Coated board of wood-based material

Abstract

A coated board of wood-based material and a method for coating a board of wood-based material, wherein the board of wood-based material is in particular a wall panel or floor panel or is intended for producing such a panel, comprising a front side and a rear side, wherein at least the surface of the front side is provided with a polymer coating and wherein the polymer coating has a hardness gradient, so that the hardness of the polymer layer decreases with increasing depth from the surface.

Claims

1. A coated board of wood-based material, comprising a board of wood-based material having a front side and a rear side, and a polymer coating on the front side of the board of wood-based material, wherein the polymer coating has an inner area predominantly formed of a first polymer having a first hardness in a cured state, an outer area predominantly formed of a second polymer having a second hardness in a cured state that is greater than the first hardness, the first polymer being different than the second polymer, and an intermediate area between the inner and outer areas, the intermediate area having a concentration gradient of the first and second polymers, the concentration of the first polymer in the intermediate area continuously decreasing going from the inner area toward the outer area and the concentration of the second polymer in the intermediate area continuously decreasing going from the outer area toward the inner area, such that the hardness of the polymer coating continuously decreases with increasing depth viewed from an outer surface of the polymer coating.

2. The coated board of wood-based material according to claim 1, wherein the polymer coating has a hardness gradient that corresponds to the following formula:
(3,0*x)+C<=Y(x)<=(0,2*x)+C wherein: x is the absolute value of the depth in m of the coating viewed from the surface of the coating; Y(x) is the absolute value of the hardness in N/mm.sup.2 at a certain depth x; and C is the absolute value of the initial hardness in N/mm.sup.2 of the coating at a depth of approximately x0-5 m.

3. The coated board of wood-based material according to claim 1, wherein the polymer coating has a hardness gradient that corresponds to the following formula:
(2,5*x)+C<=Y(x)<=(0,4*x)+C wherein: x is the absolute value of the depth in m of the coating viewed from the surface of the coating; Y(x) is the absolute value of the hardness in N/mm.sup.2 at a certain depth x; and C is the absolute value of the initial hardness in N/mm.sup.2 of the coating at a depth of approximately x0-5 m.

4. The coated board of wood-based material according to claim 1, wherein the polymer coating has a hardness gradient that corresponds to the following formula:
(2,0*x)+C<=Y(x)<=(0,6*x)+C wherein: x is the absolute value of the depth in m of the coating viewed from the surface of the coating; Y(x) is the absolute value of the hardness in N/mm.sup.2 at a certain depth x; and C is the absolute value of the initial hardness in N/mm.sup.2 of the coating at a depth of approximately x0-5 m.

5. The coated board of wood-based material according to claim 1, wherein the board of wood-based material is a chip board, MDF board, HDF board, OSB board or real wood board.

6. The coated board of wood-based material according to claim 1, wherein the polymer coating consists of polymers which are curable by means of radiation.

7. The coated board of wood-based material according to claim 1, wherein the polymer coating has an initial Martens hardness at a depth of approximately 0-5 m from 120 N/mm.sup.2 to 250 N/mm.sup.2 measured according to DIN ISO 14577.

8. The coated board of wood-based material according to claim 1, wherein the polymer coating has an initial Martens hardness at a depth of approximately 0-5 m from 130 N/mm.sup.2 to 200 N/mm.sup.2 measured according to DIN ISO 14577.

9. The coated board of wood-based material according to claim 1, wherein the polymer layer includes abrasion-resistant particles.

10. The coated board of wood-based material according to claim 9, wherein the abrasion-resistant particles include corundum particles.

11. A floor covering comprising a plurality of the coated boards of wood-based material according to claim 1.

12. A floor panel made by a method comprising the following steps: a) providing a board of wood-based material having a front side and a back side; b) applying a first liquid coating to the front side of the board of wood-based material, the first liquid coating being formed of a first polymer composition that has a first hardness in a cured state; c) applying a second liquid coating onto the still wet first liquid coating, so that a partial mixing of the first and second liquid coatings takes place, the second liquid coating being formed of a second polymer composition having a second hardness in a cured state that is greater than the first hardness, the first polymer composition being a different polymer composition than the second polymer composition; d) exposing the first and second liquid coatings to radiation to effect curing of the first and second liquid coatings to form a polymer coating on the board of wood-based material; and wherein the partial mixing of the first and second polymer compositions forms a concentration gradient of the first and second polymer compositions in an intermediate area of the polymer coating disposed between an inner area of the polymer coating predominantly formed of the first polymer composition and an outer area of the polymer coating predominantly formed of the second polymer composition, the concentration of the first composition in the intermediate area continuously decreasing going from the inner area toward the outer area and the concentration of the second composition in the intermediate area continuously decreasing going from the outer area toward the inner area, such the hardness of the polymer coating when cured decreases with increasing depth viewed from an outer surface of the polymer coating.

13. The floor panel according to claim 12, wherein the polymer coating has a hardness gradient that corresponds to the following formula:
(3,0*x)+C<=Y(x)<=(0,2*x)+C wherein: x is the absolute value of the depth in m of the coating viewed from the surface of the coating; Y(x) is the absolute value of the hardness in N/mm.sup.2 at a certain depth x; and C is the absolute value of the initial hardness in N/mm.sup.2 of the coating at a depth of approximately x0-5 m.

14. The floor panel according to claim 12, wherein the polymer coating has a hardness gradient that corresponds to the following formula:
(2,5*x)+C<=Y(x)<=(0,4*x)+C wherein: x is the absolute value of the depth in m of the coating viewed from the surface of the coating; Y(x) is the absolute value of the hardness in N/mm.sup.2 at a certain depth x; and C is the absolute value of the initial hardness in N/mm.sup.2 of the coating at a depth of approximately x0-5 m.

15. The floor panel according to claim 12, wherein the polymer coating has a hardness gradient that corresponds to the following formula:
(2,0*x)+C<=Y(x)<=(0,6*x)+C wherein: x is the absolute value of the depth in m of the coating viewed from the surface of the coating; Y(x) is the absolute value of the hardness in N/mm.sup.2 at a certain depth x; and C is the absolute value of the initial hardness in N/mm.sup.2 of the coating at a depth of approximately x0-5 m.

16. A coated board of wood-based material, comprising a board of wood-based material having a front side and a rear side, and a polymer coating on the front side of the board of wood-based material, wherein the polymer coating has an inner area predominantly formed of a first polymer having a first hardness in a cured state, an outer area predominantly formed of a second polymer having a second hardness in a cured state that is greater than the first hardness, the second polymer comprising more CC double bonds than the first polymer, and an intermediate area between the inner and outer areas, the intermediate area having a concentration gradient of the first and second polymers, the concentration of the first polymer in the intermediate area continuously decreasing going from the inner area toward the outer area and the concentration of the second polymer in the intermediate area continuously decreasing going from the outer area toward the inner area, such that the hardness of the polymer coating continuously decreases with increasing depth viewed from an outer surface of the polymer coating.

Description

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

(1) To the following, a detailed description of exemplary embodiments will be given by means of the enclosed diagrams and figures.

(2) FIG. 1 is a schematic illustration of a coating process;

(3) FIG. 2A to 2C are schematic illustrations in which the procedure of mixing of two liquid layers is shown;

(4) FIG. 3 is a diagram, which shows the course of the hardness against the depth of the coating;

(5) FIG. 4 is a diagram, which illustrates the upper and lower boundaries of the hardness gradient according to a preferred embodiment of the invention;

(6) FIG. 5 is a diagram, which illustrates the upper and lower boundaries of a more preferred embodiment of the invention; and

(7) FIG. 6 is a diagram, which illustrates the upper and lower boundaries of the hardness gradient of a further preferred embodiment.

(8) In FIG. 1 a coating plant for coating of boards of wood-based material 10 is schematically shown. The boards of wood-based material 10, such as boards of solid wood, HDF, MDF or chip boards, are guided by means of a roller conveyer plant 12 through the different stations of the coating plant. In a first coating station 14 a first liquid coating means 20 is applied in a passage coating onto the boards of wood-based material 10 by means of a rotating applicator roller 15.

(9) The applicator roller 15 is provided with coating means by means of a supply device 16. In the second coating station 17 a second liquid coating means 21 is applied onto the still wet first coating means 20 by means of a further rotating applicator roller 18. The applicator roller 18 is provided with the second liquid coating means by means of a supply device 19. It is self-evident that the applying can also be done with any other suitable applying process, such as by means of a spraying device or a coating blade or the like. Therefore, it is only important that the applying of the second layer takes place as long as the first layer is still wet enough, so that a partial mixing of the two layers can take place. Furthermore, it is self-evident that further coating stations can be provided after the second coating station 17 in order to apply for example a third liquid coating means onto the still wet second coating means 21 or also additional stations in order to apply abrasion-resistant particles onto and respectively into the wet layers.

(10) After leaving of the coating station 17 the coated boards 10 are conveyed to a hardening station 30, where the layers are hardened by means of UV radiators 31. On their way from the coating station 17 to the hardening station 30 a partial mixing of the liquid coating means 20 and 21 occurs, which particularly takes place at the boundary surfaces of the two coating means. Thereby, naturally the mixing is stronger, the closer one is located at the boundary surface of the two layers. By curing of the layers in the curing station 30 the mixing process is stopped and the once adjusted mixing proportion and therefore the mechanical properties of the produced coating is set. The extent of the mixing at the boundary surfaces which takes place itself and preferably without external mechanical action depends on the time duration which passes between the applying of the second coating means 21 onto the still wet first coating means 20 and the curing in the curing station 30. Furthermore, the mixing of the two coating means is also influenced by the respective viscosity of the coating means wherein the general rule is that the higher the viscosity, the lower the mixing per time unit.

(11) The principle of the mixing of the two applied coating means can be seen best from the schematically illustration of FIG. 2A to 2C. Therefore, FIG. 2A shows the condition of the two coating means 20 and 21 applied onto a board of wood-based material 10 immediately after applying of the second coating means 21. At that time practically no mixing has taken place. In the present case, the coating means 20 and 21 are polymers, which have respectively different numbers of CC carbon double bonds. Therefore, as schematically depicted in FIG. 2A, the first coating means 20 has a lower number of CC double bonds than the second coating means 21. Due to the higher number of CC double bonds in the coating means 21, the same will have a higher hardness after the curing than the coating means 20 which is provided with lower amount of CC double bonds.

(12) As the two coating means 20 and 21 are applied wet on wet, a mixing of the two layers occurs starting from the boundary surface 22 of the two layers, as it is indicated in FIG. 2B. This means that due to the mixing process in the area close to the boundary surface 22 there are more double bonds in the underlying layer and accordingly in the area close to the boundary surface 22 of the overlying layer there are fewer double bonds, as before the mixing. FIG. 2C shows the two layers after the mixing has advanced some more and has reached a suitable mixing grade. If at this point of time the curing of the coating means occurs, for example by means of UV radiation, this mixing rate is set, since in the hardened layers naturally no mixing can occur any more.

(13) In the diagram of FIG. 3 the hardness course of a coating according to the invention (example with hardness gradient) and a coating according to the prior art are plotted. The example according to the invention consisted of an abraded board of wood-based material provided with a primer on which the two different coating means were applied wet on wet. The first applied coating means consisted of approximately 35% 1,6 hexanediol diacrylate and approximately 65% polyester acrylate and was applied with 45 g/m.sup.2. The second coating means which was applied onto the still wet first layer consisted of approximately 70% polyurethane acrylic ester and approximately 30% dipropylene glycol diacrylate and was applied with 40 g/m.sup.2. After applying of the second layer there was a waiting time of 10 seconds in order to make it possible for the viscous liquid materials to mix. Afterwards, the two layers were completely hardened together.

(14) The example according to the state of the prior art consisted of a conventional coating, wherein multiple thin layers of materials were applied separately and wherein between the respective applying procedures the pre-applied layer was hardened. The lower three layers consisted of a mixture of 70% polyester acrylate and 30% 1,6 hexanediol diaerylate with an applying intensity of 12 g/m.sup.2. The two upper layers consisted of 70% polyurethane glycol diacrylate and 30% dipropylene acrylic ester and the two upper layers contained 15% corundum with an average particle size of D 50 of 25 m.

(15) The test was carried out according to the European standard for laminate panels DIN EN 13329 with a Taber-Abraser-Tester 5151 of Taber Industries. After 200 rotations respectively with S-41 abrasive paper the hardness and the trace depth of the samples were determined. The determination of the Martens hardness (registering hardness test under test application of a force) was carried out according to DIN EN ISO 14577. A Fischerscope H100 of Helmut Fischer GmbH was used as a test apparatus. The following test parameters were used: maximal strength: 50/30 mN as well as measuring period: 20 seconds. The determination of the trace depth was carried out with a mechanic brush analyzer. A Perthometer S3P of Perthen was used as a test apparatus.

(16) During the measurement of the samples it became apparent that probably due to the used relative soft materials more or less deviations occur in the hardness of a given layer depth. Therefore, it is necessary to measure at several points in order to get representative data by means of an average determination. During the carried out measurements the hardness as well as the trace depth was respectively measured after 200 rotations of the abrasive paper at four points. It became apparent that in most of the majority of cases four measurement points provide a sufficient accuracy. It is self-evident that one can get more accurate measurement results by using more than four measuring points, like eight for example.

(17) In the below depicted table the individual measured data for the sample of the example according to the invention are depicted. The measurement was carried out on the completely cured coating that means the condition in which respective products would be really used as floor panel.

(18) TABLE-US-00001 TABLE 1 Example with hardness gradient depth measurement depth trace of hardness Martens hardness [m] [m] [N/mm.sup.2] rotation 1 2 3 4 1 2 3 4 1 2 3 4 3.6 3.8 3.3 3.4 134.8 118.7 159.0 150.6 AV 3.5 140.8 200 20.0 20.0 20.0 20.0 3.5 3.7 4.3 3.9 139.7 125.2 93.5 112.2 AV 20.0 3.9 117.7 400 20.0 20.0 20.0 25.0 4.5 5.0 4.0 3.9 65.9 69.9 106.9 113.2 AV 21.3 4.4 84.5 600 25.0 25.0 25.0 30.0 4.7 4.7 4.3 4.0 60.5 79.6 95.0 106.1 AV 26.3 4.4 90.3 800 30.0 30.0 30.0 35.0 4.1 4.1 4.0 4.2 103.8 103.1 109.7 100.3 AV 31.3 4.1 104.2 1000 40.0 40.0 40.0 45.0 4.7 4.2 3.9 4.5 78.5 99.3 112.0 87.5 AV 41.3 4.3 94.3 1200 50.0 50.0 50.0 50.0 4.3 5.4 4.2 4.8 93.7 59.8 98.6 82.6 AV 50.0 4.6 83.7 1400 55.0 55.0 60.0 60.0 5.4 4.5 4.0 5.0 60.1 85.0 106.7 70.6 AV 57.5 4.7 80.7 1600 60.0 65.0 70.0 70.0 4.7 4.4 4.3 4.6 47.8 53.6 55.5 48.9 AV 66.3 4.5 51.5 1800 65.0 70.0 75.0 75.0 4.0 4.6 4.9 5.3 64.5 50.1 43.7 37.1 AV 71.3 4.7 48.9 2000 75.0 80.0 80.0 75.0 5.8 4.9 6.2 6.0 31.3 43.6 27.3 41.6 AV 77.5 5.5 38.0 2200 95.0 105.0 105.0 100.0 4.5 5.1 6.1 4.9 51.4 40.8 28.1 43.7 AV 101.3 5.2 41.0

(19) In the above depicted table the column rotation indicates the number of rotations which were carried out with the Taber-Abraser-Tester. The column depth trace indicates how many micrometer material of the coating starting from the original surface was removed at the four measuring points 1-4. The column depth measurement of hardness indicates how many micrometers the test pin entered into the coating at the four measuring points 1-4 respectively, in the column Martens hardness the hardness is indicated in Newton per mm.sup.2 for the four measuring points 1-4 respectively. Below the individual values the respective average value for the four measuring points is indicated. From the above depicted table it is easy to recognize that the Martens hardness decreases the deeper one penetrate into the completely cured layer. It is also apparent that at 800 and 1000 (over-all) rotations a moderate rise of the Martens hardness can be noted. This is due to the irregular mixing of the two used coating means which in the praxis can only fully be avoided.

(20) Nevertheless it is apparent in the diagram of FIG. 3 that in the example with hardness gradient there is a nearly continuous decrease of hardness without great peaks. However, the comparison example according to the state of the prior art does not show such a continuous progress of the hardness, but moreover at a depth of 60 to 80 m it has a pronounced point of discontinuity up to the original initial hardness.

(21) The average values of the test sample are depicted in the below-mentioned table 2.

(22) TABLE-US-00002 TABLE 2 Average values of the example with hardness gradient depth Martens hardness Standard deviation of the rotation [m] [N/mm.sup.2] Martens hardness [N/mm.sup.2] 3.5 140.8 15.4 200 23.9 117.7 17.0 400 25.6 94.5 17.6 600 30.7 90.3 11.0 800 42.1 104.2 3.4 1000 45.8 87.5 12.6 1200 54.8 82.8 14.9 1400 62.2 80.7 17.4 1600 70.8 51.4 3.2 1800 76.0 48.9 10.1 2000 83.0 36.9 6.8 2200 106.4 41.0 8.4

(23) The values of the comparison test sample according to the prior art are shown in the below-mentioned tables 3 and 4.

(24) TABLE-US-00003 TABLE 3 Sample according to prior art depth measurement depth trace of hardness Martens hardness [m] [m] [N/mm.sup.2] rotation 1 2 3 4 1 2 3 4 1 2 3 4 3.1 3.5 3.1 3.0 180.6 141.8 173.1 192.4 AV 3.2 172.0 200 30.0 25.0 25.0 25.0 4.2 4.2 3.7 4.7 99.9 99.6 124.5 79.3 AV 26.3 4.2 100.8 400 35.0 35.0 35.0 35.0 3.7 3.8 4.0 4.1 126.9 117.2 110.1 105.3 AV 35.0 3.9 114.9 600 45.0 45.0 45.0 45.0 3.7 3.8 4.6 4.8 128.4 122.2 83.2 74.7 AV 45.0 4.2 102.1 800 50.0 50.0 50.0 50.0 4.0 4.7 4.8 4.0 108.2 80.9 75.4 110.9 AV 50.0 4.4 93.8 1000 60.0 60.0 60.0 60.0 3.5 3.1 4.0 3.6 143.7 177.4 108.0 129.9 AV 60.0 3.6 139.8 1200 66.0 70.0 70.0 70.0 3.3 3.4 3.6 3.0 160.7 145.1 135.0 186.1 AV 68.8 3.3 156.5 1400 70.0 75.0 75.0 75.0 3.3 3.0 3.1 3.8 157.7 191.6 178.0 119.3 AV 73.8 3.3 161.7 1600 76.0 80.0 80.0 80.0 2.3 2.9 2.6 2.4 183.6 124.8 147.9 174.4 AV 78.8 2.6 157.7 1800 80.0 85.0 85.0 85.0 3.8 3.0 3.4 3.1 71.4 112.3 88.6 107.0 AV 83.8 3.3 94.5 2000 85.0 90.0 85.0 85.0 5.1 3.5 2.6 3.0 40.9 82.3 146.4 112.6 AV 86.3 3.6 95.6 2200 85.0 95.0 90.0 90.0 3.6 3.0 3.0 2.7 81.2 116.0 114.5 137.5 AV 90.0 3.1 112.3 2400 90.0 100.0 100.0 95.0 3.7 5.2 3.1 3.0 77.6 39.7 108.2 111.8 AV 96.3 3.8 84.3 2600 100.0 100.0 105.0 100.0 5.3 3.3 5.0 3.9 37.8 92.6 42.4 67.7 AV 101.3 4.4 60.1

(25) TABLE-US-00004 TABLE 4 Average values of the sample according to the prior art depth Martens hardness Standard deviation of the Martens rotation [m] [N/mm.sup.2] hardness [N/mm.sup.2] 3.2 172.0 18.7 200 30.4 100.8 16.0 400 38.9 114.9 8.1 600 49.2 102.1 23.5 800 54.4 93.8 15.9 1000 63.6 139.8 25.2 1200 72.1 156.5 18.9 1400 77.1 169.7 27.3 1600 81.3 167.7 23.1 1800 87.1 94.8 16.1 2000 89.8 95.6 38.9 2200 93.1 112.3 20.1 2400 100.0 84.3 29.0 2600 105.7 60.1 21.9

(26) It has turned out experimentally that especially good mechanical properties of the complete over-all layer can be achieved, if the hardness gradient of the finished over-all layerlike it is shown in an exemplary manner in FIG. 3essentially corresponds to the following formula:
(3.0*x)+CY(x)(0.2*x)+C wherein: x is the absolute value of the depth in m of the coating viewed from the surface of the coating; Y(x) is the absolute value of the hardness in N/mm.sup.2 at a certain depth x; and C is the absolute value of the initial hardness in N/mm.sup.2 of the coating at a depth of approximately x0-5 m.

(27) Under the absolute values it is to be understood that in the above formula only the plain numerical value is entered that means without the associated measuring unit m and N/mm.sup.2 respectively. It for example, the initial value of the above example with hardness gradient is 140.8 N/mm.sup.2 (see table 2), in the above table are inserted only the absolute values, that means C=140.8. In the same way for x is inserted only the absolute values, for example x=3.5. The result of this is, for example, upper and lower boundaries for Y(x=3.5) of 140.1 and 130.3 respectively. At a depth of x=40 m the result is then, for example, 132.8 for the upper boundary and 20.8 for the lower boundary respectively. These upper and lower boundaries for Y(x) have the measurement unit N/mm.sup.2. Important is that the absolute values, starting from the mentioned measurement units m and N/mm.sup.2, are used in the formula and not starting, for example, from mm or N/m.sup.2. It should be clear for the person skilled in the art that the above formula is no mathematical formula to the description of the hardness gradient itself, but it rather defines a range, in which it should run.

(28) The initial value of hardness of the coating is the value in the first few m of the coating. Due to the typically used measurement method by means of a test pin which penetrates a few m into the coating, it is difficulty to determine the hardness for the depth of penetration 0 m. The formulation substantially is therefore elected because it is difficulty to achieve a perfect uniform mixing of the materials so that in reality it can always come to single tiny outliers, such as the hardness value of 104.2 Newton/mm.sup.2 at a depth of 42.1 m (see table 2) of the above discussed example with hardness gradient. Furthermore, the values very close to the surface of the board of wood-based material are generally inaccurate, since the residual layer thickness to be measured must have a certain minimum thickness in order to allow useful measurements. The residual layer thickness for useful measurements should therefore be at least 5 m, preferably 10 m and further preferably at least 20 m. With other words, the last 20 m of the layer, close to the board of wood-based material, must not necessarily follow the above mentioned preferred hardness gradient although this is naturally preferred.

(29) In a further preferred embodiment the hardness gradient substantially follows the following formula:
(2.5*x)+CY(x)(0.4*x)+C

(30) And in another further preferred embodiment it substantially follows:
(2.0*x)+CY(x)(0.6*x)+C

(31) In the FIG. 4 to 6 the meaning of the above mentioned formulas of hardness gradients are illustrated according to examples with hardness gradient. It should be clear that the indicated absolute values for hardness and depth are only exemplary. It is self-evident that it is possible to apply over-all layers with significant larger thicknesses or lower thicknesses. Furthermore, the absolute value of hardness certainly depends on the used materials and can also be larger or lesser than the values of the example with hardness gradient. However, the order of magnitude of the cited values for the example with hardness gradient is most preferred and suitable for the use in a floor panel.

(32) The person skilled in the art recognizes by means of the detailed description of the method according to the invention how he can achieve a coating of a board of wood-based material according to the invention. This means naturally that all materials mentioned and named in connection with the description of the methods, such as the substances for the coating means, can also be used by the coating of the board of wood-based material according to the invention.

(33) The presented method is in particular suitable for coating of floor panels, and respectively for coating of boards of wood-based materials which are subsequently further to floor panels processed since the advantageously mechanical properties of the hardness gradient have here a strong effect. In the same way the presented coated board of wood-based material is for the same reason preferably a floor panel and respectively a coated board of wood-based material, which is intended to be further processed to a floor panel.