Powder based balancing layer

• US 10,214,913 B2
• Filed: 06/12/2015
• Issued: 02/26/2019
• Est. Priority Date: 04/12/2011
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Persson, Hans, Hakansson, Niclas, Jacobsson, Jan
• Primary Examiner(s): Ahmed, Sheeba
• Application Number:
  US14/738,274
• Publication Number:
  US 20150275526A1
• Time in Patent Office: 1,355 Days
• Field of Search: None
• CPC Class Codes: B05D 1/00 Processes for applying liquids or other fluent materials B05D5/00, B05D7/00 take precedence
• CPC Class Codes: B27K 2200/10 Articles made of particles or fibres consisting of wood or other lignocellulosic material
• CPC Class Codes: B27K 3/15 Impregnating involving polymerisation including use of polymer-containing impregnating agents macromolecular compounds derived from lignocellulosic materials C08H; compositions of lignin-containing materials C08L97/02
• CPC Class Codes: B27K 5/02 Staining or dyeing wood wood staining compositions C09D15/00; Bleaching wood bleaching wood pulp D21C9/10
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B27N 3/06 Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
• 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 21/042 of wood B32B21/13 takes precedence
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/24 Organic non-macromolecular coating
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2305/07 Parts immersed or impregnated in a matrix
• CPC Class Codes: B32B 2305/20 in the form of a non-woven mat
• CPC Class Codes: B32B 2305/30 Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• CPC Class Codes: B32B 2305/70 Scrap or recycled material
• CPC Class Codes: B32B 2310/0825 using IR radiation
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• 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 37/24 : with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 38/145 : Printing
• CPC Class Codes: C08J 2397/02 : Lignocellulosic material, e.g. wood, straw or bagasse
• CPC Class Codes: C08J 2461/28 : with melamine
• CPC Class Codes: C08J 2497/02 : Lignocellulosic material, e.g. wood, straw or bagasse
• CPC Class Codes: C08J 7/042 : with two or more layers, where at least one layer of a composition contains a polymer binder
• CPC Class Codes: C09D 161/28 : with melamine
• CPC Class Codes: C09D 5/033 : characterised by the additives
• CPC Class Codes: C09D 7/70 : characterised by shape, e.g. fibres, flakes or microspheres
• CPC Class Codes: D21H 27/00 : Special paper not otherwise provided for, e.g. made by multi-step processes
• CPC Class Codes: D21H 27/18 : Paper- or board-based structures for surface covering
• CPC Class Codes: E04F 13/0866 : composed of several layers, e.g. sandwich panels or layered panels layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence
• CPC Class Codes: E04F 13/10 : of wood or with an outer layer of wood E04F13/0864 takes precedence
• CPC Class Codes: E04F 15/04 : only of wood or with a top layer of wood, e.g. with wooden or metal connecting members rollable parquet E04F15/16
• CPC Class Codes: E04F 15/045 : Layered panels only of wood
• CPC Class Codes: Y10T 428/31982 : Wood or paper

Abstract

A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method includes applying a first layer of a first powder based mix, including wood fibers and a thermosetting binder, on a core; applying a liquid substance on the first powder based mix; drying the first powder based mix; turning the core with the dried first powder based mix such that the first powder based mix points downwards; applying a second layer on the upper part of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel.

Claims

1. A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method comprises the steps:

applying a first layer of a first powder based mix, comprising wood fibres and a thermosetting binder, on a core;

applying a liquid substance on the first powder based mix;

drying the first powder based mix;

turning the core with the dried first powder based mix such that the first powder based mix points downwards and an upper part of the core faces upwards;

applying a second layer on the upper part of the core; and

curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel.

2. The method as claimed in claim 1, wherein the building panel is a floor panel.

3. The method as claimed in claim 1, wherein the core is a HDF or MDF board.

4. The method as claimed in claim 1, wherein the step of applying said second layer comprises applying a veneer layer.

5. The method as claimed in claim 1, wherein the step of applying said second layer comprises applying a first paper sheet.

6. The method as claimed in claim 5, wherein the step of applying said second layer further comprising applying a second paper sheet.

7. The method as claimed in claim 6, wherein the step of applying said first and second paper sheets comprises arranging said first paper sheet such that the fibre direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fibre direction of the second paper sheet is extending in a second direction, said second direction being transverse to the first direction.

8. The method as claimed in claim 1, wherein the step of applying the second layer comprises applying a second powder based mix comprising wood fibres, binders, and wear resistant particles.

9. The method as claimed in claim 8, wherein the method comprises the further step of applying a print or a colour substance into the second mix.

22. The method as claimed in claim 1, wherein the step of applying the first layer of the first powder based mix is done by scattering.

23. The method as claimed in claim 1, wherein the step of drying the first powder based mix comprises applying heat, the heat being applied before the step of turning the core.

24. The method as claimed in claim 1, wherein the wood fibres of the first powder mixture possesses a moisture content of between 3-8 weight-%.

25. The method as claimed in claim 1, wherein a stabilization device applies the liquid substance on the first powder based mix.

26. The method as claimed in claim 25, wherein the stabilization device uses at least one of steam, nozzle spray coating, and ultrasonic coating to apply the liquid substance on the first powder mixture.

27. The method as claimed in claim 1, wherein the liquid substance further comprises an additive, the additive comprising at least one of a wetting agent, a release agent, a defoamer, an anti-slip agent, and a catalyst.

10. A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method comprises the steps of:

applying a first layer of a first powder based mix, comprising wood fibres and a thermosetting binder, on a carrier;

applying a liquid substance on the first powder based mix;

placing a lower surface of the core on the first powder based mix after the liquid substance has been applied on the first powder based mix;

applying a second layer on an upper surface of the core; and

curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer of the building panel.

11. The method as claimed in claim 10, wherein the building panel is a floor panel.

12. The method as claimed in claim 10, wherein the core is a HDF or MDF board.

13. The method as claimed in claim 10, wherein the carrier is a fibre based material.

14. The method as claimed in claim 10, wherein the step of applying said second layer comprises applying a veneer layer.

15. The method as claimed in claim 10, wherein the step of applying said second layer comprises applying a first paper sheet.

16. The method as claimed in claim 15, wherein the step of applying said second layer further comprising applying a second paper sheet.

17. The method as claimed in claim 16, wherein the step of applying said first and second paper sheet comprises arranging said first paper sheet such that the fibre direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fibre direction of the second paper sheet is extending in a second direction, said second direction being transverse to the first direction.

18. The method as claimed in claim 10, wherein the step of applying said second layer comprises applying a second powder based mix comprising wood fibres, binders, and wear resistant particles.

21. The method as claimed in claim 10, wherein the carrier is of a thin material with a thickness that does not exceed the thickness of the decorative surface layer.

19. A method of manufacturing a separate and continuous powder based balancing and/or protective layer, which is essentially uncured, wherein the method comprises the steps of:

applying a powder mix, comprising fibres and a thermosetting binder, on a carrier;

applying moisture on the powder mix such that the powder mix is connected together to form an uncured balancing and/or protective layer; and

releasing the uncured balancing and/or protective layer from the carrier.

20. The method as claimed in claim 19, wherein the fibres are wood fibres and the binder a melamine resin.

28. A method of manufacturing a building panel comprising the steps, performed in order, of:

applying a first layer of a first powder based mix comprising wood fibres and a thermosetting binder on a first surface of a core, the core possessing a second surface positioned opposite the first surface of the core;

applying a liquid substance on the first powder based mix;

drying the first powder based mix;

turning the core with the dried first powder based mix such that the first surface with the first powder based mix points downwards and the second surface of the core faces upwards;

applying a second layer on the second surface of the core; and

curing the first and second layers by providing heat and pressure to form the building panel, wherein the first layer forms a balancing and/or protective layer connected to the first surface of the core and the second layer forms a decorative surface layer connected to the second surface of the core.