RECYCLING OF LAMINATE FLOORINGS

• US 20100291397A1
• Filed: 11/13/2008
• Published: 11/18/2010
• Est. Priority Date: 11/19/2007
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation Belgium BvbA
• Inventors: Boucké, Eddy, Pervan, Darko, Håkansson, Niclas, Jacobsson, Jan, Lindgren, Kent, Ziegler, Göran
• Granted Patent: US 8,349,235 B2
• Time in Patent Office: Days
• US Class Current: 428/524
• CPC Class Codes: B27N 3/007 and at least partly composed of recycled material
• CPC Class Codes: B27N 3/02 from particles
• 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 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 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/06 Vegetal particles
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2264/12 Mixture of at least two particles made of different materials
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary 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 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 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B44C 5/0415 : containing metallic elements
• CPC Class Codes: B44C 5/043 : containing wooden elements
• CPC Class Codes: B44C 5/0469 : comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
• CPC Class Codes: E04B 5/00 : Floors; Floor construction with regard to insulation; Connections specially adapted therefor elements for floors, e.g. bricks, stones, filling bodies, girders, E04C; flooring as finishing work, insulation of flooring, sectional false floors, e.g. for computers E04F15/00
• CPC Class Codes: E04C 2/24 : laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
• CPC Class Codes: E04C 2/243 : one at least of the material being insulating
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/38 : with attached ribs, flanges, or the like, e.g. framed panels concerned with attaching to other panels or elements to form a structure, see the places for the relevant structure, e.g. E04B2/00
• 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 15/102 : 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: Y10S 264/913 : From fiber or filament, or fiber or filament containing article or product, e.g. textile, cloth fabric, carpet, fiberboard
• CPC Class Codes: Y10S 264/914 : From cellulose containing articles, e.g. paper
• CPC Class Codes: Y10T 428/24994 : Fiber embedded in or on the surface of a polymeric matrix
• 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 428/31942 : Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31989 : Of wood

Abstract

Recycling of laminate flooring based on a separation of the panels into particles which are connected with a binder and formed to a new sheet shaped material. A building panel includes a surface layer and a wood fiber based core, and the wood fiber based core includes aluminium oxide particles.

Claims

1. A building panel with a surface layer and a wood fibre based core wherein the core comprises aluminium oxide particles.

2. The building panel as claimed in claim 1, wherein the core further comprises particles of paper impregnated with a melamine resin.

3. A building panel as claimed in claim 1, wherein the building panel is a floor panel with a surface layer.

4. A building panel as claimed in claim 3, wherein the floor panel comprises a balancing layer.

9. A building panel as claimed in claim 2, wherein the building panel is a floor panel with a surface layer.

5. A method to recycle laminate floor panels comprising a wood fibre based core, a decorative surface layer comprising a thermosetting resin and aluminium oxide wherein the method comprises the steps of:

d) mechanical cutting of the panel into particles

e) mixing said particles with a binder

f) pressing the mixed particles and binder and thereby forming a sheet shaped material.

6. The method as claimed in claim 5, wherein the pressing is made under heat.

7. The method as claimed in claim 5 wherein the method comprises mixing said particles with a melamine formaldehyde resin.

8. The method as claimed in claim 5, wherein the method comprises the step of separating particles essentially into a first set of particles comprising substantially wood fibres and a second set of particles comprising substantially melamine before mixing at least the first set of elements with a binder.

10. The method as claimed in claim 6 wherein the method comprises mixing said particles with a melamine formaldehyde resin.

11. The method as claimed in claim 6, wherein the method comprises the step of separating particles essentially into a first set of particles comprising substantially wood fibres and a second set of particles comprising substantially melamine before mixing at least the first set of elements with a binder.

12. The method as claimed in claim 7, wherein the method comprises the step of separating particles essentially into a first set of particles comprising substantially wood fibres and a second set of particles comprising substantially melamine before mixing at least the first set of elements with a binder.