Method for producing a floorboard

• US 11,072,156 B2
• Filed: 11/11/2014
• Issued: 07/27/2021
• Est. Priority Date: 11/27/2013
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Schulte, Guido
• Primary Examiner(s): Gross, Carson
• Application Number:
  US15/039,748
• Publication Number:
  US 20160375674A1
• Time in Patent Office: 2,450 Days
• Field of Search: 156265
• CPC Class Codes: B32B 2037/1253 curable adhesive
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/1292 selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: E04F 15/02038 characterised by tongue and groove connections between neighbouring flooring elements
• CPC Class Codes: E04F 15/045 Layered panels only of wood
• 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
• CPC Class Codes: E04F 2201/0115 with snap action of the edge connectors
• CPC Class Codes: E04F 2201/023 with a continuous tongue or groove

Abstract

A method for producing a floorboard having a topside veneer includes forming a multilayer body which includes a starting carrier plate, a plurality of veneers placed on the starting carrier plate so that a gap is formed between neighboring ones of the veneers, a resin layer comprising a resin provided between the starting carrier plate and the veneers, and a balancing layer arranged on a bottom side of the starting carrier plate; joining the starting carrier plate, the resin layer, the veneers and the balancing layer by pressing the multilayer body in a press; separating the multilayer body into individual boards between the neighboring veneers in a region of the gap; profiling the individual boards at side borders of the boards; and providing the individual boards with joining means.

Claims

1. A method for producing floorboards each having a topside veneer, said method comprising:

forming a multilayer body comprising a starting carrier plate, by placing a plurality of veneers on the starting carrier plate so that a gap is formed between neighboring ones of the veneers,

placing a thermosetting resin between the starting carrier plate and the veneers, and placing a balancing layer arranged on a bottom side of the starting carrier plate;

joining the starting carrier plate, the thermosetting resin, the veneers and the balancing layer by pressing the multilayer body in a press, wherein during the pressing process, the thermosetting resin adheres to a surface of the starting carrier plate facing the veneers, a surface of the veneers facing the starting carrier plate, and outer side surfaces of the veneers to form thermosetting resin side borders;

separating the multilayer body into individual floorboards between the neighboring veneers in a region of the gap;

profiling the individual floorboards at the thermosetting resin side borders of the floorboards; and

providing the individual floorboards with joining means.

2. The method of claim 1, wherein during the pressing of the multilayer body a pressing pressure is greater than or equal to 1,000 Kilopascal, the pressing temperature is greater than or equal to 100°

C., and the pressing time is between 10 and 60 seconds.

3. The method of claim 2, wherein the pressing pressure is greater than or equal to 3,500 Kilopascal.

4. The method of claim 2, wherein the pressing temperature is greater than or equal to 120°

C.

5. The method of claim 2, wherein the pressing temperature is between 180°

C. and 210°

C.

6. The method of claim 2, further comprising applying a texture to a surface of the plurality of veneers during the pressing of the multilayer body during the press.

7. The method of claim 6, wherein the texture includes sub regions with varying glossiness.

8. The method of claim 7, wherein the texture possesses a depth of up to 0.6 mm.

9. The method of claim 6, wherein a depth of the texture is ⅔

of a thickness of each of the plurality of veneers.

10. The method of claim 2, wherein the veneers are vapored or smoked.

11. The method of claim 2, wherein the starting carrier plate is a wood board, and the veneers are one of oak, ash, larch or spruce.

12. The method of claim 1, wherein during the pressing of the multilayer body the gaps between the veneers are filled with the thermosetting resin.

13. The method of claim 1, wherein during the pressing of the multilayer body, the thermosetting resin infiltrates the veneers, wherein pores, cracks and/or gaps in the veneers are filled with the thermosetting resin.

14. The method of claim 1, wherein the pressing of the multilayer body is performed so that the thermosetting resin permeates the veneers and after the pressing the thermosetting resin is visible at a surface of the veneers.

15. The method of claim 1, further comprising during the profiling of the thermosetting resin side borders of the individual floorboards, removing a resin-filled residual gap remaining on a thermosetting resin side border of the individual floorboards after the separating step.

16. The method of claim 1, wherein during the profiling of the thermosetting resin side borders of the floorboards a border strip made of thermosetting resin is formed.

17. The method of claim 16, further comprising printing on the border strips of each of the floorboards.

18. The method of claim 1, wherein the thermosetting resin contains a filler.

19. The method of claim 18, wherein the filler is wood powder.

20. The method of claim 18, wherein the filler is mineral pigments.

21. The method of claim 1, further comprising printing a decor on a surface of the individual floorboards.

22. The method of claim 1, further comprising applying a sealing onto a surface of the individual floorboards.

23. The method of claim 1, further comprising subjecting a surface of the floorboards to a mechanical surface processing.

24. The method of claim 1, wherein the outer side surfaces of the veneers are substantially perpendicular to the surface of the starting carrier plate.

25. The method of claim 1, wherein the veneers are selected from wood veneers and cork veneers.

26. A method for producing a floorboard having a topside veneer, said method comprising:

forming a multilayer body comprising a starting carrier plate, by placing a plurality of veneers on the starting carrier plate so that a gap is formed between neighboring ones of the veneers, placing a resin between the starting carrier plate and the veneers, and placing a balancing layer arranged on a bottom side of the starting carrier plate;

joining the starting carrier plate, the resin, the veneers and the balancing layer by pressing the multilayer body in a press;

separating the multilayer body into individual boards between the neighboring veneers in a region of the gap;

profiling the individual boards at side borders of the boards; and

providing the individual boards with joining means,

wherein the resin is a resin paper impregnated with the resin, the resin paper extending over the starting carrier plate so that the plurality of veneers are each on the resin paper during the forming of the multilayer body and the pressing of the multilayer body in the press.

27. The method of claim 26, wherein

the resin paper comprises a paper having a weight of 30 g/m² to 120 g/m², and

the resin impregnating the resin paper has a weight at least two times greater than the paper.