VITS Systems GmbH Impregnation Lines For Laminate Products Part 1 The Melamine Paper Impregnating Process

Impregnation is the saturation of a basic substrate What Is Impregnation ? Impregnation is the saturation of a basic substrate Examples of impregnation are: Fibre Glass Mat Impregnated with Epoxy Resin for the printed circuit boards Woven Cloth for reinforced fabric Paper for Car Filter elements Woven Nylon for weather protective clothing Decorative and Kraft Paper for the Laminates Industry

Why Paper ? Readily available in roll form Fibrous structure Can be easily impregnated Available in different widths and strengths Can be produced in various different colours as a raw material Can be printed into high quality décors

Difference Between Impregnating and Coating Medium is applied to the outside surface of the substrate Avoids coating medium seeping into the core of the substrate Impregnation: Medium is applied to the inside or core of the substrate

The Impregnation Process Where the raw materials are brought together Success of Final Pressed Product Depends on: Raw material to Impregnation Line Impregnation Machines Impregnating Process parameters Intermediate Products Press and its Raw materials (Board) Press Process Parameters Many Different Influences on Final Product Quality !

Products of Impregnation Intermediate Papers Films for Low Pressure Direct lamination onto Boards (LPL) Single Opening Press Continuous Double Belt Press High Pressure Processing into Multi Layered laminates (HPL & CPL) Multi Opening Press

High Pressure Products Particle Board Laminated CPL or HPL e.g. Kitchen Work Surfaces, Fire Resistant Surfaces HDF/MDF Laminated with CPL e.g. Laminate Flooring (Special Overlay) MDF or Particle Board Laminated with HPL e.g. Cubicle Walls, Wall Cladding Thick Laminates (Self Supporting) e.g. Partition Walls

High Pressure Products Example of a Typical 0.8 mm Laminate (typical kitchen work surface) HPL Overlay Paper 120 gsm Final Weight Décor Paper 190 gsm Final Weight 4 Kraft Papers 215 gsm Final Weight CPL Overlay Paper 120 gsm Final Weight Décor Paper 190 gsm Final Weight 3 Kraft Papers 285gsm Final Weight

Low Pressure Products Particle Board Laminated with Melamine Foils without Overlay e.g. Kitchen & Bathroom Furniture Carcass HDF without Overlay e.g. Furniture Back Panel MDF/HDF with Overlay e.g. Laminated Flooring MDF with or without Overlay e.g. Furniture Fronts, Horizontal Surfaces Decor Paper 190 gsm Final Weight MDF Board 15 to 22 mm Balance Paper 180 to 300 gsm Final Weight Overlay Paper 120 gsm Final Weight Typical Board Make Up

Flooring Products (see also Part 2) High Pressure Flooring Product (CPL/HPL) Mel. Balance Paper 180 – 300 gsm Final Weight Abrasive Resistant Overlay Paper 120 gsm Final Weight Decor Paper 190 gsm Final Weight Carrier Board (Particle Board/MDF) 2 Kraft Papers 280 gsm Final Weight Low Pressure Flooring Product (LPL) Decor Paper 170 – 190 gsm Final Weight HDF Board 12 mm Balance Paper 180 – 300 gsm Final Weight Abrasive Resistant Overlay Paper; either pre-loaded with Al2O3 or coated with Al2O3 during impregnation (ARP) 120 - 135 gsm

The Machines - Melamine Impregnation Typical Types of Melamine Impregnating Machines: 1 stage Melamine Machines: Pure Melamine (MF) Products (Overlay, Al2O3 Overlay) CPL / HPL Decorative Products CPL / HPL / MFC Overlay LP Backer Production Speeds 25 to 50 metres per min 2 stage Melamine Machines: Urea and Melamine (UF/MF) Products MFC Decorative Products All Products from 1 stage machine Production Speeds 25 to 75 metres per min

The Standard Two Stage Melamine Impregnating Line