WO2005084945A1 - A process for the manufacturing of a decorative board - Google Patents
A process for the manufacturing of a decorative board Download PDFInfo
- Publication number
- WO2005084945A1 WO2005084945A1 PCT/SE2005/000320 SE2005000320W WO2005084945A1 WO 2005084945 A1 WO2005084945 A1 WO 2005084945A1 SE 2005000320 W SE2005000320 W SE 2005000320W WO 2005084945 A1 WO2005084945 A1 WO 2005084945A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- decor
- layer
- process according
- press
- section
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/06—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
- B44C1/24—Pressing or stamping ornamental designs on surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0469—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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/028—Paper layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/102—Oxide or hydroxide
- B32B2264/1023—Alumina
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2451/00—Decorative or ornamental articles
Definitions
- a process for the manufacturing of a decorative board is a process for the manufacturing of a decorative board.
- the present invention relates to a process for the manufacture of a decorative thermosetting laminate by means of a continuous laminate press.
- thermosetting laminates are frequent today. They are foremost used where the demand for abrasion resistance is high, but also where resistance towards different chemicals and moisture is required. As an example of such products floors, floor headings, table tops, work tops and wall panels can be mentioned.
- the thermosetting laminate most often consists of a carrying base with a decor sheet and one or more wear layers placed closest to the surface.
- the decor sheet can be provided with a desired decor or pattern.
- the most frequent patterns usually represent the image of different kinds of wood, or minerals such as marble or granite.
- the surface of the laminate can be provided with a structure during the laminating procedure which will make the decor more realistic.
- the most common way of achieving such a laminate is by first manufacturing the thermosetting laminate of a number of paper layers impregnated with melamine formaldehyde resin and then to glue this thermosetting laminate onto a core of for example fibre board or particle board. It is also known to press a few melamine formaldehyde impregnated paper webs together with sheets of particle or fibre board in a laminate press.
- thermosetting laminate will change format somewhat which will cause problems when the decor is patterned in a way that calls for accurate matching. It is very difficult to accurately match a repetition frequency of a decor pattern of a web to boards without causing great loss of material.
- press foil or press plate used for achieving the surface structure on the thermosetting laminate are rather costly portions of the process.
- the present invention relates to a process for the manufacturing of a decorative board.
- the board includes a decorative layer.
- a decor section is arranged as a surface layer on a base layer and is bonded thereto by pressing under elevated temperature and pressure.
- the decor section is arranged in a press on a predetermined position related to possible repetition frequency of a decor pattern of the decor section and a first press foil section provided with a surface structure is positioned on top of, and in alignment with the decor section.
- the positioning operation is optionally being guided through means of a computer.
- the press foil is pressed onto the decor section under elevated temperature, optionally together with an uppermost wear layer arranged between the decor layer and press foil.
- the base layer, the decor section and the optional wear layer is laminated together under heat and pressure in a laminate press after which the laminate press is opened, the laminate removed from the press wherein the process is repeated a plurality of times, each time with a new set of surface layer but with the same first press foil section.
- the press foil section is replaced after a predetermined amount of press cycles.
- the number of times the press foil can be used is very much depending on the quality of the press foil as well as the type of surface structure present on the press foil. However, it should be possible to use each press foil section from about 5 to 10 times, some times possibly even up to 20 times. It is advantageous to use the process for achieving decorative boards where the surface structure is in register with the decor.
- the press foil and/or the decor section is then positioned in relation to each other before the pressing commences.
- the press foil sections are present in the form of a web which is feed forward a predetermined distance after the predetermined amount of press cycles.
- the forward feeding of the press foil is suitably guided by means of guiding data from sensor means detecting the position of said press foil.
- These guiding data may also be compared to similar data from a sensor means detecting the position of the decor section.
- the sensor means suitably is a camera array.
- the press foil section is present in the form of a sheet which is replaced by next press foil sheet after a predetermined amount of press cycles.
- a matrix colour camera for detecting colour while a reflection camera is used for detecting surface structure.
- the cameras are preferably arranged so as to detect at least two opposite corners of the decor.
- the computer advantageously uses the data retrieved for calculating a virtual centre point of the decor which is used for aligning the decor and surface structure.
- the cameras may also be arranged so as to detect at least two opposite corners of the decor.
- the computer uses the data retrieved for calculating a virtual centre point as well as a virtual centre line of the decor layer which is used for aligning the decor and surface structure.
- the data retrieved from the control camera array is preferably used by the computer for calculating statistical process guiding of the manufacturing.
- a vision system for input to the guiding of the process.
- Such a system advantageously incorporates ccd cameras. It is of course possible to use simpler systems like photo cells and light beams, or even mechanical systems for locating edges, holes, protrusions or the like used for identifying and positioning the different substrates of the laminate. It is also advantageous to use several measuring points on each substrate to be guided in order to achieve the best match possible. Traditionally one uses one, or possibly two, adjacent edges for positioning. Since the substrates of the invention are subject to change in format due to handling, moisture content etc. it is advantageous to use identification points on all four edges and by calculation achieve a virtual middle fix point as well as a virtual centre line which is used for the matching.
- the pressure in the continuous press is suitably in the range 5 - 90 Bar, preferably 15 - 70 Bar, while the temperature is in the range 140 - 200°C, preferably 160 - 180°C.
- the decorative board suitably comprises a wear layer which is constituted by at least one web of cellulose impregnated with melamine fo ⁇ naldehyde resin and provided with small aluminium oxide particles.
- the base layer is suitably constituted of a particle board with a thickness in the range 3 - 20 mm.
- the base layer is constituted of a medium density fibre or high density fibre board with a thickness in the range 3 - 20 mm.
- the base layer is constituted of at least one base paper layer of Kraft paper impregnated with thermosetting resin.
- the laminate achieved through the process may after lamination be glued to a carrier of for example fibre board or particle board.
- At least one base paper layer of Kraft paper impregnated with thermosetting resin is arranged between the base layer and the decor layer.
- a base paper layer is then suitably impregnated with an alkaline catalysed phenol formaldehyde resin, while the paper of the decor layer is impregnated with an acidic catalysed melamine formaldehyde resin.
- the dimension stability will be easier to control due to less shrinkage during lamination by utilising this combination of layers whereby problems like warping can be avoided.
- the impact resistance will also be improved by the above combination.
- the decor layer is preferably constituted of cellulose impregnated with melamine formaldehyde resin and is stretched during impregnation to compensate for shrinking during the lamination procedure.
- the decor layer is preferably provided with positioning means, said positioning means being placed in a predetermined relation to the direction variations of the decor pattern, said positioning means being intended for detection by the camera and control camera array.
- the base layer preconditions to a predetermined moisture content and temperature prior to being provided with a decor layer. It is also advantageous to precondition the decor layer to a predetermined moisture content and temperature prior to being applied on the base layer. Also the wear layer is suitably preconditioned to a predetermined moisture content and temperature prior to being applied on the decor layer.
- balance layer In order to counteract warping of the product it is advantageous to apply at least one balance layer on the lower side of the base layer. It is of course advantageous to precondition also the balance layer to a predetermined moisture content and temperature prior to being applied on the base layer.
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE112005000520T DE112005000520T5 (en) | 2004-03-04 | 2005-03-03 | Method for producing a decorative plate |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0400527A SE527817C2 (en) | 2004-03-04 | 2004-03-04 | Process for making a decorative panel |
SE0400527-8 | 2004-03-04 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2005084945A1 true WO2005084945A1 (en) | 2005-09-15 |
Family
ID=32067302
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/SE2005/000320 WO2005084945A1 (en) | 2004-03-04 | 2005-03-03 | A process for the manufacturing of a decorative board |
Country Status (3)
Country | Link |
---|---|
DE (1) | DE112005000520T5 (en) |
SE (1) | SE527817C2 (en) |
WO (1) | WO2005084945A1 (en) |
Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3105237A1 (en) * | 1981-02-13 | 1982-09-02 | G. Siempelkamp Gmbh & Co, 4150 Krefeld | System for improving chipboards, fibre boards and the like |
DE3105236A1 (en) * | 1981-02-13 | 1982-09-09 | G. Siempelkamp Gmbh & Co, 4150 Krefeld | Process and system for manipulating the metal texture plates in a system for improving chipboards, fibre boards and the like |
DE4227726A1 (en) * | 1992-08-21 | 1994-02-24 | Siempelkamp Gmbh & Co | Laminate press for electric circuit plate, or decorative panel mfr. - has replaceable press sheets fitted to upper and lower press plate with automatic sheet changing device |
JPH0839669A (en) * | 1994-08-02 | 1996-02-13 | Dainippon Printing Co Ltd | Pattern following emboss register adjusting method |
JPH1034704A (en) * | 1996-07-19 | 1998-02-10 | Sanwa Kinpaku:Kk | Transfer foil feeding device |
EP1153736A1 (en) * | 1996-02-28 | 2001-11-14 | Perstorp Ab | A process for the manufacture of a decorative laminate |
JP2003225902A (en) * | 2002-02-04 | 2003-08-12 | Eidai Co Ltd | Apparatus for mending defect of woody material |
US20030159385A1 (en) * | 2000-06-13 | 2003-08-28 | Thiers Bernard Paul Joseph | Floor covering, floor panels for forming such floor covering, and method for realizing such floor panels |
US20030183334A1 (en) * | 2002-03-27 | 2003-10-02 | Ake Sjoberg | Process for the manufacture of a decorative laminate |
US20040016501A1 (en) * | 2001-07-13 | 2004-01-29 | Eugenio Cruz | Embossed-in-register manufacturing process |
-
2004
- 2004-03-04 SE SE0400527A patent/SE527817C2/en not_active IP Right Cessation
-
2005
- 2005-03-03 WO PCT/SE2005/000320 patent/WO2005084945A1/en active Application Filing
- 2005-03-03 DE DE112005000520T patent/DE112005000520T5/en not_active Withdrawn
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3105237A1 (en) * | 1981-02-13 | 1982-09-02 | G. Siempelkamp Gmbh & Co, 4150 Krefeld | System for improving chipboards, fibre boards and the like |
DE3105236A1 (en) * | 1981-02-13 | 1982-09-09 | G. Siempelkamp Gmbh & Co, 4150 Krefeld | Process and system for manipulating the metal texture plates in a system for improving chipboards, fibre boards and the like |
DE4227726A1 (en) * | 1992-08-21 | 1994-02-24 | Siempelkamp Gmbh & Co | Laminate press for electric circuit plate, or decorative panel mfr. - has replaceable press sheets fitted to upper and lower press plate with automatic sheet changing device |
JPH0839669A (en) * | 1994-08-02 | 1996-02-13 | Dainippon Printing Co Ltd | Pattern following emboss register adjusting method |
EP1153736A1 (en) * | 1996-02-28 | 2001-11-14 | Perstorp Ab | A process for the manufacture of a decorative laminate |
JPH1034704A (en) * | 1996-07-19 | 1998-02-10 | Sanwa Kinpaku:Kk | Transfer foil feeding device |
US20030159385A1 (en) * | 2000-06-13 | 2003-08-28 | Thiers Bernard Paul Joseph | Floor covering, floor panels for forming such floor covering, and method for realizing such floor panels |
US20040016501A1 (en) * | 2001-07-13 | 2004-01-29 | Eugenio Cruz | Embossed-in-register manufacturing process |
JP2003225902A (en) * | 2002-02-04 | 2003-08-12 | Eidai Co Ltd | Apparatus for mending defect of woody material |
US20030183334A1 (en) * | 2002-03-27 | 2003-10-02 | Ake Sjoberg | Process for the manufacture of a decorative laminate |
Non-Patent Citations (3)
Title |
---|
DATABASE WPI Week 199616, Derwent World Patents Index; Class A35, AN 1996-156056, XP002988898 * |
DATABASE WPI Week 199816, Derwent World Patents Index; Class A32, AN 1998-173457, XP002988900 * |
DATABASE WPI Week 200358, Derwent World Patents Index; Class P63, AN 2003-612414, XP002988899 * |
Also Published As
Publication number | Publication date |
---|---|
SE527817C2 (en) | 2006-06-13 |
DE112005000520T5 (en) | 2007-01-18 |
SE0400527D0 (en) | 2004-03-04 |
SE0400527L (en) | 2005-09-05 |
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