METHOD OF FORMING A BUILDING PANEL OR SURFACE ELEMENT AND SUCH A BUILDING PANEL AND SURFACE ELEMENT

• US 20160369507A1
• Filed: 06/15/2016
• Published: 12/22/2016
• Est. Priority Date: 06/16/2015
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: WINGRDH, Peter, MEIJER, Thomas, PERVAN, Darko, ZIEGLER, Gran
• Granted Patent: US 11,313,123 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/06 of metal
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/02 Layer formed of wires, e.g. mesh
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 21/04 comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/042; next to a bituminous or tarry layer B32B11/042; next to a water setting substance layer B32B13/10; next to a metal layer B32B15/10; next to a glass layer B32B17/062; next to a layer formed of natural mineral fibres or particles B32B19/042; next to a cellulosic plastic layer B32B23/044
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/026 Wood layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2305/38 Meshes, lattices or nets
• CPC Class Codes: B32B 2307/538 Roughness
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2311/00 Metals, their alloys or their compounds
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/06 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 33/00 : Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 37/06 : characterised by the heating 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 37/24 : 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 38/08 : Impregnating
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/028 : Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: E04C 2/26 : composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups of cement and mineral fibres E04C2/04
• 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

Abstract

A method of forming a building panel or a surface element, including providing a substrate, applying a sub-layer on the substrate, applying a mesh structure on the sub-layer, and applying heat and pressure to the mesh structure such that the sub-layer at least partially fills meshes of the mesh structure. Also, to such a building panel and a surface element.

Claims

1. A method of forming a building panel or a surface element, comprising

providing a substrate,

applying a sub-layer on a first surface of the substrate,

applying a mesh structure on the sub-layer, wherein a vapour permeability of the mesh structure exceeds 100 SI Perm, and

applying heat and pressure to said mesh structure such that the sub-layer at least partially fills meshes of the said mesh structure.

2. The method according to claim 1, wherein the mesh structure has a substantially uniform vapour permeability in a plane parallel to the first surface of the substrate.

3. The method according to claim 1, wherein the vapour permeability of the mesh structure exceeds 200 SI Perm, preferably exceeds 500 SI Perm.

4. The method according to claim 1, wherein applying heat and pressure comprises curing the sub-layer and thereby fixing the mesh structure to the sub-layer.

5. The method according to claim 1, wherein the mesh structure is at least partially visible after heat and pressure have been applied.

6. The method according to claim 1, wherein the sub-layer at least partially encapsulates the mesh structure.

7. The method according to claim 1, wherein a material forming the mesh structure facing the sub-layer has a surface roughness exceeding Ra 6.3.

8. The method according to claim 1, wherein the sub-layer comprises a thermosetting binder.

9. The method according to claim 1, wherein the mesh structure is formed of a metal material.

10. The method according to claim 1, wherein the mesh structure is formed of a plastic material.

11. The method according to claim 1, wherein the mesh structure is formed of a perforated foil.

12. The method according to claim 1, wherein the mesh structure is formed of a textile material.

13. The method according to claim 12, wherein the textile material comprises weaved cotton fibres.

14. The method according to claim 12, wherein a mesh size and mesh width of the textile material exceeds 0.1 mm.

15. The method according to claim 12, wherein the textile material is bonded to the sub-layer by a cured thermosetting binder, preferably melamine formaldehyde resin, when applying heat and pressure.

16. The method according to claim 12, wherein the textile material is chemically impregnated by the sub-layer by a cured thermosetting binder, preferably melamine formaldehyde resin, when applying heat and pressure.

17. The method according to claim 12, wherein a melamine formaldehyde resin powder is applied on the textile material prior to applying heat and pressure.

18. The method according to claim 12, wherein the textile material is impregnated with a thermosetting binder, preferably melamine formaldehyde resin, prior to applying heat and pressure.

19. The method according to claim 1, wherein the substrate comprises a wood-based board.

20. The method according to claim 1, wherein a temperature of 150°

C.-180°

C. and a pressure of 20-60 bar is applied on the mesh structure when applying heat and pressure.

21. A building panel, comprising

a substrate,

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

a mesh structure arranged on the sub-layer, wherein meshes of the mesh structure are at least partly filled with material from the sub-layer,

wherein a vapour permeability of the mesh structure exceeds 100 SI Perm.

22. The building panel according to claim 21, wherein the mesh structure has a substantially uniform vapour permeability in a plane parallel to the first surface of the substrate.

23. The building panel according to claim 21, wherein a vapour permeability of the mesh structure 200 SI Perm, preferably exceeds 500 SI Perm.

24. The building panel according to claim 21, wherein the mesh structure is at least partially visible.

25. The building panel according to claim 21, wherein the sub-layer at least partially encapsulates the mesh structure.

26. The building panel according to claim 21, wherein a material forming the mesh structure facing the sub-layer has a surface roughness exceeding Ra 6.3.

27. The building panel according to claim 21, wherein the sub-layer comprises a thermosetting binder.

28. The building panel according to claim 21, wherein the mesh structure is formed of a metal material.

29. The building panel according to claim 21, wherein the mesh structure is formed of a plastic material.

30. The building panel according to claim 21, wherein the mesh structure is formed of a perforated foil.

31. The building panel according to claim 21, wherein the mesh structure is formed of a textile material.

32. The building panel according to claim 21, wherein the substrate comprises a wood-based board.

33. The building panel according to claim 21, wherein the sub-layer comprises wood fibres and thermosetting resins, and wherein the substrate comprises a wood-based board comprising several layers, wherein at least a first layer comprises thermoplastic material mixed with wood fibres and wherein at least a second layer comprises thermoplastic material mixed with mineral particles.

34. The building panel according to claim 33, comprising a locking system comprising a tongue at a first edge and a tongue groove at a second edge opposite the first edge, wherein an upper part of the tongue and an upper part of the tongue groove comprise the mineral particles.

35. A surface element, comprising

a sub-layer, and

a mesh structure arranged on the sub-layer, wherein meshes of the mesh structure are at least partly filled with material from the sub-layer,

wherein a vapour permeability of the mesh structure exceeds 100 SI Perm.

36. The surface element according to claim 35, wherein the mesh structure is formed of a textile material.

37. The surface element according to claim 35, further comprising a protective layer arranged on the mesh structure.

38. The surface element according to claim 35, wherein the sub-layer comprises a thermoplastic foil.

39. The surface layer according to claim 37, wherein the protective layer comprises a thermoplastic foil.