PANEL, USE OF A PANEL, METHOD FOR MANUFACTURING A PANEL AND A PREPREG

• US 20150298433A1
• Filed: 07/01/2015
• Published: 10/22/2015
• Est. Priority Date: 06/17/2009
• Status: Abandoned Application

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Kalwa, Norbert
• Application Number:
  US14/789,339
• Publication Number:
  US 20150298433A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 2037/243 Coating
• 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 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 33/00 Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 37/06 characterised by the heating method
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: B44C 5/0476 with abrasion resistant properties
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31935 Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31942 : Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate
• CPC Class Codes: Y10T 428/31978 : Cellulosic next to another cellulosic
• CPC Class Codes: Y10T 428/31982 : Wood or paper

Abstract

Described are panels including a surface layer on a substrate. The surface layer includes a) cellulose fibers, b) at least one binder and (c) wear resistant particles. The use of different panels and a method for manufacturing is also described. A prepreg manufacturable by (a) forming a surface layer comprising cellulose fibers and at least one binder on a substrate, and subsequently (b) applying elevated pressure and temperatures to the surface layer in a prepress station.

Claims

1-15. -15. (canceled)

16. A method for manufacturing a panel, comprising

(a) applying a mixture comprising cellulose fibers, a binder, and wear resistant particles onto a substrate, the mixture forming a surface layer on a substrate,

(b) heating the mixture of step (a) on the substrate, and

(c) subsequently applying pressure and temperature to cure the mixture of step (a) on the substrate to form the panel.

17. The method according to claim 16, further comprising a step of mixing the cellulose fibers, the binder, and the wear resistant particles to form the mixture before step (a).

18. The method according to claim 17, wherein the step of mixing results in an essentially homogenous mass.

19. The method according to claim 16, wherein the heating of step (b) is done by a heating station possessing an infrared heating source.

20. The method according to claim 16, wherein the heating of step (b) is done by a heating station possessing a microwave heating source.

21. The method according to claim 16, wherein the pressure applied in step (c) is between 3 and 8 MPa, and the temperature applied in step (c) is between 150°

C. and 200°

C.

22. The method according to claim 16, further comprising a step of wetting the substrate before applying the cellulose fibers, the binder, and the wear resistant particles onto the substrate in step (a).

23. The method according to claim 16, wherein the applying of step (a) is done by scattering the cellulose fibers, the binder, and the wear resistant particles onto the substrate.

24. A method for manufacturing a panel, comprising

(a) applying substances comprising cellulose fibers, a binder and wear resistant particles onto a substrate,

(b) heating the substances of step (a) on the substrate, and

(c) subsequently applying pressure and temperature to form the substances of step (a) into a surface layer on the substrate.

25. The method according to claim 24, wherein the heating of step (b) is done by a heating station possessing an infrared heating source.

26. The method according to claim 24, wherein the heating of step (b) is done by a heating station possessing a microwave heating source.

27. The method according to claim 24, wherein the pressure applied in step (c) is between 3 and 8 MPa, and the temperature applied in step (c) is between 150°

C. and 200°

C.

28. The method according to claim 24, further comprising a step of wetting the substrate before applying the cellulose fibers, the binder, and the wear resistant particles onto the substrate in step (a).

29. The method according to claim 24, wherein the applying of step (a) is done by scattering the cellulose fibers, the binder, and the wear resistant particles onto the substrate.

30. A method for manufacturing a panel, comprising

(a) applying substances comprising cellulose fibers and a binder onto a substrate,

(b) heating the substances of step (a) on the substrate, and

(c) subsequently applying pressure and temperature to form the substances of step (a) into a surface layer on the substrate.

31. The method according to claim 30, wherein the heating of step (b) is done by a heating station possessing an infrared heating source.

32. The method according to claim 30, wherein the heating of step (b) is done by a heating station possessing a microwave heating source.

33. The method according to claim 30, wherein the pressure applied in step (c) is between 3 and 8 MPa, and the temperature applied in step (c) is between 150°

C. and 200°

C.

34. The method according to claim 30, further comprising a step of wetting the substrate before the substances onto the substrate in step (a).

35. The method according to claim 30, wherein the applying of step (a) is done by scattering the substances onto the substrate.