Panel coating

• US 10,017,950 B2
• Filed: 08/23/2012
• Issued: 07/10/2018
• Est. Priority Date: 08/26/2011
• Status: Active Grant

• Current Assignee: Ceraloc Innovation Ab (Pervan Holding AB)
• Original Assignee: Ceraloc Innovation Ab (Pervan Holding AB)
• Inventors: Pervan, Darko
• Primary Examiner(s): Mazumdar, Sonya
• Application Number:
  US14/237,617
• Publication Number:
  US 20140186610A1
• Time in Patent Office: 2,147 Days
• CPC Class Codes: B27M 3/04 of flooring elements, e.g. parqueting blocks assembling wooden elements on backings of other substances B32B, e.g. B32B21/042, E04F15/16; furniture joints F16B12/00
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/06 of paper or cardboard
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/12 on paper layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2310/0825 using IR radiation
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 29/002 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 37/10 : characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 38/06 : Embossing
• CPC Class Codes: B32B 38/08 : Impregnating
• CPC Class Codes: B32B 38/145 : Printing
• CPC Class Codes: E04F 13/165 : with an outer layer imitating natural stone, brick work, tiled surface or the like
• CPC Class Codes: E04F 15/102 : of fibrous or chipped materials, e.g. bonded with synthetic resins
• CPC Class Codes: E04F 15/107 : composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04
• CPC Class Codes: Y10T 428/249925 : Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]

Abstract

The disclosure relates to a method for coating of a floor panel and a floor panel produced by the method. The disclosure relates to a method for producing a laminated product, for example a building panel, preferably a floor panel. The method comprises applying a paper on one side of a wood fiber based core, e.g. an HDF panel, creating a décor on the paper by a digital printing process, applying a resin, preferably a melamine formaldehyde resin, on the paper, heating the décor and the paper with the resin, preferably by using an IR lamp; and applying heat and pressure in order to cure the resin and thereby obtain a laminated product. The disclosure also relates to alternative methods for producing a laminated product, and such a laminated product.

Claims

1. A method for producing a laminated building panel, wherein the method comprises:

applying a paper on one side of a wood fiber based core,

after applying the paper on the core creating a dé

cor on the paper by a digital printing process while paper is on core,

applying a resin in powder form on the paper;

heating the dé

cor and the paper with the resin; and

applying heat and pressure in order to cure the resin and thereby obtain a laminated product.

2. The method as claimed in claim 1, wherein the method further comprises applying a powder based sub layer on the core before the paper is applied on the core, said powder based sub layer comprising wood fibers and a powder resin.

3. The method as claimed in claim 2, wherein the method further comprises applying moisture on the powder based sub layer and thereafter applying heat in order to dry the powder based sub layer.

4. The method as claimed in claim 1, wherein the method further comprises:

applying a liquid resin on the core; and

drying the liquid resin before the paper is applied on the core.

5. The method as claimed in claim 1, wherein the method further comprises applying moisture on the resin, where the resin is in powder form.

6. The method as claimed in claim 1, wherein the method further comprises applying wear resistant particles on the paper before the heating of the dé

cor and the paper with the resin.

7. The method as claimed in claim 1, wherein the method further comprises applying cellulose fibers on the paper, before the heating of the dé

cor and the paper with the resin.

8. The method as claimed in claim 1, wherein the method further comprises applying a balancing layer on an opposite side of the core, before the applying of heat and pressure, to obtain a balancing layer.

9. The method as claimed in claim 8, wherein the balancing layer is a powder layer comprising wood fibers and a resin or the balancing layer is a paper.

10. The method as claimed in claim 2, wherein the paper is a thin raw paper with a weight of about 40-60 g/m².

11. The method as claimed in claim 2, wherein the paper is a thin raw paper with a weight of about 40-50 g/m².

12. The method as claimed in claim 1, wherein a digital non-contact process is used comprising a Piezo print head that applies water based drops.

13. The method as claimed in claim 12, wherein color pigments are applied in a separate step in dry form and bonded by the water based drops.

14. The method as claimed in claim 1, wherein the heating of the dé

cor and the paper is performed by an IR lamp prior to the applying of heat and pressure to cure the resin.

15. The method as claimed in claim 1, wherein the paper is a raw paper when the paper is applied on the one side of the wood fiber based core and when the dé

cor is created on the paper by the digital printing process.

16. The method as claimed in claim 1, wherein

the paper, the resin, and the dé

cor on the one side of the wood fibre based core possess a thickness, and

the thickness of the paper, the resin, and the dé

cor on the one side of the wood fibre based core after the applying of the heat and pressure is less than 80% of the thickness of the paper, the resin, and the dé

cor on the one side of the wood fiber based core before the applying of the heat and pressure.

17. The method as claimed in claim 16, wherein the thickness of the paper, the resin, and the dé

cor on the one side of the wood fiber based core after the applying of the heat and pressure is less than 50% of the thickness of the paper, the resin, and the dé

cor on the one side of the wood fiber based core before the applying of the heat and pressure.

18. A method for producing a laminated building panel, wherein the method comprises:

applying a powder based sub layer comprising wood fibers and a thermosetting resin on a wood fiber based core,

applying a raw paper on the powder based sub layer,

applying a powder comprising a melamine formaldehyde resin and aluminum oxide on said raw paper to form a protective overlay on said raw paper;

applying heat and pressure in order to impregnate the raw paper, to cure the resin and thereby obtain a laminated product.

19. The method as claimed in claim 18, wherein a powder based balancing layer comprising wood fibers and a thermosetting resin is applied on a rear side of the core.

20. The method as claimed in claim 18, wherein a paper overlay is applied directly on top of the powder protective overlay before the applying of the heat and pressure.

21. A method for producing a laminated building panel, wherein the method comprises:

applying a paper on one side of a wood fiber based core, the paper being unimpregnated when the paper is applied on the core;

digitally printing a dé

cor directly onto the paper using a digital printer while paper is on the core;

applying a resin directly on the paper while the paper is on the core and the paper remains unimpregnated;

heating the paper, the dé

cor, and the resin while the paper, the dé

cor, and the resin are on the core; and

simultaneously applying heat and pressure to cure the resin and thereby obtain a laminated product, the simultaneously applying heat and pressure being after the heating of the paper, the dé

cor and the resin.