PANEL COATING

• US 20180291638A1
• Filed: 06/18/2018
• Published: 10/11/2018
• Est. Priority Date: 08/26/2011
• Status: Active Grant

• Current Assignee: Ceraloc Innovation Ab (Pervan Holding AB)
• Original Assignee: Ceraloc Innovation Ab (Pervan Holding AB)
• Inventors: Pervan, Darko
• Granted Patent: US 10,364,578 B2
• Time in Patent Office: Days
• CPC Class Codes: B27M 3/04 of flooring elements, e.g. parqueting blocks assembling wooden elements on backings of other substances B32B, e.g. B32B21/042, E04F15/16; furniture joints F16B12/00
• 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 2255/08 on wood layer
• CPC Class Codes: B32B 2255/12 on paper layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2310/0825 using IR radiation
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 29/002 : 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 B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• 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 38/06 : Embossing
• CPC Class Codes: B32B 38/08 : Impregnating
• CPC Class Codes: B32B 38/145 : Printing
• CPC Class Codes: E04F 13/165 : with an outer layer imitating natural stone, brick work, tiled surface or the like
• 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
• CPC Class Codes: Y10T 428/249925 : Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]

Abstract

A method for coating of a floor panel and a floor panel produced by the method. A method for producing a laminated product, for example a building panel, preferably a floor panel. The method includes applying a paper on one side of a wood fiber based core, e.g., an HDF panel, creating a décor on the paper by a digital printing process, applying a resin, preferably a melamine formaldehyde resin, on the paper, heating the décor and the paper with the resin, preferably by using an IR lamp; and applying heat and pressure in order to cure the resin and thereby obtain a laminated product. Also, alternative methods for producing a laminated product, and such a laminated product.

Claims

1. (canceled)

2. A method for producing a laminated product, the method comprising:

applying a powder-based sublayer comprising wood fibers and a thermosetting resin on a wood fiber based core;

applying a paper on the powder-based sublayer;

applying a protective overlay comprising a thermosetting resin and wear-resistant particles on the paper; and

applying heat and pressure in order to impregnate the paper, to cure the resin, and thereby obtain a laminated product.

3. The method according to claim 2, wherein a powder-based balancing layer is applied on a rear side of the core.

4. The method according to claim 3, wherein the powder-based balancing layer comprises wood fibers and a thermosetting resin.

5. The method according to claim 2, wherein a paper-based balancing layer is applied on a rear side of the core.

6. The method according to claim 2, wherein the protective overlay is a powder-based overlay.

7. The method according to claim 6, wherein a paper overlay is applied on the powder-based overlay.

8. The method according to claim 6, wherein the powder-based overlay is applied by scattering.

9. The method according to claim 6, further comprising applying moisture on the powder-based overlay and drying the powder-based overlay.

10. The method according to claim 2, further comprising applying moisture on the powder-based sublayer and drying the powder-based sublayer.

11. The method according to claim 2, wherein the protective overlay is a paper-based overlay.

12. The method according to claim 2, wherein the paper is an unimpregnated paper when the paper is applied on the sublayer.

13. The method according to claim 2, further comprising providing a dé

cor on the paper by a digital printing process.

14. The method according to claim 2, wherein the sublayer further comprises color pigments.

15. The method according to claim 2, wherein protective overlay further comprises wood fibers.

16. The method according to claim 2, wherein the powder-based sublayer is applied by scattering.

17. The method according to claim 2, wherein the powder-based sublayer is a first sublayer and wherein the method further comprises:

applying a second powder-based sublayer on the paper, and

applying a transparent paper on the second powder-based sublayer.

18. The method according to claim 2, wherein the thermosetting resin and wear-resistant particles of the protective overlay comprises a melamine formaldehyde resin and aluminum oxide.

19. The method according to claim 2, wherein the thermosetting resin of the sublayer comprises melamine formaldehyde resin or a melamine/urea resin.

20. The method according to claim 2, wherein the wood fiber based core is an HDF panel.

21. The method according to claim 2, wherein the laminated product is a building panel or a floor panel.