Powder mix and a method for producing a building panel

• US 8,728,564 B2
• Filed: 04/11/2012
• Issued: 05/20/2014
• Est. Priority Date: 04/12/2011
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Ziegler, Gran, Persson, Hans, Rittinge, Rickard
• Primary Examiner(s): CAMERON, ERMA C
• Application Number:
  US13/444,604
• Publication Number:
  US 20120263878A1
• Time in Patent Office: 769 Days
• Field of Search: None
• US Class Current: 427/8
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B29C 43/34 Feeding the material to the mould or the compression means B29C43/085 takes precedence
• CPC Class Codes: C08K 2003/2227 of aluminium
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/36 Silica
• CPC Class Codes: C08K 7/02 Fibres or whiskers
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N

Abstract

A powder mix layer for a building panel and a method for producing a building panel with a decorative surface produced from a powder mix layer with a controlled loss on cure.

Claims

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

applying a powder mix layer on a substrate, the powder mix layer comprising a fiber and a binder; and

applying heat and pressure to the powder mix layer and curing the powder mix layer having a loss on cure in the range of about 2 to about 7 wt-%, and thereby obtaining a layer of the building panel formed by the powder mix layer.

2. The method according to claim 1, wherein the powder mix layer comprises wood fibres and a binder.

3. The method according to claim 2, wherein the substrate is a wood-based core and the substrate is a core of the building panel.

4. The method of claim 3, the method further comprising determining the loss on cure for the powder mix layer.

5. The method of claim 4, the method further comprising adjusting the loss on cure of the powder mix layer by a step of applying a stabilisation fluid, or a step of drying, or a combination thereof, such that the powder mix layer obtains the loss on cure in said range.

6. The method according to claim 3, wherein the powder mix layer has a loss on cure in the range of about 3.5 to about 5.5 wt-%.

7. The method according to claim 1, comprising the further step of applying a stabilisation fluid on the powder mix layer.

8. The method according to claim 7, further comprising adjusting the loss on cure of the powder mix layer by a step of applying the stabilisation fluid, or a step of drying, or a combination thereof such that the powder mix layer obtains the loss on cure in said range.

9. The method of claim 7, the method further comprising determining the loss on cure for the powder mix layer.

10. The method of claim 9, the method further comprising adjusting the loss on cure of the powder mix layer by a step of applying the stabilisation fluid, or a step of drying, or a combination thereof, such that the powder mix layer obtains the loss on cure in said range.

11. The method according to claim 1, comprising the further step of drying the powder mix layer.

12. The method according to claim 11, wherein the step of drying comprises applying heat with an effect of about 15-25 kW/m and a feeding speed of the substrate in the range of about 1-4 m/min.

13. The method according to claim 1, comprising the further step of fixing the powder mix layer to the substrate.

14. The method according to claim 13, wherein the step of fixing comprises applying stabilisation fluid and drying with an effect of about 15-25 kW/m and a feeding speed of the substrate in the range of about 1-4 m/min.

15. The method according to claim 1, wherein the powder mix layer is applied by scattering.

16. The method according to claim 1, wherein the powder mix layer is applied as a continuous powder mix sheet.

17. The method according to claim 1, wherein the substrate is a core of the building panel.

18. The method according to claim 17, wherein the layer forms a decorative surface layer arranged on the core.

19. The method according to claim 17, wherein the substrate is a wood-based core.

20. The method according to claim 1, wherein the powder mix layer has a loss on cure in the range of about 2.5 to about 7 wt-%.

21. The method according to claim 1, wherein the powder mix layer has a loss on cure in the range of about 3 to about 6 wt-%.

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

applying a powder mix layer on a substrate, the powder mix layer comprising a fiber and a binder;

determining the loss on cure for the powder mix layer and, if outside the range of about 2 to about 7 wt-%, adjusting the loss on cure of the powder mix layer by a step of applying a stabilisation fluid, or a step of drying, or a combination thereof, such that the powder mix layer obtains the loss on cure in said range; and

applying heat and pressure to the powder mix layer and curing the powder mix layer having a loss on cure in the range of about 2 to about 7 wt-%, and thereby obtaining a layer of the building panel formed by the powder mix layer.