Panel, Use of a Panel, Method for Manufacturing a Panel and a Prepreg

• US 20100323187A1
• Filed: 06/15/2010
• Published: 12/23/2010
• Est. Priority Date: 06/17/2009
• Status: Abandoned Application

• Current Assignee: Valinge Innovation AB
• Original Assignee: Flooring Technologies Ltd
• Inventors: Kalwa, Norbert
• Application Number:
  US12/815,757
• Publication Number:
  US 20100323187A1
• Time in Patent Office: Days
• US Class Current: 428/325
• CPC Class Codes: B32B 2037/243 Coating
• 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 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 33/00 Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• 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 38/145 Printing
• CPC Class Codes: B44C 5/0476 with abrasion resistant properties
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31942 : Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate
• CPC Class Codes: Y10T 428/31978 : Cellulosic next to another cellulosic
• CPC Class Codes: Y10T 428/31982 : Wood or paper

Abstract

Described are panels including a surface layer on a substrate. The surface layer includes a) cellulose fibers, b) at least one binder and (c) wear resistant particles. The use of different panels and a method for manufacturing is also described.

Claims

1. A panel comprising a surface layer on a substrate, wherein

the surface layer comprises

(a) cellulose fibers,

(b) at least one binder, and

(c) wear resistant particles.

2. The panel according to claim 1, wherein the cellulose fibers, the at least one binder and the wear resistant particles are present in one mixture on the substrate.

3. The panel according to claim 1, wherein the cellulose fibers are at least partially bleached.

4. The panel according to claim 1, wherein the at least partially bleached cellulose fibres have a white grade measured according to Berger of more than 80.

5. The panel according to claim 1, wherein the light fastness according to grey wool scale EN 20 105 of the surface layer is higher than 2.

6. The panel according to claim 1, wherein the surface layer comprises pigments.

7. The panel according to claim 1, wherein the binder comprises melamine resin, acrylate resin and/or polyurethane resin.

8. The panel according to claim 1, wherein the wear resistant particles are at least one of the following:

aluminum oxides, silicon carbides, silicon oxide, micro glass bubbles.

9. The panel according to claim 1, wherein the substrate comprises a core with at least one of the following:

wood fibers, cellulose fibers, hemp fibers, cotton fibers, plastic fibers.

10. The panel according to claim 1, wherein the surface layer and/or the core comprises a structure, especially a tile-like structure or a stone-like structure.

11. The panel according to claim 1, wherein the board is a particle board or a HDF board or a gypsum board or an OSB board.

12. A method for manufacturing the panel according to claim 1 comprising

(a) bringing cellulose fibers, at least one binder and wear resistant particles onto the substrate, and

(b) applying pressure and temperature to cure the mixture of the substances of step (a) on the substrate.

13. The method according to claim 12, wherein the pressure is between 3 and 8 MPa and the temperature is between 150°

C. and 250°

C.

14. The method according to claim 12, wherein the wear resistant particles are scattered into the surface layer together with other components of the surface layer, especially cellulose fibers and/or at least one binder.

15. A prepreg manufacturable by

(a) forming a surface layer comprising cellulose fibers and at least one binder on a substrate, and subsequently

(b) applying elevated pressure and temperatures to the surface layer in a prepress station.