Method of manufacturing a surface layer of building panels

• US 8,920,874 B2
• Filed: 06/07/2013
• Issued: 12/30/2014
• Est. Priority Date: 01/15/2010
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Ziegler, Goran, Lindgren, Kent
• Primary Examiner(s): PARKER, FREDERICK JOHN
• Application Number:
  US13/912,564
• Publication Number:
  US 20130273245A1
• Time in Patent Office: 571 Days
• Field of Search: 427201-203, 427/370
• US Class Current: 427/202
• CPC Class Codes: B05D 3/02 by baking B05D3/04 takes precedence
• CPC Class Codes: B05D 3/12 by mechanical means
• CPC Class Codes: B44C 5/043 containing wooden elements
• CPC Class Codes: E04B 1/62 Insulation or other protection; Elements or use of specified material therefor chemical compositions C01 - C11; implements for applying insulation or sealings E04F21/00; buildings to withstand, or to provide protection against, external undesired influences E04H9/00; sealing pipes in walls or partitions F16L5/02; shielding against dangerous radiation G21F
• 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 15/10 of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: Y10T 428/265 1 mil or less
• CPC Class Codes: Y10T 428/31982 Wood or paper
• CPC Class Codes: Y10T 428/31989 Of wood

Abstract

A method of manufacturing a surface layer is provided. The method includes applying a sublayer having a mix of wood fibers and a resin on a carrier, applying a powder layer having a mix of refined fibers and a binder on the sublayer, with the sublayer being arranged between the carrier and the powder layer, and curing the powder layer by applying heat and pressure.

Claims

1. A method of manufacturing a surface layer comprising the steps of:

applying a sublayer comprising a mix of wood fibres and a resin on a carrier;

applying a powder layer comprising a mix of refined fibres and a binder on the sublayer, wherein the sublayer is arranged between the carrier and the powder layer; and

curing the powder layer by applying heat and pressure on the powder layer, wherein the powder layer is cured to a surface layer.

2. The method as claimed in claim 1, wherein the mix forming the powder layer further comprises wear resistant particles.

3. The method as claimed in claim 2, wherein the wear resistant particles are aluminium oxide.

4. The method as claimed in claim 1, wherein the mix forming the powder layer further comprises pigments.

5. The method as claimed in claim 1, wherein the powder layer is a dry powder layer.

6. The method as claimed in claim 1, wherein the carrier is a wood fibre based core, and the surface layer is attached to the wood fibre based core to obtain a panel, wherein the core comprises a major part of the panel.

7. The method as claimed in claim 6, wherein the panel is a floor panel.

8. The method as claimed in claim 6, wherein the carrier is an HDF panel.

9. The method as claimed in claim 1, wherein the thickness of the surface layer is less than about 1 mm.

10. The method as claimed in claim 1, wherein the binder is a resin and the weight ratio of resin compared to refined fibres is higher than about 120%.

11. The method as claimed in claim 1, wherein the binder is a resin and the weight ratio of resin compared to refined fibres is in the range of about 120% to about 180%.

12. The method as claimed in claim 1, wherein the step of applying the sublayer on the carrier comprises scattering the mix of wood fibres and resin on the carrier.

13. The method as claimed in claim 1, further comprising a step of scattering a top layer above the powder layer.

14. The method as claimed in claim 6, wherein a balancing layer is applied to a surface of the wood fibre based core that is opposite the sublayer and the surface layer.

15. A method of manufacturing a surface layer comprising the steps of:

applying a powder layer comprising a mix of refined fibres and a resin on a carrier, wherein the weight ratio of resin to refined fibres is higher than about 120%; and

curing the powder layer to a wear resistant layer by applying heat and pressure on the powder layer.

16. The method as claimed in claim 15, wherein the mix forming the powder layer further comprises wear resistant particles.

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

18. The method as claimed in claim 15, wherein the mix forming the powder layer further comprises pigments.

19. The method as claimed in claim 15, wherein the powder layer is a dry powder layer.

20. The method as claimed in claim 15, wherein the carrier is a wood fibre based core, and the surface layer is attached to the wood fibre based core to obtain a panel.

21. The method as claimed in claim 20, wherein the panel is a floor panel.

22. The method as claimed in claim 15, wherein the thickness of the surface layer is less than about 1 mm.

23. The method as claimed in claim 20, wherein the carrier is an HDF panel.

24. The method as claimed in claim 15, wherein the weight ratio of resin compared to refined fibres is in the range of about 120% to about 180%.

25. The method as claimed in claim 15, further comprising a step of scattering a sublayer on the carrier.

26. The method as claimed in claim 15, further comprising a step of scattering a top layer above the powder layer.

27. A method of manufacturing a surface layer comprising the steps of:

applying a powder layer comprising a mix of refined fibres and a binder on a carrier,

applying a top layer comprising refined fibres on the powder layer, and

curing the powder layer to a surface layer by applying heat and pressure on the powder layer.

28. The method as claimed in claim 27, wherein the mix further comprises wear resistant particles.