METHOD OF PRODUCING A BUILDING PANEL AND A BUILDING PANEL

• US 20140199558A1
• Filed: 01/10/2014
• Published: 07/17/2014
• Est. Priority Date: 01/11/2013
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Välinge Flooring Technology AB, Valinge Innovation AB
• Inventors: PERVAN, Darko, PERSSON, Hans, HKANSSON, Niclas
• Granted Patent: US 9,181,698 B2
• Time in Patent Office: Days
• US Class Current: 428/530
• CPC Class Codes: B29C 37/0025 Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing moulding on preformed layers as inserts B29C70/68; applying fluent material to surfaces in general B05
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2038/0056 Moistening
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2038/166 Removing moisture
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/06 of paper or cardboard
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• 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 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 2607/02 Wall papers, wall coverings
• CPC Class Codes: B32B 37/0038 involving application of liquid to the layers prior to lamination, e.g. wet laminating B32B37/12 takes precedence
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: E04C 2/246 combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/40 composed of a number of smaller components rigidly or movably connected together, e.g. interlocking, hingedly connected of particular shape, e.g. not rectangular of variable shape or size, e.g. flexible or telescopic panels E04C2/041 takes precedence
• CPC Class Codes: Y10T 428/31964 Paper

Abstract

A method of producing a building panel (1), including: providing a core (2), applying a balancing layer (6) having a first moisture content on a first surface (3) of the core (2), the balancing layer (6) comprising a sheet impregnated with a thermosetting binder, applying a surface layer (12) having a second moisture content on a second surface (4) of the core (2), the surface layer (12) comprising a thermosetting binder, adjusting the first moisture content of the balancing layer (6) such that the first moisture content of the balancing layer (6) is higher than the second moisture content of the surface layer (12) prior to curing, and curing the surface layer (12) and the balancing layer (6) by applying heat and pressure. Also, a semi-finished product adapted to be cured for forming a building panel (1).

Claims

1. A method of producing a building panel, comprising:

providing a core,

applying a balancing layer on a first surface of the core, wherein the balancing layer has a first moisture content and comprises a sheet impregnated with a thermosetting binder,

applying a surface layer on a second surface of the core, wherein the surface layer has a second moisture content and comprises a thermosetting binder,

adjusting the first moisture content of the balancing layer such that the first moisture content of the balancing layer is higher than the second moisture content of the surface layer prior to curing by applying heat and pressure, and

curing the surface layer and the balancing layer by applying heat and pressure.

2. A method according to claim 1, wherein the step of adjusting the first moisture content of the balancing layer comprises applying water or steam to the first surface of the core prior to applying the balancing layer.

3. A method according to claim 1, wherein the step of adjusting the first moisture content of the balancing layer comprises applying water or steam to the balancing layer.

4. A method according to claim 1, wherein the first moisture content of the balancing layer exceeds 10% of the total weight of the balancing layer prior to curing.

5. A method according to claim 1, wherein the thermosetting binder is of the same type in the surface layer and in the balancing layer.

6. A method according to claim 1, wherein the thermosetting binder of the surface layer and/or the balancing layer is melamine formaldehyde resin.

7. A method according to claim 1, wherein the sheet is a paper sheet.

8. A method according to claim 1, wherein the surface layer comprises a dé

cor paper.

9. A method according to claim 1, wherein the surface layer comprises a layer comprising a thermosetting binder and at least one pigment.

10. A method according to claim 1, wherein the amount of the thermosetting binder in the balancing layer is lower than the amount of the thermosetting binder in the surface layer.

13. A method according to claim 2, wherein the step of adjusting the first moisture content of the balancing layer comprises applying water or steam to the balancing layer.

14. A method according to claim 1, wherein the first moisture content of the balancing layer exceeds 20% of the total weight of the balancing layer prior to curing.

15. A method according to claim 1, wherein the first moisture content of the balancing layer exceeds 30% of the total weight of the balancing layer prior to curing.

16. A method according to claim 1, wherein the surface layer comprises a resin impregnated dé

cor paper.

17. A method according to claim 1, wherein the surface layer comprises a melamine formaldehyde impregnated dé

cor paper.

11. A semi-finished product adapted to be cured for forming a building panel, comprising:

a core having a first surface and a second surface opposite the first surface,

a balancing layer arranged on the first surface of the core, wherein the balancing layer comprises a sheet impregnated with a thermosetting binder,

a surface layer arranged on the second surface of the core, wherein the surface layer comprises a thermosetting binder,

wherein a first moisture content of the balancing layer is higher than a second moisture content of the surface layer prior to curing.

12. The semi-finished product according to claim 11, wherein the first moisture content of the balancing layer exceeds 10% of the total weight of the balancing layer prior to curing.

18. The semi-finished product according to claim 11, wherein the first moisture content of the balancing layer exceeds 20% of the total weight of the balancing layer prior to curing.

19. The semi-finished product according to claim 11, wherein the first moisture content of the balancing layer exceeds 30% of the total weight of the balancing layer prior to curing.