Method for producing a building panel

• US 9,403,286 B2
• Filed: 11/25/2014
• Issued: 08/02/2016
• Est. Priority Date: 03/19/2012
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Vetter, Georg, Jacobsson, Jan, Rittinge, Rickard, Persson, Hans
• Primary Examiner(s): SELLMAN, CACHET I
• Application Number:
  US14/553,196
• Publication Number:
  US 20150079280A1
• Time in Patent Office: 616 Days
• Field of Search: 427/201, 427/180, 427/196, 156/62.2, 428/537.5, 428/528
• US Class Current: 1/1
• CPC Class Codes: B27N 7/005 Coating boards, e.g. with a finishing or decorating layer
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2260/025 Particulate layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2264/067 Wood particles
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/414 Translucent
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: E04B 1/00 Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs scaffolds, shutterings E04G; structures specially adapted for buildings for special purposes, general layout of buildings, e.g. modular co-ordination, E04H
• 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 for producing a building panel. The method includes forming a mix including wood particles, a solvent, a binder and optionally at least one additive, wherein the binder and optionally said at least one additive are homogenously distributed in the mix by means of the solvent and wherein the binder impregnates the wood particles, drying the mix, applying the mix on a substrate, and forming a layer by applying heat and pressure to the mix.

Claims

1. A method for producing a building panel, comprising

forming a mix comprising wood particles, a solvent, a binder and at least one pigment, wherein the binder and said at least one pigment are homogenously distributed in the mix by means of the solvent and wherein the binder impregnates and binds to the wood particles, thereby forming granulates, the granulate being formed by a wood particle, binder and pigment,

drying the mix to form a dried mix,

applying the dried mix on a substrate, and

forming a building panel by applying heat and pressure to the dried mix, the building panel comprising the substrate and a dried mix layer.

2. The method according to claim 1, wherein the dried mix forms at least part of a decorative surface layer.

3. The method according to claim 1, wherein the step of forming the mix comprises adding the solvent to a mix of the wood particles, the binder and said at least one pigment.

4. The method according to claim 1, wherein the step of forming the mix comprises mixing the wood particles with the solvent comprising the binder and said at least one pigment.

5. The method according to claim 1, wherein the mix further comprises wear resistant particles.

6. The method according to claim 5, wherein the wear resistant particles are aluminium oxide.

7. The method according to claim 1, wherein the substrate is a core.

8. The method according to claim 7, wherein the core is a wood-based core.

9. The method according to claim 8, wherein the wood-based core is MDF, HDF, OSB, WPC or particle board.

10. The method according to claim 1, wherein the substrate is a decorative layer.

11. The method according to claim 1, wherein the step of applying the dried mix on the substrate comprises applying the dried mix on an additional layer formed of wood particles and a dry binder, the additional layer being on the substrate.

12. The method according to claim 1, wherein the method further comprises forming an additional layer over said dried mix layer, such that said dried mix layer forms a sub-layer.

13. The method according to claim 12, wherein the additional layer is formed on the dried mix prior to the step of forming the building panel.

14. The method according to claim 1, further comprising printing a print in the dried mix.

15. The method according to claim 14, wherein the printing is a digital printing.

16. The method according to claim 1, wherein the step of forming and/or drying the mix is performed under vacuum.

17. The method according to claim 1, wherein the mix further comprises at least one additive.

18. The method according to claim 17, wherein said at least one additive is a wetting agent, a release agent, a catalyst, an antistatic agent, a curing agent, a foaming agent, a coupling agent, a plasticizer or a compatibilizer.

19. The method according to claim 1, wherein the binder is a thermosetting resin.

20. The method according to claim 18, wherein the binder is an amino resin.

21. The method according to claim 18, wherein the binder is melamine formaldehyde resin.

22. The method according to claim 1, wherein the binder is a thermoplastic resin.

23. The method according to claim 1, wherein the wood particles are recycled, virgin or processed.

24. The method according to claim 1, wherein the solvent is water, a glycol, a polyol or an alcohol.

25. The method according to claim 1, wherein the dried mix is applied directly on the substrate.

26. A method for producing a building panel, comprising

applying a dried mix on a core, and

forming a building panel by applying heat and pressure to the dried mix,

wherein the dried mix is formed by drying a mix comprising wood particles, a solvent, a binder and at least one pigment, wherein the binder, and said at least one pigment, are homogenously distributed in the mix by means of the solvent and wherein the binder impregnates and binds to the wood particles, thereby forming granulates, the granulate being formed by a wood particle, binder and pigment.