FIBRE BASED PANELS WITH A WEAR RESISTANCE SURFACE

• US 20160230400A9
• Filed: 02/27/2014
• Published: 08/11/2016
• Est. Priority Date: 11/19/2007
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: PERVAN, Darko, Lindgren, Kent, Jacobsson, Jan, Bouck, Eddy, Ziegler, Gran, Hkansson, Niclas
• Granted Patent: US 9,556,622 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 21/13 all layers being exclusively wood
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2307/102 Insulating
• 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 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/75 Printability
• 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 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 2607/00 : Walls, panels
• 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 37/00 : Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• 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: B44C 5/043 : containing wooden elements
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• 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 15/042 : the lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
• 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: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24066 : Wood grain
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24901 : including coloring matter
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/27 : Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
• CPC Class Codes: Y10T 428/3167 : Of cork
• CPC Class Codes: Y10T 428/31848 : Next to cellulosic
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31989 : Of wood
• CPC Class Codes: Y10T 442/695 : Including a wood containing layer

Abstract

Building panels with a homogenous decorative surface having a wear layer comprising fibres, binders and wear resistant particles.

Claims

1. (canceled)

2. A panel comprising:

a core,

a sub-layer arranged on a first surface of the core, and

a wood veneer layer arranged on the sub-layer,

wherein the sub-layer comprises fibres mixed with a binder.

3. The panel according to claim 2, wherein the binder is a thermosetting binder.

4. The panel according to claim 2, wherein the fibres are cork or wood fibres.

5. The panel according to claim 2, wherein the core is a wood fibre based core.

6. The panel according to claim 5, wherein the core is a HDF core.

7. The panel according to claim 2, wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.

8. The panel according to claim 2, further comprising a balancing layer arranged on a second surface of the core, opposite the first surface of the core.

9. The panel according to claim 8, wherein the balancing layer comprises wood fibres and a binder.

10. The panel according to claim 2, wherein the wood veneer layer has a thickness of 0.3-1.0 mm.

11. The panel according to claim 2, wherein the sub-layer comprises cork for reducing sound.

12. The panel according to claim 2, wherein the sub-layer comprises pigments.

13. The panel according to claim 2, wherein the wood veneer layer is formed with deep structures.

14. The panel according to claim 2, wherein the wood veneer layer comprises embossed portions.

15. The panel according to claim 2, wherein the panel is a floorboard.

16. A method of producing a panel, comprising:

providing a core,

applying a sub-layer on a first surface of the core, wherein the sub-layer comprises fibres mixed with a binder,

applying a wood veneer layer on the sub-layer, and

pressing the core, the sub-layer and the wood veneer layer together to form a panel.

17. The method according to claim 16, wherein applying the sub-layer comprises mixing the fibres with the binder, and subsequently applying the fibres mixed with the binder on the core.

18. The method according to claim 16, wherein the binder is a thermosetting binder.

19. The method according to claim 16, wherein the fibres are cork or wood fibres.

20. The method according to claim 16, wherein the sub-layer is applied on the core in powder form.

21. The method according to claim 16, wherein the sub-layer comprises pigments.

22. The method according to claim 16, further comprising applying a balancing layer on a second surface of the core, opposite the first surface of the core.

23. The method according to claim 22, wherein the balancing layer comprises wood fibres and a binder.

24. The method according to claim 16, wherein the core is a wood fibre based core.

25. The method according to claim 24, wherein the core is a HDF core.

26. The method according to claim 16, wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.

27. The method according to claim 16, wherein the wood veneer layer has a thickness of 0.3-1.0 mm.

28. The method according to claim 16, wherein the step of pressing comprises pressing with an embossed pressure matrix.

29. The method according to claim 16, wherein the panel is a floorboard.