METHOD OF PRODUCING A VENEERED ELEMENT

• US 20150197943A1
• 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: ZIEGLER, Gran, Nygren, Per, Meijer, Thomas
• Granted Patent: US 10,988,941 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 method of producing a veneered element (10), including providing a substrate (1), applying a sub-layer (2) on a surface of the substrate (1), applying a veneer layer (3) on the sub-layer (2), and applying pressure to the veneer layer (3) and/or the substrate (1), such that at least a portion of the sub-layer (2) permeates through the veneer layer (3). Also, such a veneered element (10).

Claims

1. A method of producing a veneered element, comprising

providing a substrate,

applying a sub-layer on a surface of the substrate,

applying a veneer layer on the sub-layer,

applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer, wherein the method further comprises

controlling a design of the veneer layer by determining level of permeation of the sub-layer through the veneer layer.

2. The method according to claim 1, wherein determining a level of permeation includes selecting or adjusting a fluid pressure of the sub-layer when applying pressure.

3. The method according to claim 2, wherein selecting or adjusting a fluid pressure of the sub-layer when applying pressure includes selecting or adjusting one or more of the following parameters:

concentration of a binder in the sub-layer;

moisture content of the sub-layer;

the pressure applied to the veneer layer and/or the substrate;

a gas pressure in the sub-layer;

concentration of fillers in the sub-layer; and

thickness of the veneer layer.

4. The method according to claim 1, wherein the sub-layer further comprises pigments.

5. The method according to claim 1, wherein the substrate is a wood-based board.

6. The method according to claim 2, wherein selecting or adjusting the fluid pressure of the sub-layer comprises selecting or adjusting a concentration of a binder in the sub-layer.

7. The method according to claim 2, wherein selecting or adjusting the fluid pressure comprising selecting or adjusting the moisture content of the sub-layer.

8. The method according to claim 2, wherein selecting or adjusting the fluid pressure comprises selecting or adjusting the pressure applied to the veneer layer and/or the substrate.

9. The method according to claim 2, wherein selecting or adjusting the fluid pressure comprises generating a gas pressure in the sub-layer.

10. The method according to claim 9, wherein generating the gas pressure comprises including chemical and/or physical blowing agents in the sub-layer.

11. The method according to claim 1, wherein determining level of permeation of the sub-layer through the veneer layer comprising including fillers in the sub-layer.

12. The method according to claim 1, wherein determining level of permeation of the sub-layer through the veneer layer comprises abrasive machining of the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

13. The method according to claim 12, wherein the abrasive machining comprises brushing the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

14. The method according to claim 1, wherein determining level of permeation of the sub-layer through the veneer layer comprises forming holes, cavities and/or cracks in the veneer layer.

15. The method according to claim 1, wherein determining level of permeation of the sub-layer through the veneer layer comprises controlling a thickness of the veneer layer.

16. The method according to claim 1, wherein said at least a portion of the sub-layer permeates through pores of the veneer layer.

17. The method according to claim 1, wherein said at least a portion of the sub-layer permeates through cracks and/or holes of the veneer layer.

18. The method according to claim 1, wherein the veneer layer comprises a wood veneer, a cork veneer, or a stone veneer.

19. The method according to claim 1, wherein the sub-layer comprises a binder.

20. The method according to claim 19, wherein the binder is a thermosetting binder or a thermoplastic binder.

21. The method according to claim 1, wherein the sub-layer comprises wear resistant particles.

22. The method according to claim 1, wherein after pressure has been applied, the veneer layer comprises embossed portions, wherein a portion of the sub-layer is more compressed under an embossed portion than under a non-embossed surface portion.

23. A method of producing a veneered element, comprising

providing a substrate,

applying a sub-layer on a surface of the substrate, wherein the sub-layer comprises pigments,

applying a veneer layer on the sub-layer,

applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer, wherein the method further comprises

controlling a design of the veneer layer by determining level of permeation of the sub-layer through the veneer layer.

24. A veneered element, comprising

a substrate being a wood-based board,

a sub-layer arranged on the substrate, and

a veneer layer arranged on the sub-layer,

wherein at least a portion of the sub-layer is permeated through the veneer layer such that at least a portion of the sub-layer is visible at the surface of the veneer layer facing away from the substrate, and

wherein the sub-layer comprises pigments.

25. The veneered element according to claim 24, wherein the sub-layer comprises wear resistant particles.

26. The veneered element according to claim 24, wherein the sub-layer comprises fillers.

27. The veneered element according to claim 24, wherein said at least a portion of the sub-layer is permeated through pores of the veneer layer.

28. The veneered element according claim 24, wherein the veneer layer comprises embossed portions, wherein a portion of the sub-layer is more compressed under an embossed portion than under a non-embossed surface portion.