COMPOSITE BOARDS AND PANELS

• US 20150343739A1
• Filed: 03/30/2015
• Published: 12/03/2015
• Est. Priority Date: 03/31/2014
• Status: Active Grant

• Current Assignee: Ceraloc Innovation Ab (Pervan Holding AB)
• Original Assignee: Floor Iptech AB
• Inventors: PERVAN, Darko
• Granted Patent: US 9,573,343 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2038/0076 Curing, vulcanising, cross-linking
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2264/0257 Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers
• CPC Class Codes: B32B 2264/067 Wood particles
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2264/104 Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2311/24 Aluminium
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2379/00 Other polymers having nitrogen, with or without oxygen or carbon only, in the main chain
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2479/00 Furniture upholstery B32B2601/00
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• 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 37/0007 : involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 37/08 : characterised by the cooling 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 37/1027 : Pressing using at least one press band
• CPC Class Codes: B32B 37/144 : using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding constructional features for tensioning B32B38/1825
• CPC Class Codes: B32B 37/20 : involving the assembly of continuous webs only
• CPC Class Codes: B32B 37/24 : with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B44C 5/04 : Ornamental plaques, e.g. decorative panels, decorative veneers
• CPC Class Codes: C08L 27/06 : Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 97/02 : Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: E04F 13/0894 : with tongue and groove connections
• CPC Class Codes: E04F 15/02038 : characterised by tongue and groove connections between neighbouring flooring elements
• 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: E04F 2201/0153 : by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• CPC Class Codes: E04F 2201/042 : with grooves positioned on the rear-side of the panel
• CPC Class Codes: E04F 2201/043 : with tongues and grooves being formed by projecting or recessed parts of the panel layers
• CPC Class Codes: Y10T 428/24397 : Carbohydrate
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/254 : Polymeric or resinous material
• CPC Class Codes: Y10T 428/31899 : Addition polymer of hydrocarbon[s] only

Abstract

A building panel (1) including a water resistant core (5) including thermoplastic material 21 and a surface layer (4) including thermosetting resins. Also, production methods to form a board material (1′) with a dry blend of thermoplastic particles 21a in powder form and fillers in powder form and to apply a surface layer (4) with a hot-hot lamination process to a core (5) including such board material.

Claims

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

providing a core by forming a mat shaped layer comprising a dry blend of wood particles in powder form and thermoplastic particles in powder form, heating and cooling the mat shaped layer under pressure such that a sheet is formed after pressing,

applying a surface layer comprising a powder mix comprising wood particles and thermosetting resin on the core,

laminating the powder based surface layer in a hot-hot pressing operation to the core and thereby forming a building panel, wherein the wood particles of the surface layer and of the core are bonded to each other by cured thermosetting resin.

2. A method as claimed in claim 1, wherein the surface layer comprises thermoplastic material.

3. A method as claimed in claim 1, wherein the thermosetting resin is an amino resin.

4. A method as claimed in claim 1, wherein the thermoplastic particles of the dry blend comprise polyvinyl chloride, polypropylene, or polyethylene.

5. A method as claimed in claim 1, wherein the thermoplastic particles of the dry blend have an average particle size of about 0.3 mm or less.

6. A method as claimed in claim 1, wherein the surface layer is applied as two layers arranged above each other and wherein an upper layer of said two layers comprises bleached cellulose fibres and thermosetting particles.

7. A method as claimed in claim 1, wherein the wood particles of the core, prior to providing the core, are dried to a moisture content of about 2% or less.

8. A method as claimed in claim 1, wherein the wood particles of the core prior to application are sieved to an average size of 1.0 mm or less.

9. A method as claimed in claimed in claim 1, wherein the content of the wood particles in the core is in the range of about 30-80 wt %.

10. A method as claimed in claim 1, wherein the core is formed with a pressure lower than 20 bar.

11. A method as claimed in claim 2, wherein the thermoplastic material is comprised in the powder mix of the surface layer and comprises thermoplastic particles, wherein the thermoplastic particles have an average size of about 0.2 mm or less.

12. A method as claimed in claim 1, wherein the wood particles of the surface layer are smaller than the wood particles of the core.

13. A method as claimed in claim 1, wherein the core comprises an intermediate layer and an upper layer, and wherein the intermediate layer comprises a higher amount of thermoplastic material than the upper layer.

14. A method as claimed in claim 13, wherein the intermediate layer further comprises limestone particles.

15. A method as claimed in claim 1, wherein the surface layer comprises a transparent wear layer comprising a thermosetting resin, wear resistant particles, and cellulose fibres.

16. A method as claimed in claim 15, wherein the thermosetting resin of the transparent wear layer is an amino resin.

17. A building panel comprising a core and a surface layer, wherein the core comprises a mix of thermoplastic material and wood particles, the surface layer comprises a composite material comprising wood particles bonded to each other by a cured thermosetting resin, and wherein the surface layer is bonded to the core by the cured thermosetting resin.

18. A building panel as claimed in claim 17, wherein the thermosetting resin is an amino resin.

19. A building panel as claimed in claim 17, wherein the surface layer further comprises thermoplastic particles.

20. A building panel as claimed in claim 17, wherein the thermoplastic material of the core comprises polyvinyl chloride, polypropylene, or polyethylene.

21. A building panel as claimed in claim 17, wherein the surface layer comprises thermoplastic particles with a size of about 0.2 mm or less.

22. A building panel as claimed in claim 17, wherein the wood particles of the surface layer have an average size that is smaller than an average size of the wood particles of the core.

23. A building panel as claimed in claim 17, wherein the building panel is a floor panel.

24. A building panel as claimed in claim 17, wherein one pair of opposite edges is formed with a mechanical locking system comprising a protruding strip and wherein the protruding strip comprises wood particles and thermoplastic material.

25. A building panel having a core, a surface layer and at least two opposite edges comprising a mechanical locking system comprising a tongue and groove for vertical locking and a protruding strip with a locking element in one edge cooperating with a locking groove in another edge for horizontal locking, wherein the core comprising three layers of materials, wherein each layer comprising a thermoplastic material and fillers, and wherein an upper layer and a lower layer comprises fillers of wood particles, and wherein an intermediate layer comprises fillers of mineral particles.

26. A building panel as claimed in claim 25, wherein the strip and the locking element are formed in the lower layer.

27. A building panel as claimed in claim 25, wherein the protruding strip, the locking element and the locking groove are formed in the lower layer.

28. A building panel as claimed in claim 25, wherein the building panel is a floor panel.

29. A building panel as claimed in claim 25, wherein the building panel comprises a surface layer comprising wood particles and thermosetting resins.

30. A board comprising an upper surface, a lower surface, and an intermediate portion located between the upper surface and the lower surface, wherein the intermediate portion comprises wood particles embedded in a thermoplastic material, and wherein the upper surface comprises essentially raw wood particles adapted to bond to a thermosetting resin.

31. A board as claimed in claim 30, wherein the essentially raw wood particles protrude beyond the upper surface.

32. A board as claimed in claim 30, wherein the thermoplastic material comprises polyvinyl chloride, polypropylene, or polyethylene.

33. A board as claimed in claim 30, wherein the average size of the wood particles at the upper surface is about 0.1-1.0 mm.