METHOD FOR PRODUCING A FLOORBOARD

• US 20160375674A1
• Filed: 11/11/2014
• Published: 12/29/2016
• Est. Priority Date: 11/27/2013
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Guido Schulte
• Inventors: SCHULTE, GUIDO
• Granted Patent: US 11,072,156 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 2037/1253 curable adhesive
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/1292 selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: E04F 15/02038 characterised by tongue and groove connections between neighbouring flooring elements
• CPC Class Codes: E04F 15/045 Layered panels only of wood
• 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
• CPC Class Codes: E04F 2201/0115 with snap action of the edge connectors
• CPC Class Codes: E04F 2201/023 with a continuous tongue or groove

Abstract

A method for producing a floorboard having a topside veneer includes forming a multilayer body which includes a starting carrier plate, a plurality of veneers placed on the starting carrier plate so that a gap is formed between neighboring ones of the veneers, a resin layer comprising a resin provided between the starting carrier plate and the veneers, and a balancing layer arranged on a bottom side of the starting carrier plate; joining the starting carrier plate, the resin layer, the veneers and the balancing layer by pressing the multilayer body in a press; separating the multilayer body into individual boards between the neighboring veneers in a region of the gap; profiling the individual boards at side borders of the boards; and providing the individual boards with joining means.

Claims

1-14. -14. (canceled)

15. A method for producing a floorboard having a topside veneer, said method comprising:

forming a multilayer body comprising a starting carrier plate, a plurality of veneers placed on the starting carrier plate so that a gap is formed between neighboring ones of the veneers, a resin layer comprising a resin provided between the starting carrier plate and the veneers, and a balancing layer arranged on a bottom side of the starting carrier plate;

joining the starting carrier plate, the resin layer, the veneers and the balancing layer by pressing the multilayer body in a press;

separating the multilayer body into individual boards between the neighboring veneers in a region of the gap;

profiling the individual boards at side borders of the boards; and

providing the individual boards with joining means.

16. The method of claim 15, wherein during the pressing of the multilayer body a pressing pressure is greater than or equal to 1,000 Kilopascal, preferably greater than or equal to 3,500 Kilopascal, the pressing temperature is greater than or equal to 100, in particular greater than or equal to 120°

C., preferably between 180°

C. and 210°

C. and the pressing time is between 10 and 60 seconds.

17. The method of claim 15, wherein during the pressing of the multilayer body the gaps between the veneers are filled with resin.

18. The method of claim 15, wherein the resin layer is formed by a resin paper.

19. The method of claim 15, wherein the resin layer is formed by a resin film applied to a topside of the starting carrier plate.

20. The method of claim 15, wherein the resin layer is formed by a resin film applied to a bottom side of the veneers.

21. The method of claim 15, wherein during the pressing of the multilayer body resin infiltrates the veneers, and pores, cracks and/or gaps in the veneers are filled with the resin.

22. The method of claim 15, wherein the pressing of the multilayer body is performed so that the resin permeates the veneers and after the pressing the resin is visible at a surface of the veneers.

23. The method of claim 15, further comprising during the profiling of the side borders of the individual floorboards, removing a resin-filled residual gap remaining on a side border of the individual floorboards after the separating step.

24. The method of claim 15, wherein during the profiling of the side borders of the floorboards a border strip made of resin is formed.

25. The method of claim 15, wherein the resin contains a filler.

26. The method of claims 15, further comprising printing a decor on a surface of the individual floorboards.

27. The method of claim 15, further comprising applying a sealing onto a surface of the individual floorboards.

28. The method of claim 15, further comprising subjecting a surface of the floorboards to a mechanical surface processing, in particular a grinding process and/or a brushing process and/or an embossing process.