METHOD OF MANUFACTURING A BUILDING PANEL AND A BUILDING PANEL

• US 20150017461A1
• Filed: 07/01/2014
• Published: 01/15/2015
• Est. Priority Date: 07/02/2013
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: PERSSON, Hans, ZIEGLER, Gran, LINDGREN, Kent
• Granted Patent: US 10,913,176 B2
• Time in Patent Office: Days
• US Class Current: 428/528
• CPC Class Codes: B27N 3/002 characterised by the type of binder compositions of macromolecular compounds C08L
• CPC Class Codes: B27N 3/02 from particles
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B27N 3/06 Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• 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
• CPC Class Codes: Y10T 428/31957 Wood
• CPC Class Codes: Y10T 428/31982 Wood or paper

Abstract

A method of manufacturing a building panel (10). The method includes applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a carrier for forming a first layer (11), applying a second binder and free lignocellulosic or cellulosic particles on the first layer (11) for forming a second layer (12), wherein the first binder is different from the second binder, and applying heat and pressure to the first and second layers (11, 12) to form a building panel. Also, such a building panel (10).

Claims

1. A method of manufacturing a building panel, comprising

applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a carrier for forming a first layer,

applying a second binder and free lignocellulosic or cellulosic particles on the first layer for forming a second layer,

wherein the first binder is different from the second binder, and

applying heat and pressure to the first and second layers to form a building panel.

2. A method according to claim 1, wherein the first binder is urea formaldehyde resin, a mixture comprising urea formaldehyde resin, or a co-polymer comprising urea formaldehyde resin.

3. A method according to claim 1, wherein the first binder is phenol formaldehyde resin, a mixture comprising phenol formaldehyde resin, or a co-polymer comprising phenol formaldehyde resin.

4. A method according to claim 1, wherein the second binder is melamine formaldehyde resin, a mixture comprising melamine formaldehyde resin, or a co-polymer comprising melamine formaldehyde resin.

5. A method according to claim 1, wherein the first binder comprises a thermoplastic binder and the second binder comprises a thermosetting binder.

6. A method according to claim 1, wherein applying the first binder and said free lignocellulosic or cellulosic particles comprises applying a first mix comprising the first binder and said free lignocellulosic or cellulosic particles.

7. A method according to claim 6, wherein the first mix is a first powder mix.

8. A method according to claim 1, wherein said first binder is applied in liquid form.

9. A method according to claim 8, wherein said free lignocellulosic or cellulosic particles are applied onto the liquid first binder.

10. A method according to claim 1, wherein applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles.

11. A method according to claim 10, wherein the second mix is a second powder mix.

12. A method according to claim 1, wherein said second binder is applied in liquid form.

13. A method according to claim 12, wherein said free lignocellulosic or cellulosic particles are applied onto the liquid second binder.

14. A method according to claim 1, wherein the second layer further comprises wear resistant particles.

15. A method according to claim 1, wherein the carrier is a wood based board.

16. A method according to claim 1, further comprising applying a balancing layer on a second surface of the carrier being opposite to said first surface.

17. A method according to claim 1, wherein the binder concentration of the first layer substantially correspond to the binder concentration of the second layer.

18. A method according to claim 1, wherein the building panel is a floor panel.

19. A building panel, comprising

a carrier,

a first layer arranged on a first surface of the carrier,

a second layer arranged on the first layer,

wherein the first layer comprises a mix of lignocellulosic or cellulosic particles and a first binder, and the second layer comprises a mix of lignocellulosic or cellulosic particles and a second binder, wherein the first binder is different from the second binder.

20. A building panel according to claim 19, wherein the first binder is urea formaldehyde resin, a mixture comprising urea formaldehyde resin, or a co-polymer comprising urea formaldehyde resin.

21. A building panel according to claim 19, wherein the first binder is phenol formaldehyde resin, a mixture comprising phenol formaldehyde resin, or a co-polymer comprising phenol formaldehyde resin.

22. A building panel according to claim 19, wherein the second binder is melamine formaldehyde resin, a mixture comprising melamine formaldehyde resin, or a co-polymer comprising melamine formaldehyde resin.

23. A building panel according to claim 19, wherein the first binder comprises a thermoplastic binder and the second binder comprises a thermosetting binder.

24. A building panel according to claim 19, further comprising a balancing layer arranged on a second surface of the carrier being opposite to said first surface, wherein the balancing layer comprises a mix comprising lignocellulosic or cellulosic particles and a binder.