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WO2003061967A1 - Procede permettant de faire concorder des sections decoratives de panneaux de surface - Google Patents

Procede permettant de faire concorder des sections decoratives de panneaux de surface Download PDF

Info

Publication number
WO2003061967A1
WO2003061967A1 PCT/SE2003/000115 SE0300115W WO03061967A1 WO 2003061967 A1 WO2003061967 A1 WO 2003061967A1 SE 0300115 W SE0300115 W SE 0300115W WO 03061967 A1 WO03061967 A1 WO 03061967A1
Authority
WO
WIPO (PCT)
Prior art keywords
web
decor
process according
impregnated
average
Prior art date
Application number
PCT/SE2003/000115
Other languages
English (en)
Inventor
Kent Lindgren
Original Assignee
Pergo(Europe) Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pergo(Europe) Ab filed Critical Pergo(Europe) Ab
Publication of WO2003061967A1 publication Critical patent/WO2003061967A1/fr

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
    • 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
    • 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
    • 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
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B32B2317/125—Paper, e.g. cardboard impregnated with thermosetting 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing

Definitions

  • the present invention relates to a process of matching decor sections of surface panels in bulk production.
  • 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 mostly consists of a number of base sheets with a decor sheet 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. Press plates with structure or structure foils are frequently used when manufacturing such a laminate. A negative reproduction of the structure in the press plate or the foil will be imprinted into the laminate during the laminating procedure.
  • Thermosetting laminate are for production cost reasons most often produced in rather large formats which have to be cut into smaller, more user friendly, formats. This will cause some problems as the different steps in the production will affect the format of the decor carrying parts of the thermosetting laminate. This problem will not have any greater effect on decors which are rather uniform in pattern and which has no decor section which needs to be located on a specific location on each board. However, when trying to manufacture more specific and dimension dependant decor patterns, like floor tiles with grouting and blocked wood pattern, the problem becomes almost impossible to overcome without having to introduce very large areas that are to be cut away. The latter will cause a lot of waste of the rather costly laminate.
  • the invention relates to a process for matching decor sections on decorative surface panels, A decor web with a repetitive decor pattern is impregnated with a thermosetting resin, the decor web being provided with positioning means. Said positioning means are used for guiding the tension of the web during the impregnation procedure thereby guiding the longitudinal expansion of the web. Said web is cut into sheets after the impregnation, said cut being thoroughly positioned in relation to said positioning means.
  • Said sheets are laminated and bonded to each one core layer and at least one support layer selected from the group consisting of; overlay of cellulose impregnated with thermosetting resin and underlay of cellulose impregnated with thermosetting resin wherein a raw board is achieved.
  • the raw board is cut and trimmed into panels, said cut and trimming being thoroughly positioned in relation to said positioning means.
  • the decor web is suitably made of cellulose.
  • the average fibre direction of the web is longitudinal and the average fibre direction of the web has an average deviation of less than 5° from the web centre line. It is however advantageous if the average fibre direction of the web has an average deviation of less than 3° from the web centre line.
  • the average latitudinal wet expansion rate of the web is preferably in the range 1.8 - 2.3%.
  • the average longitudinal wet expansion rate along the edges of the web is preferably not deviating more than 30%> from the average longitudinal wet expansion rate along the centre of the web.
  • the average latitudinal wet expansion rate along the edges of the web is preferably not deviating more than 30% from the average latitudinal wet expansion rate along the centre of the web.
  • the process is preferably controlled further via means of conditioning the different materials used.
  • the decor web is conditioned to a specified temperature and moisture content prior to being provided with decor.
  • the decor is applied on the decor web by means of printing. It is also important that the decor web is allowed to set for a couple of weeks after the paper manufacturing before being printed. The latter is part of the conditioning process.
  • the printed decor web is then advantageously conditioned to a specified temperature and moisture content prior to the impregnation.
  • the decor web is then preferably conditioned to a specified temperature and moisture content prior to the lamination. It is in all steps important that the conditioning process is allowed time enough for the web to set as the rolls normally used are rather large and contains rather large amounts of material.
  • the support layer is suitably conditioned to a specified temperature and moisture content prior to the impregnation.
  • the support layer is then suitably conditioned to a specified temperature and moisture content prior to the lamination. It is also here important that the conditioning process is allowed time enough for the support layers to set as the rolls normally used are rather large and contains rather large amounts of material.
  • the core layer may need some attention as it has shown to affect the final result to some extent.
  • the core layer most often consists of a particle board or a fibre board. Accordingly the core layer is suitably conditioned to a specified temperature and moisture content prior to the impregnation. It is also here important that the conditioning process is allowed time enough for the core layer to set as it contains certain amounts of material.
  • the decor section of the decor that is to be accurately matched on the final boards are accurately arranged in relation to the positioning means of the decor web. These decor sections are arranged so that a number of intended panels forms at least two columns and at least two rows on a raw board.
  • the overlay is impregnated with thermosetting resin, preferably in the form of melamine-formaldehyde resin.
  • the panels may also contain more than one layer.
  • At least one of the thermosetting resin impregnated overlays, preferably the uppermost one is coated with hard particles, for example silica, aluminium oxide and/or silicon carbide with an average size of 1 - 100 ⁇ m, preferably around 5 - 60 ⁇ m.
  • the upper side of the decorative surface panels is constituted of a decor layer and a ionomeric polymer.
  • the upper side of the decorative surface is constituted of a decor layer, a ionomeric polymer and hard particles.
  • the upper side of the decorative surface panels is constituted of a decor layer impregnated with melamine formaldehyde, a ionomeric polymer, overlay impregnated with melamine formaldehyde and sprinkled with hard particles.
  • the surface suitably is provided with an embossing with different structure pattern.
  • the pattern is selected from the group consisting of; groups of small oblong indentations, different grades of gloss to flat surface finish, ridges and recesses and combinations thereof.
  • the surface layer of the may suitably include a so called overlay paper, placed on top of the decor paper.
  • the overlay paper is suitably impregnated with melamine-formaldehyde resin.
  • At least one of the thermosetting resin impregnated sheets, preferably the uppermost one is preferably coated with hard particles, for example silica, aluminium oxide and/or silicon carbide with an average size of 1 - 100 ⁇ m, preferably around 5 - 60 ⁇ m.
  • the base layer suitably consists of a particle board or a fibre board.
  • Such a base layer may be 5 -20 mm thick.
  • a board according to the invention may for example be used as a floor board, a wall panel or a ceiling panel.
  • the most popular decor used on floor boards is different kinds of wood as for example oak, birch, beech, ash, cherry, maple, walnut, pine, rosewood, mahogany or ebony.
  • minerals like marble, granite, sandstone, soapstone and ceramic materials are popular reproductions.
  • the reproductions are suitably grouped so that they form different installation patterns like inlays, marquetry, tiling, grouting, block pattern and the like which all are intended to form a pattern when a number of boards or panels are joined.

Landscapes

  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé permettant de faire concorder des sections décoratives sur des panneaux décoratifs de surface, une bande décorative à motifs décoratifs répétitifs étant imprégnée d'une résine thermodurcissable. Cette bande décorative est dotée de moyens de positionnement servant à guider l'extension de la bande pendant la procédure d'imprégnation, en guidant l'expansion longitudinale de la bande. Après l'imprégnation, cette bande est coupée en feuilles, la coupe étant positionnée par rapport auxdits moyens de positionnement. Ces feuilles sont stratifiées et liées à chaque couche intérieure et au moins une couche support, sélectionnées dans le groupe constitué par un revêtement de cellulose imprégné de résine thermodurcissable et une sous-couche de cellulose imprégnée de résine thermodurcissable, jusqu'à l'obtention d'une planche brute. Cette planche brute est ensuite coupée et ébarbée en panneaux, la coupe et l'ébarbage étant positionnés par rapport aux moyens de positionnement.
PCT/SE2003/000115 2002-01-25 2003-01-22 Procede permettant de faire concorder des sections decoratives de panneaux de surface WO2003061967A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0200209-5 2002-01-25
SE0200209A SE523935C2 (sv) 2002-01-25 2002-01-25 Förfarande för matchning av ytpanelers dekorsektioner

Publications (1)

Publication Number Publication Date
WO2003061967A1 true WO2003061967A1 (fr) 2003-07-31

Family

ID=20286762

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/SE2003/000115 WO2003061967A1 (fr) 2002-01-25 2003-01-22 Procede permettant de faire concorder des sections decoratives de panneaux de surface

Country Status (2)

Country Link
SE (1) SE523935C2 (fr)
WO (1) WO2003061967A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6922965B2 (en) 2003-07-25 2005-08-02 Ilinois Tool Works Inc. Bonded interlocking flooring
WO2005097380A1 (fr) * 2004-04-07 2005-10-20 Pergo (Europe) Ab Procede ameliore de fabrication de stratifie decoratif
EP1541373A3 (fr) * 2003-12-11 2007-08-29 Pergo (Europe) AB Methode pour produire des panels avec une surface decorative
EP2463116A1 (fr) * 2010-12-08 2012-06-13 Spanolux N.V. - Div. Balterio Procédé de production d'un panneau comprenant une couche résistant à l'usure et un panneau
US9073295B2 (en) 2008-12-19 2015-07-07 Fiber Composites, Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
US9637920B2 (en) 2006-01-20 2017-05-02 Material Innovations Llc Carpet waste composite
EP4043228A1 (fr) 2021-02-10 2022-08-17 Flooring Industries Limited, SARL Substrat imprimé de formulation d'encre et procédé de formulation d'encre
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture
US12172421B2 (en) 2020-11-18 2024-12-24 Rise Building Products Llc Composite building materials and methods of manufacture

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2022562A1 (de) * 1969-05-08 1970-11-19 Isorel Puteaux Kontinuierliches Verfahren zur Herstellung dekorativer Platten und Vorrichtung zur Durchfuehrung des Verfahrens
US4612074A (en) * 1983-08-24 1986-09-16 American Biltrite Inc. Method for manufacturing a printed and embossed floor covering
US4704171A (en) * 1986-03-03 1987-11-03 Adolph Coors Company Laminating device with paper tension control
WO1997031776A1 (fr) * 1996-02-28 1997-09-04 Perstorp Ab Procede de structuration de surface

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2022562A1 (de) * 1969-05-08 1970-11-19 Isorel Puteaux Kontinuierliches Verfahren zur Herstellung dekorativer Platten und Vorrichtung zur Durchfuehrung des Verfahrens
US4612074A (en) * 1983-08-24 1986-09-16 American Biltrite Inc. Method for manufacturing a printed and embossed floor covering
US4704171A (en) * 1986-03-03 1987-11-03 Adolph Coors Company Laminating device with paper tension control
WO1997031776A1 (fr) * 1996-02-28 1997-09-04 Perstorp Ab Procede de structuration de surface

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6922965B2 (en) 2003-07-25 2005-08-02 Ilinois Tool Works Inc. Bonded interlocking flooring
EP1541373A3 (fr) * 2003-12-11 2007-08-29 Pergo (Europe) AB Methode pour produire des panels avec une surface decorative
WO2005097380A1 (fr) * 2004-04-07 2005-10-20 Pergo (Europe) Ab Procede ameliore de fabrication de stratifie decoratif
US10294666B2 (en) 2006-01-20 2019-05-21 Material Innovations Llc Carpet waste composite
US11773592B2 (en) 2006-01-20 2023-10-03 Material Innovations Llc Carpet waste composite
US10822798B2 (en) 2006-01-20 2020-11-03 Material Innovations Llc Carpet waste composite
US9637920B2 (en) 2006-01-20 2017-05-02 Material Innovations Llc Carpet waste composite
US10875281B2 (en) 2008-12-19 2020-12-29 Fiber Composites Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
US9073295B2 (en) 2008-12-19 2015-07-07 Fiber Composites, Llc Wood-plastic composites utilizing ionomer capstocks and methods of manufacture
WO2012076608A1 (fr) * 2010-12-08 2012-06-14 Spanolux N.V.- Div. Balterio Procédé de fabrication d'un panneau comprenant une couche résistante à l'usure et panneau
EP2463116A1 (fr) * 2010-12-08 2012-06-13 Spanolux N.V. - Div. Balterio Procédé de production d'un panneau comprenant une couche résistant à l'usure et un panneau
US11572646B2 (en) 2020-11-18 2023-02-07 Material Innovations Llc Composite building materials and methods of manufacture
US12172421B2 (en) 2020-11-18 2024-12-24 Rise Building Products Llc Composite building materials and methods of manufacture
EP4043228A1 (fr) 2021-02-10 2022-08-17 Flooring Industries Limited, SARL Substrat imprimé de formulation d'encre et procédé de formulation d'encre
WO2022172121A1 (fr) 2021-02-10 2022-08-18 Flooring Industries Limited, Sarl Substrat imprimé pour la formulation d'encre et procédé pour la formulation d'encre

Also Published As

Publication number Publication date
SE0200209D0 (sv) 2002-01-25
SE523935C2 (sv) 2004-06-01
SE0200209L (sv) 2003-07-26

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