有与上表面的装饰相配合的表面结构形状的装饰用表面元件的制造方法。
涂敷有模仿诸如木材或大理石材料的形态的产品如今被频繁应用。它们最常用在需要不太昂贵的材料的场合，还用在要求抗磨损、刻划和各种化学、潮湿的场合。可以作为这种产品的例子指出的是例如地板制品、地板护角、桌面、台面和墙板。
作为一种可指出的现有产品实例，热固层压板主要由几层基础片材和一最靠近表面放置的装饰片材构成。装饰片材可以设置有需要的装饰和图案。通常采用不同种类的木材、大理石、花岗岩类矿物所呈现的图案。层压板的表面，可以在层压过程中设置一定结构形状，使装饰更真实。在压制层压板的过程中通常采用带有纹理结构形状或结构形状箔的压板。在层压过程中，压板或箔的纹理结构形状以负像形式浮刻在层压板表面。
结构形状适宜地表现出装饰图案的特征。结构形状可以做得粗糙以模仿粗糙的岩面，或做成平滑的并带有随机设置凹痕和微裂纹以模仿磨光的大理石。当模仿木材表面时，在表面随机设置细小的扁长刻痕模仿孔隙。
很久以来，非常需要能制作一种模仿材料，其中，以漆膜作为装饰的表层涂层。迄今为止，在漆上获得表面结构形状的唯一方式是浇筑或研磨模制，这两种方式都是即费时又昂贵的方法。
根据本发明，上面指出的需求已经可以满足，已经可以得到一种带有装饰表面的表面元件，装饰表面带有表面结构形状。本发明涉及一种制选装饰表面元件的方法。该元件包括一个基础层、一个装饰层以及一个UV或电子束固化的漆的耐磨层。本发明特征在于，形成或者多个滚子或模具的制压纹的表面的一个或多个具有结构形状的表面可能在使漆已固化至所需粘度之后被放置到装饰涂漆的表面的表层上，并被连续或不连续地压到其上。以此漆将具有增强装饰层的装饰效果的表面结构形状。之后，耐磨层被完全固化。漆膜最好由UV固化或电子束固化的丙烯酸或顺丁烯二酰亚胺漆构成。最好分几个步骤来施加耐磨层，中间带有部分固化。耐磨层最好还包括平均粒径范围在50nm-150μm的硬质颗粒。基础层可以适当地由碎料板或纤维板构成，也可以由如聚氨酯类的聚合物材料构成。
为了使形成结构形状的过程平滑进行，表面元件最好包括一个在完全固化前具有弹性的层。该弹性层从基础层、底层、装饰层和耐磨层的组合中来选择。
形成结构形状的过程中通常会导致表面上不理想的突起部分。这些部分可以通过在完全固化阶段之前朝向具有表面结构形状的耐磨层表面压一个或多个上光滚子来整平。具有结构形状的滚子最好加热到高于40℃的表面温度，最好在50℃-150℃范围内，这可以将形成裂纹的风险降到最低。同样理由，上光滚子最好也加热到高于30℃的表面温度，最好在35℃-100℃范围内。
根据本发明另外的实施例，形成结构形状可以通过模具完成。模具的具有结构形状的表面被加热到高于40℃的表面温度，最好在50℃-150℃范围内。具有结构形状的模具表面施加的压力为50-200巴，最好为65-100巴。
上光过程将使表面易于清理。也可以通过向具有结构形状的耐磨层的表层上施加一个薄的表层涂层来得到。此类薄的表层涂层当然可以在上光阶段之后施加到耐磨层的表层上。更好地是一个薄的表层涂层在上光阶段之前施加到具有结构形状的耐磨层的表层上。然后该表层涂层在上光前被部分固化。该表层涂层适当地由丙烯酸、环氧或顺丁烯二酰亚胺漆构成，并可以具有作为添加剂的平均粒径范围在50nm-150μm的硬质颗粒。
每个具有结构形状的滚子均设有一相对的保持滚子，表面元件从其之间通过。每个上光滚子最好也设置一相对的保持滚子，使表面元件从其之间通过。表面元件具有厚度T，各具有结构形状的滚子与相应的相对的保持滚子之间的距离最好设置在T减去0.5至1.2mm，最好是0.7mm-0.9mm的范围。各具有结构形状的滚子与它的相应的相对的保持滚子之间的压力为50-200巴，最好为65-100巴。
表面元件具有厚度T，各上光滚子与相应的相对的保持滚子之间的距离设置在T减去0.7mm-1.2mm，最好0.7mm-0.9mm的范围内。各上光滚子与它的相应的相对的保持滚子之间的适宜的压力为0.1-10巴，最好为0.5-5巴的范围内。
添加到漆中的硬质颗粒，可由例如氧化硅、α-铝氧化物或碳化硅构成。根据本发明的一种实施例，硬质颗粒主要部分是由例如氧化硅、α-铝氧化物或碳化硅构成，同时，还有少量的硬质颗粒由金刚石构成。由金刚石构成的硬质颗粒具有在50nm-2μm之间的平均粒径，并被施加在接近耐磨层的上表面处。
当使用超过一个具有结构形状的滚子时，这些具有结构形状的滚子可以设置有不同的表面结构形状。由此可得到带有与可见装饰相对应的变化的表面结构形状。

Claims (25)

1.一种装饰用的表面元件的制造方法，该元件包括一基础层、一装饰层以及一由UV或电子束固化的漆构成的耐磨层，其特征在于，可能在使漆固化到所需的粘度之后，形成一个或多个滚子或模具的制压纹的表面的一个或多个具有结构形状的表面，被放置到装饰用的涂漆的表面的表层上，并被连续或不连续地压到其上，以此漆将被提供有增强装饰层的装饰效果的表面结构形状，之后耐磨层被完全固化。
2.根据权利要求1的方法，其特征在于，漆是由丙烯酸或顺丁烯二酰亚胺漆构成。
3.根据权利要求1或2的方法，其特征在于，耐磨层被分几个步骤来施加，中间进行部分固化。
4.根据权利要求1至3任一项的方法，其特征在于，耐磨层包括平均粒径范围在50nm-150μm的硬质颗粒。
5.根据权利要求1的方法，其特征在于，基础层由碎料板或纤维板构成。
6.根据权利要求1的方法，其特征在于，基础层主要由如聚氨酯类的聚合物材料构成。
7.根据权利要求1至6任一项的方法，其特征在于，表面元件包括一个至少在完全固化前具有弹性的层，该弹性层从基础层、底层、装饰层和耐磨层的组合中来选择。
8.根据权利要求1至7任一项的方法，其特征在于，在完全固化阶段之前，朝向表面具有结构形状的耐磨层压一个或多个上光滚子。
9.根据权利要求1至8任一项的方法，其特征在于，具有结构形状的滚子被加热到高于40℃的表面温度，最好在50℃-150℃范围内。
10.根据权利要求1至8任一项的方法，其特征在于，上光滚子被加热到高于30℃的表面温度，最好在35℃-100℃范围内。
11.根据权利要求1至7或9之一的方法，其特征在于，向具有结构形状的耐磨层的表层上施加一个薄的表层涂层。
12.根据权利要求8-10任一项的方法，其特征在于，在上光阶段之后向具有结构形状的耐磨层的表层上施加一个薄的表层涂层。
13.根据权利要求8-10任一项的方法，其特征在于，在上光阶段之前向具有结构形状的耐磨层的表层上施加一个薄的表层涂层，并在上光之前使该表层涂层部分固化。
14.根据权利要求11-13任一项的方法，其特征在于，表层涂层由丙烯酸或顺丁烯二酰亚胺漆，以及可能的平均粒径范围在50nm-10μm的硬质颗粒形式的添加剂组成。
15.根据权利要求1-14任一项的方法，其特征在于，每个具有结构形状的滚子设有一相对的保持滚子，表面元件从其之间通过。
16.根据权利要求8-15任一项的方法，其特征在于，每个上光滚子设有一相对的保持滚子，表面元件从其之间通过。
17.根据权利要求15的方法，其特征在于，表面元件具有厚度T，每个具有结构形状的滚子与相应的相对的保持滚子之间的距离设置在T减去0.5-1.2mm，最好是0.7mm-0.9mm的范围。
18.根据权利要求17的方法，其特征在于，每个具有结构形状的滚子与它的相应的相对的保持滚子之间的压力为50-200巴，最好为65-100巴。
19.根据权利要求16的方法，其特征在于，表面元件具有厚度T，每个上光滚子与相应的相对的保持滚子之间的距离设置在T减去0.7-1.2mm，最好是0.7mm-0.9mm的范围。
20.根据权利要求19的方法，其特征在于，每个上光滚子与它的相应的相对的保持滚子之间的压力为0.1-10巴，最好为0.5-5巴。
21.根据权利要求1-8任一项的方法，其特征在于，模具的具有结构形状的表面被加热到高于40℃的表面温度，最好在50℃-150℃范围内。
22.根据权利要求21的方法，其特征在于，具有结构形状的模具表面施加的压力为50-200巴，最好为65-100巴。
23.根据权利要求4-22任一项的方法，其特征在于，硬质颗粒由例如氧化硅、α-氧化铝或碳化硅构成。
24.根据权利要求4-22任一项的方法，其特征在于，硬质颗粒的主要部分由例如氧化硅、α-氧化铝或碳化硅构成，硬质颗料的少量部分的金刚石构成。
25.根据权利要求24的方法，其特征在于，金刚石构成的硬质颗粒的平均粒径在50nm-2μm之间，且金刚石构成的硬质颗料的被施加到接近耐磨层的上表面处。
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