METHOD OF MANUFACTURING A LAYER

• US 20120264853A1
• Filed: 04/12/2012
• 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, Bergelin, Marcus, Jacobsson, Jan, Ryberg, Melker
• Granted Patent: US 9,352,499 B2
• Time in Patent Office: Days
• US Class Current: 524/13
• CPC Class Codes: B27N 1/00 Pretreatment of moulding material
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B27N 3/18 Auxiliary operations, e.g. preheating, humidifying, cutting-off
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B29C 41/28 by depositing flowable material on an endless belt
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2105/246 Uncured, e.g. green
• CPC Class Codes: B29L 2007/008 Wide strips, e.g. films, webs
• CPC Class Codes: C08L 61/28 with melamine
• CPC Class Codes: E04F 15/102 of fibrous or chipped materials, e.g. bonded with synthetic resins

Abstract

A method of manufacturing a separate and continuous layer being essentially uncured. The method includes applying a powder mix including fibres and a thermosetting binder on a carrier, forming a powder mix layer, wherein the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured, and releasing the powder mix layer from the carrier. Also, a layer and a method for manufacturing a building panel.

Claims

1. A method of manufacturing a separate and continuous layer being essentially uncured, comprising

applying a powder mix comprising fibres and a thermosetting binder on a carrier,

forming a powder mix layer, wherein the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured, and

releasing the powder mix layer from the carrier.

2. The method according to claim 1, wherein said layer is flexible.

3. The method according to claim 1, wherein the step of forming the powder mix layer includes applying moisture on the powder mix such that the powder mix is connected together.

4. The method according to claim 3, wherein a liquid forming the moisture is water, an alcohol, an ink, a binder, preferably a thermosetting binder, more preferably melamine formaldehyde, or a mixture thereof.

5. The method according to claim 1, wherein the step of forming the powder mix layer includes heating the powder mix such that the powder mix is connected together.

6. The method according to claim 1, wherein the step of forming the powder mix layer includes drying the powder mix such that the powder mix is connected together.

7. The method according to claim 1, wherein the step of forming the powder mix layer includes applying pressure on the powder mix such that the powder mix is connected together.

8. The method according to claim 1, wherein the fibres are wood fibres, plastic fibres, mineral fibres or vegetable fibres such as jute, linen, flax, cotton, hemp, bamboo, bagasse and sisal, or a mixture thereof.

9. The method according to claim 1, wherein the thermosetting binder is a melamine resin.

10. The method according to claim 1, wherein the step of applying the powder mix on the carrier comprises applying the powder mix on a supporting layer arranged on the carrier.

11. The method according to claim 1, further comprising arranging a reinforcement structure in the powder mix.

12. The method according to claim 10, wherein the supporting layer comprises a non-woven sheet, a paper sheet, mineral fibres, carbon fibres, textile fibres or nylon fibres.

13. The method according to claim 1, further comprising printing a print in the powder mix and/or in the powder mix layer.

14. The method according to claim 13, further comprising printing a print on both sides of the powder mix layer.

15. The method according to claim 1, further comprising applying liquid in a pattern.

16. The method according to claim 1, further comprising tearing the powder mix layer into smaller portions forming decorative elements.

17. The method according to claim 1, further comprising curing the power mix layer.

18. The method according to claim 1, wherein the power mix layer is a protective layer.

24. A method for manufacturing a building panel, comprising

providing a powder mix layer manufactured according to claim 1,

arranging the powder mix layer on a core, and

attaching the powder mix layer to the core by applying heat and pressure.

26. The method according to claim 11, wherein the reinforcement structure comprises a non-woven sheet, a paper sheet, mineral fibres, carbon fibres, textile fibres or nylon fibres.

27. The method according to claim 13, wherein the printing is by means of digital printing.

29. The method according to claim 15, wherein the pattern is applied by means of digital printing.

19. A method of manufacturing a continuous layer being essentially uncured, comprising

applying moisture to a web,

applying a powder mix comprising fibres and a thermosetting binder on the web,

forming a powder mix layer by heating the powder mix, whereby the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured.

20. The method according to claim 19, further comprising cutting the web having the powder mix applied thereon into separate sheets.

21. The method according to claim 19, wherein the web is formed by a flexible sheet.

22. The method according to claim 19, wherein the step of applying the powder mix comprise applying the powder mix on both sides of the web.

23. The method according to claim 19, wherein the fibres are wood fibres, plastic fibres, mineral fibres or vegetable fibres such as jute, linen, flax, cotton, hemp, bamboo, bagasse and sisal, or a mixture thereof.

28. The method according to claim 21, wherein the flexible sheet is a non-woven sheet.

30. A method for manufacturing a building panel, comprising

providing a powder mix layer manufactured according to claim 19,

arranging the powder mix layer on a core, and

attaching the powder mix layer to the core by applying heat and pressure.

25. A separate and continuous layer being essentially uncured, comprising

a powder mix layer comprising a powder mix including fibres and a thermosetting binder, wherein the powder mix is connected together to form the powder mix layer, and wherein the powder mix is essentially uncured.