A METHOD TO PRODUCE A BUILDING PANEL AND A SEMI-FINISHED PRODUCT

• US 20180370278A1
• Filed: 12/20/2016
• Published: 12/27/2018
• Est. Priority Date: 12/21/2015
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: PERSSON, Hans, BERGELIN, Marcus
• Granted Patent: US 11,090,972 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• 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 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 2250/02 2 layers
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2255/00 Coating on the layer surface
• CPC Class Codes: B32B 2255/08 on wood layer
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/12 on paper layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2307/4023 on the layer surface, e.g. ink
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/7246 : Water vapor barrier
• CPC Class Codes: B32B 2307/73 : Hydrophobic
• CPC Class Codes: B32B 2307/75 : Printability
• 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 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2479/00 : Furniture
• 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 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 29/00 : Layered products comprising a layer of paper or cardboard
• 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 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 3/14 : characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side B32B5/02 takes precedence
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 38/14 : Printing or colouring
• CPC Class Codes: B32B 38/145 : Printing
• CPC Class Codes: B32B 5/00 : Layered products characterised by the non- homogeneity or physical structure , i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B44C 1/24 : Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: B44C 5/04 : Ornamental plaques, e.g. decorative panels, decorative veneers
• CPC Class Codes: B44C 5/0476 : with abrasion resistant properties
• CPC Class Codes: B44C 5/0492 : containing wooden elements
• CPC Class Codes: E04F 15/02 : Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• 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 to produce a building panel, including: providing a substrate, applying a thermosetting binder in dry form on the substrate for forming a sub-layer, applying a sheet on the sub-layer, and pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet from below. Also, a semi-finished product.

Claims

1. A method to produce a building panel, comprising

providing a substrate,

applying a thermosetting binder in dry form on the substrate for forming a sub-layer,

controlling the moisture content of the sub-layer when arranged on the substrate,

applying a sheet on the sub-layer, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and

pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet.

2. The method according to claim 1, wherein controlling the moisture content of the sub-layer comprises one or more of the following:

applying steam on the substrate prior to applying the sub-layer,

applying steam on the sub-layer when arranged on the substrate,

applying steam on the sheet,

applying liquid on the substrate prior to applying the sub-layer,

applying liquid on the sub-layer when arranged on the substrate,

applying liquid on the sheet, and/or

drying the sub-layer and/or the sheet.

3. The method according to claim 1, wherein the moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.

4. The method according to claim 1, wherein the sheet is at least substantially unimpregnated when applied on the sub-layer.

5. The method according to claim 1, wherein the sub-layer consists essentially of the thermosetting binder.

6. The method according to claim 1, further comprising printing a dé

cor on the sheet when arranged on the sub-layer.

7. The method according to claim 6, wherein the sheet is adhered to the sub-layer prior to printing.

8. A method to produce a building panel, comprising

providing a substrate,

controlling relative humidity (RH) of ambient air enclosing an application device adapted to apply a thermosetting binder in dry form,

applying a thermosetting binder in dry form on the substrate by said application device for forming a sub-layer,

applying a sheet on the sub-layer, and

pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet.

9. The method according to claim 8, wherein the relative humidity (RH) is 35% RH.

10. The method according to claim 8, wherein the sheet is at least substantially unimpregnated when applied on the sub-layer.

11. The method according to claim 8, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet.

12. The method according to claim 8, wherein the sub-layer consists essentially of the thermosetting binder.

13. The method according to claim 8, further comprising printing, preferably by digital printing, a dé

cor on the sheet when arranged on the sub-layer.

14. The method according to claim 13, wherein the sheet is adhered to the sub-layer prior to printing.

15. The method according to claim 8, further comprising applying moisture to the thermosetting binder, the sub-layer, the sheet, and/or the substrate prior to pressing.

16. The method according to claim 8, wherein a moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.

17. A method to produce a building panel, comprising

providing a substrate,

applying at least one thermosetting binder on the substrate,

controlling reactivity of said at least one thermosetting binder by applying different types and/or forms of thermosetting binders on the substrate,

applying a sheet on said at least one thermosetting binder, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and

pressing the substrate, said at least one thermosetting binder and the sheet together to form a building panel, thereby said at least one thermosetting binder impregnates the sheet.

18. The method according to claim 17, wherein controlling reactivity of said at least one thermosetting binder comprises applying a first thermosetting binder in liquid form and applying a second thermosetting binder in powder form on the first thermosetting binder.

19. The method according to claim 17, wherein the sheet is at least substantially unimpregnated when applied on said at least one thermosetting binder.

20. A method to produce a building panel, comprising

providing a substrate,

applying a thermosetting binder in dry form on the substrate for forming a sub-layer,

applying a sheet on the sub-layer, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and

pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet.

21. The method according to claim 20, wherein the sheet is at least substantially unimpregnated when applied on the sub-layer.

22. The method according to claim 20, wherein the sub-layer consists essentially of the thermosetting binder.

23. The method according to claim 20, wherein the sub-layer comprises the thermosetting binder and non-absorbing fillers.

24. The method according to claim 20, further comprising applying moisture to the thermosetting binder, the sub-layer, the sheet, and/or the substrate prior to pressing.

25. The method according to claim 20, wherein a moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.

26. The method according to claim 20, further comprising

printing, preferably by digital printing, a dé

cor on the sheet when arranged on the sub-layer.

27. The method according to claim 26, wherein the sheet is adhered to the sub-layer prior to printing.

28. A semi-finished product adapted to form, or form part of, a building panel, comprising

a substrate,

a sub-layer arranged on the substrate,

a sheet arranged on the sub-layer, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and

wherein the moisture content of the sub-layer is 5-35 wt %, such that the sheet is adhered to the sub-layer.

29. The method according to claim 28, wherein the sub-layer

consists essentially of the thermosetting binder.

30. The method according to claim 28, wherein the sub-layer comprises the thermosetting binder and non-absorbing fillers.

31. The semi-finished product according to claim 28, wherein the thermosetting binder is a B-stage thermosetting binder.

32. The semi-finished product according to claim 28,

wherein the thermosetting binder is in A-stage and B-stage.

33. The semi-finished product according to claim 28, wherein the sub-layer has impregnated less than half the thickness of the sheet.