POWDER OVERLAY

• US 20110247748A1
• Filed: 04/12/2011
• Published: 10/13/2011
• Est. Priority Date: 04/13/2010
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Ceraloc Innovation Belgium BVBA
• Inventors: ZIEGLER, Goran, PERVAN, Darko
• Granted Patent: US 8,480,841 B2
• Time in Patent Office: Days
• US Class Current: 156/220
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 3/12 by mechanical means
• CPC Class Codes: B05D 5/02 to obtain a matt or rough surface
• CPC Class Codes: B05D 5/06 to obtain multicolour or other optical effects B05D5/02 takes precedence
• CPC Class Codes: B05D 7/06 to wood
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2305/30 Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2317/02 Cork
• CPC Class Codes: B32B 2317/125 impregnated with thermosetting resin
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 38/0036 Heat treatment for heating or cooling of layers during lamination B32B37/06, B32B37/08
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: B44C 5/0476 with abrasion resistant properties
• CPC Class Codes: B44C 5/0492 containing wooden elements
• CPC Class Codes: C23C 16/44 characterised by the method of coating C23C16/04 takes precedence
• CPC Class Codes: Y10T 156/1041 : Subsequent to lamination

Abstract

A method is disclosed of manufacturing a transparent wear resistant surface layer (1). The method may include the steps of, applying a decorative material on a carrier, applying a dry powder layer comprising a mix of processed wood fibres, binder and wear resistant particles above the decorative layer, curing the mix to a decorative surface, including the transparent wear resistant layer, by applying heat and pressure on the mix. In a preferred embodiment the method includes the step of pressing the mix against an embossed matrix to create an embossed decorative surface with high wear resistance.

Claims

1. A method of manufacturing a building panel, wherein the method comprises the steps of:

applying a decorative layer on a carrier;

applying a dry powder layer, comprising a mix of processed wood fibres, binder and wear resistant particles, on the decorative layer; and

curing the mix by applying heat and pressure to obtain a decorative surface layer comprising a transparent wear resistant layer.

2. The method as claimed in claim 1, wherein the panel is a floor panel.

3. The method as claimed in claim 1, wherein the carrier is a wood based board.

4. The method as claimed in claim 1, wherein the carrier is an HDF or MDF board.

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

6. The method as claimed in claim 1, wherein the decorative layer is a printed paper.

7. The method as claimed in claim 1, wherein the curing step comprises pressing mix is against an embossed matrix.

8. The method as claimed in claim 7, wherein the pressing against the embossed matrix creates an embossing depth that exceeds a thickness of the decorative layer.

9. The method as claimed in claim 7, wherein the pressing against the embossed matrix creates an embossing depth that exceeds the combined thickness of the decorative layer and the transparent wear layer.

10. The method as claimed in claim 1, wherein the decorative layer comprises a transparent paper based overlay comprising aluminium oxide.

11. The method as claimed in claim 1, wherein the decorative layer comprises a transparent paper based overlay comprising aluminium oxide applied over a lower dry powder layer, the lower dry powder layer comprising wood fibres and a binder.

12. The method as claimed in claim 1, wherein the processed wood fibres are essentially all smaller than 1.0 mm.

13. The method as claimed in claim 1, wherein the processed wood fibres are essentially all smaller than 0.5 mm

14. The method as claimed in claim 1, wherein the heat and pressure is applied during 5-200 seconds.

15. The method as claimed in claim 1, wherein heat and pressure is applied during 5-30 seconds.

16. The method as claimed in claim 1, wherein the heat applied is in the range of about 140 °

C. to about 200 °

C.

17. The method as claimed in claim 1, wherein the pressure applied is in the range of about 20 to about 60 kg/cm2.

18. The method as claimed in claim 1, wherein the thickness of the transparent surface layer exceeds the thickness of the decorative layer.

19. The method as claimed in claim 1, wherein the decorative surface layer is embossed and the thickness of the transparent surface layer varies such that the thickness in an upper portion exceeds a thickness of a lower portion.

20. A method of manufacturing a building panel, wherein the method comprises the steps of:

applying a decorative layer on a carrier;

applying a dry powder layer, comprising a mix of a thermoplastic material and wear resistant particles, on the decorative layer; and

applying heat and pressure on the powder layer to obtain a decorative surface layer comprising a transparent wear resistant layer.

21. The method as claimed in claim 20, wherein the wear resistant particles comprise aluminium oxide and/or silica.

22. The method as claimed in claim 20, wherein the mix comprises processed wood fibres.