POWDER MIX AND A METHOD FOR PRODUCING A BUILDING PANEL

• US 20120263878A1
• Filed: 04/11/2012
• Published: 10/18/2012
• Est. Priority Date: 04/12/2011
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Ceraloc Innovation Belgium BVBA
• Inventors: ZIEGLER, Göran, Persson, Hans, Rittinge, Rickard
• Granted Patent: US 8,728,564 B2
• Time in Patent Office: Days
• US Class Current: 427/277
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B29C 43/34 Feeding the material to the mould or the compression means B29C43/085 takes precedence
• CPC Class Codes: C08K 2003/2227 of aluminium
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/36 Silica
• CPC Class Codes: C08K 7/02 Fibres or whiskers
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N

Abstract

A powder mix layer for a building panel and a method for producing a building panel with a decorative surface produced from a powder mix layer with a controlled loss on cure.

Claims

1. A powder mix layer for producing a building panel, wherein the powder mix layer has a loss on cure in the range of about 2.5 to about 7 wt-%.

2. The powder mix as claimed in claim 1, wherein the powder mix is a substantially homogenous mix of wood fibres, a binder, and wear resistant particles.

3. The powder mix as claimed in claim 2, wherein the binder is a melamine resin.

4. The powder mix as claimed in claim 2, wherein the wear resistant particles are essentially of aluminium oxide or of a silica powder.

16. The powder mix as claimed in claim 1, wherein the layer has a loss on cure in the range of about 3 to about 6 wt-%.

5. A method of producing a building panel comprising the steps of:

applying a powder mix layer on a substrate; and

applying heat and pressure to the powder mix layer and curing the powder mix layer having a loss on cure in the range of about 2 to about 7 wt-%, and thereby obtaining a layer formed by the powder mix layer.

6. The method according to claim 5, wherein the powder mix layer comprises wood fibres and a binder.

7. The method according to claim 5, comprising the further step of applying a stabilisation fluid on the powder mix layer.

8. The method according to claim 5, comprising the further step of drying the powder mix layer.

9. The method according to claim 5, comprising the further steps of fixing the powder mix layer to the substrate.

10. The method according to claim 5, further comprising adjusting the loss on cure of the powder mix layer by the step of applying the stabilisation fluid, or the step of drying, or a combination thereof such that the powder mix layer obtains the loss on cure in said range.

11. The method according to claim 5, wherein the powder mix layer is applied by scattering.

12. The method according to claim 5, wherein the powder mix layer is applied as a continuous powder mix sheet.

13. The method according to claim 5, wherein the substrate is a core.

14. The method according to claim 13, wherein the layer forms a decorative surface layer arranged on the core.

15. The method according to claim 5, wherein the powder mix layer has a loss on cure in the range of about 2.5 to about 7 wt-%.

17. The method according to claim 5, wherein the powder mix layer has a loss on cure in the range of about 3 to about 6 wt-%.

18. The method according to claim 8, wherein the step of drying comprises applying heat with an effect of about 15-25 kW/m and a feeding speed in the range of about 1-4 m/min.

19. The method according to claim 9, wherein the step of fixing comprises applying stabilisation fluid and drying with an effect of about 15-25 kW/m and a feeding speed in the range of about 1-4 m/min.

20. The method according to claim 13, wherein the substrate is a wood-based core.