Process for the manufacturing of decorative boards

• US 20050003099A1
• Filed: 03/13/2002
• Published: 01/06/2005
• Est. Priority Date: 03/14/2001
• Status: Active Grant

• Current Assignee: Pergo AB (Mohawk Industries Incorporated)
• Original Assignee: Pergo AB (Mohawk Industries Incorporated)
• Inventors: Miller, Peter, Quist, Magnus, Ericsson, Jan
• Granted Patent: US 7,985,444 B2
• Time in Patent Office: Days
• US Class Current: 427/532
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 3/0209 Multistage baking
• CPC Class Codes: B05D 3/0254 After-treatment
• CPC Class Codes: B05D 3/067 Curing or cross-linking the coating
• CPC Class Codes: B05D 3/068 using ionising radiations (gamma, X, electrons)
• CPC Class Codes: B05D 5/06 to obtain multicolour or other optical effects B05D5/02 takes precedence
• CPC Class Codes: B05D 7/08 using synthetic lacquers or varnishes
• CPC Class Codes: B44C 1/20 Applying plastic materials and superficially modelling the surface of these materials
• CPC Class Codes: B44C 1/24 Pressing or stamping ornamental designs on surfaces

Abstract

A process of the manufacturing of decorative boards with an abrasion resistant surface and edges with joining functionality, the process comprising the steps: a) cutting a carrier board to the desired dimension and molding edges with joining functionality, b) treating at least the upper surface of the board, c) applying radiation curable dry acrylic lacquer powder by means of electrostatic spray nozzles, d) heating the acrylic lacquer so that it melts, e) curing the acrylic lacquer by means of radiation being selected from the group consisting of UV-radiation and electron beam radiation.

Claims

1. A process for the manufacturing of decorative boards with an abrasion resistant surface and edges with joining functionality, the process comprising the steps:

a) cutting a carrier board to the desired dimension and molding edges with joining functionality,

b) treating at least the upper surface of the board,

c) applying radiation curable dry acrylic lacquer powder by means of electrostatic spray nozzles,

d) heating the acrylic lacquer so that it melts,

e) curing the acrylic lacquer by means of radiation, the radiation being selected from the group consisting of UV-radiation and electron beam radiation.

2. A process according to claim 1, wherein at least the upper surface of the board is sanded smooth before applying the acrylic lacquer.

3. A process according to claim 1, wherein at least the upper surface of the board is pressed with a heated calendar roller, the surface temperature of the calendar roller being in the range 45-150°

C. and that the calendar roller exerts a pressure on the board in the range 10-100 bar.

4. A process according to claim 1, wherein a primer is applied on the board before applying the acrylic lacquer.

5. A process according to claim 1, wherein a decorative foil is applied on the board before applying the acrylic lacquer.

6. A process according to claim 1, wherein a decor is printed on the upper surface before applying the acrylic lacquer.

7. A process according to claim 1, wherein an upper surface of the board is coated with a bonding layer to an amount of 10-40 g/m², that hard particles with an average particle size in the range 40-150 μ

m are sprinkled to an amount of 1-30 g/m² on the sticky bonding layer, that the hard particles are selected from the group consisting of aluminum oxide, silicon oxide, silicon carbide and mixtures thereof.

8. A process according to claim 7, wherein the bonding layer is a wet UV-curable acrylic lacquer, which bonding layer is cured after having applied the hard particles.

9. A process according to claim 7, wherein the bonding layer is a UV- or electron beam curable acrylic lacquer.

10. A process according to claim 1, wherein the board is preheated before applying the acrylic lacquer.

11. A process according to claim 10, wherein the preheating is arranged so that a surface temperature of the board is in the range 40-150°

C. when the application of acrylic lacquer is initiated.

12. A process according to claim 10, wherein the preheating is arranged so that a core temperature of the board is in the range 40-150°

C. when the application of acrylic lacquer is initiated.

13. A process according to claim 1, wherein the acrylic lacquer is applied to an amount of 10-250 g/m².

14. A process according to claim 13, wherein the acrylic lacquer is applied to an amount of 50-250 g/m² on an upper surface of the board.

15. A process according to claim 13, wherein the acrylic lacquer is applied to an amount of 10-70 g/m² on a lower surface of the board.

16. A process according to claim 13, wherein the acrylic lacquer is applied to an amount of 10-100 g/m² on the edges of the board.

17. A process according to claim 13, wherein the acrylic lacquer applied on an upper surface comprises hard particles selected from the group consisting of aluminum oxide, silicon oxide and silicon carbide.

18. A process according to claim 17, wherein the hard particles have an average particle size in the range 1-150 μ

m.

19. A process according to claim 17, wherein the hard particles have an average particle size in the range 1-50 μ

m.

20. A process according to claim 13, wherein the hard particles are mixed with the acrylic lacquer in the nozzles during the coating process.

21. A process according to claim 13, wherein the acrylic lacquer is applied by separate groups of nozzles, the groups comprising an upper surface coating group, a rear surface coating group and at least one edge coating group.

22. A process according to claim 13, wherein the acrylic lacquer is applied by separate groups of nozzles, the groups comprising an upper surface coating group, a rear surface coating group and two edge coating groups.

23. A process according to claim 13, wherein the acrylic lacquer is applied by separate groups of nozzles, the groups comprising an upper surface coating group, a rear surface coating group and four edge coating groups.

24. A process according to claim 21, wherein the acrylic lacquer applied on the edges is guided by means of an air stream, the air stream being achieved by means of a narrow air evacuation tube, the air evacuation tube having a suction nozzle which is arranged adjacent to recesses and pockets molded in the edge whereby a more uniform coating is achieved on the edge.

25. A process according to claim 13, wherein the acrylic lacquer is melted by means of hot air environment.

26. A process according to claim 13, wherein the acrylic lacquer is melted by means of infrared radiation.

27. A process according to claim 26, wherein the acrylic lacquer applied on the edges is illuminated with the infrared radiation via reflectors.

28. A process according to claim 1, wherein the molten acrylic lacquer is cured by means of UV radiation, that the acrylic lacquer applied on the edges are illuminated with UV light via reflectors.

29. (Cancelled)