Fibre based panels with a decorative wear resistance surface

• US 8,784,587 B2
• Filed: 12/22/2010
• Issued: 07/22/2014
• Est. Priority Date: 01/15/2010
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Lindgren, Kent, Jacobsson, Jan, Pervan, Darko
• Primary Examiner(s): Goff, John
• Assistant Examiner(s): Kwon, Hannuri L
• Application Number:
  US12/976,478
• Publication Number:
  US 20110189448A1
• Time in Patent Office: 1,308 Days
• Field of Search: 427/195, 427/198, 427/201, 427/202, 427/203, 427/260, 427/277, 427/356, 427/189, 428/103, 428/104, 156/279, 156/296, 156/297, 156/63, 156/71, 156/283, 156/298, 156/307.1, 156/307.3, 156/307.7, 156/308.2, 523/091, 523/093, 523/091.5, 264/109, 264/112, 264/113, 264/118, 264/119, 264/123, 264/125, 264/245
• US Class Current: 156/71
• CPC Class Codes: B44C 1/24 Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: B44C 3/005 Removing selectively parts of at least the upper layer of a multi-layer article
• CPC Class Codes: B44C 5/0461 used as wall coverings
• 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: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree

Abstract

Building panels and a method to produce such panels including a solid decorative surface having a decorative wear layer including fibers, binders, color substance and wear resistant particles. A method of manufacturing a building panel having a decorative surface connected to a core wherein the surface has at least two homogenous layers, a lower sub layer and an upper decorative layer, the upper decorative layer including fibers, a first color substance a binder and wear resistant particles, the lower sub layer including fibers, a second color substance, and a binder, whereby the method including the steps of applying the layers comprising a mix of fibers, binder, wear resistant particles and color substance on a core wherein the layers comprise different colors, displacing particles from their original position such that particles from the sub layer are visible on the decorative surface, and curing the layers by providing heat and pressure.

Claims

1. A method of manufacturing a building panel having a decorative surface connected to a core wherein the surface comprises at least two homogenous layers, the at least two homogenous layers comprising a lower sub layer and an upper decorative layer,

the upper decorative layer comprising a first powder mix of fibres, a first colour substance, a binder and wear resistant particles,

the lower sub layer comprising a second powder mix of fibres, a second colour substance, and a binder,

whereby the method comprises the steps of:

applying the lower sub layer comprising the second powder mix over a core, and applying the upper decorative layer comprising the first powder mix over the lower sub layer wherein the colour of the upper decorative layer is different from the colour of the lower sub layer;

displacing a portion of the first powder mix from an original position such that a portion of the second powder mix from the sub layer is visible on the decorative surface; and

after displacement, curing the upper decorative layer and the lower sub layer by providing heat and pressure, such that an upper surface of the visible portion of the second powder mix from the sub-layer is in the same plane as an upper surface of the first powder mix.

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

3. The method as claimed in claim 1, wherein the core is a High Density Fibreboard board.

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

5. The method as claimed in claim 1, wherein the first colour substance comprises a first colour pigment and wherein the second colour substance comprises a second colour pigment.

6. The method as claimed in claim 2, wherein the core is a High Density Fibreboard board.

7. The method as claimed in claim 2, wherein the first colour substance comprises colour pigments and wood fibres.

8. The method as claimed in claim 3, wherein the first colour substance comprises colour pigments and wood fibres.

9. The method as claimed in claim 1, wherein the portion of the first powder mix is displaced from an original position by using a mechanical tool.

10. The method as claimed in claim 9, wherein the tool is a needle.

11. The method as claimed in claim 1, wherein the portion of the first powder mix is displaced from an original position by using a vacuum to remove powder.

12. The method as claimed in claim 1, wherein the portion of the first powder mix is displaced from an original position by adding first powder mix in a manner to displace second powder mix.

13. The method as claimed in claim 1, the method further comprising, after curing, treating the surface with a laser to create a design effect.

14. The method as claimed in claim 1, the method further comprising, after curing, treating the surface with a steel brush in order to remove softer material surface.

15. The method as claimed in claim 1, the curing step comprising using a structured press plate that is coordinated with a pattern created by the displacement of powder between the layers.

16. The method as claimed in claim 1, wherein the displacement forms a mixture of the first and second powder mixes.