Method of manufacturing a layer

• US 9,352,499 B2
• Filed: 04/12/2012
• Issued: 05/31/2016
• Est. Priority Date: 04/12/2011
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Ryberg, Melker, Ziegler, Gran, Bergelin, Marcus, Jacobsson, Jan
• Primary Examiner(s): Heincer, Liam J
• Assistant Examiner(s): HILL, NICHOLAS E
• Application Number:
  US13/445,379
• Publication Number:
  US 20120264853A1
• Time in Patent Office: 1,510 Days
• Field of Search: 523/13, 427/209, 427/389.9, 427/394
• US Class Current: 1/1
• CPC Class Codes: B27N 1/00 Pretreatment of moulding material
• CPC Class Codes: B27N 3/04 from fibres
• CPC Class Codes: B27N 3/18 Auxiliary operations, e.g. preheating, humidifying, cutting-off
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B29C 41/28 by depositing flowable material on an endless belt
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2105/246 Uncured, e.g. green
• CPC Class Codes: B29L 2007/008 Wide strips, e.g. films, webs
• CPC Class Codes: C08L 61/28 with melamine
• CPC Class Codes: E04F 15/102 of fibrous or chipped materials, e.g. bonded with synthetic resins

Abstract

A method of manufacturing a separate and continuous layer being essentially uncured. The method includes applying a powder mix including fibers and a thermosetting binder on a carrier, forming a powder mix layer, wherein the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured, and releasing the powder mix layer from the carrier. Also, a layer and a method for manufacturing a building panel.

Claims

1. A method of manufacturing a layer being essentially uncured, comprising:

applying a powder mix comprising fibres and a thermosetting binder directly on, without an intervening layer, a surface of a web, the web being one of a paper sheet, a rice sheet, a sugar paper, a netting, mineral fibres, carbon fibres, textile fibres or nylon fibres, and

after applying the powder mix, forming a powder mix layer, wherein the powder mix is connected together, with the thermosetting binder binding the fibers, such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured.

3. The method according to claim 1, wherein said powder mix layer is flexible.

4. The method according to claim 1, wherein the step of forming the powder mix layer includes applying moisture on the powder mix such that the powder mix is connected together.

5. The method according to claim 4, wherein a liquid forming the moisture is water, an alcohol, an ink, a binder, or a mixture thereof.

6. The method according to claim 1, wherein the step of forming the powder mix layer includes drying the powder mix such that the powder mix is connected together.

7. The method according to claim 1, wherein the step of forming the powder mix layer includes applying pressure on the powder mix such that the powder mix is connected together.

8. The method according to claim 1, wherein the fibres are wood fibres, plastic fibres, mineral fibres or vegetable fibres, or a mixture thereof.

9. The method according to claim 1, wherein the thermosetting binder is a melamine formaldehyde resin.

10. The method according to claim 1, further comprising printing a print in the powder mix and/or in the powder mix layer.

11. The method according to claim 10, further comprising printing a print on both sides of the powder mix layer.

12. The method according to claim 1, further comprising applying liquid in a pattern.

13. The method according to claim 1, further comprising tearing the powder mix layer into smaller portions forming decorative elements.

14. The method according to claim 1, further comprising curing the powder mix layer.

15. The method according to claim 1, wherein the powder mix layer is a protective layer.

16. The method according to claim 10, wherein the printing is by means of digital printing.

17. The method according to claim 12, wherein the pattern is applied by means of digital printing.

18. The method according to claim 1, wherein the web is a paper sheet, a rice sheet or a sugar paper.

19. The method according to claim 1, wherein the web comprises a paper sheet, mineral fibres, carbon fibres, textile fibres or nylon fibres.

20. The method according to claim 1, where in the web is provided from a supply roll.

21. The method according to claim 1, wherein the step of applying the powder mix on the web comprises applying the powder mix on a carrier and arranging a first face of the web on the powder mix.

22. The method according to claim 21, wherein the web comprises a paper sheet, mineral fibres, carbon fibres, textile fibres or nylon fibres.

23. The method according to claim 21, further comprises releasing the powder mix layer from the carrier.

24. The method according to claim 21, further comprises applying additional powder mix comprising fibres and a thermosetting binder on a second face of the web.

25. The method according to claim 24, further comprises releasing the powder mix layer from the carrier.

26. The method according to claim 1, further comprising the step of applying moisture on the web prior to applying the powder mix.

27. The method according to claim 26, wherein a liquid forming the moisture is water, an alcohol, an ink, a binder or a mixture thereof.

2. A method of manufacturing a layer being essentially uncured, comprising:

applying a powder mix comprising fibres and a thermosetting binder directly on, without an intervening layer, a surface of a web, wherein the web consists of only one of a paper sheet, a rice sheet, a sugar paper, a netting, a wire structure, mineral fibres, carbon fibres, textile fibres or nylon fibres, and

after applying the powder mix, forming a powder mix layer, wherein the powder mix is connected together, with the thermosetting binder binding the fibers, such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured.