Wood fibre based panel with a surface layer

• US 10,100,535 B2
• Filed: 01/09/2015
• Issued: 10/16/2018
• Est. Priority Date: 01/10/2014
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Pervan, Darko, Ziegler, Goran
• Primary Examiner(s): Vonch, Jeffrey A
• Application Number:
  US14/593,521
• Publication Number:
  US 20150197942A1
• Time in Patent Office: 1,376 Days
• Field of Search: None
• CPC Class Codes: B27G 1/00 Machines or devices for removing knots or other irregularities or for filling-up holes filling up cracks or holes in a veneer cutting block B27L5/00; caulking decks B63B5/065
• CPC Class Codes: B27N 3/005 and foam
• CPC Class Codes: B27N 3/02 from particles
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B27N 3/08 Moulding or pressing presses in general B30B
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• 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 21/08 of synthetic resin
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2264/062 Cellulose particles, e.g. cotton
• CPC Class Codes: B32B 2266/0214 Materials belonging to B32B27/00
• CPC Class Codes: B32B 2266/0285 Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
• CPC Class Codes: B32B 2266/14 Adhesive foam
• CPC Class Codes: B32B 2305/073 partially
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2317/02 Cork
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 37/10 : characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/1284 : Application of adhesive
• CPC Class Codes: B32B 37/18 : involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 38/06 : Embossing
• CPC Class Codes: B32B 5/142 : Variation across the area of the layer
• CPC Class Codes: B44C 1/24 : Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: B44C 5/043 : containing wooden elements
• CPC Class Codes: B44C 5/0438 : containing stone elements
• CPC Class Codes: E04F 15/042 : the lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
• CPC Class Codes: E04F 15/045 : Layered panels only of wood
• CPC Class Codes: E04F 15/082 : with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass in combination with a lower layer of other material
• CPC Class Codes: E04F 15/085 : The lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24132 : including grain, strips, or filamentary elements in different layers or components parallel
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24314 : Slit or elongated
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24339 : Keyed
• CPC Class Codes: Y10T 428/24521 : with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/24603 : Fiber containing component
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24893 : including particulate material
• CPC Class Codes: Y10T 428/24992 : Density or compression of components
• CPC Class Codes: Y10T 428/249925 : Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
• CPC Class Codes: Y10T 428/24994 : Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/24995 : Two or more layers
• CPC Class Codes: Y10T 428/249959 : Void-containing component is wood or paper
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249985 : Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/249986 : Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/256 : Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/257 : Iron oxide or aluminum oxide
• CPC Class Codes: Y10T 428/3167 : Of cork
• CPC Class Codes: Y10T 428/31862 : Melamine-aldehyde
• CPC Class Codes: Y10T 428/31866 : Impregnated or coated cellulosic material
• CPC Class Codes: Y10T 428/31957 : Wood
• CPC Class Codes: Y10T 428/31989 : Of wood

Abstract

A building panel with a surface layer (1) including a wood veneer, a wood fibre based core (2) and a sub-layer (3) between the surface layer (1) and the core (2). The sub-layer (3) includes wood fibres (4) and a binder (5). The surface layer (1) has surface portions (6) including material from the sub-layer (3). The surface portions (6) including material from the sub-layer (3) extend into the wood veneer.

Claims

1. A building panel comprising:

a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,

a wood fibre based core, and

a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core,

wherein the sub-layer comprises wood fibres and a binder,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and

wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions.

2. The building panel as claimed in claim 1, wherein the surface portions comprising material from the sub-layer are flush with at least a portion of the surface layer.

3. The building panel as claimed in claim 1, wherein the sub-layer comprises colour pigments and/or a colorant.

4. The building panel as claimed in claim 1, wherein the sub-layer comprises wear resistant particles.

5. The building panel as claimed in claim 1, further comprising a powder-based balancing layer.

6. The building panel as claimed in claim 1, wherein the wood veneer comprises holes and/or cracks, wherein the sub-layer fills the holes and/or cracks of the wood veneer.

7. The building panel as claimed in claim 1, further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.

8. The building panel as claimed in claim 1, wherein the binder is liquid.

9. The building panel as claimed in claim 1, wherein the binder in the sub-layer is a thermosetting resin.

10. The building panel as claimed in claim 1, wherein the binder in the sub-layer is a melamine formaldehyde resin.

11. The building panel as claimed in claim 1, wherein the sub-layer comprises a foaming agent.

12. The building panel as claimed in claim 11, wherein the foaming agent includes a chemical blowing agent additive.

13. The building panel as claimed in claim 1, further comprising:

a second surface layer comprising a second wood veneer, the second surface layer being arranged on an opposite side of the core from the surface layer; and

a second sub-layer arranged between the second surface layer and the core,

wherein the second surface layer has surface portions comprising material from the second sub-layer extending into the second wood veneer.

14. A building panel comprising:

a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,

a wood fibre based core, and

a sub-layer arranged between the surface layer and the wood fibre based core,

wherein the sub-layer comprises wood fibres, a binder and colour pigments and/or a colorant,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and

wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the non-porous portions of the wood veneer form the protrusions by containing less of the binder than the porous portions.

15. The building panel as claimed in claim 14, further comprising a powder-based balancing layer.

16. The building panel as claimed in claim 15, further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.

17. A building panel comprising:

a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,

a wood fibre based core, and

a sub-layer arranged between the surface layer and the wood fibre based core,

wherein the sub-layer comprises wood fibres, a binder and wear resistant particles,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer,

wherein the binder is between 40-60 wt-% of the sub-layer, and

wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions.

18. The building panel as claimed in claim 17, wherein the binder is liquid.

19. The building panel as claimed in claim 17, wherein the sub-layer comprises a foaming agent.

20. The building panel as claimed in claim 17, further comprising a powder-based balancing layer.

21. The building panel as claimed in claim 20, further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.

22. A building panel comprising:

a surface layer comprising a wood veneer, the wood veneer comprising relatively high-density portions and relatively low-density portions,

a wood fibre based core, and

a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core,

wherein the sub-layer comprises wood fibres and a binder,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and

wherein the surface layer comprises embossed portions and protrusions, wherein the binder of the sub-layer bonds the relatively low-density portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the relatively high-density portions of the wood veneer in the compressed position so that the relatively high-density portions of the wood veneer form the protrusions.