POWDER OVERLAY

• US 20160186318A1
• Filed: 03/04/2016
• Published: 06/30/2016
• Est. Priority Date: 04/13/2010
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: PERVAN, DARKO, ZIEGLER, GORAN
• Granted Patent: US 10,344,379 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 3/12 by mechanical means
• CPC Class Codes: B05D 5/02 to obtain a matt or rough surface
• CPC Class Codes: B05D 5/06 to obtain multicolour or other optical effects B05D5/02 takes precedence
• CPC Class Codes: B05D 7/06 to wood
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2305/30 Fillers, e.g. particles, powders, beads, flakes, spheres, chips
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2317/02 Cork
• CPC Class Codes: B32B 2317/125 impregnated with thermosetting resin
• 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 38/0036 Heat treatment for heating or cooling of layers during lamination B32B37/06, B32B37/08
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: B44C 5/0476 with abrasion resistant properties
• CPC Class Codes: B44C 5/0492 containing wooden elements
• CPC Class Codes: C23C 16/44 characterised by the method of coating C23C16/04 takes precedence
• CPC Class Codes: Y10T 156/1041 : Subsequent to lamination

Abstract

A method is disclosed of manufacturing a transparent wear resistant surface layer (1). The method may include the steps of, applying a decorative material on a carrier, applying a dry powder layer comprising a mix of processed wood fibres, binder and wear resistant particles above the decorative layer, curing the mix to a decorative surface, including the transparent wear resistant layer, by applying heat and pressure on the mix. In a preferred embodiment the method includes the step of pressing the mix against an embossed matrix to create an embossed decorative surface with high wear resistance.

Claims

1. (canceled)

2. A method of manufacturing a building panel, wherein the method comprises the steps of:

applying a first layer on a carrier;

applying a dry powder layer, comprising a binder and wear resistant particles, on the first layer; and

applying heat on the dry powder layer to obtain a transparent wear resistant layer.

3. The method according to claim 2, wherein the step of applying heat further comprises applying pressure.

4. The method according to claim 2, wherein the wear resistant particles comprise aluminum oxide and/or silica.

5. The method according to claim 2, wherein the dry powder layer further comprises processed wood fibres.

6. The method according to claim 2, wherein the first layer is a decorative layer.

7. The method according to claim 6, wherein the decorative layer is a printed paper.

8. The method according to claim 6, wherein the decorative layer is wood veneer.

9. The method according to claim 2, wherein the binder is a thermosetting resin.

10. The method according to claim 2, wherein the binder is a thermoplastic material.

11. The method according to claim 10, wherein the thermoplastic material comprises vinyl particles.

12. The method according to claim 10, wherein the thermoplastic material comprises E-PVC, S-PVC, PVA, PET, PS, SAN, or PMMA.

13. The method as claimed in claim 2, wherein the carrier is a wood based board.

14. The method as claimed in claim 2, wherein the carrier is an HDF or MDF board.

15. The method as claimed in claim 3, wherein the pressings step comprises pressing the dry powder layer against an embossed matrix.

16. The method as claimed in claim 15, wherein the pressing against the embossed matrix creates an embossing depth that exceeds the combined thickness of the first layer and the transparent wear layer.

17. The method as claimed in claim 2, wherein the first layer is applied on the carrier before the dry powder layer is applied on the first layer.

18. A method of manufacturing a building panel, wherein the method comprises the steps of:

applying a wood veneer layer on a carrier;

applying a dry powder layer, comprising a binder and wear resistant particles, on the first layer; and

applying heat on the dry powder layer to obtain a transparent wear resistant layer.

19. The method according to claim 18, wherein the wood veneer layer is placed on powder mix comprising wood fibres and a binder.

20. The method according to claim 19, wherein the powder mix further comprises pigments.

21. The method according to claim 19, wherein the powder mix further comprises wear resistant particles.

22. The method according to claim 18, wherein the binder is a thermosetting resin.

23. The method according to claim 18, wherein the binder is a thermoplastic material.

24. The method according to claim 18, wherein the step of applying heat further comprises applying pressure.

25. A method of manufacturing a building panel, wherein the method comprises the steps of:

applying a first layer on a carrier;

applying a dry powder layer, comprising a binder and wear resistant particles, on the first layer; and

applying pressure on the dry powder layer to obtain a transparent wear resistant layer.