Floor, wall, or ceiling panel and method for producing same

• US 10,442,164 B2
• Filed: 03/27/2014
• Issued: 10/15/2019
• Est. Priority Date: 11/27/2013
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Schulte, Guido
• Primary Examiner(s): Gray, Linda L
• Application Number:
  US15/039,638
• Publication Number:
  US 20170120564A1
• Time in Patent Office: 2,028 Days
• Field of Search: None
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 13/10 of wood; of wood particle board
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 19/042 of wood
• CPC Class Codes: B32B 19/045 of synthetic resin
• CPC Class Codes: B32B 19/046 of paper or cardboard
• 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 21/06 of paper or cardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 21/12 next to a particulate layer
• CPC Class Codes: B32B 21/13 all layers being exclusively wood
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/026 Wood layer
• CPC Class Codes: B32B 2260/028 : Paper layer
• CPC Class Codes: B32B 2260/044 : Water-setting substance, e.g. concrete, plaster
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2262/065 : Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2262/067 : Wood fibres
• CPC Class Codes: B32B 2264/065 : Lignocellulosic particles, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/4026 : within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/406 : Bright, glossy, shiny surface
• CPC Class Codes: B32B 2307/412 : Transparent
• CPC Class Codes: B32B 2307/536 : Hardness
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/75 : Printability
• CPC Class Codes: B32B 2317/16 : Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2419/04 : Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/14 : next to a particulate layer
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 29/04 : next to a particulate layer
• 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 3/26 : characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• 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 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/1292 : selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B32B 38/06 : Embossing
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 9/045 : being laminated
• CPC Class Codes: E04F 13/10 : of wood or with an outer layer of wood E04F13/0864 takes precedence
• CPC Class Codes: E04F 13/16 : of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• 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: F16D 65/0978 : acting on one pad only
• CPC Class Codes: Y10T 156/1062 : Prior to assembly
• CPC Class Codes: Y10T 156/1066 : Cutting to shape joining edge surfaces only
• CPC Class Codes: Y10T 156/1075 : of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1079 : Joining of cut laminae end-to-end

Abstract

A floor, wall, or ceiling panel has a base made of a wood material and an upper veneer. The base and the veneer are hot-pressed together while incorporating a resin layer. During the pressing process, pores, cracks, and/or gaps in the veneer are filled with resin. In particular, the pressing process is carried out such that the veneer is saturated with resin, and the resin can be seen on the surface of the veneer after the pressing process The adhesion of the veneer to the base and the smoothing of the veneer are thus carried out in one operation.

Claims

1. A method for producing panels, said method comprising:

providing a basic carrier plate, the basic carrier plate comprising a top surface and a bottom surface;

providing a veneer, the veneer possessing pores, cracks, and/or gaps;

applying a resin layer on the top surface of the basic carrier plate, the resin layer being applied as a powder;

forming a multilayer body comprising the basic carrier plate, the veneer, the resin layer interposed between the basic carrier plate and the veneer, and a balancing layer arranged on the bottom surface of the basic carrier plate;

joining the basic carrier plate, the resin layer, the veneer, and the balancing layer by pressing the multilayer body in a press, wherein a pressing pressure, a pressing temperature and a pressing time are adjusted so that during the pressing of the multilayer body in the press, the pores, the cracks, and/or the gaps in the veneer are filled with resin from the resin layer

separating the pressed multilayer body into individual panels; and

profiling the panels at side borders of the panels and providing the panels with joining means,

wherein the pressing of the multilayer body is carried out so that the resin permeates through the veneer so that after the pressing the resin is visible at a surface of the veneer.

2. The method of claim 1, wherein the resin layer is formed by a polymer resin or a urea formaldehyde condensation product.

3. The method of claim 2, wherein

the press comprises a press plate, and

the press plate is heated to a temperature of between 100°

C. and 140°

C. during the pressing in the press.

4. The method of claim 1, wherein the resin layer comprises wood fibers admixed to the powder.

5. The method of claim 1, further comprising printing a decor on the veneer.

6. The method of claim 1, further comprising applying a sealing to the veneer.

7. The method of claim 1, further comprising after the pressing, subjecting the veneer to a mechanical surface processing comprising a grinding process and/or a brushing process.

8. The method of claim 1, further comprising embossing a texture into the veneer during the pressing in the press.

9. The method of claim 1, wherein the base carrier plate is rectangular with a length of 2,000 mm to 5,000 mm and a width of 1,200 mm to 2,100 mm.

10. The method of claim 1, wherein the pressing comprising simultaneously subjecting the multilayer body to a temperature of between 100°

C. and 140°

C.

11. The method of claim 1, wherein

the press comprises a press plate,

the resin of the resin layer is a thermosetting resin, and

the press plate is heated to a temperature of between 180°

C. and 210°

C. during the pressing in the press.

12. The method of claim 1, wherein the resin of the resin layer is a polyvinyl acetate.

13. The method according to claim 1, wherein the pressing is performed at greater than or equal to 3500 kPA for between 10 seconds and 60 seconds.

14. The method according to claim 1, further comprising cooling the multilayer body to room temperature before separating the multilayer body into the individual panels.

15. The method according to claim 1, wherein the balancing layer is a second veneer.

16. The method according to claim 1, further comprising providing a circumferential chamfer at a top border of the panels after the separating of the pressed multilayer body into individual panels.

17. The method according to claim 1, wherein the basic carrier plate has a thickness of between 5 mm and 12 mm, and the veneer has a thickness of between 0.6 mm and 1.2 mm.

18. The method according to claim 1, wherein

the resin layer comprises wood fibers, and

the wood fibers and the resin fill the pores, the cracks, and/or the gaps in the veneer during the pressing.

19. A method for producing panels, said method comprising:

providing a basic carrier plate, the basic carrier plate comprising a top surface and a bottom surface;

providing a veneer, the veneer being a single wood component, the veneer possessing pores, cracks, and/or gaps;

applying a resin layer on the top surface of the basic carrier plate;

forming a multilayer body comprising the basic carrier plate, the single veneer, the resin layer interposed between the basic carrier plate and the single veneer, and a balancing layer arranged on the bottom surface of the basic carrier plate;

joining the basic carrier plate, the resin layer, the veneer, and the balancing layer by pressing the multilayer body in a press, wherein a pressing pressure, a pressing temperature and a pressing time are adjusted so that during the pressing of the multilayer body in the press, the pores, the cracks, and/or the gaps in the veneer are filled with resin from the resin layer

separating the pressed multilayer body into individual panels; and

profiling the panels at side borders of the panels and providing the panels with joining means,

wherein the pressing of the multilayer body is carried out so that the resin permeates through the veneer so that after the pressing the resin is visible at a surface of the veneer,

wherein the resin layer is applied as a watery resin solution,

wherein the watery resin solution consists of two weight parts of resin powder and one weight part of water.

20. A method for producing panels, said method comprising:

providing a basic carrier plate, the basic carrier plate comprising a top surface and a bottom surface;

providing a veneer, the veneer possessing pores, cracks, and/or gaps;

applying a resin layer on the top surface of the basic carrier plate;

forming a multilayer body comprising the basic carrier plate, the veneer, the resin layer interposed between the basic carrier plate and the veneer, and a balancing layer arranged on the bottom surface of the basic carrier plate;

joining the basic carrier plate, the resin layer, the veneer, and the balancing layer by pressing the multilayer body in a press, wherein a pressing pressure, a pressing temperature and a pressing time are adjusted so that during the pressing of the multilayer body in the press, the pores, the cracks, and/or the gaps in the veneer are filled with resin from the resin layer

separating the pressed multilayer body into individual panels; and

profiling the panels at side borders of the panels and providing the panels with joining means,

wherein the pressing of the multilayer body is carried out so that the resin permeates through the veneer so that after the pressing the resin is visible at a surface of the veneer, and

wherein the pressing is performed at greater than or equal to 1000 kPA for between 10 seconds and 60 seconds.

21. A method for producing panels, said method comprising:

providing a basic carrier plate, the basic carrier plate comprising a top surface and a bottom surface;

providing a veneer, the veneer possessing pores, cracks, and/or gaps;

applying a resin layer on the top surface of the basic carrier plate;

forming a multilayer body comprising the basic carrier plate, the veneer, the resin layer interposed between the basic carrier plate and the veneer, and a balancing layer arranged on the bottom surface of the basic carrier plate;

joining the basic carrier plate, the resin layer, the veneer, and the balancing layer by pressing the multilayer body in a press, wherein a pressing pressure, a pressing temperature and a pressing time are adjusted so that during the pressing of the multilayer body in the press, the pores, the cracks, and/or the gaps in the veneer are filled with resin from the resin layer

separating the pressed multilayer body into individual panels; and

profiling the panels at side borders of the panels and providing the panels with joining means, wherein

the pressing of the multilayer body is carried out so that the resin permeates through the veneer so that after the pressing the resin is visible at a surface of the veneer,

the resin layer is applied on the top surface of the basic carrier plate in liquid form, and

the applying of the resin layer comprises partially drying the resin layer to adhere the resin layer to the basic carrier plate as a gel or wax layer.

22. A method for producing panels, said method comprising:

providing a basic carrier plate, the basic carrier plate comprising a top surface and a bottom surface;

providing a veneer, the veneer possessing pores, cracks, and/or gaps;

applying a resin layer on the top surface of the basic carrier plate;

forming a multilayer body comprising the basic carrier plate, the single veneer, the resin layer interposed between the basic carrier plate and the single veneer, and a balancing layer arranged on the bottom surface of the basic carrier plate;

joining the basic carrier plate, the resin layer, the veneer, and the balancing layer by pressing the multilayer body in a press, wherein a pressing pressure, a pressing temperature and a pressing time are adjusted so that during the pressing of the multilayer body in the press, the pores, the cracks, and/or the gaps in the veneer are filled with resin from the resin layer

separating the pressed multilayer body into individual panels; and

profiling the panels at side borders of the panels and providing the panels with joining means, wherein

the pressing of the multilayer body is carried out so that the resin permeates through the veneer so that after the pressing the resin is visible at a surface of the veneer,

the press comprises a press plate, and

the press plate is heated to a temperature of between 180°

C. and 210°

C. during the pressing in the press.

23. The method of claim 22, wherein the resin layer is formed by a resin film.

24. The method of claim 22, wherein the resin layer is applied as a liquid, pasty film, and wherein color pigments and wood based fillers are added to the resin.