WOOD FIBRE BASED PANEL WITH A SURFACE LAYER

• US 20150197942A1
• Filed: 01/09/2015
• Published: 07/16/2015
• Est. Priority Date: 01/10/2014
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: PERVAN, Darko, ZIEGLER, Goran
• Granted Patent: US 10,100,535 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B27G 1/00 Machines or devices for removing knots or other irregularities or for filling-up holes filling up cracks or holes in a veneer cutting block B27L5/00; caulking decks B63B5/065
• CPC Class Codes: B27N 3/005 and foam
• CPC Class Codes: B27N 3/02 from particles
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B27N 3/08 Moulding or pressing presses in general B30B
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• 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 21/08 of synthetic resin
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2264/062 Cellulose particles, e.g. cotton
• CPC Class Codes: B32B 2266/0214 Materials belonging to B32B27/00
• CPC Class Codes: B32B 2266/0285 Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
• CPC Class Codes: B32B 2266/14 Adhesive foam
• CPC Class Codes: B32B 2305/073 partially
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2317/02 Cork
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 37/10 : characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/1284 : Application of adhesive
• CPC Class Codes: B32B 37/18 : involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 38/06 : Embossing
• CPC Class Codes: B32B 5/142 : Variation across the area of the layer
• CPC Class Codes: B44C 1/24 : Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: B44C 5/043 : containing wooden elements
• CPC Class Codes: B44C 5/0438 : containing stone elements
• CPC Class Codes: E04F 15/042 : the lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
• CPC Class Codes: E04F 15/045 : Layered panels only of wood
• CPC Class Codes: E04F 15/082 : with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass in combination with a lower layer of other material
• CPC Class Codes: E04F 15/085 : The lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24132 : including grain, strips, or filamentary elements in different layers or components parallel
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24314 : Slit or elongated
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24339 : Keyed
• CPC Class Codes: Y10T 428/24521 : with component conforming to contour of nonplanar surface
• CPC Class Codes: Y10T 428/24603 : Fiber containing component
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24893 : including particulate material
• CPC Class Codes: Y10T 428/24992 : Density or compression of components
• CPC Class Codes: Y10T 428/249925 : Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
• CPC Class Codes: Y10T 428/24994 : Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/24995 : Two or more layers
• CPC Class Codes: Y10T 428/249959 : Void-containing component is wood or paper
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249985 : Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/249986 : Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/256 : Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/257 : Iron oxide or aluminum oxide
• CPC Class Codes: Y10T 428/3167 : Of cork
• CPC Class Codes: Y10T 428/31862 : Melamine-aldehyde
• CPC Class Codes: Y10T 428/31866 : Impregnated or coated cellulosic material
• CPC Class Codes: Y10T 428/31957 : Wood
• CPC Class Codes: Y10T 428/31989 : Of wood

Abstract

A building panel with a surface layer (1) including a wood veneer, a wood fibre based core (2) and a sub-layer (3) between the surface layer (1) and the core (2). The sub-layer (3) includes wood fibres (4) and a binder (5). The surface layer (1) has surface portions (6) including material from the sub-layer (3). The surface portions (6) including material from the sub-layer (3) extend into the wood veneer.

Claims

1. A building panel comprising:

a surface layer comprising a wood veneer,

a wood fibre based core, and

a sub-layer arranged between the surface layer and the wood fibre based core, wherein the sub-layer comprises wood fibres and a binder,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer.

2. The building panel as claimed in claim 1, wherein the surface portions comprising material from the sub-layer are flush with a remainder of the surface layer.

3. The building panel as claimed in claim 1, wherein the surface layer comprises embossed portions and wherein a part of the sub-layer is more compressed under an embossed portion than under a non-embossed surface portion.

4. The building panel as claimed in claim 1, wherein the sub-layer comprises colour pigments and/or a colorant.

5. The building panel as claimed in claim 1, wherein the sub-layer comprises wear resistant particles.

6. The building panel as claimed in claim 1, further comprising a powder-based balancing layer.

7. The building panel as claimed in claim 1, wherein the wood veneer comprises holes and/or cracks, wherein the sub-layer fills the holes and/or cracks of the wood veneer.

8. The building panel as claimed in claim 1, further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.

9. The building panel as claimed in claim 1, wherein the binder in the sub-layer is a thermosetting resin.

10. The building panel as claimed in claim 1, wherein the binder in the sub-layer is a melamine formaldehyde resin.

11. The building panel as claimed in claim 1, wherein the sub-layer comprises a foaming agent.

12. The building panel as claimed in claim 1, wherein the surface layer is a cork layer.

13. A building panel comprising:

a surface layer comprising a wood veneer,

a wood fibre based core, and

a sub-layer arranged between the surface layer and the wood fibre based core, wherein the sub-layer comprises wood fibres, a binder and wear resistant particles,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer.

14. A building panel comprising:

a surface layer comprising a wood veneer,

a wood fibre based core, and

a sub-layer arranged between the surface layer and the wood fibre based core, wherein the sub-layer comprises wood fibres, a binder and colour pigments and/or a colorant,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer.

15. A building panel comprising:

a surface layer comprising a veneer,

a core, and

a sub-layer arranged between the surface layer and core,

wherein the surface layer has surface portions comprising material from the sub-layer extending into the veneer.

16. A method to produce a building panel, the method comprising:

applying a wood fibre powder and a binder on a wood fibre based core, to obtain a sub-layer;

applying a wood veneer, comprising holes through the veneer, on the sub-layer,

applying heat and pressure to bond the veneer, the sub-layer and the wood fibre based core together, wherein a portion of the wood fibre powder and the binder is pressed into the holes.

17. The method as claimed in claim 16, further comprising applying a foaming agent in the sub-layer.

19. The method as claimed in claim 16, further comprising applying different colour pigments, such that the colour of the visible sub-layer portion varies along the building panel, or such that the portion of the sub-layer in the holes forms a pattern.

20. The method as claimed in claim 16, wherein after applying pressure, the wood veneer comprises embossed portions, and wherein a part of the sub-layer is more compressed under an embossed surface portion than under a non-embossed surface portion.

21. The method as claimed in claim 16, further comprising applying a protective overlay with wear resistant particles on the wood veneer, preferably prior to pressing.

22. The method as claimed in claim 16, wherein the sub-layer comprises colour pigments and/or a colorant.

23. The method as claimed in claim 16, wherein the sub-layer comprises wear resistant particles.

18. The method as claimed in clam 16, wherein the wood fibre powder comprises lignocellulosic particles or cellulose particles.