Fibre based panels with a wear resistance surface

• US 9,783,996 B2
• Filed: 11/13/2008
• Issued: 10/10/2017
• Est. Priority Date: 11/19/2007
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Pervan, Darko, Lindgren, Kent, Jacobsson, Jan, Hkansson, Niclas, Bouck, Eddy, Ziegler, Gran
• Primary Examiner(s): Chevalier, Alicia
• Application Number:
  US12/270,257
• Publication Number:
  US 20090155612A1
• Time in Patent Office: 3,253 Days
• Field of Search: None
• 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 21/13 all layers being exclusively wood
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof
• CPC Class Codes: B32B 2471/00 : Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2605/00 : Vehicles
• 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: B32B 37/00 : Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• CPC Class Codes: B32B 37/1027 : Pressing using at least one press band
• CPC Class Codes: B32B 37/153 : at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 37/156 : at least one layer is calendered and immediately laminated
• CPC Class Codes: B32B 37/24 : with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate B32B37/15 takes precedence
• CPC Class Codes: B32B 38/06 : Embossing
• CPC Class Codes: B32B 38/145 : Printing
• CPC Class Codes: B44C 5/043 : containing wooden elements
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• 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 15/042 : the lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins
• CPC Class Codes: E04F 2201/0138 : by moving the sheets, plates or panels perpendicular to the main plane
• CPC Class Codes: E04F 2201/0153 : by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• CPC Class Codes: E04F 2201/0541 : adapted to be moved along the joint edge
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/24066 : Wood grain
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24901 : including coloring matter
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/27 : Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
• CPC Class Codes: Y10T 428/3167 : Of cork
• CPC Class Codes: Y10T 428/31848 : Next to cellulosic
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31989 : Of wood
• CPC Class Codes: Y10T 442/695 : Including a wood containing layer

Abstract

Building panels with a homogenous decorative surface having a wear layer comprising fibers, binders and wear resistant particles.

Claims

1. A building panel comprising a surface layer and a core,

the core comprising wood fibres, and

the surface layer comprising a substantially uniformly dispersed mix of wood fibres, a binder and wear resistant particles,

the wood fibres in the mix comprising unrefined wood fibers,

wherein the mix is in direct contact with the wood fibers of an upper part of the core.

2. The building panel as claimed in claim 1, wherein the panel is a floor panel comprising a balancing layer.

3. The building panel as claimed in claim 2, wherein the binder is a thermosetting or thermoplastic resin.

4. The building panel as claimed in claim 3 wherein the binder is a thermosetting resin.

5. The building panel as claimed in claim 4, wherein the wear resistant particles comprise aluminium oxide.

6. The building panel as claimed in claim 5, wherein the core is HDF or particleboard, wherein the surface layer further comprises colour pigments, and wherein the wood fibres in the surface layer comprise fibres of the same material type as in the core.

7. The building panel as claimed in claim 4, wherein the binder comprises a melamine formaldehyde resin.

8. The building panel as claimed in claim 7, wherein the wear resistant particles are bonded to the wood fibres with the melamine formaldehyde resin.

9. The building panel as claimed in claim 5, wherein the surface layer comprises a vertical portion with three horizontal planes extending parallel with the main plane of the panel wherein a first upper plane located in an upper part of the surface layer comprises a first aluminium oxide particle, a second intermediate plane located under the first aluminium oxide particle comprising wood particles and a third lower plane under the second plane comprising a second aluminium oxide particle and wherein aluminium oxide particles are in direct contact with an upper part of the core.

10. The building panel as claimed in claim 5, wherein the weight content of the aluminium oxide particles in the surface layer is in the range of about 5% to about 30% of the total weight of the surface layer.

11. The building panel as claimed in claim 5, wherein the weight content of the aluminium oxide particles in the surface layer is at least 100 gr/m2.

12. The building panel as claimed in claim 1, wherein the core is HDF.

13. The building panel as claimed in claim 1, wherein the core is a particleboard.

14. The building panel as claimed in claim 1, wherein the surface layer further comprises a print that extends into the surface below upper wear resistant particles.

15. The building panel as claimed in claim 1, wherein the surface layer comprises brushed portions with different fibre structures.

16. The building panel as claimed in claim 1, wherein the surface layer comprises brushed portions with different wear resistance.

17. The building panel as claimed in claim 1, wherein the surface layer comprises wood fibres that comprise lignin.

18. The building panel as claimed in claim 1, wherein the surface layer wood fibres are essentially smaller than 1 mm.

19. The building panel as claimed in claim 1, wherein the surface layer wood fibres are in powder form and essentially smaller than 0.5 mm.

20. The building panel as claimed in claim 1, wherein a panel edge comprises a mechanical locking system for locking of the panel with similar other panels and wherein such locking system is formed in the core.

21. A building panel comprising a surface layer connected to a core,

the core comprising wood fibres,

wherein the surface layer, which gives the panel decorative effect and wear resistance, is a substantially uniformly dispersed layer comprising a mix of wood fibres, colour pigments, binders and wear resistant particles, and

wherein the mix is in direct contact with the wood fibers of an upper part of the core.

22. The building panel as claimed in claim 21, wherein all parts of the surface layer are present at an outer surface of the surface layer and at an inner lower part which is connected to the core.

23. The building panel as claimed in claim 21, wherein the panel is a floor panel comprising a balancing layer.

24. The building panel as claimed in claim 21, wherein the binder is a thermosetting or thermoplastic resin.

25. The building panel as claimed in claim 24 wherein the binder is a thermosetting resin.

26. The building panel as claimed in claimed in claim 21, wherein the wear resistant particles comprise aluminium oxide.

27. The building panel as claimed in claim 24, wherein the binder comprises a melamine formaldehyde resin.

28. The building panel as claimed in claim 27, wherein the wear resistant particles are bonded to the fibres with the melamine formaldehyde resin.

29. The building panel as claimed claim 21, wherein the surface layer comprises a vertical portion with three horizontal planes extending parallel with the main plane of the panel wherein a first upper plane located in an upper part of the surface layer comprises a first aluminium oxide particle, a second intermediate plane located under the first aluminium oxide particle comprising wood particles and a third lower plane under the second plane comprising a second aluminium oxide particle and wherein aluminium oxide particles are in direct contact with an upper part of the core.

30. The building panel as claimed in claim 26, wherein the weight content of the aluminium oxide particles in the surface layer is in the range of about 5% to about 30% of the total weight of the surface layer.

31. The building panel as claimed in claim 26, wherein the weight content of the aluminium oxide particles in the surface layer is at least 100 gr/m2.

32. The building panel as claimed in claim 21, wherein the core is HDF.

33. The building panel as claimed in claim 21, wherein the core is a particleboard.

34. The building panel as claimed in claim 21, wherein the surface layer further comprises a print that extends into the surface below upper wear resistant particles.

35. The building panel as claimed in claim 21, wherein the surface layer comprises brushed portions with different fibre structures.

36. The building panel as claimed in claim 21, wherein the surface layer comprises brushed portions with different wear resistance.

37. The building panel as claimed in claim 21, wherein the surface layer comprises mineral fibres.

38. The building panel as claimed in claim 37, wherein the surface layer wood fibres are essentially smaller than 1 mm.

39. The building panel as claimed in claim 34, wherein the surface layer wood fibres are in powder form and essentially smaller than 0.5 mm.

40. The building panel as claimed in claim 21, wherein a panel edge comprises a mechanical locking system for locking of the panel with similar other panels and wherein such locking system is formed in the core.

41. A building panel comprising a surface layer and a core,

the core comprising wood fibres, and

the surface layer comprising a substantially uniformly dispersed mix of wood fibres, a binder and wear resistant particles,

the wood fibres in the mix comprising unrefined wood fibers, and

a connection between the core and the surface layer comprises one of (i) wood fibres from the core and surface layer that are mixed and fused together and (ii) the binder penetrating into an upper part of the core.

42. A building panel comprising a surface layer, a glue and a core,

the core comprising wood fibres, and

the surface layer comprising a substantially uniformly dispersed mix of wood fibres, a binder and wear resistant particles,

the wood fibres in the mix comprising unrefined wood fibers,

wherein the mix is in direct contact with the glue, wherein the glue is in direct contact with the wood fibers of an upper part of the core.

43. A building panel comprising a surface layer and a core,

the core comprising wood fibres, and

the surface layer comprising a substantially uniformly dispersed mix of wood fibres, a binder and wear resistant particles,

wherein the surface layer is opaque,

wherein the mix is in direct contact with the wood fibers of an upper part of the core.

44. The building panel as claimed in claim 43, wherein the wood fibres of the mix comprise natural resins.

45. A building panel comprising a surface layer and a core,

the core comprising wood fibres, and

the surface layer comprising a substantially uniformly dispersed mix of wood fibres, a binder and wear resistant particles,

wherein the mix is in direct contact with the wood fibers of an upper part of the core.