BRIGHT COLOURED SURFACE LAYER

• US 20110177354A1
• Filed: 12/22/2010
• Published: 07/21/2011
• Est. Priority Date: 01/15/2010
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation Belgium BvbA
• Inventors: Ziegler, Goran, Lindgren, Kent
• Granted Patent: US 8,481,111 B2
• Time in Patent Office: Days
• US Class Current: 428/537.1
• CPC Class Codes: B05D 3/02 by baking B05D3/04 takes precedence
• CPC Class Codes: B05D 3/12 by mechanical means
• CPC Class Codes: B44C 5/043 containing wooden elements
• CPC Class Codes: E04B 1/62 Insulation or other protection; Elements or use of specified material therefor chemical compositions C01 - C11; implements for applying insulation or sealings E04F21/00; buildings to withstand, or to provide protection against, external undesired influences E04H9/00; sealing pipes in walls or partitions F16L5/02; shielding against dangerous radiation G21F
• 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 15/10 of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/31982 Wood or paper
• CPC Class Codes: Y10T 428/31989 Of wood

Abstract

A method to produce a pale and/or plain coloured wear resistant surface layer by using a dry powder layer comprising a mix of refined fibres binder, pigment and wear resistant particles.

Claims

1. A method of manufacturing a wear resistant surface layer comprising the steps of:

applying a dry powder layer comprising a mix of refined fibres, binder, pigments and wear resistant particles on a carrier; and

curing the mix to a pale coloured wear resistant layer by applying heat and pressure on the mix.

4. The method as claimed in claim 1, wherein the wear resistant particles are aluminium oxide.

5. The method as claimed in claim 1, wherein the thickness of the cured layer is less than about 1 mm.

6. The method as claimed in claim 1, wherein the pale coloured wear resistant surface layer is bright white or red.

10. The method as claimed in claim 5, wherein the thickness of the cured layer is less than about 0.3 mm.

18. The method as claimed in claim 1, wherein the surface layer is pale and/or plain coloured.

2. The method as claimed in claim 2, wherein the decorative layer is attached to a wood fibre based core to obtain a panel.

3. The method as claimed in claim 2, wherein the panel is a floor panel.

7. The method as claimed in claim 2, wherein the decorative layer is attached to an HDF panel.

8. The method as claimed in claim 2, wherein the wear resistant particles are aluminium oxide.

9. The method as claimed in claim 2, wherein the thickness of the cured layer is less than about 1 mm.

11. The method as claimed in claim 2, wherein the thickness of the cured layer is less than about 0.3 mm.

12. The method as claimed in claim 2, wherein the pale coloured wear resistant surface layer is bright white or red.

13. The method as claimed in claim 2, wherein the weight ratio of resin compared to refined fibres is higher than about 100%,

14. The method as claimed in claim 2, wherein the weight ratio of resin compared to refined fibres is higher than about 120%

15. The method as claimed in claim 2, wherein the weight ratio of resin compared to refined fibres is in the range of about 120% to about 180%.

16. The method as claimed in claim 2, comprising the step of scattering a sublayer on the core.

17. The method as claimed in claim 2, comprising the step of scattering a top layer above the dry powder layer.

19. A floor panel produced according to the method in claim 3.

20. A floor panel as claimed in claim 19, wherein the surface layer of the floor panel is pale and/or plain coloured.