EP3858639A1 - Method for producing panels - Google Patents

Abstract

A method for producing packaged primed panels as semi-finished products at a laminate manufacturer with subsequent finishing of the primed panels with the following steps in this order: a) providing a large-format wood-based panel (1), b) applying a primer (24) in the form of a synthetic resin layer at least one top side of the wood-based panel (1), c) applying a coating to an underside of the wood-based panel (1) opposite the top of the wood-based panel (1), d) pressing the layer structure made of wood-based panel (1), primer (24) and coating under pressure - and possibly the influence of temperature, wherebyie) dividing the primed and coated wood-based panel (1) into individual panels (12), f) transport-safe machining of side surfaces of the panels (12) for processing connecting and locking means, g) packaging the primed panels ( 12), h) Delivery of the primed n Panels in the transport-safe packaging at a processing company, and subsequent finishing of a panel in the processing company with the following additional steps: i) unpacking a panel from the transport-safe packaging, j) selecting a special decoration from a large number of stored decorations or an individually present decor, k) selecting a defined number of panels that are to be printed with the decor, I) applying a decor layer with the selected decor to each individual panel, wherebyim) applying the decor layer and the at least one wear layer by the following steps happens: m ₁) providing the at least one wear layer on a carrier medium, m ₂) printing the decorative layer onto the at least one wear layer, m ₃) Laying the layer structure of the carrier medium, at least one wear layer and decorative layer on the primer or the primer, so that ss the decorative layer is arranged on the primer or the primer, m ₄) pressing the layer structure with the panel, m ₅) removing the carrier medium, and n) for structuring the panels ( 12) either: n ₁) a relief is embossed into the wood-based panel (1) and / or ₂) during pressing in step d) a structure (28) into the primer (24) is embossed, and / or ₃) during pressing in step m ₄) a structure in which at least one wear layer is embossed and / or _{4 </ sub>) the at least one wear layer consists of at least one structure-forming lacquer layer over which a structure is introduced during curing and / or ₅) agents that interfere with the flow of the lacquer are introduced into at least one lacquer layer and / or < sub> 6}) a digitally controlled print head is used to apply a structure-forming amount of varnish only to certain points on the surface of the panel, u m to produce structure-forming elevations and depressions.

Description

The invention relates to a method for producing panels.

Laminate panels have been state of the art for some time and are now indispensable in a wide range of applications, especially as a replacement for real wood panels. A particularly large area of application is the cladding of walls, ceilings and floors, where the respective cladding is put together from corresponding wall, ceiling and floor panels. Of course, different requirements are placed on the surface properties of such laminate panels in different areas of application. A floor panel is naturally exposed to much greater loads than, for example, wall or ceiling cladding.

The large-scale production of laminate panels comprises a whole series of production steps that are largely the same for the various types of panel. First, a carrier board, for example made of a wood material such as MDF, HDF or OSB, is provided and this is coated with several layers of possibly different materials. A decorative layer is applied to an optionally pretreated surface of a wood-based panel that was provided as the core of the panel to be produced. This can take place, for example, in the form of a printed impregnated paper. The paper can also be placed directly on top of the Wood-based panel can be printed on. This can be done using pressure rollers or a digital printer. Before the decor is printed on, a primer layer can optionally also be applied to the surface of the wood-based panel. This decoration must be covered by at least one wear layer, especially if the panel is to be used as a floor panel. This can for example consist of a lacquer or a synthetic resin. Abrasion-resistant particles (for example corundum) are advantageously mixed in, which make the surface of the finished panel more resistant to the stress caused by walking on it. The layer structure with possibly several synthetic resin layers is then pressed in a press under the influence of pressure and temperature, as in FIG EP 1 454 763 B1 - to which reference is made in full - disclosed. The wood-based panel, which is still large in size, is then divided into individual panels. After division into individual panels, connecting means in the form of a tongue and a groove with integrated locking means are attached to the side surfaces, so that two panels can be connected to one another by means of a so-called "click connection" and locked to one another in the vertical and horizontal direction. In order to increase the realistic impression of a laminate panel, it is known to emboss a structure (embossed-in-register) that corresponds to the decor when the layer structure is pressed into the top. The laminate panel is not only matched optically but also haptically, for example, to a real wood panel.

Alternatively, the coating can also be carried out with layers of lacquer, which are then cured using high-energy radiation, for example electron and UV radiation. In this case, too, the large-format coated carrier plate is only divided into panels after the applied layers have cured completely.

Laminate panels, in particular floor panels, are on the market to observe a demand for more and more different decor variants. Not only is there a constant demand for new wood reproductions, but also increasingly tile and stone decors as well as fantasy decors in a wide variety of forms. Retrofitting a large-scale production plant for laminate panels to a new decor is, however, relatively cumbersome, time-consuming and therefore costly. In addition, in the event that the decor is placed on the wood-based core in the form of a printed decor paper, decor papers with different decors must be stored. This requires a lot of storage space and also ties up an unnecessarily large amount of capital due to the large amount of decor paper to be kept available.

If, for example, the decoration is printed directly onto the wood-based panel using pressure rollers, a separate set of rollers must be kept available for each decoration, which are particularly costly to purchase. If a structure is to be embossed in the top, the press plates or press plates must also be engraved, which is expensive. In addition, the replacement of such press plates or press plates takes time in which the production plant is standing, which increases the production costs for laminate panels.

For the reasons mentioned above, it only makes economic sense to produce relatively large numbers of laminate panels with a decor that has been chosen before panels with a different decor are produced.

In addition to the demand for more and more different decor variants, however, an increasing reduction in the requested order sizes can also be observed. However, if there is a demand for laminate panels with a certain decor that is too small, they cannot be produced economically. As a result, individual orders have to be "collected" from retailers or wholesalers, which results in long delivery times for the end customer, which he does not accept, especially in the do-it-yourself sector. Part of the demand must therefore remain unsatisfied.

From the WO 2010/055429 A2 a method for producing a panel having the features a) to f) of claim 1 is known, in which a primer is first applied to the top of a large-sized wood-based panel. The wood-based panel primed in this way is pressed if necessary and then divided into individual panels. Only then are the individual panels printed with the desired decor.

The disadvantage is that although the production system itself can be made smaller and more compact by the method described in the cited publication, since it is no longer the large-format wood-based panels but rather smaller panels that have to be printed, usually no faster delivery times for small batches with individual decors can be achieved . If a customer orders a small amount of panels with a desired decor from a panel dealer, for example, he will collect the incoming orders until he orders a sufficient number of panels from the panel manufacturer. This is necessary in order to keep the transport costs within reasonable limits, since laminate panels are transported, for example, with large trucks which, in order to be able to work economically, have to be fully utilized to a certain extent. Through that in the WO 2010/055429 A2 Although the method described can increase the economic efficiency of the manufacturing process through the use of smaller systems, flexibility in particular with regard to the fast delivery of small and very small batch sizes with individual decorations is not achieved.

The problem to be solved according to the invention is that with the current way in which the laminate panels desired by the end customer are produced, it is not possible, for economic reasons, to satisfy even unusual customer requests within a reasonable delivery time, provided that a minimum lot size is not required, and that even if the minimum lot size should be reached (for example in the commercial sector, i.e. the furnishing of large offices or hotels), a longer delivery time must be accepted, because of course the system at the panel manufacturer must first be converted accordingly which is not possible within a few hours or days, even with the worst order situation.

This problem can be solved in that the chain of the manufacturing process is interrupted and the dealer who accepts the decor request from the end customer can apply the decor to the panels himself. However, the dealer cannot handle and divide wood-based panels in dimensions of several meters.

The invention is therefore based on the object of proposing a method with which the possibility is created that a dealer who is provided with raw panels can then decorate them according to the customer's request, so that even the smallest order sizes are flexible and economical can be produced and at the same time the storage and material costs are reduced.

1. a) Bereitstellen einer Holzwerkstoffplatte,
2. b) Aufbringen einer Grundierung in Form einer Kunstharzschicht auf wenigstens eine Oberseite der Holzwerkstoffplatte,
3. c) Aufbringen einer Beschichtung auf eine der Oberseite der Holzwerkstoffplatte gegenüberliegende Unterseite der Holzwerkstoffplatte,
4. d) Verpressen des Schichtaufbaus aus Holzwerkstoffplatte, Grundierung und Beschichtung unter Druck- und gegebenenfalls Temperatureinfluss,
5. e) Aufteilen der Holzwerkstoffplatte in einzelne Paneele,
6. f) Spanabhebendes Bearbeiten von Seitenflächen der Paneele zum Anarbeiten von Verbindungs- und Verriegelungsmitteln,
7. g) Transportsicheres Verpacken der grundierten Paneele,
8. h) Anlieferung der fertig grundierten Paneele in der transportsicheren Verpackung bei einem weiterverarbeitenden Betrieb,
   und sich daran anschließendes Veredeln eines Paneels mit folgenden weiteren Schritten:
9. i) Auspacken eines Paneels aus der transportsicheren Verpackung,
10. j) Auswählen eines speziellen Dekors aus einer Vielzahl von abgelegten Dekoren oder eines individuell vorliegenden Dekors,
11. k) Auswählen einer definierten Anzahl von Paneelen, die mit dem Dekor bedruckt werden sollen,
12. l) Aufbringen einer Dekorschicht mit dem ausgewählten Dekor auf jedes einzelne Paneel,
13. m) Aufbringen wenigstens einer Nutzschicht auf die Dekorschicht.

The invention initially solves the problem posed by a method for manufacturing primed panels as semi-finished products with the following steps:

1. a) Provision of a wood-based panel,
2. b) applying a primer in the form of a synthetic resin layer to at least one top side of the wood-based panel,
3. c) Applying a coating to an underside of the wood-based panel opposite the top of the wood-based panel,
4. d) pressing the layer structure made of wood-based panel, primer and coating under the influence of pressure and, if necessary, temperature,
5. e) dividing the wood-based panel into individual panels,
6. f) Machining of side surfaces of the panels for the preparation of connecting and locking means,
7. g) Transport-safe packaging of the primed panels,
8. h) Delivery of the primed panels in the transport-safe packaging to a processing company,
   and then finishing a panel with the following additional steps:
9. i) Unpacking a panel from the transport-safe packaging,
10. j) Selecting a special decor from a large number of stored decors or an individually available decor,
11. k) Selecting a defined number of panels that are to be printed with the decor,
12. l) applying a decorative layer with the selected decor to each individual panel,
13. m) applying at least one wear layer to the decorative layer.

This process first creates a semi-finished product that is not yet marketable on its own. However, the retailer can buy semi-finished products according to his needs and store them on his own. The primed raw panels have already been produced by the manufacturer in such a way that they fulfill their function from a technical point of view. They are therefore suitable for being connected to one another by the connecting and locking means and to be used as wall, ceiling or floor panels. However, since there is no wear layer on the surface of the panels, the panels are exposed to the stresses, especially when used as a floor panel, largely without protection. They also have no decor. The primed raw panels, which are also created by the method described, differ from finished panels only in the lack of a decorative layer and the lack of at least one wear layer. The end customer can Choose a decor and a color for the panels from the dealer, who will print the individual pre-assembled panels and seal the decor. This means that customers can react extremely flexibly to their wishes, because the decor can be combined as desired, both in terms of the grain (wood decor) and its color. The manufacturer of the semi-finished product can produce economically because only one type of panel is produced, which is then delivered to the various dealers and stored there. The dealer can reduce his inventory of panels because he can immediately fulfill every request of the customer.

The primer can be applied in the form of a resin-impregnated paper or a synthetic resin applied directly to the top. Alternatively, the primer can also be glued to the top of the wood-based panel in the form of a film that is coated in particular with a synthetic resin. An adhesive containing synthetic resin can also be used here.

During the pressing of the layer structure, a structure is advantageously embossed into the primer.

It has proven to be particularly advantageous if a quality check is carried out after the machining.

In order to increase the printability of the surface of the primed panel to be produced, the primer is advantageously colored. In order to improve the adhesion of the paint to be applied later to the primer, a primer can also be applied to the primer.

The connecting and locking means are advantageously milled out of the panel. The panels are preferably cleaned before they are packaged in such a way that they are safe for transport.

A panel according to the invention has a core made of a wood-based panel, on the top of which only a primer in the form of a synthetic resin layer and optionally a primer is applied, which are pressed with the core, a coating being applied to the bottom and to opposite side surfaces of the panel mutually corresponding connecting and locking devices are provided.

The roughness of an upper side of the panel is advantageously less than 20 μm, particularly preferably less than 10 μm. ISO 4287-1 is mainly used as the test standard for surface roughness. In order to ensure particularly good printability of the panel, a brightness parameter L is greater than 92 and a red-green value A is between -5 and +5, preferably between -2 and +, for the color of an upper side of the panel in the CIELAB color space 2, and a yellow-blue value B is between -15 and +15, preferably between -8 and +8. The DIN 6174 standard serves as the normative basis for this color space.

The upper side of the panel advantageously has a structure. The connecting and locking devices can be formed in one piece with the wood-based panel. Connection and locking means that correspond to one another are particularly preferably provided on all opposite side surfaces.

The invention is based on the idea of making the production of laminate panels, in particular for use as wall, ceiling and floor coverings, more flexible, simpler and more cost-effective. For this purpose, it is provided that only primed panels are manufactured as semi-finished products in the context of large-scale production. These have a core made of wood-based material, which can be designed as OSB, MDF or HDF, for example. This will be with coated with a primer that is pressed with the core of the wood-based panel. This creates an easily printable surface that has the necessary properties to ensure an excellent print image when printing later. The primer in the form of a synthetic resin layer can be applied to the core made of wood-based material in a wide variety of forms. It is conceivable, for example, to apply it in the form of resin-impregnated paper, as a synthetic resin layer applied directly to the top, or in the form of a finish film that is laminated, for example, with an adhesive that can contain synthetic resin. All these primers applied lead to a particularly high surface quality. Depending on the primer applied to the wood-based panel, a coating is applied to the underside opposite the top of the wood-based panel. This can, for example, take on the function of a counter-move. This is particularly necessary if, when the primer applied is drying, a tensile force is exerted on the wood-based panel parallel to the surface of the wood-based panel. By applying a corresponding coating to the underside of the wood-based panel, a corresponding force is also exerted on the underside, so that arching or bowling of the wood-based panel is effectively prevented.

If the primer is applied, for example, in the form of a coated film that has already cured, the application of a counter-layer may be unnecessary. The coating applied to the underside can then, for example, prevent moisture from being absorbed into the underside of the wood-based panel, or it can only have optical reasons. The acceptance of a panel on the market by the end user can be increased in particular by the fact that the wood-based panel functioning as the core can no longer be seen on the underside of the panels, which is no longer visible in the installed state.

After the primer has been applied to the top and the coating to the underside of the wood-based panel, the layer structure is pressed. This can be done under the influence of pressure and temperature. This is particularly necessary if at least one of the applied layers is to be connected to the wood-based material core. If the primer is laminated on in the form of a fully cured film, pressing under pressure is sufficient.

After pressing the layer structure, the still large, coated and pressed wood-based panel is divided into individual panels. Side surfaces of the panels are then machined in order to work on connecting and locking means. These connecting and locking means can consist of simple tongue and groove profiles or comprise more complicated profiles with which locking of two connected panels is ensured, for example, both in the vertical and in the horizontal direction. In addition, connecting and locking means can also be incorporated on the side edges of panels into which separate connecting elements, which can consist of plastic, for example, are inserted. For laying or connecting two identical panels, however, it is advantageous if connecting and locking means are worked out of the panel, for example milled out, so that two identical panels can be connected to one another and locked without additional connecting elements.

The primed panels produced in this way are then packed securely for transport. A quality control can be carried out beforehand in order to ensure the highest possible quality of the primed panels.

Since the laminate manufacturer only produces primed panels on which no decorative layer has to be applied, both storage and material costs are reduced for the laminate manufacturer. It doesn't have to be Decor papers are stored in different decors or embossing rollers or embossing plates are provided in order to be able to produce panels with different decors. This significantly reduces both the required storage space and the capital tied up. In addition, changeover times are eliminated, as all panels have the same primer. As a result, the production plant can work more economically and the manufacturing costs are further reduced.

In order to ensure particularly good printability of the panels produced in this way, the primer is in particular colored. In particular, several colors are possible here, white or beige may be mentioned as examples. For example, colored papers are used as the printing base, the color of which corresponds to the lightest shade of the decor to be printed. If, as here, the decor to be applied is not yet known, a white or at least very light primer is advantageous. Any other color is also conceivable as a primer. In order to achieve special effects during the later printing of panels primed in this way, a structure can already be incorporated into the primer. This takes place advantageously when the layer structure is pressed, in particular by means of the embossing plates or embossing rollers used for this.

However, pre-primed panels produced in this way have a very smooth surface overall. In particular, the surface is homogeneous and, if the primer is colored, provides good coverage. In combination with a very low frequency of defects due to surface defects or dirt particles, this is very important, especially for digital printing, in which the pre-primed panel is printed directly by means of a digital printer. A colored wood-based panel can at least partially take on the function of a primer.

Due to the very low surface roughness of the top of the panel, the is for example smaller than 20 μm, particularly preferably even smaller than 10 μm, a very good print image is achieved during later printing. ISO 4287-1 is mainly used as the test standard for surface roughness. If the wood-based panel or the primer is colored, it is advantageous for the color that a brightness parameter L is greater than 92, a red-green value A between -5 and +5, preferably between -2 and +2 and a yellow-blue Value B is between -15 and +15, preferably between -8 and +8. The specified values describe colors in the CIELAB color space. The normative basis of this color space is DIN 6174. The color of the primer or the colored wood-based panel should correspond to the lightest color in the decor to be applied. If this is not yet known, as is the case here, a particularly light, in particular white, surface color is naturally appropriate.

Such pre-primed panels are stored at the laminate manufacturer in a central warehouse, for example a high-bay warehouse. In particular, they can be cleaned and packaged beforehand in such a way that they can be printed or processed directly in the processing plant without the panels having to be cleaned again there. However, this only needs to be kept for a single type of panel, so that space-intensive storage of panels with different decors, different surface structures or different surface qualities is no longer necessary.

The primed panels are then transported to a processing company. This can be, for example, a franchise company associated with the laminate manufacturer, a hardware store, an interior designer, dealer or flooring company.

In this case, the pre-primed panels are unpacked from the transport-safe packaging. Then a decorative layer with a decor Applied to the primer or primer at the customer's immediate request and covered by at least one wear layer.

The decorative layer can be applied to the primer or the primer in different ways.

The decorative layer can in particular be printed directly onto the primer or the primer. The pre-primed panel runs through a printing unit, which is advantageously a digital printer. This makes it possible, in particular, to print different decors quickly and easily one after the other on different panels without having to convert the printing unit to the new decor. Because only individual panels have to be printed and not, as is common in the prior art, entire large-format wood-based panels, the printing unit can be made small and compact and thus space-saving and inexpensive. Alternatively, a decor paper, which can be kept in the form of large rolls, can be printed with a decor and then laminated onto the primer or primer as a decor layer.

In both cases, the decorative layer should be covered by at least one wear layer. The number and type of wear layers applied depends to a large extent on the planned location of the panels decorated in this way. In the case of wall and ceiling panels in particular, it is often sufficient if the at least one wear layer covers the decorative layer in a smudge-proof manner. However, if the printed panels are used as floor panels, they are exposed to significantly higher loads. In this case, in particular, several wear layers can be applied to which additives are added which increase the abrasion and / or scratch resistance of the upper side of the then finished panels.

The at least one wear layer can consist of a synthetic resin and hardened after application by pressing under the influence of pressure and temperature. During pressing, a structure that corresponds in particular to the decor of the decor layer can also be embossed into the at least one wear layer in order, for example, to make the natural appearance of a real wood decor more realistic.

Alternatively, the at least one wear layer can also be designed in the form of at least one lacquer layer, which then cures using high-energy radiation, for example electron or UV radiation. In this case, a structure-forming lacquer can also be applied, via which a structure can be introduced into the at least one wear layer during curing.

When curing by high-energy radiation and by pressing, a surface of the panel that can be walked on can in particular be guaranteed. This happens especially when the panel is to be used as a floor panel.

In all the cases mentioned so far, the decorative layer must be covered with at least one layer of a synthetic resin or a lacquer and then cured in the processing company, for example in a hardware store. This requires a relatively high outlay in terms of equipment, which, in addition to the increased use of space, also entails relatively high investment costs. In addition, it may be necessary to employ skilled personnel to operate a device for carrying out the process steps required in the further processing operation, in particular when coating with synthetic resin or lacquer.

The decorative layer and the at least one wear layer can therefore be applied to the pre-primed panel in a particularly simple manner using the following process steps. The at least one wear layer is provided on a carrier medium, for example a film. Should have several wear layers If necessary, they are in reverse order on the carrier medium. The wear layer, which is to form the upper side of the finished panel, is consequently located directly on the carrier medium and is covered by the wear layers that lie beneath it in the finished panel. During the further processing operation, different layer structures of this at least one wear layer are kept on the carrier medium. The wear layer, which is intended to cover the decorative layer in the finished panel, is consequently at the top of the layer structure on the carrier medium. This is now printed with the decor to be applied to the panel. The entire layer structure is then placed on the primer or the primer in such a way that the decoration now rests directly on the primer or the primer and is covered by the at least one wear layer. The carrier medium, for example the carrier film, is now located at the very top of the layer structure. This layer structure is now pressed with the pre-primed panel. For this it is sufficient if pressure is exerted on the layer structure. Since the at least one wear layer, which is located on the carrier medium, has already cured completely, exposure to an increased temperature influence is unnecessary.

The carrier medium is then peeled off and the decorative layer and the at least one wear layer remain on the primer or primer. In this way it is possible to finish the primed panel without applying liquid resins and lacquers that still have to be cured. This significantly reduces both the outlay on equipment and the investment volume. In this embodiment, too, when the layer structure is pressed, a structure can be embossed into the at least one wear layer, which structure corresponds in particular to the decor of the decor layer.

A device for finishing a panel according to a method just described comprises in particular a printing unit for printing the decoration onto the primer or the primer, the decorative paper or the one with the at least one wear layer coated carrier medium in basically any desired color and grain and also an input device with which a selection of a decoration can be entered, which is stored in a data memory in the form of electronic data. The device also includes an electrical control which is set up to read the selected decoration from the data memory and to control the printing unit in such a way that the selected decoration is printed. Particularly convenient for the customer, this device also includes a display device via which the available decors are displayed to the user.

Specifically, such a method can take place as follows, for example in a hardware store.

A customer who needs panels for a certain room size first receives information about the number of panels he needs. On a display device of a device with which the primed panel can be refined as described above, he can view various decors that are available for selection. These decorations are stored in the form of electronic data in a data memory within the device. Alternatively, the device could, for example, also have a drive, for example for a CD, DVD or the like. The customer can then also bring along a corresponding data carrier on which decorations are stored in a predetermined data format. In this way, it is possible for the customer to have their own individual decor printed on panels.

After the customer has selected a decor, he enters this selection via the input device. In addition, the customer can choose how many panels should be printed with the selected decor and what he would like to use these panels for. Depending on the intended use, different wear layers are applied to the panel.

Within the device, the desired decor is then applied to a pre-primed profiled panel and this is covered with the combination of wear layers found to be necessary. After these have hardened, if necessary, the customer can receive and use the panels printed with their individual decor.

Should he notice that he has not had enough panels printed or that it becomes necessary, for example, to replace individual panels that have worn out over time, it is possible at any time to reorder individual panels on a device described.

As a result, the flexibility in the production of laminate panels is significantly increased and even the smallest order quantities with a wide variety of decors can be produced economically.

Figur 1-

eine schematische Darstellung eines Ausführungsbeispiels des Verfahrens zum Herstellen grundierter Paneele,

Figur 2-

einen Querschnitt durch ein gemäß dem Verfahren nach Figur 1 hergestellten Paneel mit einem vergrößerten Ausschnitt daraus, und

Figur 3-

eine schematische Darstellung eines Ausführungsbeispiels des Verfahrens zum Veredeln eines Paneels, wie es in einem weiterverarbeitenden Betrieb durchgeführt wird.

The method described is explained in more detail below with the aid of a drawing. It shows:

Figure 1-

a schematic representation of an embodiment of the method for producing primed panels,

Figure 2-

a cross section through a according to the method according to Figure 1 manufactured panel with an enlarged section from it, and

Figure 3-

a schematic representation of an embodiment of the method for finishing a panel, as it is carried out in a further processing company.

Figure 1 shows the schematic representation of a method for producing a primed panel as a semi-finished product, as can be carried out by the laminate manufacturer. The processing direction is indicated by arrows. The manufacturing process begins in Figure 1 bottom left.

The method begins with a large-format wood-based panel 1. The wood-based panel 1 is first fed to a pretreatment device 2 in which the large-format wood-based panel 1 is prepared for carrying out the method. Within this pretreatment device 2, for example, an upper side of the wood-based panel 1 can be ground, or the surface can be smoothed in some other way. The wood-based panel 1 is prepared in such a way that a layer of material can be applied to the top. For this purpose, the wood-based panel 1 can, for example, additionally be cleaned and / or heated in the pretreatment device 2. In addition, quality assurance can take place in order to ensure that the surface of the wood-based panel 1 is suitable for carrying out the method.

After the wood-based panel 1 has been prepared in the pretreatment device 2, it is fed to a priming device 4. In the priming device 4, a primer in the form of a synthetic resin layer is applied to the top of the wood-based panel 1. This can be done, for example, by applying a liquid synthetic resin layer or in the form of a resin-impregnated paper. Alternatively, for example, a film that is coated in particular with a synthetic resin can be glued onto the top of the wood-based panel 1. An adhesive containing synthetic resin can also be used for this purpose.

After the wood-based panel 1 has passed through the priming device 4, it is in the in Figure 1 The embodiment shown is supplied to a drying device 6. Here, the primer in the form of a synthetic resin layer applied to the top of the wood-based panel 1 in the priming device 4 is dried.

The coated wood-based panel 1 then runs through the in Figure 1 The method shown is a short-cycle press 8 in which the wood-based panel 1 is pressed with the primer applied in the priming device 4 in the form of a synthetic resin layer under the influence of pressure and temperature. Of course, other forms of press, for example a belt press, are also conceivable. In particular, if the primer is applied in the form of a synthetic resin layer in the form of a synthetic resin layer, for example already fully cured, by means of a film, pressing only under the influence of pressure without increased temperature may be sufficient.

The primed wood-based panels 1 pressed in the short-cycle press 8 then pass through a cutting device 10 in which the large-format wood-based panel 1 is divided into smaller panels 12. On the side edges of the panels 12 profiles are then worked on, which a Allow two identical panels 12 to be connected to one another. First of all, longitudinal profiles are milled out of the side surfaces of the panels 12 in a first milling device 14. This makes it possible to connect two identical panels 12 to one another along their longer side surfaces.

The panels 12 then pass through a second milling device 16 in which the short side surfaces are also provided with a profile, in this case a transverse profile. This means that identical panels 12 can also be connected to one another along their short side edges.

The panels that are primed and provided with connecting means then pass through a quality assurance system 18 before they are packaged in a packing station 20 in a manner that is safe for transport.

When the wood-based panel coated with the primer is pressed in a short-cycle press 8 or in another pressing device, a structure can in particular be embossed into the primer. In addition or as an alternative to this, a relief can also be provided in the large-format wood-based panel 1. In order to be able to emboss a relief in the wood-based panel 1, the wood-based panel 1 in particular can be sprayed with water in the priming device 4 before the primer is applied. An exemplary procedure is in DE 10 2008 008 240 has been described.

Figure 2 shows a section along the line AA Figure 1 by a pre-primed panel 12, as well as an enlarged section from it. The panel 12 includes a core 22 to which a primer 24 has been applied. The top of the core 22 shows a relief 26 in the form of an uneven surface of the core 22. A structure 28 is embossed in the primer 24, which has significantly finer elements than the relief 26 embossed in the core 22. Figure 3 shows the schematic representation of a method for finishing a panel, as it can be carried out in a processing company, for example a franchisee associated with the laminate manufacturer, a hardware store or the like. The processing direction is indicated by arrows. The processing procedure begins in Figure 3 bottom left.

The finished, primed panels 102 are delivered in a transport-safe packaging 104 from the laminate manufacturer to the further processing company. In a first method step, the panels 102 are removed from this transport-safe packaging 104. In the in Figure 3 The illustrated embodiment of the method, the panels 102 are then fed to a cleaning device 106, in which the surface of the panels 102 is cleaned of possibly adhering dirt residues and dust and is thus prepared for the application of the decorative layer. It is also conceivable, however, that the panels 102 have been suitably cleaned during the laminate manufacturer's operation for later printing. These can then be cleaned and placed in the transport-safe packaging 104. For example, by airtight welding of the transport pack 104 in a film, it can be ruled out that the panels 102 then have to be cleaned again before they are printed.

After the panels 102 have possibly passed through the cleaning device 106, they are aligned on an acceleration section 108 and spaced from one another to the desired distance. The panels 102 are then fed to a printing unit 110. Here, the surface of the panel 102 is printed with the decorative layer to be applied. For this purpose, the printing unit 110 in in Figure 3 The embodiment shown has three print heads 112. Depending on the desired decoration, the printing unit 110 can also have more or fewer print heads 112. An electronic data processing device 114 is connected to the printing unit 110. This has a in Figure 3 Input device, not shown, by means of which the user of a device for carrying out the method can select the desired decor. For this purpose, the electronic data processing device 114 has a display device 116 via which the available decorations, which are stored, for example, on an electronic storage medium, are displayed to the user. From this selection the user can choose the decor that he would like to have printed on his panels.

In the in Figure 3 The embodiment shown, the electronic data processing device 114 also has a scanner 118. If a user of the device for refining the panel 102 brings an individual decoration, for example in the form of a paper printout, the pattern can be read into the electronic data processing device 114 via the scanner 118 and are applied to the top of the panel via the print heads 112 of the printing unit 110. The user is therefore no longer restricted to the selection of patterns stored in the electronic data processing device 114.

In addition, the electronic data processing device 114 in in Figure 3 The exemplary embodiment shown via a camera 120. This camera 120 makes it possible, for example, to photograph decorations of surfaces that the customer has brought with him, for example, but which cannot be scanned, and thus to read them into the electronic data processing device. Such decorations can also be applied to the upper side of the panel 102 via the print heads 112 of the printing unit 110. For example, a CD-ROM drive can also be provided, via which the customer can have a decoration stored in a defined format on a CD-ROM read into the data processing device 114.

So that the panels 102 remain exactly aligned when the decoration is applied by the print heads 112, they are guided in the printing unit 110 by guide elements 122 led.

In order to ensure the best possible result, the decor proposals stored in the data memory of the electronic data processing device 114 are optimized for the possible formats of the panels 102 to be printed. Individual decorations of a user of the described device, which have been read into the electronic data processing device 114, for example via the scanner 118, the drive or the camera 120, can be adapted to the panel formats. The decor selection stored in the data memory of the electronic data processing device 114 can in particular be updated online.

After the top of the panels 102 has been printed with a decoration, the panels 102 leave the printing unit 110 and are fed to a coating device 124. In the in Figure 3 The illustrated embodiment includes these three application devices 126, via each of which a wear layer can be applied to the top of the panel. The application devices 126 are controlled by a second electronic data processing device 128. This has a mixing program with which the composition of the individual wear layers is controlled. The second electronic data processing device 128 can control various storage containers 130 and mix their contents to form the respectively desired useful layer. The base material of each individual wear layer, which can be a synthetic resin or a lacquer, for example, is located in one of these storage containers 130. The further storage containers 130 contain, for example, hardener, corundum to increase the abrasion resistance of the finished coated panel and further additives which are selected depending on the intended use of the finished panel.

As in the printing unit 110, different panel formats can also be processed in the coating device 124. Also within the coating device 124, the panels 102 to be coated are guided over guide elements 122. A possible layer structure consists of several layers of radiation-curable lacquer. For example, two layers of an anti-abrasive UV base lacquer are applied with a roller system in an application amount of, for example, 35 g / m ² to the upper side of the panel 102 to be coated. Each application device 126 is designed in the form of a roller system. After the two layers of the anti-abrasive base lacquer have been applied, two further layers of a UV abrasive base can also be applied each with an application device 126, which is designed as a roller system. The amount applied here is, for example, 15 g / m ² per grinding base layer. Finally, a layer of a UV topcoat is applied in an application amount of, for example, 35 g / m ² via a further application device 126. If necessary, the previously applied lacquer layer is cured by means of UV or electron beams before each lacquer layer is applied. In the in Figure 3 In the exemplary embodiments shown, the various wear layers, which can in particular also consist of a synthetic resin, are applied directly one after the other without the wear layer previously applied by an application device 126 being dried.

An application device 126 in the form of rollers can be operated both in the same direction and in the opposite direction. In order to be able to coat as many panels 102 as possible in a given time, high feed speeds of such application devices 126 are preferred. In particular, feed speeds between 10 m / min and 30 m / min are suitable here.

If paint layers are applied as wear layers by the application devices 126 in the coating device 124, these application devices 126 can also be in the form of a spray or spray painting device, a digital print head, a pouring head or a vacuum being. In each applied layer, abrasion-resistant particles, for example corundum, or other additives can be contained. These depend on the later use of the finished panel.

After the panels 102 have left the coating device 124, they are guided to a first curing device 132. In the in Figure 3 The exemplary embodiment shown, the wear layers applied in the coating device 124, which may be in the form of a lacquer, for example, are only gelled by high-energy rays, for example electrons or UV rays. Subsequently, in an embossing device 134, a structure is embossed into the top side of the coated panel, that is to say the wear layers. This structure corresponds in particular to the selected decor of the decor layer applied in the printing unit 110.

The structure can be embossed, for example, by means of a structured roller, a structured tape or a structure donor paper or a structure donor film.

Alternatively, an overlay sheet of paper can also be placed and then pressed in a short-cycle press under the effect of pressure and heat. In this case, structures are provided in particular in the press plates, which are impressed on the upper side of the panel 102 during the pressing.

In particular when lacquers are used as wear layers, a structure-forming amount of lacquer can also be applied by means of a, for example, digitally controlled print head. Alternatively, a means is also conceivable that disrupts the flow of the paint. This agent can also be applied using a digitally controlled print head. By using such a print head, it is possible to apply the agent or the lacquer only to certain points on the surface of the panel 102 and thus to produce structure-forming depressions and elevations. Should the in If the structure embossed on the top corresponds to the decoration of the decorative layer, the panel 102 must be aligned before it passes through the embossing device 134. In the in Figure 3 After passing through the embossing device 134, the panel 102 passes through a second curing device 136 in the illustrated embodiment.

The panels 102 then go through a quality assurance 138, possibly a labeling 140 or the like, possibly also a cleaning device and are finally packaged and can be taken away by the customer.

The electronic data processing device 114 is particularly advantageously coupled to the second electronic data processing device 128. A customer is then given various selection options in the processing company, for example by means of a program. He can, for example, choose whether the panel 102 is to be used privately or commercially, in dry or damp areas, with references to various commercial usage classes being given. In addition, the customer can decide whether the panel 102 to be coated will later be a floor, wall or ceiling panel. This information is important for the useful layers to be applied in the coating device 124. In a device for finishing a panel, the wear layers required to achieve a certain wear class, for example AC3 in accordance with DIN EN 13329, with the necessary additives and additives are then automatically applied. Painting and curing take place automatically.

The customer can also select the format of the panel and the thickness of the carrier plate as well as the desired decor and, if necessary, a structure to be embossed. By means of these specifications from the customer, both the printing unit 110 and the coating device 124 can be set to the thickness and the format of the panels 102 to be coated.

Further options for the customer are, for example, the choice of specific packaging. The panels can simply be placed in a cardboard box or packed with a film, for example a shrink film, so that they are protected against splashing water. In addition, the customer can decide, for example, whether he would like to take the finished panels with him or pick them up himself at a later point in time, or whether they should be delivered by an external company. An installation option by a specialist company is also conceivable. In addition, the customer can select warranty and guarantee options, if necessary at an additional cost, and decide whether to buy or rent the panels.

The painting and curing of the paint layers can take place automatically within a system for finishing a panel using the method described. Since the lacquers or resin layers used, which are applied as wear layers, can be optimized for this application, in particular with regard to their viscosity, a smooth application can be ensured without applying more or less lacquer at the beginning and at the end of the panels 102 to be coated. In order to protect the connecting and locking elements already molded onto the panels 102, masks can be used which prevent these connecting and locking elements from soiling or contamination. In particular when curing applied lacquer layers, the adhesion of the individual layers to one another and the final curing can be realized and guaranteed by adjusting the radiation intensity. For multiple orders, the corresponding part of the system, that is to say the coating device 124 and the first curing device 132 and the second curing device 136, can be run through several times.

For the optimal use of such a system, several orders can be produced one after the other. After an order has been completed, the application devices 126 in particular can be cleaned fully automatically in order to be able to provide a clean system for the following order.

The method described has a number of advantages. After finishing the surface, the customer can immediately take the finished product with him in the desired quantity and quality. In particular, this solves the problem of small quantities for the laminate panel manufacturer, since he only has to produce one type of panel, namely pre-primed and structured panels, possibly in different dimensions. Since the connecting and locking means are milled onto pre-primed panels in this process or worked on in some other form, the resulting milling waste is reduced in particular by the fact that no decorative paper or overlay paper is applied to the pre-primed panels. This significantly reduces the manufacturing costs. In addition, the method described significantly reduces transport damage or transmission errors in orders, since the customer can stand directly in front of the device and enter his wishes. It is no longer necessary to transfer an order to a laminate manufacturer.

List of reference symbols:

1

Wood-based panel

2

Pre-treatment facility

4th

Primer device

6th

Drying device

8th

Short-cycle press

10

Cutting device

12th

Panel

14th

first milling device

16

second milling device

18th

quality control

20th

packing station

22nd

core

24

primer

26th

relief

28

structure

102

Panel

104

transport-safe packaging

106

Cleaning device

108

Acceleration distance

110

Printing unit

112

Printhead

114

electronic data processing equipment

116

Display device

118

scanner

120

camera

122

Guide element

124

Coating device

126

Application device

128

second electronic data processing device

130

Storage container

132

first curing device

134

Embossing device

136

second curing device

138

quality control

140

Labeling

Claims (15)

Process for the production of packaged primed panels as semi-finished products at a laminate manufacturer with subsequent finishing of the primed panels with the steps in this order: a) providing a large-format wood-based panel (1), b) applying a primer (24) in the form of a synthetic resin layer to at least one upper side of the wood-based panel (1), c) applying a coating to an underside of the wood-based panel (1) opposite the top of the wood-based panel (1), d) pressing the layer structure made of wood-based panel (1), primer (24) and coating under the influence of pressure and, if appropriate, temperature, wherein e) dividing the primed and coated wood-based panel (1) into individual panels (12), f) transport-safe machining of side surfaces of the panels (12) for the preparation of connecting and locking means, g) packing the primed panels (12), h) Delivery of the primed panels in the transport-safe packaging to a processing company,
and the subsequent finishing of a panel in the processing company with the following additional steps: i) Unpacking a panel from the transport-safe packaging, j) Selecting a special decor from a large number of stored decors or an individually available decor, k) Selecting a defined number of panels that are to be printed with the decor, l) Applying a decorative layer with the selected decor on each individual panel, wherein m) the decorative layer and the at least one wear layer are applied by the following steps: m ₁ ) providing the at least one wear layer on a carrier medium, m ₂ ) printing of the decorative layer on the at least one wear layer, m ₃ ) laying the layer structure of the carrier medium, at least one wear layer and decorative layer on the primer or the primer, so that the decorative layer is arranged on the primer or the primer, m ₄ ) pressing the layer structure with the panel, m ₅ ) Remove the carrier medium, and n) for structuring the panels (12) either: n ₁ ) a relief is embossed into the wood-based panel (1) and / or n ₂ ) during the pressing in step d) a structure (28) is embossed into the primer (24), and / or n ₃ ) during the pressing in step m ₄ ) a structure in which at least one wear layer is embossed and / or n ₄ ) the at least one wear layer consists of at least one structure-forming lacquer layer over which a structure is introduced during curing and / or n ₅ ) agents which interfere with the flow of the lacquer are introduced into at least one lacquer layer and / or n ₆ ) by means of a digitally controlled print head, a structure-forming amount of lacquer is only applied to certain points on the surface of the panel in order to produce structure-forming elevations and depressions. Method according to Claim 1, characterized in that the primer (24) is applied to the top of the wood-based panel (1) in the form of resin-impregnated paper. Method according to Claim 1, characterized in that the primer (24) is a synthetic resin applied directly to the top of the wood-based panel (1). Method according to Claim 1, characterized in that the primer (24) is glued to the top of the wood-based panel (1) in the form of a film. Method according to one of the preceding claims, characterized in that the wood-based panel (1) is heated in a pretreatment device (2) before a layer of material is applied to the top. Method according to one of the preceding claims, characterized in that the primer (24) is colored. Method according to one of the preceding claims, characterized in that a primer is applied to the primer (24). Method according to one of the preceding claims, characterized in that the connecting and locking means are milled out of the panel (12). Method according to one of the preceding claims, characterized in that a relief is embossed into the wood-based panel (1). Method according to one of the preceding claims, characterized in that the panels (12) before the transport-safe The packaging must be cleaned in order to prepare it for the later printing process. Method according to one of the preceding claims, characterized in that the panels (102) are guided in a printing unit (110) by guide elements (122). Method according to one of the preceding claims, characterized in that the decor suggestions stored in a data memory of an electronic data processing system (114) are optimized for the possible formats of the panels (102) to be printed. Method according to one of the preceding claims, characterized in that the structure in the at least one wear layer corresponds to the decor of the decor layer. Method according to one of the preceding claims, characterized in that the structure is embossed in step n ₃ ) by means of a structured roller, a structured tape, a structure generator paper or a structure generator film. Method according to one of the preceding claims, characterized in that the agent which interferes with the course of the lacquer is applied only to certain points of the panel by means of a digitally controlled print head in order to produce structure-forming depressions and elevations.

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