Abrasion-resistant wood board

Abstract

An abrasion-resistant wood-based panel having a top side and a bottom side, with at least one decorative layer arranged on the top side, in particular with a structure synchronous with the decoration, is disclosed herein.

Claims

1. A wood-based panel with at least one decorative layer arranged on an upper side with the following layer structure, viewed from bottom to top: a backing layer of six layers of resin; a wood-based panel; a primer layer; a print decoration layer; a protective layer; a first resin layer with cellulose fibres; a layer of abrasion-resistant particles; a second resin layer; a third resin layer with glass beads; a fourth resin layer with glass beads; a fifth resin layer with glass beads; and a sixth resin layer without glass beads, wherein a total thickness of the first, second, third, fourth, fifth, and sixth resin layers is between 120 and 200 m, wherein an amount of glass beads in each of the third, fourth, and fifth resin layers is 10 to 50 g/m.sup.2, and wherein an amount of abrasion-resistant particles is 10 to 50 g/m.sup.2.

2. The wood-based panel according to claim 1 with markings in the decorative layer for aligning the wood-based panel in a press.

3. The wood-based panel according to claim 1, wherein the resin layers are based on aqueous formaldehyde-containing resins.

4. The wood-based panel according to claim 1, wherein the first, second, and third resin layers each have a solids content of between 60 and 80% by weight.

5. The wood-based panel according to claim 1, wherein the fourth, fifth and sixth resin layers each have a solids content of between 50 and 70% by weight.

6. The wood-based panel according to claim 1, wherein the abrasion- resistant particles are corundum particles.

7. The wood-based panel according to claim 1, wherein the glass beads have a diameter of 90 to 150 m.

8. The wood-based panel according to claim 1, with an abrasion value in abrasion classes AC4 to AC6.

9. The wood-based panel according to claim 1, wherein an amount of cellulose fibres in the first resin layer is between 0.1 and 1 wt %.

10. The wood-based panel according to claim 1, wherein the wood-based panel is a medium-density fibre (MDF), high-density fibre (HDF) or chipboard, oriented strand board (OSB) a plywood panel, and/or a wood-plastic panel.

11. A production line for manufacturing a wood-based panel according to claim 1 comprising the following elements: a first application device for applying the first resin layer containing cellulose fibres, to the upper side of the wood-based panel; at least one device arranged downstream of the first application device in a processing direction for scattering a predetermined amount of abrasion-resistant particles; a second application device arranged behind the first application device and scattering device in the processing direction for applying the second resin layer to the upper side of the wood-based panel; at least one first drying device arranged behind the second application device in the processing direction for drying a layer structure of the first and second resin layers; a third application device arranged downstream of the at least one first drying device in the processing direction for applying the third resin layer containing glass beads to the upper side and, optionally, a resin layer in parallel to a lower side of the wood-based panel; at least one second drying device arranged behind the third application device in the processing direction for drying the upper third and the corresponding optional lower resin layer, if present; a fourth application device arranged downstream of the at least one second drying device in the processing direction for applying the fourth resin layer containing glass beads to the upper side and, optionally, a resin layer without glass beads in parallel to the lower side of the wood-based panel; at least one third drying device arranged behind the fourth application device in the processing direction for drying the upper fourth resin layer and the corresponding lower resin layer, if present; a fifth application device arranged downstream of the at least one third drying device in the processing direction for applying the fifth resin layer with glass beads to the upper side, and optionally, a resin layer without glass beads in parallel to the lower side of the wood-based panel; at least one fourth drying device arranged downstream of the fifth application device for drying the upper fifth resin layer and the corresponding lower resin layer, if present; a sixth application device arranged downstream of the at least one fourth drying device in the processing direction for applying the sixth resin layer without glass beads to the upper side, and, optionally, a resin layer in parallel to the lower side of the wood-based panel; at least one fifth drying device arranged downstream of the sixth application device in the processing direction for drying the upper sixth resin layer and the corresponding lower resin layer, if present; and at least one short-cycle press arranged downstream of the last drying device in the processing direction.

12. The wood-based panel according to claim 3, wherein the resin layers are melamine-formaldehyde resin, urea-formaldehyde resin or melamine-urea-formaldehyde resin.

13. The wood-based panel according to claim 1, wherein the first, second and third resin layers each have a solids content of between 65 and 70% by weight.

14. The wood-based panel according to claim 1, wherein the fourth, fifth and sixth resin layers each have a solids content of 55 and 65% by weight.

15. The wood-based panel according to claim 1, wherein a total thickness of the first, second, third, fourth, fifth, and sixth resin layers is between 150 and 200 m.

16. The wood-based panel according to claim 1, wherein the amount of abrasion-resistant particles is 10 to 30 g/m.sup.2.

17. The wood-based panel according to claim 1, wherein an amount of glass beads in each of the third, fourth, and fifth resin layers is 10 to 30 g/m.sup.2.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) The solution is explained in more detail below with reference to the FIGURES in the drawings, using an example of an embodiment.

(2) FIG. 1 shows a schematic representation of a production line of a wood-based panel using the method according to the proposed solution.

DETAILED DESCRIPTION OF THE INVENTION

(3) The production line shown schematically in FIG. 1 includes an IR dryer 1a which is switched off. Removal of the IR dryer 1a from the production line avoids the electrostatic charging of the plate surface that would otherwise take place in the IR dryer, which makes it possible to form a homogeneous scattering curtain of corundum.

(4) The production line further comprises a single-sided applicator unit 1 (grooved roller), and five double applicator units 2, 3, 4, 5, 6 for simultaneous application of the respective resin layer to the upper side and the lower side of the separated printed material boards, e.g. of printed HDF boards, as well as four convection dryers 2a, 3a, 4a, 5a, 6a arranged behind each of the applicator units in the processing direction.

(5) Downstream of the first applicator roll 1, a first scattering device 20 is provided for uniformly scattering the abrasion-resistant material such as corundum onto the first resin layer on the top side of the HDF board. The abrasion resistant material used is F200 corundum, which measures about 53-75 m in diameter according to FEPA standards. The scattering device 20 essentially consists of a supply hopper, a rotating, structured spiked roller and a scraper. The application rate of the material is determined by the rotational speed of the scattering roller. Depending on the required abrasion class of the product, between 12-25 g/m.sup.2 of corundum is scattered onto the resin-coated board (AC4 (according to EN 13329)=20 g/m.sup.2). From the spiked roller, the corundum falls onto the melamine resin treated board at a distance of 5 cm. Since the first resin layer is still liquid at the time of scattering, the abrasion-resistant particles can sink into the resin layer. Under the present scattering device, at least one hopper (not shown) is provided in front of the scattering roller for collecting excess abrasion-resistant particles (i.e., abrasion-resistant particles not scattered on the at least one wood-based panel, but rather falling down in front of the wood-based panel before the wood-based panel is moved in by means of the transport device under the scattering roller).

(6) In the double-sided coating unit 2, the board coated with melamine-formaldehyde resin and corundum is coated with further melamine-formaldehyde resin (about 20 g/m.sup.2). At the same time, the unattached corundum is removed in small amounts and accumulates in the melamine resin liquor until saturation (about 10 wt. %) occurs. This lost portion of the corundum is now continuously reapplied to the board by the roller application of coating unit 1-1. The second application covers the corundum grains with liquid resin or incorporates them into the overlay layer. This prevents the corundum from being removed in the convection dryer due to the high air turbulence.

(7) The build-up of first and second resin layers is dried in convection dryer 2a.

(8) Downstream of the third double coater 3 for applying the third resin layer, there may be another scattering device 20 for applying glass beads to the third resin layer followed by a third convection dryer 3a for drying the third resin layer. The scattering device 20 for the glass beads is optional. The glass beads may also be applied together with the third resin layer.

(9) After application of the fourth to sixth resin layers in a fourth to sixth double coater 4, 5, 6 and drying in a convection dryer 4a, 5a, 6a respectively, the layer structure is cured in a short-cycle press 7 at a pressing temperature of 180-220 C. and a pressing time of 8 to 10 seconds under a specific pressure of 40 kg/cm.sup.2. The pressed sheets are cooled and stored.

(10) While this disclosure has been described as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.