FIBRE BASED PANELS WITH A WEAR RESISTANCE SURFACE

• US 20100300030A1
• Filed: 11/13/2008
• Published: 12/02/2010
• Est. Priority Date: 11/19/2007
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation Belgium BvbA
• Inventors: Hakansson, Niclas, Pervan, Darko, Jacobsson, Jan, Lindgren, Kent, Boucké, Eddy, Ziegler, Göran
• Granted Patent: US 8,431,054 B2
• Time in Patent Office: Days
• US Class Current: 52/588.1
• CPC Class Codes: B27N 3/00 Manufacture of substantially flat articles, e.g. boards, from particles or 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: B30B 15/062 Press plates
• CPC Class Codes: B30B 3/005 Roll constructions
• 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 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 21/13 all layers being exclusively wood
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/025 Particulate layer
• 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 2262/10 Inorganic fibres
• CPC Class Codes: B32B 2264/02 Synthetic macromolecular particles
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• 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 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/75 : Printability
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2479/00 : Furniture
• CPC Class Codes: B32B 2607/00 : Walls, panels
• 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 3/30 : 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 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/06 : permitting easy separation
• CPC Class Codes: B32B 9/02 : comprising animal or vegetable substances , e.g. cork, bamboo, starch
• CPC Class Codes: B44C 5/0476 : with abrasion resistant properties
• CPC Class Codes: B44C 5/0484 : containing metallic elements
• CPC Class Codes: B44C 5/0492 : containing wooden elements
• 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: 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: Y10T 428/249925 : Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]

Abstract

Building panels with a homogenous decorative surface having a wear layer including fibres, binders and wear resistant particles.

Claims

1. A building panel comprising a surface layer and a core, the core comprises wood fibres, characterised in that the surface layer comprises a substantially homogenous mix of wood fibres, which comprise natural resins, a binder and wear resistant particles.

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

3. The building panel as claimed in claim 2, wherein the binder is a thermosetting or thermoplastic resin.

4. The building panel as claimed in claim 3 wherein the binder is a thermosetting resin.

5. The building panel as claimed in claim 4, wherein the wear resistant particles comprise aluminium oxide.

6. The building panel as claimed in claim 5, wherein the core is a board, wherein the surface layer further comprises colour pigments and wherein the wood fibres in the surface layer comprise fibres of the same material type as in the core.

7. The building panel as claimed in claim 4, wherein the binder comprises a melamine resin.

8. The building panel as claimed in claim 7 wherein the wear resistant particles are bonded to the wood fibres with the melamine resin.

9. The building panel as claimed in claim 5, wherein the surface layer comprises a vertical portion with three horizontal planes extending parallel with the main plane of the panel wherein a first upper plane located in an upper part of the surface layer comprises a first aluminium oxide particle, a second intermediate plane located under the first aluminium oxide particle comprising wood and a third lower plane under the second plane comprising a second aluminium oxide particle and wherein the second aluminium oxide particle is in direct contact with an upper part of the core.

10. The building panel as claimed in claim 5, wherein the weight content of the aluminium oxide particles in the surface layer is in the range of about 5% to about 30% of the total weight of the surface layer.

11. The building panel as claimed in claim 5, wherein the weight content of the aluminium oxide particles in the surface layer is at least 100 gr/m2.

12. The building panel as claimed in claim 1, wherein the core is HDF.

13. The building panel as claimed in claim 1, wherein the core is a particleboard.

14. The building panel as claimed in claim 1, wherein the surface layer further comprises a print that extends into the surface below the upper wear resistant particles.

15. The building panel as claimed in claim 1, wherein the surface layer comprises brushed portions with different fibre structures.

16. The building panel as claimed in claim 1, wherein the surface layer comprises brushed portions with different wear resistance.

17. The building panel as claimed in claim 1, wherein the surface layer comprises wood fibres that are unrefined and comprise lignin.

18. The building panel as claimed in claim 1, wherein the surface layer wood fibres are essentially smaller than 1 mm.

19. The building panel as claimed in claim 1, wherein the surface layer comprises wood fibres in powder form which are essentially smaller than 0.5 mm.

20. The building panel as claimed in claim 1, wherein a panel edge comprises a mechanical locking system for locking of the panel with similar other panels and wherein such locking system is formed in the core.

21. A building panel comprising a surface layer connected to a core, the core comprising wood fibres, characterised in that the surface layer is a homogenous layer comprising parts of fibres, colour pigments, binders and wear resistant particles.

22. The building panel as claimed in claim 21, wherein all parts of the surface layer are present at the outer surface of the surface layer and at an inner lower part, which is connected to the core.

23. The building panel as claimed in claim 21, wherein the panel is a floor panel comprising a balancing layer.

24. The building panel as claimed in claim 21, wherein the binder is a thermosetting resin.

25. The building panel as claimed in claim 24, wherein the binder comprises a melamine resin.

27. The building panel as claimed in claim 21, wherein the binder is a thermoplastic resin.

28. The building panel as claimed in claimed in claim 21, wherein the wear resistant particles comprise aluminium oxide.

29. The building panel as claimed in claim 28, wherein the surface layer comprises a vertical portion with three horizontal planes extending parallel with the main plane of the panel wherein a first upper plane located in an upper part of the surface layer comprises a first aluminium oxide particle, a second intermediate plane located under the first aluminium oxide particle comprising fibre and a third lower plane under the second plane comprising a second aluminium oxide particle and wherein the second aluminium oxide particle particle is in direct contact with an upper part of the core.

30. The building panel as claimed in claim 28, wherein the weight content of the aluminium oxide particles in the surface layer is in the range of about 5% to about 30% of the total weight of the surface layer.

31. The building panel as claimed in claim 28, wherein the weight content of the aluminium oxide particles in the surface layer is at least 100 gr/m2.

32. The building panel as claimed in claim 21, wherein the core is HDF.

33. The building panel as claimed in claim 21, wherein the core is a particleboard.

34. The building panel as claimed in claim 21, wherein the surface layer further comprises a print that extends into the surface below upper wear resistant particles.

35. The building panel as claimed in claim 21, wherein the surface layer comprises brushed portions with different fibre structures.

36. The building panel as claimed in claim 21, wherein the surface layer comprises brushed portions with different wear resistance.

37. The building panel as claimed in claim 21, wherein the surface layer comprises mineral fibres.

38. The building panel as claimed in claim 21, wherein the surface layer comprises wood fibres that are essentially smaller than 1 mm.

39. The building panel as claimed in claim 21, wherein the surface layer comprises wood fibres in powder form and essentially smaller than 0.5 mm.

40. The building panel as claimed in claim 21, wherein a panel edge comprises a mechanical locking system for locking of the panel with similar other panels and wherein such locking system is formed in the core.

26. The building panel as claimed in claim 26, wherein the wear resistant particles are bonded to the fibres with the melamine resin.

41. A method of manufacturing a building panel comprising the steps of:

mixing particles comprising fibres or fibres with binders, colour pigments and small wear resistant particles; and

bringing the particles or the fibres, the colour pigments, the binder and the small wear resistant particles under high pressure and temperature and forming them to a building panel.

42. The method as claimed in claim 41, wherein the panel is a floor panel.

43. The method as claimed in claim 41, wherein the fibres are wood fibres.

44. The method as claimed in claim 41, wherein the binder is a thermoplastic resin.

45. The method as claimed in claim 41, wherein the binder is a thermosetting resin.

46. The method as claimed in claim 41, wherein the small hard particles comprise aluminium oxide.

47. The method as claimed in claim 41, wherein the method further comprises the step of applying the mixed particles on a core comprising a wood fibre based board.

48. The method as claimed in claim 47, wherein the wood fibre based board is HDF.

49. The method as claimed in claim 47, wherein the wood fibre based board is a particleboard.

50. The method as claimed in claim 41, wherein the method further comprises a pre pressing prior to the final pressing.

51. The method as claimed in claim 41, wherein the method further comprises a printing operation prior to the final pressing.

52. The method as claimed in claim 41, wherein the method comprises a machining operation comprising forming the building panel to a floor panel with mechanical locking systems at opposite edges.

53. A method as claimed in claim 41, wherein the method further comprises the steps of:

arranging the particles on a core layer comprising wood fibres and a binder;

arranging said core layer on a balancing layer comprising wood fibres and a binder; and

applying heat and pressure to the three layers comprising the particles, the core and the balancing layer.

54. The method as claimed in claim 53 wherein the method comprises applying a balancing layer that has a higher density than the core layer.

55. The method as claimed in claim 53, wherein the binder is a thermosetting resin and the wear resistant particles comprise aluminium oxide.

56. The method as claimed in claim 56, wherein the wood fibres, the binder, the colour pigments and the wear resistant particles are in dry form.

57. A building panel comprising a surface layer and a core, wherein the surface layer is a homogenous layer comprising cork particles, a binder and wear resistant particles of aluminium oxide.

58. The building panel as claimed in claim 57, wherein the core comprises wood fibres or cork particles.

59. The building panel as claimed in claim 57, wherein the panel is a floor panel.

60. The building panel as claimed in claim 59, wherein the core comprises cork particles and a binder of a thermosetting resin and wherein the majority of the cork particles in the panel are smaller then 1.0 mm, and that the density of the panel exceeds 600 kg/m3.

61. A method of manufacturing floor panels with a decorative surface layer comprising the steps of:

providing first and second original floorboards with different designs or structures;

separating the original floorboards into a first type of floor elements;

connecting the first type of floor elements to a combi floorboard that comprise at least one floor element of the first and second original floorboards;

separating the combi floorboard into a second type of combi floor elements, which comprises surface portions of the first and second original floorboards; and

forming a mechanical locking system on at least two opposite edges of the second type of combi floor elements.

62. The method as claimed in claim 61, wherein the surface layer comprises a homogenous layer of fibres, binders, colour pigments and wear resistant particles.

63. The method as claimed in claim 61, wherein the floor panel is a laminate floor panel.