SINGLE LAYER SCATTERING OF POWDER SURFACES

• US 20140044872A1
• Filed: 08/08/2013
• Published: 02/13/2014
• Est. Priority Date: 08/09/2012
• Status: Active Grant

• Current Assignee: Ceraloc Innovation Ab (Pervan Holding AB)
• Original Assignee: Välinge Flooring Technology AB
• Inventors: PERVAN, Darko
• Granted Patent: US 8,993,049 B2
• Time in Patent Office: Days
• US Class Current: 427/205
• CPC Class Codes: B05C 19/04 the particulate material being projected, poured or allowed to flow onto the surface of the work B05C19/02 takes precedence; involving spraying or electrostatic projection B05B B05C19/005 takes precedence
• CPC Class Codes: B05D 1/36 Successively applying liquids or other fluent materials, e.g. without intermediate treatment
• CPC Class Codes: B05D 1/38 with intermediate treatment intermediate treatment per se B05D3/00
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 7/56 Three layers or more
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: E04F 15/102 of fibrous or chipped materials, e.g. bonded with synthetic resins
• CPC Class Codes: E04F 15/107 composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04

Abstract

Methods and equipment to apply a decorative surface on a building panel wherein the surface includes a mix of fibres, binders, wear resistant particles and pigments. Layers may be applied as separate layers with equipment that applies essentially only one of the materials in the surface mix.

Claims

1. A method of forming a surface layer comprising a first, second and third layer, the method comprising:

forming a first layer comprising mainly fibres,

forming a second layer comprising mainly wear resistant particles, and

forming a third layer comprising mainly particles of a thermosetting binder.

2. The method as claimed in claim 1, wherein the first layer is applied on a substrate.

3. The method as claimed in claim 2, wherein the substrate is a core.

4. The method as claimed in claim 3, wherein the core is a wood fibre based board.

5. The method as claimed in claim 3, wherein the surface layer and the core form a panel.

6. The method as claimed in claim 1, wherein the fibres are wood fibres.

7. The method as claimed in claim 1, wherein the thermosetting binder is a melamine formaldehyde binder.

8. The method as claimed in claim 7, wherein the melamine formaldehyde binder is in powder form.

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

10. The method as claimed in claim 1, wherein the second layer is applied on the first layer and the third layer is applied on the second layer.

11. The method as claimed in claim 1, wherein the first, second and third layers each comprises essentially one material with a material content of at least about 80% of the total weight of the layer.

12. The method as claimed in claim 1, wherein the first layer comprises colour pigments and at least about 80% by weight wood fibres.

13. A method of forming a surface layer on a substrate, the method comprising:

forming a first layer of a first material,

applying a second layer of a second material on the first layer,

mixing the first and second layers into a mix comprising the first and the second material, and

applying the mix on a substrate for forming a surface layer.

14. The method as claimed in claim 13, wherein the first and second layers are applied on a moveable transportation device.

15. The method as claimed in claim 13, wherein the substrate is a core.

16. The method as claimed in claim 15, wherein the core and the surface layer form a panel.

17. The method as claimed in claim 13, wherein the first material comprises fibres, and the second material comprises a thermosetting binder.

18. The method as claimed in claim 13, wherein the first material comprises thermosetting binder, and the second material comprises fibres.

19. The method as claimed in claim 13, further comprising forming a third layer of a third material.

20. The method as claimed in claim 19, wherein the third material comprises wear resistant particles or colour pigments.

21. The method as claimed in claim 13, further comprising forming a fourth layer of a fourth material.

22. The method as claimed in claim 21, wherein the fourth material comprises wear resistant particles or colour pigments.

23. A scattering equipment for mixing a first and second material, wherein the equipment comprises:

a first dispensing device,

a second dispensing device,

at least one moveable transportation device, and

a mixing device,

wherein the first dispensing device is adapted to apply a first material on said transportation device, the second dispensing device is adapted to apply a second material on the first material, said transportation device is moveable between the first and the second dispensing devices, and the mixing device is adapted to mix the first and second material and to remove the first and second material from said transportation device.

24. A scattering equipment as claimed in claim 23, wherein the first dispensing device comprises a hopper and a roller, wherein the hopper is adapted to dispense the first material to the roller, and the roller is adapted to dispense the first material to said transportation device, and the second dispensing device comprises a hopper adapted to dispense the second material to said transportation device.

25. A scattering equipment as claimed in claim 23, wherein the first dispensing device comprises a hopper adapted to dispense the first material to said transportation device, and the second dispensing device comprises a hopper and a roller, wherein the hopper is adapted to dispense the second material to the roller, and the roller is adapted to dispense the second material to said transportation device.

26. A scattering equipment as claimed in claim 23, wherein both the first and the second dispensing devices comprise a hopper and a roller, respectively, wherein the hoppers are adapted to dispense the first and the second material, respectively, to the rollers, and the rollers are adapted to dispense the first and second material to said transportation device.

27. A scattering equipment as claimed in claim 23, wherein both the first and the second dispensing devices comprise a hopper adapted to dispense the first and second material to said transportation device.

28. A scattering equipment as claimed in claim 23, wherein the first material comprises fibres, and the second material comprises a thermosetting binder.

29. A scattering equipment as claimed in claim 23, wherein the first material comprises a thermosetting binder, and the second material comprises fibres.

30. A scattering equipment as claimed in claim 23, further comprising a third dispensing device being adapted to dispense a third material.

31. A scattering equipment as claimed in claim 30, wherein the third material comprises wear resistant particles or colour pigments.

32. A scattering equipment as claimed in claim 23, further comprising a fourth dispensing device being adapted to dispense a fourth material.

33. A scattering equipment as claimed in claim 32, wherein the fourth material comprises wear resistant particles or colour pigments.

34. A scattering equipment as claimed in claim 23, wherein said transportation device comprises a scattering belt.

35. A scattering equipment as claimed in claim 23, wherein said transportation device comprises a roller.

36. A scattering equipment as claimed in claim 23, wherein the mixing device comprises a moving brush.