Presentation on theme: "VITS Systems GmbH Impregnation Lines For Laminate Products"— Presentation transcript:
1 VITS Systems GmbH Impregnation Lines For Laminate Products Part 1 The Melamine Paper Impregnating Process
2 Impregnation is the saturation of a basic substrate What Is Impregnation ?Impregnation is the saturation of a basic substrateExamples of impregnation are:Fibre Glass Mat Impregnated with Epoxy Resin for the printed circuit boardsWoven Cloth for reinforced fabricPaper for Car Filter elementsWoven Nylon for weather protective clothingDecorative and Kraft Paper for the Laminates Industry
3 Why Paper ? Readily available in roll form Fibrous structure Can be easily impregnatedAvailable in different widths and strengthsCan be produced in various different colours as a raw materialCan be printed into high quality décors
4 Difference Between Impregnating and Coating Medium is applied to the outside surface of the substrateAvoids coating medium seeping into the core of the substrateImpregnation:Medium is applied to the inside or core of the substrate
5 The Impregnation Process Where the raw materials are brought togetherSuccess of Final Pressed Product Depends on:Raw material to Impregnation LineImpregnation MachinesImpregnating Process parametersIntermediate ProductsPress and its Raw materials (Board)Press Process ParametersMany Different Influences on Final Product Quality !
6 Products of Impregnation Intermediate Papers Films forLow Pressure Direct lamination onto Boards (LPL)Single Opening PressContinuous Double Belt PressHigh Pressure Processing into Multi Layered laminates (HPL & CPL)Multi Opening Press
7 High Pressure Products Particle Board Laminated CPL or HPL e.g. Kitchen Work Surfaces, Fire Resistant SurfacesHDF/MDF Laminated with CPL e.g. Laminate Flooring (Special Overlay)MDF or Particle Board Laminated with HPL e.g. Cubicle Walls, Wall CladdingThick Laminates (Self Supporting) e.g. Partition Walls
8 High Pressure Products Example of a Typical 0.8 mm Laminate(typical kitchen work surface)HPLOverlay Paper 120 gsm Final WeightDécor Paper 190 gsm Final Weight4 Kraft Papers 215 gsm Final WeightCPLOverlay Paper 120 gsm Final WeightDécor Paper 190 gsm Final Weight3 Kraft Papers 285gsm Final Weight
9 Low Pressure ProductsParticle Board Laminated with Melamine Foils without Overlay e.g. Kitchen & Bathroom Furniture CarcassHDF without Overlay e.g. Furniture Back PanelMDF/HDF with Overlay e.g. Laminated FlooringMDF with or without Overlay e.g. Furniture Fronts, Horizontal SurfacesDecor Paper 190 gsm Final WeightMDF Board 15 to 22 mmBalance Paper 180 to 300 gsm Final WeightOverlay Paper 120 gsm Final WeightTypical Board Make Up
10 Flooring Products (see also Part 2) High Pressure Flooring Product (CPL/HPL)Mel. Balance Paper 180 – 300 gsm Final WeightAbrasive Resistant Overlay Paper 120 gsm Final WeightDecor Paper 190 gsm Final WeightCarrier Board (Particle Board/MDF)2 Kraft Papers 280 gsm Final WeightLow Pressure Flooring Product (LPL)Decor Paper 170 – 190 gsm Final WeightHDF Board 12 mmBalance Paper 180 – 300 gsm Final WeightAbrasive Resistant Overlay Paper; either pre-loaded with Al2O3 or coated with Al2O3 during impregnation (ARP) gsm
11 The Machines - Melamine Impregnation Typical Types of Melamine Impregnating Machines:1 stage Melamine Machines:Pure Melamine (MF) Products (Overlay, Al2O3 Overlay)CPL / HPL Decorative ProductsCPL / HPL / MFC OverlayLP BackerProduction Speeds 25 to 50 metres per min2 stage Melamine Machines:Urea and Melamine (UF/MF) ProductsMFC Decorative ProductsAll Products from 1 stage machineProduction Speeds 25 to 75 metres per min
12 The Standard Two Stage Melamine Impregnating Line
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