FLOOR, WALL, OR CEILING PANEL AND METHOD FOR PRODUCING SAME

• US 20170120564A1
• Filed: 03/27/2014
• Published: 05/04/2017
• Est. Priority Date: 11/27/2013
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Guido Schulte
• Inventors: SCHULTE, GUIDO
• Granted Patent: US 10,442,164 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 13/10 of wood; of wood particle board
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 19/042 of wood
• CPC Class Codes: B32B 19/045 of synthetic resin
• CPC Class Codes: B32B 19/046 of paper or cardboard
• 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 21/042 of wood B32B21/13 takes precedence
• CPC Class Codes: B32B 21/06 of paper or cardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 21/12 next to a particulate 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 2250/02 2 layers
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• 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 2260/026 Wood layer
• CPC Class Codes: B32B 2260/028 : Paper layer
• CPC Class Codes: B32B 2260/044 : Water-setting substance, e.g. concrete, plaster
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2262/065 : Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2262/067 : Wood fibres
• CPC Class Codes: B32B 2264/065 : Lignocellulosic particles, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/4026 : within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/406 : Bright, glossy, shiny surface
• CPC Class Codes: B32B 2307/412 : Transparent
• CPC Class Codes: B32B 2307/536 : Hardness
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/75 : Printability
• CPC Class Codes: B32B 2317/16 : Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2419/04 : Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/14 : next to a particulate layer
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 29/04 : next to a particulate layer
• 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 3/26 : characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• 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 37/12 : 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 38/06 : Embossing
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 9/045 : being laminated
• CPC Class Codes: E04F 13/10 : of wood or with an outer layer of wood E04F13/0864 takes precedence
• CPC Class Codes: E04F 13/16 : of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• 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 15/045 : Layered panels only of wood
• CPC Class Codes: F16D 65/0978 : acting on one pad only
• CPC Class Codes: Y10T 156/1062 : Prior to assembly
• CPC Class Codes: Y10T 156/1066 : Cutting to shape joining edge surfaces only
• CPC Class Codes: Y10T 156/1075 : of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1079 : Joining of cut laminae end-to-end

Abstract

A floor, wall, or ceiling panel has a base made of a wood material and an upper veneer. The base and the veneer are hot-pressed together while incorporating a resin layer. During the pressing process, pores, cracks, and/or gaps in the veneer are filled with resin. In particular, the pressing process is carried out such that the veneer is saturated with resin, and the resin can be seen on the surface of the veneer after the pressing process The adhesion of the veneer to the base and the smoothing of the veneer are thus carried out in one operation.

Claims

1-22. -22. (canceled)

23. A floor, wall, or ceiling panel, comprising:

a carrier plate, a veneer arranged on a topside of the carrier plate, and a layer of a resin provided between the carrier plate and the veneer, wherein the resin layer and the veneer are pressed together, and wherein the layer of the resin is formed from a resin powder containing at least one of binders, hardeners and fillers, said resin permeating the veneer.

24. The floor, wall, or ceiling panel of claim 23, wherein the fillers are wood-based fillers.

25. The floor, wall, or ceiling panel of claim 23, wherein the resin layer is formed by a foamable polymer resin, in particular a urea-formaldehyde condensation product.

26. The floor, wall, or ceiling panel of claim 23, wherein the resin layer is formed by a resin film applied onto the topside of the carrier plate.

27. The floor, wall, or ceiling panel of claim 23, wherein the resin layer is formed by a resin film applied to the bottom side of the carrier plate.

28. The floor, wall, or ceiling panel of claim 23, wherein the resin of the resin layer permeates the veneer up to the topside of the veneer.

29. The floor, wall, or ceiling panel of claim 23, further comprising a balancing layer arranged on a bottom side of the carrier plate.

30. The floor, wall, or ceiling panel of claim 23, wherein a topside of the veneer is grinded, brushed and/or sealed.

31. The floor, wall, or ceiling panel of claim 23, wherein a texture is embossed into a topside of the veneer.

32. A method for producing a floor, wall, or ceiling panel, said method comprising:

providing a large-area basic carrier plate

providing a veneer;

forming a multilayer body comprising a basic carrier plate, the veneer and a resin layer interposed between the basic carrier plate and the veneer and a balancing layer arranged on a bottom side of the basic carrier plate;

joining the basic carrier plate, the resin layer and the veneer and the balancing layer by pressing the multilayer body in a press, wherein a pressing pressure, a pressing temperature and a pressing time are adjusted so that during the pressing of the multilayer body pores, cracks and/or gaps in the veneer are filled with resin.

separating the pressed multilayer body into individual panels;

profiling the panels at side borders of the panels and providing the panels with joining means.

33. The method of claim 32, wherein the resin layer is formed by a polymer resin or a urea formaldehyde condensation product.

34. The method of claim 32, wherein the resin layer is formed by a resin film applied to a top side of the basic carrier plate.

35. The method of claim 32, wherein the resin layer is formed by a resin film applied to the bottom side of the carrier plate.

36. The method of claim 32, wherein the resin layer is applied in form of a powder, and wherein hardening and/or binding means and/or dies and/or fillers are admixed to the powder.

37. The method of claim 32, wherein the resin layer is applied as a liquid, pasty film, and wherein a hardener, dies, color pigments and fillers are added to the resin.

38. The method of claim 32, wherein the resin layer is applied as a liquid, pasty film, and wherein a hardener, dies or color pigments and wood based fillers are added to the resin.

39. The method of claim 32, wherein the pressing of the multilayer body is carried out so that the rein permeates the veneer and after the pressing the resin is visible at a surface of the veneer.

40. The method of claim 32, further comprising printing a decor on the veneer.

41. The method of claim 32, further comprising applying a sealing to the veneer.

42. The method of claim 32, further comprising after the pressing, subjecting the veneer to a mechanical surface processing, in particular a grinding process and/or a brushing process.

43. The method of claim 32, further comprising during the pressing embossing a texture into the veneer.