STAINABLE DECORATIVE BOARD

Abstract

The invention relates to a method for producing a synthetic resin surface or lacquered surface with a variable color, having the steps of providing a support layer with a lower face and an upper face, impregnating the support layer with a liquid impregnant without using a pickling additive and at least drying the impregnated support layer. The aim of the invention is to provide a decorative surface, the coloring of which by the end consumer can be modified in a particularly simple manner and which is particularly inexpensive and resistant. This is achieved in that a layer of coating agent is deposited on the upper face of the support layer and is dried, and the support layer is then connected to a material, wherein the layer is cured in order to form an open-pore layer which is at least as transparent as possible upon drying and/or connecting to the upper face.

Claims

1. A method for producing a color-changeable synthetic resin surface or lacquer surface, comprising the steps: provide a backing layer having a bottom side and a top side, fully impregnate the backing layer with a liquid impregnant without a stain additive, at least slightly dry the impregnated backing layer, apply a layer of a coating agent to the top side of the backing layer, dry the at least one coating agent layer, bond the backing layer to a material, wherein the one layer cures to an open-pore, at least largely transparent layer upon drying and/or bonding on the top side.

2. The method according to claim 1, wherein a mixture comprising a synthetic resin with a stain additive, or a mixture comprising a lacquer and a stain additive are applied as the coating agent.

3. The method according to claim 2, wherein kaolin, alumina, silica, chalk, mica, quartz sand, silicate, cellulose or natural fibers, glass spheres or glass powder is used as the stain additive.

4. The method according to claim 2, wherein kaolin is used in a hydrated and/or calcined form as a stain additive.

5. The method according to claim 2, wherein the percent weight of the stain additive in the coating agent is 10% by weight to 60% by weight.

6. The method according to claim 1, wherein a synthetic resin, or a lacquer based on an aminoplast, in particular a urea resin such as UF or MUF, of acrylate, PUR, phenol resin, polyester, alkyd, nitrocellulose, latex or a mixture, or respectively a combination of at least two of the aforementioned substances is used as the coating agent.

7. The method according to claim 1, wherein a synthetic resin, or a lacquer based on an aminoplast, in particular a urea resin such as UF or MUF, of acrylate, PUR, urea resin, phenol resin or a mixture of at least two of the aforementioned substances is used as the impregnant.

8. The method according to claim 1, wherein the coating agent is applied to the top side of the backing layer using a roller device, a squeegee or a spray device.

9. The method according to claim 1, wherein before bonding, at least one layer of an adhesive resin is applied to the bottom side of the backing layer which adheres the backing layer to the material for bonding under the effect of pressure and heat.

10. The method according to claim 1, wherein the dried backing layer in order to bond to an adhesive is laminated to a material.

11. The method according to claim 10, wherein a fiber cement material, a gypsum fiber material, WPC material or a wood composite, a fiber material, CDF material, MDF material, HDF material, chip material or OSB material is used as the material.

12. The method according to claim 1, wherein a material formed as a material board is used.

13. A material comprising a color-changeable synthetic resin surface or lacquer surface at least having: a backing layer bonded to the material, wherein the backing layer is fully impregnated with an impregnant without a stain additive, an adhesive resin or adhesive arranged between the backing layer and a top side of the material adhering the backing layer and material, and an at least largely transparent, open-pore and cured layer of a coating agent arranged on a visible top side of the backing layer.

14. A decorative paper with a color-changeable, predried synthetic resin surface, comprising: a backing layer that is fully impregnated with an impregnant that does not contain a stain additive, a layer of a coating agent applied to the top side and dried that forms an open-pore surface in a cured state.

15. A finish film with a color-changeable, predried lacquer surface comprising: a backing layer that is fully impregnated with an impregnant that does not contain a stain additive, and an at least largely transparent and cured layer of a coating agent applied to a top side of the backing layer that includes a lacquer and forms an open-pore surface.

16. The method according to claim 3, wherein the stain additive is in a silanized form.

17. The method according to claim 5, wherein the percent weight of the stain additive in the coating agent is 20% by weight to 50% by weight.

18. The method according to claim 5, wherein the percent weight of the stain additive in the coating agent is 30% by weight to 50% by weight.

19. The method according to claim 10, wherein a hotmelt PUR or PVAC glue is used as the adhesive.

20. The method according to claim 12, wherein the material board is a fiber cement board, gypsum fiber board, WPC board or a wood composite board.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] Hereinafter the invention will be further explained with reference to exemplary embodiments. It is shown in:

[0073] FIG. 1 an inventive material board produced according to the inventive method with a synthetic resin surface in an exploded view;

[0074] FIG. 2 a material board produced according to the inventive method with a lacquered finish film in an exploded view;

[0075] Example 1 describes another method for producing a color-changeable decorative surface.

DETAILED DESCRIPTION

[0076] FIG. 1 shows, in a side perspective, a material 1 with a stainable synthetic resin surface 8 in an exploded view. In contrast to the view, the individual layers (2, 3, 4, 7) in the shown sequence are firmly and unreleasably connected to each other.

[0077] The material 1 has a material top side 2. A layer of synthetic resin 3 is arranged on the material top side 2. A backing layer 4 with a bottom side 5 and top side 6 is shown above the synthetic resin 3. The bottom side 5 of the backing layer 4 borders the synthetic resin 3 that adheres the backing layer 4 and the material 1 to each other. A coating 7 is arranged on the top side 6 that comprises the synthetic resin 7a. All of the layers are completely cured.

[0078] The coating 7 with the synthetic resin 7a is configured open-pore (not shown here). The open-pore configuration in this case is realized in particular by arranging a filler 7b in the region of the coating 7 that has been applied as a coating 7 as a mixture together with the synthetic resin 7a.

[0079] In the exemplary embodiment shown here, the material 1 consists of a material board. The material board is formed from a fiber material, in this case an MDF material. That is, the material board is a wood composite board but could alternatively also be for example formed from WPC material, chip material, HDF material or CDF material.

[0080] The backing layer 4 has been fully impregnated with a urea resin (not shown here), or alternatively with a melamine resin. The synthetic resin 3 adhering the backing layer 4 to the material 1 comprises melamine resin in this case. The synthetic resin 3 adheres the top side 2 of the material 1 to the bottom side 5 of the backing layer 4.

[0081] Furthermore a decorative print (not shown here) is present on the top side 6 of the backing layer 4. The decorative print in this case shows a colored wood decoration, but however could also be configured as a color decoration or in grayscales. In this case, the decorative print replicates both the structure of the wood as well as the hue of the wood.

[0082] The coating 7 applied to the top side 6 comprises a urea resin configured as a synthetic resin 7a with kaolin as a filler 7b. The mixture of kaolin and urea resin was applied liquid to the top side 6. In this case, the weight ratio between the urea resin and kaolin before applying the mixture is 50% by weight:50% by weight, preferably 20% by weight kaolin to 80% by weight liquid resin. After the sandwich has been produced from the individual layers, it was introduced into a cycle press and pressed together under the effect of pressure and heat.

[0083] FIG. 2 schematically shows a side exploded view of a color-changeable lacquer surface 11 on a material 1 produced according to the inventive method. The material 1 in this case is also configured as a board but however can also have any other desired shape. The material 1 is a wood composite in this case an MDF board. A backing layer 4 configured here as a finish film 10 is laminated onto the material board 1. To accomplish this, an adhesive 9, in this case a hot melt, has been arranged between the bottom side 5 of the backing layer 4 and the material top side 2 of the material board 1. The material 1 and the coated, cured backing layer 4 (finish film) have been bonded together on a lamination system (not shown here).

[0084] The finish film 10 comprises a paper layer (backing layer 4) that is fully impregnated with a liquid acrylate (not shown here), and a decoration (not shown) is printed on its top side 6. Impregnation occurs in an impregnation bath (not shown). The fully impregnated backing layer 4 does not have any stain additive 7b. After impregnation, the backing layer 4 was dried using heat.

[0085] Then a layer 7 of a coating agent was applied to the top side 6 of the backing layer 4 using a spray device (not shown here). The coating agent is configured as a lacquer and comprises an acrylate 12 and stain additive 7b, and can alternatively if desired also be configured without a stain additive if the acrylate is to be cured open-pore. After application, the coating agent is also dried using heat, and cured. Due to the stain additives 7b, the surface of the layer 7 is configured open-pore and can absorb the color pigments of a stain.

[0086] The layer 7 of coating agent is given kaolin as stain additives. Before applying the coating agent, the ratio was 20% by weight kaolin to 80% by weight acrylate.

Example 1

[0087] Another exemplary embodiment for producing a subsequently changeable synthetic resin or lacquer surface provides impregnating a backing layer with a liquid impregnant without a stain additive. In this case, the impregnant consists of melamine resin and/or urea resin. Moreover, additives such as wetting agents, release agents and/or anti-dust agents are added, but no stain additives. Impregnation is carried out with an amount between 80% by weight and 250% by weight relative to the backing layer. In this case, the backing layer is a paper. The paper has a color decoration and is therefore a decorative paper. The end weight of the impregnated backing layer after the impregnation process is approximately 120/m.sup.2 to 220 g/m.sup.2.

[0088] After impregnation, the impregnated backing layer is dried. Drying is done thermally. It can be performed at temperatures between 60 and 200, but it is done in particular however at temperatures between 40 and 60. Drying is performed until a residual moisture and/or a residue of volatile contents of 4% to 10% is reached relative to the end weight of the backing layer. Drying is performed in particular in a drying channel in a suspension process.

[0089] After the drying procedure, a layer of the coating agent is applied to the backing layer. In so doing, 15-30 g/m.sup.2 of the coating agent is applied. Given the very thin application of the coating agent layer (10-90 m), existing, for example embossed structures in the surface remain.

[0090] Application is done in particular by a roller application using a rubber roller. The rubber roller preferably has a Shore A hardness of 40 (Shore A 40). After application, the coating agent layer is also thermally dried. This can also be done in a drying channel. The drying temperatures are preferably between 60 and 180, and the drying time is between approximately 10 sec. to 20 sec.

[0091] After drying, the backing layer can be bonded to a material, in particular a material board, for example a wood composite board such as a fiberboard or chipboard. To accomplish this, the impregnated and coated backing layer is pressed with a material board in a short cycle press. This is done in particular at a pressure between 200 N/cm to 750 N/cm, a temperature between 140 C. and 200 C. at the surface of the backing layer, and over approximately 8 sec. to 40 sec.

[0092] The coating agent in this case is a multicoat lacquer based on acrylic resins that can be used as a primer, for example the coating agent Hydro-UV multicoat lacquer HUE 8656X by the company Hesse-Lignal. From the drying passes, the thin application method with the rubber roller and pressing in the short cycle press, both coating lacquers form a ready-to-use stainable surface that has a sufficient porosity so that subsequently applied color particles can accumulate in the outermost surface layer.

[0093] The completely cured decorative surface is ready-to-use. To subsequently modify the color of this decorative surface, for example conventional stains based on water or other solvents can be used. For example, the stain Parquet-Colour by the company Hesse-Lignal can be used. The stained and dried surface can moreover be subsequently overcoated again with a corresponding protective layer (or fixing layer). For this, a multicoat lacquer based on a two-component PUR acrylic resin lacquer is useful. Accordingly for example, the coating agent PUR SUN-CAPE DE 4800X by the company Hesse-Lignal can be used.

LIST OF REFERENCE NUMBERS

[0094] 1. Material [0095] 2. Material top side [0096] 3. Adhesive resin [0097] 4. Backing layer [0098] 5. Backing layer bottom side [0099] 6. Backing layer top side [0100] 7. Layer of coating agent [0101] 7a Synthetic resin [0102] 7b Stain additive [0103] 8. Synthetic resin surface [0104] 9. Adhesive [0105] 10. Finish film [0106] 11. Lacquer surface [0107] 12. Acrylate