Method for Producing an Abrasion-Resistant Wood Composite Board, and Production Line Therefor

Patent metadata

Field	Value
Publication number	US-2020376886-A1
Application number	US-201816761937-A
Country	US
Kind code	A1
Filing date	Nov 5, 2018
Priority date	Nov 6, 2017
Publication date	Dec 3, 2020
Grant date	—

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

1 - 15 . (canceled)

16 . A method of producing an abrasion-resistant wood-based panel having a top side and a bottom side, wherein at least one decorative layer, in particular as a print decoration, is provided on the top side, and wherein a protective layer of a not yet completely cured resin is applied to the decorative layer, comprising the steps:
applying at least one first resin layer to the at least one decorative layer on the top side of the wood-based panel, wherein the wood-based panel provided with the protective layer and decorative layer is not heated in a dryer before the application of the first resin layer, even scattering of abrasion-resistant particles on 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, applying at least a second layer of resin to the first, moist resin layer on the top side of the wood-based panel, which is provided with the abrasion-resistant particles, and subsequent drying of the structure consisting of the first resin layer and the second resin layer on the top side of the wood-based panel in at least one drying device.

17 . The method according to claim 16 , wherein the resin layers are based on aqueous formaldehyde-containing resins, in particular melamine-formaldehyde resin, urea-formaldehyde resin or melamine-urea-formaldehyde resin.

18 . The method according to claim 16 , wherein the first resin layer is applied in an amount between 10-100 g/m 2 , preferably 40-80 g/m 2 , in particular preferably 45-60 g/m 2 .

19 . The method according to claim 16 , wherein the amount of scattered abrasion-resistant particles is 10 to 50 g/m 2 , preferably 10 to 30 g/m 2 , in particular preferably 15 to 25 g/m 2 .

20 . The method according to claim 16 , wherein the second resin layer to be applied to the top side of the wood-based panel is applied in an amount between 10-50 g/m 2 , preferably 20-30 g/m 2 , in particular preferably 20-25 g/m 2 .

21 . The method according to claim 16 , wherein at least one further resin layer, preferably a third, fourth, fifth and sixth resin layer, is applied to the dried first and second resin layer provided with the abrasion-resistant particles on the top side of the wood-based panel and is dried after each application.

22 . The method according to claim 21 , wherein in that the at least one further resin layer comprises glass beads and/or fibres, in particular wood fibres or cellulose fibres.

23 . The method according to claim 16 , wherein at least one resin layer is applied to the bottom side of the wood-based panel together with the second resin layer to be applied to the top side of the wood-based panel.

24 . The method according to claim 16 , wherein the at least one wood-based panel is a medium density fibre (MDF), high density fibre (HDF) or coarse particle board (OSB) or plywood panel and/or a wood-plastic panel.

25 . A production line for carrying out a method according to claim 16 , the production line comprising:
at least a first application device for applying a first resin layer to the top side of the wood-based 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 arranged behind the first application device and scattering device in the processing direction for applying a second resin layer to the top side of the wood-based 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 carrier board and subsequent drying device for drying the further top and/or bottom resin layer; and a short-cycle press (KT press) arranged downstream of the last drying device in the processing direction.

26 . The production line according to claim 25 , 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 wood-based 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

• B44C5/0476 Primary

  with abrasion resistant properties · CPC title