VENEERED ELEMENT AND METHOD OF PRODUCING SUCH A VENEERED ELEMENT

• US 20170305119A1
• Filed: 04/25/2017
• Published: 10/26/2017
• Est. Priority Date: 04/25/2016
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: BERGELIN, Marcus, ZIEGLER, Gran
• Granted Patent: US 10,828,881 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 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 19/042 of wood
• CPC Class Codes: B32B 19/046 of paper or cardboard
• CPC Class Codes: B32B 19/06 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2037/1215 Hot-melt adhesive
• 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 21/06 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 21/13 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 2250/05 5 or more layers
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/24 Organic non-macromolecular coating
• 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 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2262/06 : Vegetal fibres
• CPC Class Codes: B32B 2262/062 : Cellulose fibres, e.g. cotton
• 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 2262/10 : Inorganic fibres layered products comprising a layer of natural mineral fibres B32B19/00
• CPC Class Codes: B32B 2264/06 : Vegetal particles
• CPC Class Codes: B32B 2264/062 : Cellulose particles, e.g. cotton
• CPC Class Codes: B32B 2264/065 : Lignocellulosic particles, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2264/067 : Wood particles
• CPC Class Codes: B32B 2264/10 : Inorganic particles
• CPC Class Codes: B32B 2264/102 : Oxide or hydroxide
• CPC Class Codes: B32B 2264/104 : Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
• CPC Class Codes: B32B 2264/108 : Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2307/10 : having particular acoustical properties
• CPC Class Codes: B32B 2307/212 : Electromagnetic interference shielding
• CPC Class Codes: B32B 2307/302 : Conductive
• CPC Class Codes: B32B 2307/402 : Coloured
• CPC Class Codes: B32B 2307/4026 : within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/536 : Hardness
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/554 : Wear resistance
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/584 : Scratch resistance
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2317/12 : Paper, e.g. cardboard
• 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 2479/00 : Furniture upholstery B32B2601/00
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 29/005 : next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary 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 3/10 : characterised by a discontinuous layer, i.e. formed of separate pieces of material
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• 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 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/1207 : Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 37/1284 : Application of adhesive
• CPC Class Codes: B32B 38/08 : Impregnating
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/145 : Variation across the thickness of the layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/04 : Interconnection of layers
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 9/005 : comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/042 : of wood
• CPC Class Codes: B32B 9/047 : made of fibres or filaments
• CPC Class Codes: B32B 9/06 : of paper or cardboard

Abstract

A veneered element, including a substrate, a wood veneer layer having a first surface and a second surface, the first surface being opposite to the second surface, an adhesive layer adapted to adhere the first surface of the wood veneer layer to a surface of the substrate, wherein adhesive from the adhesive layer is present in a first portion of the wood veneer layer, extending from the first surface of the wood veneer layer into the wood veneer layer, and wherein the second surface of the wood veneer layer is substantially free from adhesive from the adhesive layer. Also, a method of producing such a veneered element).

Claims

1. A method of producing a veneered element, comprising

providing a substrate and a wood veneer layer having a first surface and a second surface, the first surface being opposite to the second surface,

arranging an adhesive layer on the substrate and/or the on first surface of the wood veneer layer,

pressing the wood veneer layer to the substrate,

wherein, after pressing, adhesive from the adhesive layer is present in a first portion of the wood veneer layer extending from the first surface of the wood veneer layer and into at least 10% of the thickness of the wood veneer layer,

wherein, after pressing, the second surface of the wood veneer layer is substantially free from adhesive from the adhesive layer, and

wherein, after pressing, the wood veneer layer is compressed to a thickness being less than or equal to 80% of its thickness prior to pressing.

2. The method according to claim 1, wherein, after pressing, less than 40% of pores or tracheids of the wood veneer layer extending into the second surface of the wood veneer layer are filled with the adhesive from the adhesive layer up to the second surface of the wood veneer layer.

3. The method according to claim 1, wherein, after pressing, a second portion of the wood veneer layer extending from the second surface of the wood veneer layer and into the wood veneer layer is substantially free from adhesive from the adhesive layer.

4. The method according to claim 3, wherein, after pressing, less than 40% of pores or tracheids of the wood veneer layer are filled with the adhesive from the adhesive layer in the second portion of the wood veneer layer.

5. The method according to claim 3, wherein the second portion of the wood veneer layer is extending from the second surface of the wood veneer layer and into at least 0.5% of the thickness of the wood veneer layer.

6. The method according to claim 3, wherein the second portion of the wood veneer layer is extending from the second surface of the wood veneer layer and into at least 70% of the thickness of the wood veneer layer.

7. The method according to claim 1, wherein the first portion is extending into at least 20% of the thickness of the wood veneer layer.

8. The method according to claim 1, wherein pressing the wood veneer layer to the substrate comprises applying heat and pressure.

9. The method according to claim 1, wherein the pressure applied is at least 15 bar.

10. The method according to claim 1, wherein, after pressing, the wood veneer layer is compressed to a thickness being less than or equal to 70% of its thickness prior to pressing.

11. The method according to claim 1, wherein the substrate comprises at least one wood veneer layer.

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

13. The method according to claim 1, wherein the substrate comprises a sheet such as a paper sheet or sheet of non-woven.

14. The method according to claim 1, wherein the adhesive layer comprises a resin impregnated paper.

15. The method according to claim 1, wherein the adhesive layer comprises a thermoplastic binder, such as a hot melt or pressure sensitive adhesive.

16. The method according to claim 1, wherein the adhesive layer comprises a thermosetting binder.

17. The method according to claim 15, wherein the adhesive is applied in powder form.

18. The method according to claim 15, wherein the adhesive is applied in liquid form.

19. A veneered element, comprising

a substrate,

a wood veneer layer having a first surface and a second surface, the first surface being opposite to the second surface,

an adhesive layer adapted to adhere the first surface of the wood veneer layer to a surface of the substrate,

wherein adhesive from the adhesive layer is present in a first portion of the wood veneer layer, extending from the first surface of the wood veneer layer and into at least 10% of the thickness of the wood veneer layer,

wherein the second surface of the wood veneer layer is substantially free from adhesive from the adhesive layer, and

wherein the wood veneer layer is compressed to a thickness being less than or equal to 80% of its original thickness.

20. The veneered element according to claim 19, wherein, less than 40% of pores or tracheids of the wood veneer layer extending into the second surface of the wood veneer layer are filled with the adhesive from the adhesive layer up to the second surface of the wood veneer layer.

21. The veneered element according to claim 19, wherein, a second portion of the wood veneer layer extending from the second surface of the wood veneer layer and into the wood veneer layer is substantially free from adhesive from the adhesive layer.

22. The veneered element according to claim 21, wherein less than 40% of pores or tracheids of the wood veneer are filled with the adhesive from the adhesive layer in the second portion of the wood veneer layer.

23. The veneered element according to claim 21, wherein the second portion of the wood veneer layer is extending from the second surface of the wood veneer layer and into at least 0.5% of the thickness of the wood veneer layer.

24. The method according to claim 21, wherein the second portion of the wood veneer layer is extending from the second surface of the wood veneer layer and into at least 70% of the thickness of the wood veneer layer.

25. The veneered element according to claim 19, wherein the first portion is extending into at least 20% of the thickness of the wood veneer layer.

26. The veneered element according to claim 19, wherein the wood veneer layer has a density of at least 1000 kg/m3.

27. The veneered element according to claim 19, wherein the substrate comprises at least one wood veneer layer.

28. The veneered element according to claim 19, wherein the substrate comprises a wood-based board.

29. The veneered element according to claim 19, wherein the substrate comprises a sheet such as a paper sheet or sheet of non-woven.

30. The veneered element according to claim 19, wherein the adhesive layer comprises a resin impregnated paper.

31. The veneered element according to claim 19, wherein the adhesive layer comprises a thermosetting binder.

32. The veneered element according to claim 19, wherein the adhesive layer comprises a thermoplastic binder, such as a hot melt or pressure sensitive adhesive.

33. A method of producing a veneered element, comprising

providing a substrate and a wood veneer layer having a first surface and a second surface, the first surface being opposite to the second surface,

arranging an adhesive layer on the substrate and/or on the first surface of the wood veneer layer,

pressing the wood veneer layer to the substrate,

wherein, after pressing, adhesive from the adhesive layer is present in a first portion of the wood veneer layer extending from the first surface of the wood veneer layer into the wood veneer layer,

wherein, after pressing, the second surface of the wood veneer layer is substantially free from adhesive from the adhesive layer, and

wherein, after pressing, a second portion of the wood veneer layer extending from the second surface of the wood veneer layer and into at least 70% or the thickness of the wood veneer layer is substantially free from adhesive from the adhesive layer.

34. A veneered element, comprising

a substrate,

a wood veneer layer having a first surface and a second surface, the first surface being opposite to the second surface,

an adhesive layer adapted to adhere the first surface of the wood veneer layer to a surface of the substrate,

wherein adhesive from the adhesive layer is present in a first portion of the wood veneer layer, extending from the first surface of the wood veneer layer into the wood veneer layer,

wherein the second surface of the wood veneer layer is substantially free from adhesive from the adhesive layer, and

wherein a second portion of the wood veneer layer extending from the second surface of the wood veneer layer and into at least 70% or the thickness of the wood veneer layer is substantially free from adhesive from the adhesive layer.