PRODUCTION METHOD

• US 20110293906A1
• Filed: 05/31/2011
• Published: 12/01/2011
• Est. Priority Date: 05/31/2010
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation Belgium BvbA
• Inventors: JACOBSSON, Jan
• Granted Patent: US 10,315,219 B2
• Time in Patent Office: Days
• US Class Current: 428/206
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 3/0254 After-treatment
• CPC Class Codes: B05D 3/0473 for heating, e.g. vapour heating
• CPC Class Codes: B05D 3/12 by mechanical means
• CPC Class Codes: B05D 5/06 to obtain multicolour or other optical effects B05D5/02 takes precedence
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2310/049 using steam or damp
• 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 2607/00 Walls, panels
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B44C 5/043 containing wooden elements
• CPC Class Codes: B44F 5/00 Designs characterised by irregular areas, e.g. mottled patterns imitating natural patterns or artistic work B44F9/00, B44F11/00
• CPC Class Codes: Y10T 428/24893 including particulate material

Abstract

A method for producing a panel is disclosed. The method includes the step of applying steam on a dry powder layer on a core. Thereafter is a heat and pressure applied to the powder layer in order to bond the powder together.

Claims

1. A method of manufacturing a panel comprising a core and a decorative surface layer comprising the steps of:

applying a dry powder layer on a core; and

applying steam to the powder layer.

2. The method as claimed in claim 1, wherein the steam is a vapour comprising water.

3. The method as claimed in claim 1, wherein the steam is a saturated vapour consisting essentially of water.

4. The method as claimed in claim 1, the method further comprising the step of bonding the powder in the powered layer together by applying heat and pressure, and thereby forming a decorative surface layer.

5. The method as claimed in claim 1, wherein the dry powder layer comprises a mix of fibres and binder(s).

6. The method as claimed in claim 1, wherein the dry powder layer comprises a mix of wood fibres and binder(s).

7. The method as claimed in claim 1, wherein the core is a wood fibre based core.

8. The method as claimed in claim 1, wherein the core is an HDF panel.

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

10. The method as claimed in claim 1, wherein the powder layer comprises wear resistant particles.

11. The method as claimed in claim 1, wherein the powder layer comprises aluminium oxide.

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

13. The method as claimed in claim 1, wherein the thickness of the cured layer is less than about 0.3 mm.

14. The method as claimed in claim 1, wherein the steam is substantially uniformly applied over the powder layer.

15. The method as claimed in claim 1, wherein the steam is unevenly applied over the powder layer, in order to obtain a designed pattern.

16. A floor panel produced according to the method in claim 1.

17. A floor panel produced according to the method in claim 14.

18. A floor panel produced according to the method in claim 15.