Fibre based panels with a decorative wear resistance surface

• US 8,349,234 B2
• Filed: 12/22/2010
• Issued: 01/08/2013
• Est. Priority Date: 01/15/2010
• Status: Expired due to Fees

• Current Assignee: Valinge Innovation AB
• Original Assignee: Ceraloc Innovation Belgium BVBA
• Inventors: Ziegler, Göran, Jacobsson, Jan
• Primary Examiner(s): Theisen, Mary F
• Application Number:
  US12/976,350
• Publication Number:
  US 20110175251A1
• Time in Patent Office: 748 Days
• Field of Search: None
• US Class Current: 264/112
• CPC Class Codes: B29C 43/021 characterised by the shape of the surface
• CPC Class Codes: B29C 43/14 in several steps
• CPC Class Codes: B29C 43/145 for making multicoloured articles
• CPC Class Codes: B29L 2007/002 Panels; Plates; Sheets
• CPC Class Codes: B29L 2031/10 Building elements, e.g. bricks, blocks, tiles, panels, posts, beams frameless domes B29L2025/00, doors B29L2031/724
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B44C 1/24 Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: B44C 5/0476 with abrasion resistant properties
• CPC Class Codes: E04F 13/0871 having an ornamental or specially shaped visible surface E04F13/0867 takes precedence
• CPC Class Codes: E04F 13/0875 having a basic insulating layer and at least one covering layer
• CPC Class Codes: Y10T 156/1041 Subsequent to lamination
• CPC Class Codes: Y10T 428/24901 including coloring matter
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix

Abstract

A method to produce building panels is disclosed which method includes the step of applying a layer (5) comprising a mix of fibers (14), binder (12), and wear resistant particles (12) on a carrier (6), pressing the layer (5) with an embossed matrix (2a, 2b) and providing embossed portions (4) and filling the embossed portions with decorative a substance (3).

Claims

1. A method of manufacturing a building panel comprising the steps of:

applying a layer comprising a mix of fibres, binder, and wear resistant particles on a carrier;

pressing the layer with an embossed matrix and providing embossed portions; and

after pressing, and in a separate step, filling the embossed portions with a decorative substance.

2. The method as claimed in claim 1, wherein the panel is a floor panel.

3. The method as claimed in claim 1, the step further comprising an additional pressing that is made after filling of the embossed portions.

4. The method as claimed in claim 1, wherein the carrier is a HDF board.

5. The method as claimed in claim 1, wherein the decorative substance comprises wear resistant particles and a binder.

6. The method as claimed in claim 1, wherein the decorative substance comprises colour pigments and wood fibres.

7. The method as claimed in claim 2, wherein the carrier is a HDF board.

8. The method as claimed in claim 3, wherein the carrier is a HDF board.

9. The method as claimed in claim 5, wherein the wear resistant particles of the decorative substance are aluminium oxide particles.

10. The method as claimed in claim 2, where the decorative substance comprises wear resistant particles.

11. The method as claimed in claim 10, wherein the wear resistant particles of the decorative substance are aluminium oxide particles.

12. The method as claimed in claim 3, where the decorative substance comprises wear resistant particles.

13. The method as claimed in claim 12, wherein the wear resistant particles of the decorative substance are aluminium oxide particles.

14. The method as claimed in claim 4, where the decorative substance comprises wear resistant particles.

15. The method as claimed in claim 14, wherein the wear resistant particles of the decorative substance are aluminium oxide particles.

16. The method as claimed in claim 1, wherein the wear resistant particles are aluminium oxide particles.

23. The method as claimed in claim 1, where the decorative substance comprises wear resistant particles.

24. The method as claimed in claim 23, wherein the decorative substance further comprises a color pigment.

17. A method of manufacturing a building panel comprising the steps of:

applying a layer comprising a mix of fibres, binder, and wear resistant particles on a carrier;

pressing the layer with an embossed matrix and providing an embossed portion; and

filling the entirety of the volume of the embossed portion with a decorative substance.

25. The method as claimed in claim 17, where the decorative substance comprises wear resistant particles.

18. A method of manufacturing a building panel comprising the steps of:

applying a layer comprising a mix of fibres, binder, and wear resistant particles on a carrier;

pre-pressing the layer with an embossed matrix and providing embossed portions;

filling the embossed portions with a decorative substance; and

curing the layer under heat and pressure.

19. The method of claim 18, wherein the filling step comprises filling the entirety of the volume of the embossed portion with a decorative substance.

20. The method of claim 19, wherein the cured layer is flat across the embossed portion.

26. The method as claimed in claim 18, where the decorative substance comprises wear resistant particles.

21. A method of manufacturing a building panel comprising the steps of:

applying a layer comprising a mix of fibres, binder, and wear resistant particles on a carrier;

pressing the layer with an embossed matrix and providing embossed portions; and

filling the embossed portions with a powdered colour pigment in a dry form.

27. The method as claimed in claim 21, where the decorative substance comprises wear resistant particles.

22. A method of manufacturing a building panel comprising the steps of:

applying a layer comprising a mix of fibres, binder, and wear resistant particles on a carrier;

pressing the layer with an embossed matrix and providing embossed portions; and

filling the embossed portions with a decorative substance, by applying the decorative substance by scattering combined with vibration.

28. The method as claimed in claim 22, where the decorative substance comprises wear resistant particles.