EP3858639B1 - Method for producing panels - Google Patents

Description

The invention relates to a method for manufacturing panels.

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

The large-scale production of laminate panels includes a whole range of production steps that are largely the same for the different types of panels. First, a carrier board, for example made of a wood-based material such as MDF, HDF or OSB, is provided and this is coated with several layers of optionally different materials. A decorative layer is applied to an optionally pretreated surface of a wood-based material board that was provided as the core of the panel to be produced. This can be done, for example, in the form of a printed impregnated paper. The paper can also be printed directly onto the top of the wood-based panel. This can be done using printing rollers or a digital printer. Before the decoration is printed on, a primer layer can optionally also be applied to the surface of the wood-based panel be raised. This decor must be covered by at least one wear layer, particularly if the panel is to be used as a floor panel. This can consist of a paint or a synthetic resin, for example. Advantageously, abrasion-resistant particles (eg corundum) are added, which make the surface of the finished panel more resistant to the stresses of walking on it. The layer structure, optionally with several layers of synthetic resin, is finally 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-revealed. The still large-format, now coated wood-based panel is then divided into individual panels. After the 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 corresponding to the decor (embossed-in-register) into the upper side when the layer structure is pressed. The laminate panel is thus not only visually but also haptically more similar to a real wood panel, for example.

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

On the market for laminate panels, especially floor panels, there is a demand for more and more different decor variants. Not only new wood imitations are in demand, but also increasingly tile and stone decors as well as fantasy decors in a wide variety Shape. However, converting a large-scale production plant for laminate panels to a new decor is relatively cumbersome, time-consuming and therefore expensive. In addition, for example, in the event that the decor is placed on the wood-based material 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 decorative paper to be kept available.

If the decor is printed directly onto the wood-based panel, for example using printing rollers, a separate set of rollers must be kept available for each decor, and these rollers are particularly expensive to purchase. If a structure is to be embossed into the upper side, the press plates or press plates must also be engraved, which is expensive. In addition, the replacement of such press plates or press sheets takes time during which the production plant is idle, which increases the manufacturing costs for laminate panels.

For the above reasons, it only makes economic sense to produce relatively large quantities of laminate panels with a decor once selected, 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 order sizes requested can also be observed. However, if too small quantities of laminate panels with a specific decor are requested, they cannot be produced economically. As a result, individual orders have to be "collected" from retailers or wholesalers, resulting in long delivery times for the end customer, which the latter - especially in the do-it-yourself sector - does not accept. Part of the demand must therefore remain unsatisfied.

From the WO 2010/055429 A2 is a process for manufacturing a panel known with the features a) to f) of claim 1, in which a primer is first applied to the upper side of a large-format wood-based panel. The wood-based panel primed in this way is optionally pressed and then divided into individual panels. Only then are the individual panels printed with the desired decor.

The disadvantage is that although the production plant itself can be made smaller and more compact using the method described in the publication mentioned, since it is no longer the large-format wood-based panels that have to be printed, but rather smaller panels, generally no faster delivery times for small batch sizes with individual decors can be achieved . If a customer orders a small quantity of panels with a desired decor, for example from a panel dealer, the latter will collect the incoming orders until he has ordered 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 with large trucks, for example, which have to be fully utilized to a certain extent in order to be able to work economically. Through that in the WO 2010/055429 A2 Although the process described can increase the economic efficiency of the production process by using smaller systems, flexibility, particularly with regard to the rapid delivery of small and very small batch sizes with individual decorations, is not achieved.

The problem to be solved according to the invention is therefore that, given 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 requirements within a reasonable delivery time, unless a minimum lot size is required, and that even if the minimum batch size is reached (e.g. in the property sector, i.e. the furnishing of large offices or hotels), a longer delivery time is accepted because of course the panel manufacturer's system first has to 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 broken and the retailer, who receives 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 with 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 provide them with a decoration according to the customer's wishes, so that even the smallest order sizes are flexible can be produced economically and at the same time the storage and material costs are reduced.

1. a) Bereitstellen einer großformatigen 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 (24) und Beschichtung unter Druck- und gegebenenfalls Temperatureinfluss, wobei
5. e) Aufteilen der grundierten und beschichteten 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 in dem weiterverarbeitenden Betrieb mit folgenden weiteren Schritten:

• i) Auspacken eines Paneels aus der transportsicheren Verpackung,
• j) Auswählen eines speziellen Dekors aus einer Vielzahl von abgelegten Dekoren oder eines individuell vorliegenden Dekors,
• k) Auswählen einer definierten Anzahl von Paneelen, die mit dem Dekor bedruckt werden sollen,
• l) Aufbringen einer Dekorschicht mit dem ausgewählten Dekor und Aufbringen mindestens einer Nutzschicht auf die Dekorschicht auf jedes einzelne Paneel, wobei
• m) das Aufbringen der Dekorschicht und der wenigstens einen Nutzschicht durch folgende Schritte geschieht:
  • m₁) Bereitstellen der wenigstens einen Nutzschicht auf einem Trägermedium,
  • m₂) Aufdrucken der Dekorschicht auf die wenigstens eine Nutzschicht,
  • m₃) Auflegen des Schichtaufbaus aus dem Trägermedium, wenigstens einer Nutzschicht und Dekorschicht auf die Grundierung oder den Primer, sodass die Dekorschicht auf der Grundierung oder dem Primer angeordnet wird,
  • m₄) Verpressen des Schichtaufbaus mit dem Paneel,
  • m₅) Entfernen des Trägermediums, und
• n) zur Strukturierung der Paneele entweder:
  • n₁) ein Relief in die Holzwerkstoffplatte eingeprägt wird,und/oder
  • n₂) beim Verpressen in Schritt d) eine Struktur in die Grundierung eingeprägt wird, und/oder
  • n₃) beim Verpressen in Schritt m₄) eine Struktur in die wenigstens eine Nutzschicht eingeprägt wird, oder
  • n₄) die wenigstens eine Nutzschicht aus wenigstens einer strukturbildenden Lackschicht besteht, über die beim Aushärten eine Struktur eingebracht wird, oder
  • n₅) in mindestens eine Lackschicht den Verlauf des Lackes störende Mittel eingebracht werden, oder
  • n₆) mittels eines digital angesteuerten Druckkopfes eine strukturbildende Menge Lack nur an bestimmten Stellen der Oberfläche des Paneels angebracht wird, um so strukturbildende Erhöhungen und Vertiefungen zu erzeugen.

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

1. a) providing a large-format wood-based panel,
2. b) applying a primer in the form of a synthetic resin layer to at least one upper side of the wood-based panel,
3. c) application of a coating to an underside of the wood-based panel opposite the top side of the wood-based panel,
4. d) pressing of the layer structure made of wood-based panel, primer (24) and coating under the influence of pressure and optionally temperature, wherein
5. e) dividing the primed and coated wood-based panel into individual panels,
6. f) machining of side faces of the panels to Working on connecting and locking devices,
7. g) safe transport packaging of the primed panels,
8. h) Delivery of the ready-primed panels in transport-safe packaging to a processing company,

and subsequent finishing of a panel in the processing plant with the following further 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 to be printed with the decor,
• l) applying a decorative layer with the selected decor and applying at least one wear layer to the decorative layer on each 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 useful layer on a carrier medium,
  • m ₂ ) printing the decorative layer onto the at least one wear layer,
  • m ₃ ) placing the layer structure made 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 of the layer structure with the panel,
  • m ₅ ) removing the carrier medium, and
• n) to structure the panels either:
  • n ₁ ) a relief is embossed into the wood-based panel, and/or
  • n ₂ ) during pressing in step d) a structure in the primer is impressed, and/or
  • n ₃ ) during pressing in step m ₄ ) a structure is embossed into the at least one wear layer, 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, or
  • n ₅ ) in at least one coat of paint the leveling of the paint disturbing agents are introduced, or
  • n ₆ ) a structure-forming amount of paint is applied only to certain points on the surface of the panel by means of a digitally controlled print head, in order to produce structure-forming elevations and depressions.

This process first creates a semi-finished product that is not marketable on its own. However, the dealer can buy semi-finished products according to his needs and store them at his premises. 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 for being used as wall, ceiling or floor panels. However, since there is no wear layer on the surface of the panels, the panels are largely exposed to the stresses, especially when used as floor panels, without any protection. They also have no decoration. The primed raw panels, which are also created using the method described, differ from finished panels only by the lack of a decorative layer and the lack of at least one wear layer. The end customer can choose a decor and color for the panels from the retailer, who then prints the individual pre-assembled panels and seals the decor. This allows us to react extremely flexibly to customer requests, because the decor depends on the grain (wood decor) as well as its color can be combined in any way. 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 retailer can reduce his inventory of panels because he can fulfill every customer request immediately.

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

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

It has turned out 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. To improve the adhesion of the paint to be applied later on the primer, a primer can also be applied to the primer.

Advantageously, the connecting and locking means are milled out of the panel. The panels are preferably cleaned before they are packed for safe 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 with the Core are pressed, wherein a coating is applied to the underside and mutually corresponding connecting and locking devices are provided on opposite side surfaces of the panel.

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 lightness parameter L for the color of an upper side of the panel in the CIELAB color space is greater than 92 and a red-green value A is 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 DIN 6174 standard serves as the normative basis for this color space.

The top of the panel has a texture. The connecting and locking devices are designed in one piece with the wood-based panel. Particularly preferably, mutually corresponding connecting and locking means are 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 cheaper. For this purpose, it is planned that only primed panels will be manufactured as semi-finished products in the context of large-scale production. These have a core made of wood material, which can be designed as OSB, MDF or HDF, for example. This is 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 printed later. The primer in the form of a synthetic resin layer can be applied to the wood-based material core 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 upper side, or in the form of a finish film which is laminated on, for example, with an adhesive that can contain synthetic resin. All of these applied primers 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 upper side of the wood-based panel. This can, for example, take on the function of a countermove. This is particularly necessary if, during drying of the applied primer, 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 the wood-based panel is effectively prevented from buckling or cupping.

If the primer is applied, for example, in the form of a coated film that has already fully cured, it may not be necessary to apply a balancing sheet. The coating applied to the underside can then, for example, prevent the absorption of moisture into the underside of the wood-based panel or can only be for visual reasons. The acceptance of a panel on the market by the end consumer can be increased in particular by the fact that the wood-based material board acting as the core can no longer be seen on the underside of the panel, which is no longer visible when laid.

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 happen under the influence of pressure and temperature. This is particularly necessary when at least one of the applied layers should connect with the wood-based material core. If the primer is laminated on in the form of a fully cured foil, pressing under pressure is sufficient.

After the layer structure has been pressed, the still large-format, coated and pressed wood-based panel is divided into individual panels. Lateral 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 more complicated profiles with which a 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 attached to the side edges of panels, into which separate connecting elements, which can be made of plastic, for example, can be 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, in such a way that two identical panels can be connected and locked to one another 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 to ensure the highest possible quality of the primed panels.

Since the laminate manufacturer now only produces primed panels to which no decorative layer has to be applied, both the storage and the material costs are reduced for the laminate manufacturer. There is no need to stock decorative papers in different decors or to provide embossing rollers or embossing plates in order to be able to produce panels with different decors. This significantly reduces both the storage space required and the tied-up capital. In addition, changeover times are eliminated since 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 colored in particular. In this case, in particular, several colors are possible, examples being white or beige. In this case, for example, colored papers are used as the printing basis, the color of which corresponds to the lightest shade in 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. However, any other color is also conceivable as a primer. In order to achieve special effects when subsequently printing panels that have been pre-primed in this way, a structure can already be introduced into the primer. This is advantageously done when the layer structure is pressed, in particular by means of embossing plates or embossing rollers used in the process.

Overall, however, pre-primed panels produced in this way have a very smooth surface. 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 using a digital printer. A colored wood-based panel can at least partially assume the function of a primer.

Due to the very low surface roughness of the upper side of the panel, which is less than 20 μm, for example, and particularly preferably even less than 10 μm, a very good print image is achieved during subsequent printing. ISO 4287-1 is mainly used as the test standard for surface roughness. If the wood-based panel or the primer is stained, the following applies to the Color advantageously that a lightness 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 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 shade 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 of course appropriate.

Such pre-primed panels are stored by 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 further processing plant without the panels having to be cleaned again there. However, this only has to be provided for a single type of panel, so that space-consuming 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 further processing company. This can be, for example, a franchise operation associated with the laminate manufacturer, a hardware store, an interior decorator, dealer or a floor installer.

Here the pre-primed panels are unpacked from the transport-safe packaging. Then a decorative layer with a decoration according to the customer's direct request is applied to the base coat or the primer and covered by at least one wear layer.

Applying the decorative layer to the base coat or primer can happen in different ways.

The decorative layer can in particular be printed directly onto the base coat 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. Due to the fact that only individual panels have to be printed and not, as is usual in the prior art, entire large-format wood-based material panels, the printing unit can be designed to be small and compact and therefore space-saving and cost-effective. 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 base coat or the 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 heavily on the planned place of use 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 wipe-proof manner. However, if the printed panels are used as floor panels, they are exposed to significantly higher loads. In this case, in particular, multiple wear layers can be applied, to which additives are added that increase the abrasion and/or scratch resistance of the upper side of the panels that are then finished.

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

Alternatively, the at least one wear layer can also be in the form of at least one lacquer layer, which then hardens 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 means of high-energy radiation and by pressing, a walkable surface of the panel can be ensured in particular. This happens in particular 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 paint and then cured in the further processing operation, for example in a hardware store. This requires a relatively high outlay in terms of equipment, which, in addition to an increased space requirement, also entails relatively high investment costs. In addition, it may be necessary to use specialist personnel to operate a device for carrying out the process steps required in further processing, in particular when coating with synthetic resin or paint.

The decorative layer and the at least one wear layer can therefore be applied to the preprimed panel in a particularly simple manner using the following method steps. The at least one wear layer is provided on a carrier medium, for example a film. If several useful layers are required, they are located in reverse order on the carrier medium. The wear layer, which is to form the upper side of the finished panel, is therefore located directly on the carrier medium and is covered by the wear layers that lie underneath it in the finished panel. When processing During operation, different layer structures of this at least one useful layer are kept on the carrier medium. The wear layer, which is intended to cover the decorative layer in the finished panel, is therefore 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 base coat or the primer in such a way that the decoration now rests directly on the base coat or the primer and is covered by the at least one wear layer. The carrier medium, for example the carrier foil, is located at the 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 fully cured, exposure to an increased temperature influence is unnecessary.

The carrier medium is then removed and the decorative layer and the at least one wear layer remain on the base coat or the primer. In this way it is possible to finish the primed panel without applying liquid resins and varnishes that still have to be hardened. This significantly reduces both the outlay on equipment and the investment volume. In this configuration, too, a structure can be embossed into the at least one wear layer when the layer structure is pressed, which structure corresponds in particular to the decoration of the decorative 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 base coat or the primer, the decorative paper or the carrier medium coated with the at least one wear layer in basically any desired color and grain and also a 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 controller that is set up to read the selected decoration from the data memory and to control the printing unit so that the selected decoration is printed. In a particularly convenient manner for the customer, this device also includes a display device, via which the available decorations are displayed to the user.

In concrete terms, such a method can proceed 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 finished as described above, he can view various decors that are available to choose from. These decorations are stored in the form of electronic data in a data memory within the device. Alternatively, the device could also have a drive, for example for a CD, DVD or the like. The customer can then also bring along a corresponding data medium on which decors 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 now applied to a pre-primed, profiled panel and this is covered with the combination of wear layers found necessary. After this has hardened If necessary, the customer can receive and use the panels printed with his individual decor.

If he notices that he has not had enough panels printed or that it becomes necessary, for example, to replace individual panels that have become worn over time, it is possible at any time to reorder individual panels using a device described.

This significantly increases flexibility in the production of laminate panels and even the smallest application quantities with a wide variety of decors can be produced in an economically viable manner.

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 figure 1 manufactured panel with an enlarged section thereof, 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 plant.

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

The process 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-sized wood-based panel 1 is prepared for carrying out the process. Within this pretreatment device 2, for example, an upper side of the wood-based panel 1 can be sanded, or the surface can be smoothed in some other way. The wood-based panel 1 is prepared so that a layer of material can be applied to the top. For this purpose, the wood-based panel 1 can be additionally cleaned and/or heated in the pre-treatment device 2, for example. In addition, quality assurance can take place 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 pre-treatment device 2 , it is fed to a priming device 4 . In the priming device 4, a primer in the form of a layer of synthetic resin is applied to the upper side of the wood-based panel 1. This can be done, for example, by applying a liquid synthetic resin layer or in the form of resin-impregnated paper. Alternatively, for example, a foil that is coated in particular with a synthetic resin can be glued to 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 figure 1 shown embodiment of a drying device 6 is supplied. Here, if necessary, the primer applied to the upper side of the wood-based panel 1 in the primer device 4 is dried in the form of a layer of synthetic resin.

The coated wood-based panel 1 then runs through in figure 1 Method shown 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 a press, for example a belt press, are also conceivable. In particular, if in the priming device 4 the primer is applied in the form of a synthetic resin layer, for example by means of a film, already fully cured, pressing under the influence of pressure without increased temperature may also be sufficient.

The primed wood-based material boards 1 pressed in the short-cycle press 8 then run through a cutting device 10 in which the large-format wood-based material board 1 is divided into smaller panels 12 . On the side edges of the panels 12 profiles are then processed, the one Allow two identical panels 12 to be joined together. In this case, longitudinal profiles are first 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 faces.

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 primed panels, which have been provided with fasteners, then go through quality assurance 18 before they are packed in a packing station 20 to be 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 material board 1 . In order to be able to emboss a relief into the wood-based panel 1, the wood-based panel 1 can in particular be sprayed with water in the priming device 4 before the primer is applied. An exemplary method is in the DE 10 2008 008 240 been described.

figure 2 shows a section along de line AA figure 1 by a pre-primed panel 12, and an enlarged detail thereof. The panel 12 includes a core 22 to which a primer 24 has been applied. The upper side 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 further processing company, for example a franchisee associated with the laminate manufacturer, a hardware store or the like. The direction of processing 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 figure 3 In the exemplary embodiment of the method shown, the panels 102 are then fed to a cleaning device 106 in which the surface of the panels 102 is cleaned of any adhering dirt residue and dust and is thus prepared for the application of the decorative layer. However, it is also conceivable that the panels 102 were suitably cleaned for subsequent printing at the laminate manufacturer's plant. These can then be cleaned and placed in the transport-safe packaging 104 . For example, by sealing the transport pack 104 airtight 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 optionally passed through the cleaning device 106, they are aligned on an acceleration section 108 and spaced apart from one another by 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, the printing unit 110 in in figure 3 embodiment shown three print heads 112. Depending on the desired decor, 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, via 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 select the decor they would like printed on their panels.

in figure 3 In the exemplary embodiment shown, the electronic data processing device 114 also has a scanner 118. If a user of the device for finishing 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 applied to the top of the panel via the printheads 112 of the printing unit 110. The user is thus no longer restricted to the pattern selection stored in the electronic data processing device 114 .

In addition, the electronic data processing device 114 has in figure 3 shown embodiment via a camera 120. This camera 120 makes it possible, for example, to photograph decors of surfaces that the customer has brought along, for example, but which cannot be scanned, and thus 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 . A CD-ROM drive can also be provided, for example, via which the customer can have a decoration stored on a CD-ROM in a defined format read into the data processing device 114 .

So that the panels 102 remain precisely 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 device described, which were 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 decoration selection stored in the data memory of the electronic data processing device 114 can be updated online in particular.

After the upper side 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 figure 3 The exemplary embodiment illustrated includes these three application devices 126, via each of which a wear layer can be applied to the upper side of the panel. The application devices 126 are controlled by a second electronic data processing device 128 . This has a mixing program that controls the composition of the individual wear layers. The second electronic data processing device 128 can control different reservoirs 130 and mix their contents to form the desired wear layer. One of these reservoirs 130 contains the base material for each individual wear layer, which can be a synthetic resin or a paint, for example. The other reservoirs 130 contain, for example, hardeners, corundum to increase the abrasion resistance of the finished coated panel and other 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 inside the coating device 124, the panels 102 to be coated are guided via guide elements 122. A possible layer structure consists of several layers of radiation-curable lacquer. In this case, for example, two layers of an anti-abrasive UV base coat are applied with a roller system in an application quantity 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 coat have been applied, two further layers of a UV base coat 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 abrasive base coat. Finally, a further application device 126 is used to apply a layer of a UV top coat in an application quantity of, for example, 35 g/m ² . If necessary, before each coat of lacquer is applied, the previously applied coat of lacquer is cured by means of UV or electron beams. in the in figure 3 In the exemplary embodiments shown, the various wear layers, which in particular can 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. Feed speeds between 10 m/min and 30 m/min are particularly suitable here.

If paint layers are applied as useful layers by the application devices 126 in the coating device 124, these application devices 126 can also be designed in the form of a spray painting or spray painting device, a digital print head, a casting head or a vacuum device be. Abrasion-resistant particles, for example corundum, or other additives can be contained in each applied layer. 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 figure 3 In the exemplary embodiment shown, the wear layers applied in the coating device 124, which can be in the form of a paint, for example, are only gelled by high-energy rays, for example electrons or UV rays. A structure is then embossed in an embossing device 134 into the upper side of the coated panel, ie 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 belt or a structure-providing paper or a structure-providing film.

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

In particular when using paints as wear layers, a structure-forming amount of paint can also be applied by means of a digitally controlled print head, for example. Alternatively, an agent that disrupts the flow of the paint is also conceivable. 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 paint only at specific 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 upper side corresponds to the decoration of the decorative layer, the panel 102 must be aligned before passing through the embossing device 134 . in figure 3 In the exemplary embodiment illustrated, the panel 102 passes through a second curing device 136 after passing through the embossing device 134. Here the wear layers that may have gelled are completely cured, so that a surface suitable for the selected use of the panel 102 is produced.

The panels 102 then go through quality assurance 138, possibly 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 options in the further processing operation, for example by means of a program. He can choose, for example, whether the panel 102 is to be used privately or commercially, in dry or wet areas, with information on different commercial use 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 wear layers to be applied in the coating device 124 . In a device for finishing a panel, the wear layers required to achieve a specific wear class, for example AC3 according to DIN EN 13329, are then automatically applied with the necessary additives and additives. Coating and curing take place automatically.

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

Further choices for the customer are, for example, the choice of a specific packaging. For example, the panels can simply be placed in a cardboard box or packaged in a way that protects them against splashing water using a film, for example a shrink film. In addition, the customer can decide, for example, whether he wants to take the finished panels with him straight away or pick them up himself at a later date, 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, possibly for a surcharge, and decide whether to buy or rent the panels.

Within a system for finishing a panel according to the method described, the painting and the hardening of the layers of paint can take place automatically. Since the paints 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 guaranteed without more or less paint applications at the beginning and at the end of the panels 102 to be coated. In order to protect the connecting and locking elements already formed on the panels 102, masks can be used which prevent these connecting and locking elements from getting dirty or contaminated. In particular, when applied paint layers are curing, 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, ie coating device 124 and first curing device 132 and second curing device 136, can be run through several times.

For optimal use of such a system, several orders can be produced directly 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 or processed in some other way in this process, the milling waste that occurs 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, transport damage or transmission errors in orders are significantly reduced by the method described, 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.

Reference list:

1

wood-based panel

2

pre-treatment device

4

priming facility

6

drying device

8th

short-cycle press

10

cutting device

12

panel

14

first milling device

16

second milling device

18

quality assurance

20

packing station

22

core

24

primer

26

relief

28

structure

102

panel

104

safe transport packaging

106

cleaning device

108

acceleration track

110

printing unit

112

printhead

114

electronic data processing device

116

display device

118

scanner

120

camera

122

guide element

124

coating device

126

application device

128

second electronic data processing device

130

reservoir

132

first curing device

134

embossing device

136

second curing device

138

quality assurance

140

labeling

Claims (15)

1. A method for producing packaged, primed panels as semi-finished products at a laminate producer with the subsequent finishing of the primed panels comprising the following steps in the order below:

   a) providing a large-size wood-based material panel (1)

   b) applying a primer coating (24) in the form of a synthetic resin layer to at least one upper side of the wood-based material panel (1),

   c) applying a coating to a lower side of the wood-based material panel (1) opposite the upper side of the wood-based material panel (1),

   d) pressing the layered structure made up of wood-based material panel (1), primer coating (24) and coating under the influence of pressure and, where appropriate, temperature, wherein

   e) division of the primed and coated wood-based material panel (1) into individual panels (12),

   f) machining of lateral surfaces of the panels (12) for the preparation of bonding and sealing agents,

   g) transport-safe packing of the primed panels (12),

   h) delivery of the ready-primed panels in the transport-safe packaging to a further processing facility,

   and the subsequent finishing of a panel at the further processing facility comprises the following steps:

   i) unpacking a panel from the transport-safe packaging,

   j) selecting a particular decorative pattern from a range of stored decorative patterns or an individually available decorative pattern,

   k) selecting a defined number of panels onto which the decorative pattern is to be printed,

   l) applying a decorative layer with the selected decorative pattern and applying at least one use-surface to the decorative layer on each individual panel, wherein

   m) the application of the decorative layer and the at least one use-surface is carried out by way of the following steps:

   m₁) providing the at least one use-surface on a carrier medium,

   m₂) printing the decorative layer onto the at least one use-surface,

   m₃) placing the layered structure made up of the carrier medium, at least one use-surface and decorative layer onto the primer coating or the primer, so that the decorative layer is arranged on the primer coating or the primer,

   m₄) pressing the layered structure with the panel,

   m₅) removing the carrier medium, and

   n) for structuring the panels (12) either:

   n₁) embossing a relief into the wood-based material panel (1) and/or

   n₂) during the pressing in step d), embossing a structure (28) into the primer coating (24) and/or

   n₃) during the pressing in step m⁴, embossing a structure into the at least one use-surface or

   n₄) the at least one use-surface being composed of at least one structural paint layer via which a structure is introduced during curing or

   n₅) introducing agents that disrupt the spreading of the paint into at least one paint layer, or

   n₆) by means of a digitally controlled button, applying a structural quantity of paint only at certain points on the surface of the panel so as to create structural elevations and depressions.
2. The method according to claim 1, characterised in that the primer coating (24) is applied in the form of a resin-impregnated paper to the upper side of the wood-based material panel (1).
3. The method according to claim 1, characterised in that the primer coating (24) is a synthetic resin applied directly to the upper surface of the wood-based material panel (1).
4. The method according to claim 1, characterised in that the primer coating (24) is glued to the upper side of the wood-based material panel (1) in the form of a film.
5. The method according to one of the preceding claims, characterised in that the wood-based material panel (1) is heated in a pre-treatment facility (2) before a material layer is applied to the upper side.
6. The method according to one of the preceding claims, characterised in that the primer coating (24) is dyed.
7. The method according to one of the preceding claims, characterised in that a primer is applied to the primer coating (24).
8. The method according to one of the preceding claims, characterised in that the bonding and sealing agents are milled out of the panel (12).
9. The method according to one of the preceding claims, characterised in that a relief is embossed into the wood-based material panel (1).
10. The method according to one of the preceding claims, characterised in that the panels (12) are cleaned before transport-safe packing in order to prepare them for the subsequent printing process.
11. The method according to one of the preceding claims, characterised in that the panels (102) are guided in a printing unit (110) by guide elements (122).
12. The method according to one of the preceding claims, characterised in that the decorative pattern suggestions stored in a memory of an electronic data processing device (114) are optimised to the possible formats of the panels to be printed (102).
13. The method according to one of the preceding claims, characterised in that the structure in the at least one use-surface corresponds to the decorative pattern of the decorative pattern layer.
14. The method according to one of the preceding claims, characterised in that the structure in step n₃) is embossed by means of a structured roller, a structured belt, a structural paper or a structural film.
15. The method according to one of the preceding claims, characterised in that the agent that disrupts the spreading of the paint is only applied at certain points on the panel by means of a digitally controlled button in order to generate structural depressions and elevations.

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