Single layer scattering of powder surfaces

• US 8,993,049 B2
• Filed: 08/08/2013
• Issued: 03/31/2015
• Est. Priority Date: 08/09/2012
• Status: Active Grant

• Current Assignee: Ceraloc Innovation Ab (Pervan Holding AB)
• Original Assignee: Välinge Flooring Technology AB
• Inventors: Pervan, Darko
• Primary Examiner(s): PARKER, FREDERICK JOHN
• Application Number:
  US13/962,272
• Publication Number:
  US 20140044872A1
• Time in Patent Office: 600 Days
• Field of Search: 427/196, 427/202, 427/203
• US Class Current: 427/196
• CPC Class Codes: B05C 19/04 the particulate material being projected, poured or allowed to flow onto the surface of the work B05C19/02 takes precedence; involving spraying or electrostatic projection B05B B05C19/005 takes precedence
• CPC Class Codes: B05D 1/36 Successively applying liquids or other fluent materials, e.g. without intermediate treatment
• CPC Class Codes: B05D 1/38 with intermediate treatment intermediate treatment per se B05D3/00
• CPC Class Codes: B05D 2401/32 applied as powders
• CPC Class Codes: B05D 7/56 Three layers or more
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: E04F 15/102 of fibrous or chipped materials, e.g. bonded with synthetic resins
• CPC Class Codes: E04F 15/107 composed of several layers, e.g. sandwich panels layered products in general B32B; producing decorative panels or veneers B44C5/04

Abstract

A method of forming a surface layer, the surface layer including a first, second and third layer, the method including: forming a first layer including at least 50% by weight of fibers, forming a second layer including at least 50% by weight of wear resistant particles, forming a third layer including at least 50% by weight of particles of a thermosetting binder, and pressing, under heat and pressure, the first, second, and third layers together to combine and mix the fibers of the first layer, the wear resistant particles of the second layer, and the thermosetting binder of the third layer to form the surface layer.

Claims

1. A method of forming a surface layer, the surface layer comprising a first, second and third layer, the method comprising:

forming a first layer comprising at least 50% by weight of fibres,

forming a second layer comprising at least 50% by weight of wear resistant particles,

forming a third layer comprising at least 50% by weight of particles of a thermosetting binder, and

pressing, under heat and pressure, the first, second, and third layers together to combine and mix the fibres of the first layer, the wear resistant particles of the second layer, and the thermosetting binder of the third layer to form the surface layer.

2. The method as claimed in claim 1, wherein the first layer is applied on a substrate prior to pressing.

3. The method as claimed in claim 1, wherein the first, second and third layers are applied on a core prior to pressing.

4. The method as claimed in claim 3, wherein the core is a wood fibre based board.

5. The method as claimed in claim 3, wherein the surface layer and the core form a panel.

6. The method as claimed in claim 1, wherein the fibres are wood fibres.

7. The method as claimed in claim 1, wherein the thermosetting binder is a melamine formaldehyde binder.

8. The method as claimed in claim 7, wherein the melamine formaldehyde binder is in powder form.

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

10. The method as claimed in claim 1, wherein the second layer is applied on the first layer and the third layer is applied on the second layer.

11. The method as claimed in claim 1, wherein the first, second and third layers each comprises a material with a material content of at least about 80% of the total weight of the layer.

12. The method as claimed in claim 1, wherein the first layer comprises colour pigments and at least about 80% by weight wood fibres.

13. The method as claimed in claim 1, where the first layer comprises at least 80% by weight of fibres.

14. The method as claimed in claim 1, where the second layer comprises at least 80% by weight of wear resistant particles.

15. The method as claimed in claim 1, where the third layer comprises at least 80% by weight of particles of a thermosetting binder.

16. The method as claimed in claim 1, wherein at least one of the first, second or third layers further comprises colour pigments.

17. The method as claimed in claim 1, further comprising forming a fourth layer comprises colour pigments, wherein the fourth layer is pressed with the first, second, and third layers to form the surface layer.

18. The method as claimed in claim 1, wherein the first layer is applied in powder form.

19. The method as claimed in claim 1, wherein the second layer is applied in powder form.

20. The method as claimed in claim 1, wherein the third layer is applied in powder form.

21. The method as claimed in claim 1, wherein the first and second layers are applied in powder form.

22. The method as claimed in claim 3, further comprising pressing the first layer, second layer, third layer, and core, under heat and pressure to form the surface layer on the core.

23. The method as claimed in claim 22, wherein the core comprises a front side and a rear side, the core comprising a balancing layer on a rear side, the surface layer being formed on the front side.

24. The method as claimed in claim 23, wherein the balancing layer is in powder form.