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

Abstract

A method for producing an abrasion-resistant wood-based panel with a top side and a bottom side. At least one decorative layer, in particular as a printed decoration, is provided on the top side. The method 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. The first resin layer on the top side of the wood-based panel provided with the abrasion-resistant particles is not dried after application. The method also includes 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, and 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.

The invention claimed is: 
     
         1 . A method for producing an abrasion-resistant wood-based panel with a top side and a bottom side, wherein at least one decorative layer is provided on the top side in the form of a printed decoration, and wherein a protective layer of a not yet fully cured resin is applied to the decorative layer, comprising the steps of:
 applying at least one first resin layer to the at least one decorative layer on the upper surface 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 provided with the abrasion-resistant particles on the upper surface of the wood-based panel is not dried after application;   applying at least a second resin layer to the first wet resin layer provided with the abrasion-resistant particles on the upper surface of the wood-based panel;   subsequent drying of the assembly of first resin layer and second resin layer on the upper surface of the wood-based panel in at least one drying device;   applying at least one further resin layer to the dried first and second resin layers provided with the abrasion-resistant particles on the upper surface of the wood-based panel and then drying after the respective application; and,   pressing the layer structure following the last drying step in a short-cycle press.   
     
     
         2 . The method according to  claim 1 , wherein the resin layers are based on aqueous formaldehyde-containing resins, such as melamine-formaldehyde resin, urea-formaldehyde resin or melamine-urea-formaldehyde resin. 
     
     
         3 . The method according to  claim 1 , wherein the first resin layer is applied in an amount between 10 to 100 g/m 2 . 
     
     
         4 . The method according to  claim 1 , wherein the first resin layer is applied in an amount between 40 to 80 g/m 2 . 
     
     
         5 . The method according to  claim 1 , wherein the first resin layer is applied in amount between 45 to 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 1 , wherein the amount of scattered abrasion-resistant particles is 10 to 30 g/m 2 . 
     
     
         8 . The method according to  claim 1 , wherein the amount of scattered abrasion-resistant particles is 15 to 25 g/m 2 . 
     
     
         9 . The method according  claim 1 , wherein the second resin layer applied to the upper surface of the wood-based panel is applied in an amount between 10 to 50 g/m 2 . 
     
     
         10 . The method according to  claim 1 , wherein the second resin layer applied to the upper surface of the wood-based panel is applied in an amount between 20 to 30 g/m 2 . 
     
     
         11 . The method according to  claim 1 , wherein the second resin layer applied to the upper surface of the wood-based panel is applied in an amount between 20 to 25 g/m 2 . 
     
     
         12 . The method according to  claim 1 , wherein 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 upper surface of the wood-based panel, and each is dried after application. 
     
     
         13 . The method according to  claim 12 , wherein the at least one of the third, fourth, fifth and sixth resin layer comprises glass beads or fibers. 
     
     
         14 . The method according to  claim 13 , wherein the glass beads or fibers comprise wood fibers or cellulose fibers. 
     
     
         15 . The method according to  claim 1 , wherein an at least one resin layer is applied to the bottom surface of the wood-based panel together with the second resin layer to be applied to the top surface of the wood-based panel. 
     
     
         16 . The method according to  claim 1 , wherein the at least one wood-based panel is a medium density fiber (MDF), high density fiber (HDF) or rough chipboard (OSB) or plywood panel and/or a wood-plastic panel. 
     
     
         17 . A production line for carrying out a process according to  claim 1 , comprising:
 at least one first applicator device for applying a first resin layer to the upper surface of the wood-based panel, wherein no active drying device is provided upstream of the first applicator device; and wherein the at least one first applicator is designed as a single-sided applicator with a grooved roller;   at least one device for scattering a predetermined quantity of abrasion-resistant particles, arranged downstream of the first applicator device in the processing direction;   at least one second applicator device arranged downstream of the first applicator device and spreader device for applying a second resin layer to the upper surface of the wood-based panel,   wherein no drying device is provided between the spreading 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 layer 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 upper side and/or lower side of the carrier plate and subsequent drying device for drying the further upper and/or lower resin layer; and,   a short-cycle press (KT press) arranged downstream of the last drying device.   
     
     
         18 . The production line according to  claim 17 , wherein the second applicator for applying the second resin layer is formed as a double applicator, so that a resin layer is applied to the underside of the wood-based panel simultaneously with the second resin layer on the upper side. 
     
     
         19 . A method of producing a panel, the method 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 the 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 to 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 penetrated into 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 the abrasion-resistant particles,   applying at least one further resin layer to the dried first and second resin layers provided with the abrasion-resistant particles on the upper surface of the wood-based panel and then drying after the respective application; and,   pressing of the layer structure following the last drying step in a short-cycle press.