WOOD FIBRE BASED PANELS WITH A THIN SURFACE LAYER

• US 20160114495A1
• Filed: 12/28/2015
• Published: 04/28/2016
• Est. Priority Date: 04/07/2008
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Pervan, Darko, Jacobsson, Jan, Lindgren, Kent, Ziegler, Goran, Hakansson, Niclas, Boucke, Eddy
• Granted Patent: US 11,235,565 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B27M 1/08 by multi-step processes
• CPC Class Codes: B27M 3/04 of flooring elements, e.g. parqueting blocks assembling wooden elements on backings of other substances B32B, e.g. B32B21/042, E04F15/16; furniture joints F16B12/00
• 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: 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 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 37/1027 Pressing using at least one press band
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 37/156 at least one layer is calendered and immediately laminated
• 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 38/06 Embossing
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: E04C 2/16 of fibres, chips, vegetable stems, or the like
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/30 : characterised by the shape or structure translucent E04C2/54
• CPC Class Codes: E04C 2002/005 : Appearance of panels
• CPC Class Codes: E04F 15/02 : Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/181 : Insulating layers integrally formed with the flooring or the flooring elements
• CPC Class Codes: E04F 2201/0138 : by moving the sheets, plates or panels perpendicular to the main plane
• 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 2201/0541 : adapted to be moved along the joint edge
• CPC Class Codes: E04F 2290/042 : with a facing or top layer for sound insulation
• CPC Class Codes: Y10T 156/1002 : with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31989 : Of wood

Abstract

A method of manufacturing a building panel, including mixing wood fibre particles and a binder to form a first mix, applying the first mix, while the first mix is in powder form, on a core for forming a sub layer on the core, applying a surface layer on the sub layer, wherein the surface layer comprises a second mix of wood fibre particles and a binder, pressing the core, the surface layer, and the sub layer, under increased pressure and temperature, and forming them into a building panel. A building panel formed by the method.

Claims

1-20. -20. (canceled)

21. A method of manufacturing a building panel, comprising:

mixing wood fibres particles and a binder to form a first mix;

applying the first mix on a core for forming a sub layer on the core;

applying a surface layer on the sub layer, and

pressing;

the core,

the surface layer, and

the sub layer,

under increased pressure and temperature, and forming them into a building panel.

22. The method as claimed in claim 21, wherein the first mix is applied on the core while the first mix is in powder form.

23. The method as claimed in claim 21, wherein the method further comprises the step of pressing the surface layer with an embossed pressing matrix such that the surface layer obtains upper portions and embossed portions lower than the upper portions, such that the embossed portions extends into the sub layer.

24. The method as claimed in claim 21, wherein the surface layer is a printed paper.

25. The method as claimed in claim 21, wherein the surface layer is a wood veneer.

26. The method as claimed in claim 21, wherein the surface layer is a foil.

27. The method as claimed in claim 21, wherein the surface layer comprises a second mix of wood fibre particles and a binder, wherein the second mix is of a different composition than the first mix.

28. The method as claimed in claim 21, wherein the surface layer is a resilient surface.

29. The method as claimed in claim 21, wherein the surface layer is an overlay.

30. The method as claimed in claim 21, wherein the surface layer is a print, paint or coating.

31. The method as claimed in claim 21, wherein the binder in the sub layer is a thermosetting resin.

32. The method as claimed in claim 21, wherein the surface layer comprises a thermosetting resin.

33. The method as claimed in claim 21, wherein the surface layer comprises a thermoplastic resin.

34. The method as claimed in claim 21, wherein the first mix comprises colour pigments.

35. The method as claimed in claim 21, further comprising applying a balancing layer on a surface of the core opposite the sub layer.

36. A building panel, comprising:

a core,

a sub layer arranged on the core, the sub layer comprising wood fibres particles and a binder,

a surface layer arranged on the core, wherein the surface layer comprises upper portions and embossed portions lower than the upper portions, wherein the embossed portions extends into the sub layer.

37. The building panel as claimed in claim 36, wherein the surface layer is a printed paper.

38. The building panel as claimed in claim 36, wherein the surface layer is a wood veneer.

39. The building panel as claimed in claim 36, wherein the surface layer a foil.

40. The building panel as claimed in claim 36, wherein the surface layer comprises a second mix of wood fibre particles and a binder, wherein the second mix is of a different composition than the first mix.

41. The method as claimed in claim 36, wherein the surface layer is a resilient surface.

42. The method as claimed in claim 36, wherein the surface layer is an overlay.

43. The method as claimed in claim 36, wherein the surface layer is a print, paint or coating.

44. The building panel as claimed in claim 36, wherein the binder in the sub layer is a thermosetting resin.

45. The building panel as claimed in claim 36, wherein the surface layer comprises a thermosetting resin.

46. The building panel as claimed in claim 36, wherein the surface layer comprises a thermoplastic resin.

47. The building panel as claimed in claim 36, wherein the first mix comprises colour pigments.

48. The building panel as claimed in claim 36, further comprising a balancing layer.

49. A method of production an overlay, comprising

mixing a thermosetting binder in dry or wet form with aluminium oxide to form a mix,

applying the mix on a decorative layer prior to pressing,

pressing the mix to the decorative layer to obtain an overlay.

50. The method according to claim 49, wherein the decorative layer is a wood veneer.

51. The method according to claim 49, wherein the thermosetting binder is melamine powder.