METHOD FOR PRODUCING A DECORATIVE LAMINATE

• US 20100307677A1
• Filed: 12/19/2008
• Published: 12/09/2010
• Est. Priority Date: 12/21/2007
• Status: Active Grant

• Current Assignee: Surface Technologies GmbH & Co. KG
• Original Assignee: Surface Technologies GmbH & Co. KG
• Inventors: Buhlmann, Carsten
• Granted Patent: US 9,174,423 B2
• Time in Patent Office: Days
• US Class Current: 156/277
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/06 of paper or cardboard
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/12 on paper layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 2607/02 Wall papers, wall coverings
• CPC Class Codes: B32B 37/02 characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/14 characterised by the properties of the layers
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B44C 1/10 : Applying flat materials, e.g. leaflets, pieces of fabrics paperhanging B44C7/00
• CPC Class Codes: B44C 5/043 : containing wooden elements

Abstract

A method for producing a decorated laminate having a plate-shaped core made of wood or wood material, a decorative layer on at least one side of the core, and a cover layer having aminoplast on the decorative layer, comprising the following steps: providing the plate-shaped core, fastening a cellulose nonwoven material on at least one side of the core, printing the decoration on the exposed side of the cellulose nonwoven material, attaching at least one curable cover layer on the printed decoration, and curing the curable layers.

Claims

1. A process for producing a decorated laminate comprising a plate-shaped core of wood or wood material, a decorative layer on at least one side of the core and a cover layer having aminoplast on the decorative layer, comprising the steps:

providing the plate-shaped core,

fixing a cellulose nonwoven material on at least one side of the core,

printing the decoration onto the exposed side of the cellulose nonwoven material,

applying at least one hardenable cover layer to the printed decoration, and

hardening the hardenable layers.

2. A process according to claim 1, wherein the cellulose nonwoven material is glued onto the core.

3. A process according to claim 2, wherein the prior to the step of gluing on the cellulose nonwoven material at least one side of

the core is coated with an adhesive.

4. A process according to claim 2, wherein prior to the gluing operation the cellulose nonwoven material is coated on one side with adhesive.

5. A process according to claim 3, wherein a liquid hardening glue is used as the adhesive.

6. A process according to claim 5, wherein the hardening glue is a urea formaldehyde glue.

7. A process according to claim 1, wherein the cellulose nonwoven material is a paper.

8. A process according to claim 7, wherein the paper is a printing base paper.

9. A process according to claim 7, wherein the paper has a weight in relation to surface area of between 20 and 200 g per square metre, preferably from 40 to 80 g per square metre.

10. A process according to one of claims 5, wherein the nonwoven material is joined to the plate-shaped core under pressure and heat with at least partial hardening of the glue.

11. A process according to claim 1, wherein the decoration is applied by printing by offset printing, indirect intaglio printing, flexoprinting or a digital printing process.

12. A process according to claim 1, wherein the decoration is printed in one colour.

13. A process according to claim 1, wherein the decoration is printed in a plurality or colours.

14. A process according to claim 1, wherein the at least one cover layer is formed from an aminoplast.

15. A process according to claim 14, wherein the aminoplast is a melamine formaldehyde resin.

16. A process according to claim 14, wherein there is a particulate hard solid material in at least one cover layer.

17. A process according to claim 16, wherein the solid material is aluminium oXide, silicon dioxide, silicon carbide or boron nitride.

18. A process according to one of claims 14, wherein the cover layer is applied in the form of an overlay.

19. A process according to one of claims 14, wherein a plurality of cover layers are applied.

20. A process according to claim 19, wherein each cover layer is surface-dried after the application operation.

21. A process according to claim 19, wherein the hard solid material is applied with the lowermost layer and the uppermost layer contains no solid material.

22. A process according to claim 1, wherein the laminate of at least core, cellulose nonwoven material and a cover layer is hardened under pressure and heat.

23. A process according to claim 22, wherein the laminate is heated and pressed in a double-belt or short-cycle press.

24. A process according to claim 22, wherein the heating and pressing procedure a structure is embossed into the surface of the outermost cover layer.

25. A process according to claim 24, wherein the structure is in relation to the decoration.

26. A process according to claim 1, wherein a stabilising layer is applied on the side of the core, that is remote from the decoration.

27. A process according to claim 26, wherein stabilising layer is applied simultaneously with the decoration layers.