Wood fibre based panels with a thin surface layer

• US 8,419,877 B2
• Filed: 04/06/2009
• Issued: 04/16/2013
• Est. Priority Date: 04/07/2008
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Ceraloc Innovation Belgium BVBA
• Inventors: Pervan, Darko, Jacobsson, Jan, Lindgren, Kent, Hkansson, Niclas, Bouck, Eddy, Ziegler, Gran
• Primary Examiner(s): Nguyen, Khanh P
• Assistant Examiner(s): BLADES, JOHN A
• Application Number:
  US12/418,955
• Publication Number:
  US 20100092731A1
• Time in Patent Office: 1,471 Days
• Field of Search: 156/196, 156/219
• US Class Current: 156/219
• CPC Class Codes: B27M 1/08 by multi-step processes
• 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: B27N 3/06 Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
• 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 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 37/1027 Pressing using at least one press band
• CPC Class Codes: B32B 37/153 at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 37/156 at least one layer is calendered and immediately laminated
• CPC Class Codes: B32B 37/24 with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/145 Printing
• CPC Class Codes: E04C 2/16 of fibres, chips, vegetable stems, or the like
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/30 : characterised by the shape or structure translucent E04C2/54
• CPC Class Codes: E04C 2002/005 : Appearance of panels
• 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 15/181 : Insulating layers integrally formed with the flooring or the flooring elements
• CPC Class Codes: E04F 2201/0138 : by moving the sheets, plates or panels perpendicular to the main plane
• CPC Class Codes: E04F 2201/0153 : by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• CPC Class Codes: E04F 2201/0541 : adapted to be moved along the joint edge
• CPC Class Codes: E04F 2290/042 : with a facing or top layer for sound insulation
• CPC Class Codes: Y10T 156/1002 : with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1039 : Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31989 : Of wood

Abstract

Building panels with a thin and embossed surface layer and a sub layer between a surface layer and a core.

Claims

1. A method of manufacturing a floor board comprising a wood fibre based core, a thin surface layer and a sub layer between the surface layer and the core, the sub layer comprises wood fibres and a binder, wherein the method comprises the steps of:

mixing particles comprising wood fibres and an uncured binder for the sub layer;

applying the wood fibres and the uncured binder in a powder form for the sub layer on the core;

applying a surface layer on the wood fibres and the uncured binder; and

pressing;

the core,

the surface layer, and

the wood fibres and the uncured binder, in powder form, under increased pressure and temperature with an embossed pressing matrix such that the surface layer obtains upper portions and embossed portions lower than the upper portions, such that the embossed portions extend into the sub layer, and forming them into a floor board by curing the binder.

2. The method as claimed in claim 1, wherein the core is HDF.

3. The method as claimed in claim 1, wherein the thin surface layer has a thickness of about 0.3-1.0 mm.

4. The method as claimed in claim 1, wherein the binder in the sub layer is a thermosetting resin.

5. The method as claimed in claim 1, wherein the method further comprises applying water or a liquid resin on the core or into the fibres of the sub layer prior to pressing.

6. The method as claimed in claim 1, wherein the surface layer comprises a homogenous mix of wood fibre particles, wear resistant particles, binders and colour pigments.

7. The method as claimed in claim 6, wherein the wear resistant particles comprise aluminum oxide.

8. The method as claimed in claim 1, wherein the surface layer comprises a binder of a thermosetting resin.

9. The method as claimed in claim 1, wherein the surface layer comprises a binder of a thermoplastic resin.

10. The method as claimed in claim 1, wherein the surface layer is a printed paper with an overlay.

11. The method as claimed in claim 1, wherein the surface layer is a wood veneer.

12. The method as claimed in claim 1, wherein the method comprises a machining operation comprising forming the floor board to a floor panel with mechanical locking systems at opposite edges.

13. The method as claimed in claim 1, wherein the step of applying the wood fibres and the binder comprises scattering the wood fibres and the binder with a roller comprising needles or engraved protruding portions.

14. The method as claimed in claim 13, wherein the amount of needles or the engraved protruding portions is about 40-120 per cm².

15. The method as claimed in claim 1, wherein the step of applying the wood fibres and the binder comprises scattering a dry powder mixture of the wood fibres and the binder onto the core.

16. The method as claimed in claim 1, wherein the wood fibres have an average length to thickness ratio of about 30 or smaller.

17. The method as claimed in claim 1, wherein the wood fibres have an average length to thickness ratio of about 10 or smaller.

18. The method as claimed in claim 1, wherein the wood fibres have an average length smaller than 0.5 mm.

19. The method as claimed in claim 1, wherein the wood fibres have an average length of 0.1 to 0.3 mm.

20. The method as claimed in claim 1, wherein the sub layer comprises about 70-85% (weight) wood fibers and about 15-30% (weight) melamine resin.

21. The method as claimed in claim 1, wherein the step of applying the surface layer comprises scattering a dry powder mixture of wood fibre particles, wear resistant particles, binders and colour pigments.