Method for producing an abrasion-resistant wood composite board and production line therefor

Patent metadata

Field	Value
Publication number	US-11198319-B2
Application number	US-201816761937-A
Country	US
Kind code	B2
Filing date	Nov 5, 2018
Priority date	Nov 6, 2017
Publication date	Dec 14, 2021
Grant date	Dec 14, 2021

Abstract

A method for producing an abrasion-resistant wood-based panel with a top side and a bottom side, wherein at least one decorative layer, in particular as a printed decoration, is provided on the top side, includes applying at least one first resin layer to the at least one decorative layer on the top side of the wood-based panel, uniformly scattering abrasion-resistant particles onto the first resin layer on the top side of the wood-based panel; wherein the first resin layer on the top side of the wood-based panel provided with the abrasion-resistant particles is not dried after application, and applying at least one second resin layer to the first, moist resin layer provided with the abrasion-resistant particles on the top side of the wood-based panel, then drying the assembly of first resin layer and second resin layer on the top side of the wood-based panel in at least one drying apparatus.

First claim

The invention claimed is:

1. A method of producing a panel comprising:
providing a panel comprising wood and having a top side and a bottom side, wherein at least one decorative layer is provided on the top side, and wherein a protective layer of a partially but not yet completely cured resin is applied to a decorative layer;
applying a first resin layer to the protective layer on the top side of the panel, wherein the provided panel including the decorative layer and the protective layer is not heated in a dryer before the application of the first resin layer;
scattering abrasion-resistant particles on the first resin layer on the top side of the panel, wherein the first resin layer on the top side of the panel provided with the abrasion-resistant particles is not dried after application;
applying a second layer of resin on the first resin layer on the top side of the panel; and
subsequently, drying the structure consisting of the first resin layer and the second resin layer on the top side of the panel in at least one drying device,
wherein the abrasion-resistant particles comprise one or more of corundum, boron carbide, silicon dioxide, and silicon carbide, and
wherein the second resin layer is applied using a roller applicator and at least a portion of the abrasion-resistant particles scattered on the first resin layer and not fixed to or perpetrated onto the first resin layer are taken up by the roller applicator and entrained in the resin applied as the second resin layer such that, after drying, both the first and second resin layers contain abrasion-resistant particles.

2. The method according to claim 1 , wherein the first resin layer and the second resin layer are aqueous formaldehyde-containing resins.

3. The method according to claim 1 , wherein the first resin layer is applied in an amount of 10-100 g/m 2 .

4. The method according to claim 3 , wherein the first resin layer is applied in an amount of 40-80 g/m 2 .

5. The method according to claim 3 , wherein the first resin layer is applied in an amount of 45-60 g/m 2 .

6. The method according to claim 1 , wherein the amount of scattered abrasion-resistant particles is 10 to 50 g/m 2 .

7. The method according to claim 6 , wherein the amount of scattered abrasion-resistant particles is 10 to 30 g/m 2 .

8. The method according to claim 6 , wherein the amount of scattered abrasion-resistant particles is 15 to 25 g/m 2 .

9. The method according to claim 1 , wherein the second resin layer applied to the top side of the panel is applied in an amount of 10-50 g/m 2 .

10. The method according to claim 9 , wherein the second resin layer to be applied to the top side of the panel is applied in an amount of 20-30 g/m 2 .

11. The method according to claim 9 , wherein the second resin layer to be applied to the top side of the wood based panel is applied in an amount of 20-25 g/m 2 .

12. The method according to claim 1 , wherein the second resin layer comprises 5-15 wt % of abrasion-resistant particles.

13. The method according to claim 1 , wherein at least one further resin layer is applied to the dried first and second resin layer on the top side of the panel and is dried after each application.

14. The method according to claim 13 , wherein the at least one further resin layer comprises glass beads and/or fibres.

15. The method according to claim 14 , wherein the at least one further resin layer comprises wood fibres or cellulose fibres.

16. The method according to claim 13 , wherein a third, fourth, fifth and sixth resin layer are applied to the dried first and second resin layer provided with the abrasion-resistant particles on the top side of the panel and each resin layer is dried after application.

17. The method according to claim 1 , wherein at least one resin layer is applied to the bottom side of the panel together with the second resin layer to be applied to the top side of the panel.

18. The method according to claim 1 , wherein the panel is medium density fibre (MDF), high density fibre (HDF), coarse particle board, plywood and/or a wood-plastic panel.

19. The method according to claim 1 , wherein each of the first resin layer and the second resin layer are selected from the group consisting of melamine-formaldehyde resin, urea-formaldehyde resin and melamine-urea-formaldehyde resin.

20. A production line for carrying out a method according to claim 1 , the production line comprising:
at least a first application device for applying the first resin layer to the top side of the panel, wherein no active drying device is provided in front of the first application device;
at least one device arranged downstream of the first application device in a processing direction for scattering a predetermined quantity of abrasion-resistant particles;
at least one second application device having a roller applicator and arranged downstream of the first application device and scattering device in the processing direction for applying a second resin layer to the top side of the panel,
wherein no drying device is provided between the scattering device and the second application device;
at least one first drying device arranged downstream of the second application device in the processing direction for drying the layered structure of first and second resin layers;
at least one further application device arranged downstream of the first drying device in the processing direction for applying a further resin layer to the top and/or bottom side of the panel and a subsequent drying device for drying the further top and/or bottom resin layer; and
a short-cycle press arranged downstream of the last drying device in the processing direction.

21. The production line according to claim 20 , wherein the second application device for applying the second resin layer is designed as a double applicator, so that a resin layer is applied to the bottom side of the panel simultaneously with the second resin layer on the top side.

Assignees

• Flooring Technologies Ltd

Inventors

• Denk Andre
• George Maika
• Pfeiffer Sabrina
• Burgmann Björn

Classifications

• B44C5/043

  containing wooden elements · CPC title

• B44C5/0407

  containing glass elements · CPC title

• B05D5/08 Primary

  to obtain an anti-friction or anti-adhesive surface (rendering particulate materials free-flowing in general, e.g. making them hydrophobic B01J2/30) · CPC title

• B05D1/36

  Successively applying liquids or other fluent materials, e.g. without intermediate treatment · CPC title

• B05D7/542

  the two layers being cured or baked together · CPC title