Method and System For Producing Coated Chipboard Having A Functional Surface

Abstract

A method for producing coated chipboard (9) having a functional surface, wherein the chipboard (9), in a first step (S1), is covered continuously and simultaneously and on both sides using melamine-impregnated paper (90) and a functional carrier material (91), wherein the melamine-impregnated paper (90) and the functional carrier material (91) are laid continuously and simultaneously by two rolls (10) and (11) in each case on the chipboard (9). A system for carrying out the above method and for producing a coated chipboard (9) includes, for continuously operating the system and for continuously carrying out the method, in each case a suitable functional carrier material and paper unwinding device (1), a suitable cutting device (2), a suitable press (3), and a suitable functional carrier material draw-off device (4).

Claims

1. A method for producing coated chipboard (9) having a functional surface, wherein the chipboard (9), in a first step (S1), is covered continuously and simultaneously and on both sides using melamine-impregnated paper (90) and a functional carrier material (91), wherein in a first step (S1), the melamine-impregnated paper (90) and the functional carrier material (91) are laid continuously and simultaneously by two rolls (10) and (11) in each case on the chipboard (9), wherein the functional carrier material (91) is a transfer lacquer carrier or an overlay, and wherein in the first step (S1), the paper (90) and the functional carrier material (91) are continuously subjected to pressure on the chipboard (9) by two rollers (12) and are prefixed on the chipboard (9), wherein in addition a continuous feed of the covered chipboard (9) in a production direction (P) is exerted at the same time by the rollers (12), and wherein, in a second step (S2), the covering, namely the coating paper (90) and the functional carrier material (91) are trimmed jointly and at the same time by laser cutting technology and are subsequently statically charged.

2. The method as claimed in claim 1, wherein in a third step (S3), a functional material is transferred from the functional carrier material (91) to the melamine-impregnated coating paper (90) of the covered chipboard (9) by a short-cycle hot pressing method, wherein a final functional surface of the chipboard (9) is provided by a direct coating, the surface properties or functions of which are provided from the composite of the chipboard (9), the melamine-impregnated coating paper (90), and the functional material.

3. The method as claimed in claim 2, wherein the functional surface is additionally embossed by structuring plates during the hot pressing method, so that a predetermined surface structuring is provided.

4. The method as claimed in claim 2, wherein in a fourth step (S4), the functional carrier material (91) is continuously drawn off from the chipboard (9) directly coated using the melamine-impregnated coating paper (90), wherein the drawn-off functional carrier material (91) is continuously wound onto rolls (41), wherein the functional carrier material is supplied via suitable shredding to the recycling immediately after it is drawn off.

5. The method as claimed in claim 1, wherein a system for producing coated chipboard (9) is used, wherein the system includes a functional carrier material and paper unwinding device (1), a cutting device (2), a press (3), and a functional carrier material draw-off device (4).

6. The method as claimed in claim 5, wherein the system additionally includes a quality checking device (5), a protective film device (6), a dividing device (7), and a stacking device (3), wherein the coated chipboard (9) is subjected in a fifth step (S5) to a visual quality check; and wherein the coated chipboard (9), in a sixth step (S6), is provided and protected on both sides using an additional protective film (96); wherein the coated and protected chipboard (9) is divided multiple times in a seventh step (S7); and wherein the coated chipboard (9) is stacked in a stacking device (8) in an eighth step (S8).

7. The method as claimed in claim 5, wherein the system includes a transport device (100) to transport the chipboard (9) in the production direction (P) of the system.

8. The method as claimed in claim 5, wherein the first (S1), second (S2), third (S3), and fourth (S4) step are continuously executed, wherein the chipboards (9) can be treated in succession simultaneously in the system by the method, wherein in addition the fifth (S5), sixth (S6), seventh (S7), and eighth (S8) step can be continuously executed and in this case the chipboards (9) can be treated in parallel in the system by the method.

9. The method as claimed in claim 8, wherein the system is continuously operated suitably cyclically, wherein a supply of chipboards (9) into the functional carrier material and paper unwinding device (1) of the system is also carried out continuously, and wherein the system includes a suitable controller for the suitably cyclic, continuous performance, which is matched to one another, of steps (S1) to (S8) and the transport device (100).

10. The method as claimed in claim 1, wherein the coating material of the functional carrier material is selected in such a way that the chipboard is coated using a functional surface, which is scratch proof and/or abrasion resistant and/or anti-slip and/or water repellent and/or stain resistant also having anti-fingerprint properties and/or antibacterial and/or antimicrobial and/or has various matte and gloss levels.

11. The method as claimed in claim 1, wherein chipboard having a thickness of 8 mm to 80 mm is coated using a functional surface, wherein a paper having a thickness of 40 to 350 g/m.sup.2 is selected as the paper and a functional carrier material having a thickness of 50 to 280 g/m.sup.2 is selected as the functional carrier material, so that a coating of chipboard having a functional surface of 8 mm to 50 mm is provided.

12. A system for producing coated chipboard (9) having a functional surface and for carrying out the method as claimed in claim 1, comprising: a functional carrier material and paper unwinding device (1), a cutting device (2), a press (3), a functional carrier material draw-off device (4), a quality checking device (5), a protective film device (6), a dividing device (7), a stacking device (8), and a controller for its cyclic operation for carrying out the method.

13. A method for producing coated chipboard having a functional surface, comprising: continuously and simultaneously covering a chipboard on both sides with a melamine-impregnated paper and a functional carrier material, wherein the functional carrier material comprises a transfer lacquer carrier or an overlay; continuously subjecting the covered chipboard to a predetermined pressure by two rollers, one roller on each side of the covered chipboard, thereby prefixing the melamine-impregnated paper and the functional carrier material on both sides of the chipboard, continuously feeding the covered chipboard in a production direction by the two rollers; jointly trimming the coating paper and the functional carrier material by laser cutting; and statically charging the coating paper and the functional carrier material.

14. The method as claimed in claim 13, further comprising transferring a functional material from the functional carrier material to the melamine-impregnated coating paper of the covered chipboard by short-cycle hot pressing, thereby providing a final functional surface of the chipboard.

Description

IN THE SPECIFIC FIGURES

[0030] FIG. 1A and

[0031] FIG. 2A show devices of a system for producing coated chipboard having a functional surface according to one embodiment of the invention; and

[0032] FIG. 1B and

[0033] FIG. 2B show a flow chart of steps of a method for producing coated chipboard having a functional surface according to one embodiment of the invention.

[0034] FIGS. 1A and 2A show a schematic illustration of a system for producing coated chipboard 9 having a functional surface according to one embodiment of the invention having a transfer lacquer carrier and paper unwinding device 1, a cutting device 2, a press 3, a functional carrier material draw-off device 4, a quality checking device 5, a protective film device 6, a dividing device 7, and a stacking device 8, which is suitably (but not necessarily) arranged in succession in this sequence, and wherein a transport device 100 can suitably be provided for the transport of the chipboard 1 in the production direction P between the mentioned devices.

[0035] FIGS. 1B and 2B show a flow chart of steps S1 to S8 of a method for producing coated chipboard 9 having a functional surface according to one embodiment of the invention, wherein steps S1, S2, S3, S4, S5, S6, S7, and S8 are suitably executed in succession in this sequence, and in each case correspond to the functional carrier material and paper unwinding device 1, the cutting device 2, the press 3, the functional carrier material draw-off device 4, the quality checking device 5, the protective film device 6, the dividing device 7, and the stacking device 8. The drawings, corresponding to one another, FIG. 1A of the system and FIG. 1B of the method or FIG. 2A of the system and FIG. 2B of the method, respectively, are also each shown together on a drawing sheet 1/2 and 2/2 for better understanding.

[0036] The functional carrier material and paper unwinding device 1 includes two rolls 10 for continuously covering the chipboard 9 on both sides with melamine-impregnated paper 90. The paper 90 is laid by the rolls 10 on the chipboard 9. An additional functional carrier material is also laid on both sides on the chipboard 9 by means of a functional carrier material 91. For this purpose, the functional carrier material and paper unwinding device 1 includes two further rolls 11, from which the functional carrier material 91 is supplied to the chipboard 9 and at the same time is laid on both sides in each case on the coating paper 90.

[0037] At the outlet of the functional carrier material and paper unwinding device 1, two rollers 12 are provided on both sides of the chipboard 9 covered on both sides with the melamine-impregnated coating paper 90 and the functional carrier material 91, which rollers exert a predetermined two-sided pressure on the covered chipboard 9 and at the same time prefix the coating paper 90 and the functional carrier material 91 on the chipboard 9. In addition, a feed of the covered chipboard 9 in the production direction P is provided by means of a rotation of the rollers 12.

[0038] Following the functional carrier material and paper unwinding device 1, the covered chipboard 9 is supplied by means of the transport device 100 to a cutting device 2, by means of which the covering of the chipboard 9, namely the coating paper 90 and the functional carrier material 91, is trimmed to its predetermined dimensions in a second step S2 of the method described hereinafter.

[0039] Following the cutting device 2, the cover of the chipboard is statically charged and supplied together with the chipboard 9 by means of the transport device 100 to a press 3, which is configured in such a way that the functional carrier material is transferable from the functional carrier material 91 to the melamine-impregnated coating paper 90 by means of a short-cycle hot pressing method. In this case, cross-linking of the functional carrier material with the melamine-impregnated coating paper 90 occurs, after which the final surface of the directly coated chipboard 9 is provided. The surface properties or functions of this direct coating result from the composite of the chipboard 9, the melamine-impregnated coating paper 90, and the functional material. The press 3 can additionally include structuring plates and can be configured in this case in such a way that the functional carrier material is embossed during the hot pressing procedure by means of the structuring plates, so that it has a predetermined surface structuring.

[0040] The surface structuring can be made decoratively predetermined by the use of various structuring plates. The structuring plates (not shown in the drawing) are arranged in the press 3 in each case on both sides above and below the covered chipboard 9. The press 3 as described above is accordingly configured in such a way that the covered chipboard 9 can be permanently coated using the melamine-impregnated coating paper 90 in the press 3 in a third step S3 of the method described hereinafter, which paper can be decorated at the same time by means of the functional carrier material 91 and optionally provided with a surface structuring by means of the structuring plates.

[0041] Following the hot pressing method having the pressing procedure in the press 3 and the discharge of the coated chipboard 9 from the press 3, the coated and possibly decorated and structured chipboard 9 is supplied by means of the transport device 100 to a functional carrier material draw-off device 4. The functional carrier material draw-off device 4 is configured here in such a way that the functional carrier material 91, in a fourth step S4 of the method described hereinafter, can be removed, also in the continuous process, from the chipboard 9 directly coated using the melamine-impregnated coating paper 90. For this purpose, rolls 41 for continuously winding up the drawn-off functional carrier material 91 are suitably provided in the functional carrier material draw-off device 4.

[0042] Following the functional carrier material draw-off device 4, the coated chipboard 9 is supplied by means of the transport device 100 to a quality check, which is suitably configured in such a way that the coated chipboard 9 is subjected in a suitable manner to a visual quality check in a fifth step S5 of the method described hereinafter.

[0043] Following the quality checking device 5, the coated chipboard 9 can be supplied by means of the transport device 100 to a protective film device 6, in which the coated chipboard 9 can be protected by means of an additional protective film 96 in a sixth step S6 of the method described hereinafter.

[0044] At the end of the system for producing coated chipboard 9, the chipboard 9, which is coated using the melamine-impregnated coating paper 90 and decorated and possibly structured, is supplied by means of the transport device 100 to an optional dividing system 7 and also divided multiple times therein. The chipboards 9 are then supplied to a stacking device 8 and stacked in an eighth step S8 of the method described hereinafter.

[0045] FIGS. 1B and 2B show, as mentioned above, a flow chart of steps S1 to S8 of a method for producing coated chipboard 9 having a functional surface according to an embodiment of the invention, wherein steps S1, S2, S3, S4, S5, S6, S7, and S8 are suitably executed in this sequence in succession, and respectively correspond here to the functional carrier material and paper unwinding device 1, the cutting device 2, the press 3, the transfer lacquer carrier draw-off device 4, the quality checking device 5, a protective film device 6, the dividing device 7, and the stacking device 8.

[0046] In step S1 of the method for producing coated chipboard 9 having a functional surface, the chipboard 9 is advantageously covered continuously and simultaneously on both sides using melamine-impregnated paper 90 and a functional carrier material 91, wherein the melamine-impregnated paper 90 and the functional carrier material 91 are suitably laid continuously and simultaneously from two rolls 10 and 11 in each case on the chipboard 9. The paper 90 is laid by the rolls 10 on the chipboard 9 and the functional carrier material 91 is laid by the rolls 11 on the chipboard 8. The paper 90 and the transfer lacquer carrier 91 on the chipboard 9 are suitably subjected to pressure here by means of two rollers 12 and in this way pre-fixed on the chipboard 9, wherein in addition a continuous feed of the covered chipboard 9 in the production direction P is exerted by means of the rollers 12.

[0047] In step S2 of the method, the covering of the covered chipboard 9, namely the coating paper 90 and the functional carrier material 91, are jointly trimmed in a step and then the covering is statically charged.

[0048] In step S3 of the method, the functional carrier is transferred from the functional carrier material 91 by means of a short-cycle hot pressing method to the melamine-impregnated coating paper 90, wherein cross-linking of the functional carrier with the melamine-impregnated coating paper 90 takes place, so that a final functional surface of the directly-coated chipboard 9 is provided. In step S3, an advantageous direct coating is carried out, the surface properties or functions of which are provided from the composite of the chipboard 9, the melamine-impregnated coating paper 90, and the functional carrier. In step S3, the functional surface can additionally be embossed during the hot pressing method by means of structuring plates, so that a predetermined surface structuring can be provided.

[0049] In step S4 of the method, the functional carrier material 91 on the coated and possibly decorated and structured chipboard 9 is removed, also in an advantageously continuous process, from the chipboard 9 directly coated using the melamine-impregnated coating paper 90, wherein the drawn-off functional carrier material 91 is suitably continuously wound onto rolls 41 and dis-charged from the process. The functional carrier material is supplied to the recycling here via suitable shredding.

[0050] In step S5 of the method, the coated and possibly decorated and structured chipboard 9 can be suitably subjected to a visual quality check.

[0051] In step S6 of the method, the coated chipboard 9 can be provided and protected by means of an additional protective film 96, wherein the protective film 96 is applied on both sides to the surface of the chipboard 9.

[0052] In step S7, the coated chipboard 9 can be divided multiple times and then in a further step S8 of the method it can be stacked in a stacking device 8.

[0053] Preceding steps S1 to S8 are suitably carried out in succession, wherein to provide the most continuous method possible, a system described above with reference to FIGS. 1A and 2A is suitably used, and wherein the chipboard 9 is advantageously transported in the system by means of a transport device 100 to the devices of the system, in which steps S1 to S8 are respectively carried out.

[0054] In the method for producing coated chipboard 9 according to one embodiment of the invention, at least particularly advantageous steps S1 to S4 and suitably steps S1 to S8 are continuously executed. For this purpose, the system having its above-described devices 1 to 8 and also the transport device 100 is suitably continuously operated cyclically. It is clear that a supply of chipboards 9 into the functional carrier material and paper unwinding device 1 of the system is also continuously carried out here, and the system includes a suitable controller for the suitable cyclic, continuous control, which is matched to one another, of its above-described devices for carrying out steps S1 to S8 of the method and the transport device 100.

[0055] Numerous modifications and refinements of the described exemplary embodiments are implementable.

REFERENCE SIGNS

[0056] 1 functional carrier material and paper unwinding device [0057] 10 roll [0058] 11 roll [0059] 12 roller [0060] S1 step [0061] 2 cutting device [0062] S2 step [0063] 3 press [0064] S3 step [0065] 4 functional carrier material draw-off device [0066] 41 roll [0067] S4 step [0068] 5 quality checking device [0069] S5 step [0070] 6 protective film device [0071] S6 step [0072] 7 dividing device [0073] S7 step [0074] 8 stacking device [0075] S8 step [0076] 9 chipboard [0077] 90 paper, coating paper [0078] 91 functional carrier material [0079] 96 protective film [0080] 100 transport device [0081] P production direction