Method for producing decorated wooden composite boards and panel produced from the wooden composite board, in particular floor panel, and use of a wooden composite board produced according to the method

Patent metadata

Field	Value
Publication number	US-10059030-B2
Application number	US-201515302809-A
Country	US
Kind code	B2
Filing date	May 8, 2015
Priority date	May 9, 2014
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

A method for producing an impregnated article comprising a cellulose layer which is impregnated with a melamine resin in order for a core impregnation to be formed is characterized in that a layer of a liquid medium having a moiety of isocyanate groups is applied to the top face and/or the bottom face of the core-impregnated cellulose layer.

First claim

What is claimed is:

1. A process for production of decorated wooden boards comprising:
a) scattering of glued wood fibers or wood chips to give a cake of wood material,
b) pressing of the cake of wood material at elevated temperature to give a substrate board which is provided in press-finished condition and, at least on one of an upper side thereof, has a press skin that arose during production thereof,
c) application of a base coat made of a melamine-based liquid resin to the press skin, which is untreated, of the upper side of the substrate board, whereupon the resin penetrates at least to some extent into an upper peripheral layer of the substrate board, and thus at least to some extent penetrates into the press skin,
d) drying of the base coat,
e) application of a base color to the base coat,
f) drying of the base color,
g) in order to produce a decorative effect, application of at least one water-based printing ink enriched with coloring pigments to the base color which is dried,
h) drying of the decorative effect,
i) application, to the decorative effect, of a sealing system made of at least one melamine-based resin,
j) drying of the sealing system, and
k) pressing of the substrate board with the base coat that has been applied on an upper side, the base color, the decorative effect, and the sealing system, and also with a counterbalancing material that has been applied to an underside, with exposure to pressure and heat, to form a laminate,
wherein the base color used comprises a water-based ink which is applied by a digital printer to the base coat which is dried, and the sealing resin is applied in liquid form.

2. The process as claimed in claim 1 , wherein the base color is applied to the base coat in a plurality of individual steps, and the base color that is applied to the base coat in the plurality of individual steps is dried after each step.

3. The process as claimed in claim 1 , wherein the ink of the base color has white pigmentation.

4. The process as claimed in any of claim 1 , wherein the decorative effect is applied by a digital printer.

5. The process as claimed in claim 4 , wherein the decorative effect is applied in only a single layer.

6. The process as claimed in claim 1 , wherein, as print base for the decorative effect, a primer is applied to the base color.

7. The process as claimed in claim 6 , wherein the primer is transparent.

8. The process as claimed in claim 1 , wherein the liquid resin for the base coat and the sealing system is aqueous.

9. The process as claimed in claim 1 , wherein the resin forming the sealing system is enriched with abrasion-resistant particles, glass, and/or cellulose.

10. The process as claimed in claim 1 , wherein during the pressing of the cake of wood material a surface structure is formed.

11. The process as claimed in claim 10 , wherein the surface structure is at least to some extent brought into register with the decorative effect.

12. A panel made of a wooden board, produced as claimed in claim 1 , with features comprising:
a) an upper side, an underside, and two pairs of opposite lateral edges,
b) the upper side and the underside of the core have a press skin which arose during the pressing process,
c) applied at least to the press skin on the upper side: a base coat layer, an ink layer composed of white ink dots, at least one decorative layer and one abrasion-resistant layer,
d) applied on the underside of the core, there are a base coat layer and a layer of counterbalancing material,
e) the base coat layer has penetrated at least to some extent into the press skin on the upper side, and
f) on the opposite lateral edges there are connection means and interlocking means provided for connection of a plurality of panels without use of glue.

13. The panel as claimed in claim 12 , wherein there is a transparent primer layer arranged between the ink layer and the decorative layer.

14. The panel as claimed in claim 12 , wherein the wooden board is an MDF, HDF, or particle board.

15. The process as claimed in claim 1 , wherein the base color has white pigmentation and is applied in only a single layer with a single dryer drying the base color.

16. The process as claimed in claim 15 , wherein the base color is applied by another digital printer.

17. The process as claimed in claim 16 , wherein a size and number of color dots from the other digital printer can be adjusted, to achieve precise adjustment of a quantity of ink required to produce a coherent surface as primer layer that is uniformly white and is immediately suitable for an application of the decorative effect.

18. The process as claimed in claim 17 , wherein the base coat is dried by a nozzle dryer, under which the substrate board is passed.

19. The process as claimed in claim 18 , further comprising:
applying a protective covering layer made of a water-based melamine resin to a dried decorative effect;
drying the protective covering layer; and
stacking the substrate board on another substrate board that have the protective covering layer before it is introduced to a further coating process.

Assignees

• Flooring Technologies Ltd

Inventors

• Oldorff Frank

Classifications

• B27N7/005 Primary

  Coating boards, e.g. with a finishing or decorating layer · CPC title

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title

• B44C5/04

  Ornamental plaques, e.g. decorative panels, decorative veneers · CPC title

• B27N3/04

  from fibres · CPC title

• B27N3/08

  Moulding or pressing (presses in general B30B) · CPC title