METHOD OF MANUFACTURING A LAYER

• US 20160368180A1
• Filed: 05/24/2016
• Published: 12/22/2016
• Est. Priority Date: 04/12/2011
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: RYBERG, Melker, ZIEGLER, Gran, BERGELIN, Marcus, JACOBSSON, Jan
• Granted Patent: US 11,633,884 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B27N 1/00 Pretreatment of moulding material
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B27N 3/18 Auxiliary operations, e.g. preheating, humidifying, cutting-off
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B29C 41/28 by depositing flowable material on an endless belt
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2105/246 Uncured, e.g. green
• CPC Class Codes: B29L 2007/008 Wide strips, e.g. films, webs
• CPC Class Codes: C08L 61/28 with melamine
• CPC Class Codes: E04F 15/102 of fibrous or chipped materials, e.g. bonded with synthetic resins

Abstract

A method of manufacturing a separate and continuous layer being essentially uncured. The method includes applying a powder mix including fibres and a thermosetting binder on a carrier, forming a powder mix layer, wherein the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured, and releasing the powder mix layer from the carrier. Also, a layer and a method for manufacturing a building panel.

Claims

1-30. -30. (canceled)

31. A method of manufacturing a layer, comprising

applying a powder mix comprising fibres and a binder on a surface of a supporting layer, and

applying moisture on the powder mix such that the powder mix is connected together by the binder, forming a powder mix layer.

32. The method according to claim 31, wherein the supporting layer is a paper sheet.

33. The method according to claim 32, wherein the paper sheet is impregnated.

34. The method according to claim 31, wherein the supporting layer is a non-woven sheet.

35. The method according to claim 31, wherein the supporting layer is one of a rice sheet, a sugar paper, a netting, mineral fibres, carbon fibres, textile fibres or nylon fibres.

36. The method according to claim 31, wherein the binder is a thermosetting binder.

37. The method according to claim 31, wherein the binder is a thermoplastic binder.

38. The method according to claim 31, wherein the step of forming the powder mix layer includes drying the powder mix such that the powder mix is connected together.

39. The method according to claim 31, wherein the layer is essentially uncured.

40. The method according to claim 31, wherein the powder mix layer is flexible.

41. The method according to claim 31, further comprising curing the powder mix layer.

42. The method according to claim 31, further comprising applying the layer to a core.

43. The method according to claim 42, wherein the layer is attached to the core by an adhesive.

44. The method according to claim 31, wherein the fibres are wood fibres, plastic fibres, mineral fibre or vegetable fibres, or a mixture thereof.

45. The method according to claim 31, further comprising printing a print in the powder mix and/or powder mix layer.

46. The method according to claim 45, wherein the printing is by digital printing.

47. A method of manufacturing a layer, comprising

applying particles on a surface of a supporting layer, wherein the supporting layer is an impregnated paper sheet, and

applying moisture on the particles or on the supporting layer such that the particles are connected together.

48. The method according to claim 47, wherein the particles comprises wood particles.

49. The method according to claim 47, wherein the particles comprises a binder.

50. The method according to claim 49, wherein the binder is a thermosetting binder.

51. The method according to claim 49, wherein the binder is thermoplastic binder.

52. A method of manufacturing a layer, comprising

applying a powder mix comprising fibres and a thermosetting binder on a surface of a supporting layer, and

applying moisture on the powder mix such that the powder mix is connected together, forming a powder mix layer,

curing the powder mix layer, p1 after curing, attaching the cured powder mix layer to a core.

53. The method according to claim 52, wherein the supporting layer is a paper sheet.

54. The method according to claim 53, wherein the paper sheet is impregnated.

55. The method according to claim 52, wherein the supporting layer is a non-woven sheet.