WOOD FIBRE BASED PANELS WITH A THIN SURFACE LAYER

• US 20100092731A1
• Filed: 04/06/2009
• Published: 04/15/2010
• Est. Priority Date: 04/07/2008
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation Belgium BvbA
• Inventors: PERVAN, Darko, Håkansson, Niclas, Jacobsson, Jan, Lindgren, Kent, Boucké, Eddy, Ziegler, Göran
• Granted Patent: US 8,419,877 B2
• Time in Patent Office: Days
• US Class Current: 428/172
• CPC Class Codes: B27M 1/08 by multi-step processes
• 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: 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: 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 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 37/1027 Pressing using at least one press band
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 37/156 at least one layer is calendered and immediately laminated
• 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 38/06 Embossing
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: E04C 2/16 of fibres, chips, vegetable stems, or the like
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/30 : characterised by the shape or structure translucent E04C2/54
• CPC Class Codes: E04C 2002/005 : Appearance of panels
• CPC Class Codes: E04F 15/02 : Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/181 : Insulating layers integrally formed with the flooring or the flooring elements
• CPC Class Codes: E04F 2201/0138 : by moving the sheets, plates or panels perpendicular to the main plane
• CPC Class Codes: E04F 2201/0153 : by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• CPC Class Codes: E04F 2201/0541 : adapted to be moved along the joint edge
• CPC Class Codes: E04F 2290/042 : with a facing or top layer for sound insulation
• CPC Class Codes: Y10T 156/1002 : with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31989 : Of wood

Abstract

Building panels with a thin and embossed surface layer and a sub layer between a surface layer and a core.

Claims

1. A method of manufacturing a floor board (1) comprising a wood fibre based core (6), a thin surface layer (5) and a sub layer (6a) between the surface layer and the core, the sub layer comprises wood fibres (14) and a binder (19), wherein the method comprises the steps of:

mixing particles comprising wood fibres (14) and an uncured binder (19) for the sub layer (6a);

applying the wood fibres (14) and the uncured binder (19) for the sub layer on the core (6);

applying a surface layer (5) on the wood fibres (14) and the uncured binder (19); and

bringing the core (6), the surface layer (5), the wood fibres (14) and the uncured binder (19) under increased pressure and temperature and forming them into a floor board (1) by curing the binder (19).

2. The method as claimed in claim 1, wherein the method further comprises the step of pressing the surface layer 5) with an embossed pressing matrix (23) such that the surface layer (5) obtains upper portions (5a) and embossed portions (5b) lower than the upper portions essentially by shaping of the sublayer.

3. The method as claimed in claim 1, wherein the core (6) is HDF.

4. The method as claimed in claim 1, wherein the thin surface layer (5) has a thickness of about 0.3-1.0 mm.

5. The method as claimed in claim 1, wherein the binder (19) in the sub layer (6) is a thermosetting resin.

6. The method as claimed in claim 1, wherein the method further comprises applying water or a liquid resin on the core (6) or into the fibres (14) of the sub layer (6a) prior to pressing.

7. The method as claimed in claim 1, wherein the surface layer (5) comprises a homogenous mix of wood fibre particles (14), wear resistant particles (12), binders (19) and colour pigments (15).

8. The method as claimed in claim 7, wherein the wear resistant particles (12) comprise aluminum oxide.

9. The method as claimed in claim 1, wherein the surface layer (5) comprises a binder (19) of a thermosetting resin.

10. The method as claimed in claim 1, wherein the surface layer (5) comprises a binder (19) of a thermoplastic resin.

11. The method as claimed in claim 1, wherein the surface layer (5) is a printed paper (10) with an overlay (13).

12. The method as claimed in claim 1, wherein the surface layer (5) is a wood veneer.

13. The method as claimed in claim 1, wherein the method comprises a machining operation comprising forming the floor board to a floor panel (1) with mechanical locking systems (4, 4′

) at opposite edges.

14. The method as claimed in claim 1, wherein the step of applying the wood fibres and the binder is with a roller (53) comprising needles (62) or engraved protruding portions (63).

15. The method as claimed in claim 14, wherein the amount of needles (62) or the engraved protruding portions (63) is about 40-120 per cm².

16. A building panel comprising a thin surface layer (5), a wood fibre based core (6) and a sub layer (6a) between the surface layer (5) and the core (6), the sub layer (6a) comprises wood fibres (14) and a binder (19) wherein the sub layer (6a) comprises fibres with an average length (L2) which is shorter than the average length (L1) of the wood fibres in the core (6).

17. The building panel as claimed in claim 16, wherein the surface layer (5) comprises upper portions (5a) and embossed portions (5b) lower than the upper portions (5a) whereby a part of the sub layer (6a) is more compressed under an embossed portion (5b) than under an upper portion (5a).

18. The building panel as claimed in claim 16, wherein the average length (L2) of the fibres in the sub layer (6a) does not exceed 50% of the average length (L1) of the fibres in the core (6).

19. The building panel as claimed in claim 18, wherein the length (L2) of the fibres in the sub layer (6a) does not exceed 30% of the length (L1) of the fibres in the core (6).

20. The building panel as claimed in claim 16, wherein the building panel is a floor panel comprising a balancing layer (7).

21. The building panel as claimed in claim 16, wherein the binder (19) in the sub layer (6a) is a thermosetting resin.

22. The building panel as claimed in claim 21 wherein the binder (19) in the sub layer (6a) is a melamine resin.

23. The building panel as claimed in claim 16, wherein the binder (19) in the sub layer (6a) comprises a thermosetting resin.

24. The building panel as claimed in claim 16, wherein the core (6) comprises HDF.

25. The building panel as claimed in claim 16, wherein the thin surface layer (5) comprises a substantially homogenous mix of wood fibres (14), which comprise natural resins, a binder (19) and wear resistant particles (12).

26. The building panel as claimed in claim 25, wherein the wear resistant particles (12) comprise aluminum oxide.

27. The building panel as claimed in claim 26, wherein the surface layer (5) further comprises colour pigments (15) and a melamine resin.

28. The building panel as claimed in claim 16, wherein the surface layer (5) is a wood veneer.

29. The building panel as claimed in claim 16, wherein the surface layer (5) comprises a decorative paper (10) and an overlay (13).

30. The building panel as claimed in claim 17, wherein the surface layer (5) comprises a decorative paper (10) and an overlay (13) and the embossed portions (5b) comprise a part with an edge which is formed with an angle (A) exceeding 45 degrees to the horizontal plane (HP).

31. The building panel as claimed in claim 30, wherein the embossed portions (5b) comprise a part with a depth (D) that exceeds the thickness of the surface layer (5) and wherein the upper part of the core (6) is flat and essentially parallel with a horizontal plane (HP).

32. The building panel as claimed in claim 16, wherein the surface layer (5) comprises a foil comprising a thermoplastic resin.

33. The building panel as claimed in claim 16, wherein the surface layer has a thickness which does not exceed 1.0 mm.

34. The building panel as claimed in claim 16, wherein the sub layer comprises cork particles.

35. Floorboard production equipment (60) comprising a roller (53) with needles (62) or engraved protruding portions (63) and a brush (54) for applying dry materials comprising small wood fibres (14) and binders (19) on a board material (6).

36. The equipment as claimed in claim 35, wherein the amount of needles (62) or the engraved protruding portions (63) is more than about 20 pieces per cm².

37. The equipment as claimed in claim 35, wherein the amount of needles (62) or the engraved protruding portions (63) is about 40-120 pieces per cm₂.

38. The equipment as claimed in claim 35, wherein the dry materials comprise wear resistant particles (12) and colour pigments (15).

39. A building panel comprising a thin surface layer, a wood fiber core, and a sub layer between the surface layer and the core, the sub layer comprising wood fibers and a binder, wherein the sub layer is formed by applying loose wood fiber particles and an uncured binder on the wood fiber core, and the sub layer and the surface layer are connected to each other under heat and pressure so as to cure the binder in the sub layer.

40. A building panel comprising a thin surface layer, a wood fiber core, and a sub layer between the surface layer and the core, the sub layer comprising wood fibers and a binder, wherein the surface layer and sub layer are connected to each other under heat and pressure by curing scattered wood fiber particles of the sub layer.

41. A building panel comprising a thin surface layer, a wood fiber core, and a sub layer between the surface layer and the core, the sub layer comprising wood fibers and a binder, wherein the wood fibers of the sub layer are oriented randomly.

42. A building panel comprising a thin surface layer, a wood fiber core, and a sub layer between the surface layer and the core, the sub layer comprising wood fibers and a binder, wherein panel is formed by a method comprises the steps of:

mixing particles comprising loose wood fiber particles and an uncured binder for the sub layer;

applying the loose wood fiber particles and the uncured binder for the sub layer on the core;

applying a surface layer on the loose wood fiber particles and the uncured binder; and

bringing the core, the surface layer, the loose wood fiber particles and the uncured binder under increased pressure and temperature and forming them into a floor board by curing the binder.