# US 11,440,341 B2 · Method for producing an abrasion-resistant wood board > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,440,341 B2 - Document ID: US11440341B2 - Status: Granted - Kind: B2 - Application number: 17/424,696 - Filed: 2020-01-08 - Published: 2022-03-31 - Granted: 2022-09-13 - Earliest claimed: 2019-01-22 - Assignees: Flooring Technologies Ltd. - Applicants: Flooring Technologies Ltd. - Inventors: Christoph Schumacher; Stefan Zick - Web page: https://patentgrep.com/patent/US11440341B2 ## CPC - B44C 5/0476: {with abrasion resistant properties} - B05D 7/584: {at least some layers being let to dry, at least partially, before applying the next layer (B05D7/587 takes precedence)} - B44C 5/0407: {containing glass elements} - B44C 5/0492: {containing wooden elements} - B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)} - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) ## Abstract A method for producing an abrasion-resistant wood-based panel having a top side and a bottom side, with at least one decorative layer arranged on the top side, in particular with a structure synchronous with the decoration, is disclosed herein. ## Claims ### Claim 1 A method for producing an abrasion-resistant wood-based panel with an upper side and a bottom side, with at least one decorative layer arranged on the top side, the method comprising the steps of: applying at least one first resin layer to the at least one decorative layer on the upper side of the wood-based panel, wherein the first resin layer has a solids content of between 60 and 80% by weight; even scattering of abrasion-resistant particles on the at least one first resin layer on the upper side of the wood-based panel; applying at least one second resin layer to the at least one first resin layer provided with the abrasion-resistant particles on the upper side of the wood-based panel, the second resin layer having a solids content of between 60 and 80% by weight; subsequent drying of the structure consisting of the at least one first resin layer and the at least one second resin layer in at least one drying device; applying at least a third resin layer, wherein the third resin layer has a solids content between 60 and 80% by weight, and contains glass beads; subsequent drying of the applied at least one third resin layer in at least one further drying device; applying at least one fourth resin layer, wherein the fourth resin layer has a solids content of between 50 and 70% by weight, and contains glass beads; subsequent drying of the applied at least one fourth resin layer in at least one further drying device; applying at least a fifth resin layer, wherein the fifth resin layer has a solids content of between 50 and 70% by weight, and contains glass beads; subsequent drying of the applied at least one fifth resin layer in at least one further drying device; applying at least one sixth resin layer, wherein the sixth resin layer has a solids content of between 50 and 70% by weight and does not contain glass beads; subsequent drying of the applied at least one sixth resin layer in at least one further drying device; and pressing of the layer structure in a short-cycle press, wherein the at least one first resin layer on the upper side of the wood-based panel with the abrasion-resistant particles is not dried after application. ### Claim 2 (depends on 1) The method according to claim 1, wherein the wood-based panel provided with the decorative layer is not heated in a dryer before the application of the at least one first resin layer. ### Claim 3 (depends on 1) The method according to claim 1, wherein the resin layers are based on aqueous formaldehyde-containing resins. ### Claim 4 (depends on 1) The method according to claim 1, wherein the at least one first resin layer contains cellulose fibres or wood fibres. ### Claim 5 (depends on 1) The method according to claim 1, wherein the amount of scattered abrasion-resistant particles is 10 to 50 g/m2. ### Claim 6 (depends on 1) The method according to claim 1, wherein the at least one second resin layer to be applied to the upper side of the wood-based panel does not contain glass beads. ### Claim 7 (depends on 1) The method according to claim 1, wherein the glass beads have a diameter of 90 to 150 μm. ### Claim 8 (depends on 1) The method according to claim 1, wherein the total thickness of the applied resin layers is between 60 and 200 μm. ### Claim 9 (depends on 1) The method according to claim 1, wherein the addition of a hardener to the respective resin to be applied is only carried out at the respective application device for the resin. ### Claim 10 (depends on 1) The method according to claim 1, wherein the drying of the resin layers takes place at dryer temperatures between 150 and 220° C. in a convection dryer. ### Claim 11 (depends on 1) The method according to claim 1, wherein the pressing of the layered structure is carried out under the influence of pressure and temperature in the short-cycle press at temperatures between 150 and 250° C. and at a pressure between 30 and 60 kg/cm2. ### Claim 12 (depends on 1) The method according to claim 1, wherein the coated wood-based panel is aligned in the short-cycle press to a structured press plate located in the short-cycle press by means of markings on the wood-based panel and a congruence is established between the decoration on the wood-based panel and the structure of the press plate to be embossed. ### Claim 13 (depends on 1) A wood-based panel made according to the method of claim 1, comprising a layer structure, when viewed from bottom to top, the layer structure comprises: a backing layer of six resin layers; a wood-based panel; a primer layer; a print decoration layer; a first resin layer with cellulose fibers; a layer of abrasion-resistant particles; a second resin layer; a third resin layer with glass beads; a fourth resin layer with glass beads; a fifth resin layer with glass beads; and a sixth resin layer without glass beads; wherein the layer structure has a total layer thickness between 120 and 200 μm. ### Claim 14 (depends on 3) The method according to claim 3, wherein the resin layers are based on melamine formaldehyde resin, urea formaldehyde resin, or melamine urea formaldehyde resin. ### Claim 15 (depends on 5) The method according to claim 5, wherein the amount of scattered abrasion-resistant particles is 10 to 30 g/m2. ### Claim 16 (depends on 15) The method according to claim 15, wherein the amount of scattered abrasion-resistant particles is 15 to 25 g/m2. ### Claim 17 (depends on 8) The method according to claim 8, wherein the total thickness of the applied resin layers is between 90 and 150 μm. ### Claim 18 (depends on 17) The method according to claim 17, wherein the total thickness of the applied resin layers is between 100 and 120 μm. ### Claim 19 (depends on 10) The method according to claim 10, wherein the drying of the resin layers takes place at dryer temperatures between 180 and 210° C. ### Claim 20 (depends on 11) The method according to claim 11, wherein the temperatures in the short-cycle press are between 180 and 230° C.