Method and apparatus for manufacturing laminate floor panels comprising a core containing wood/plastic composite, as well as such panels

• US 8,956,714 B2
• Filed: 04/10/2008
• Issued: 02/17/2015
• Est. Priority Date: 04/10/2007
• Status: Active Grant

• Current Assignee: Flooring Industries Limited Sarl (Mohawk Industries Incorporated)
• Original Assignee: Spanolux N.V.-Div. Balterio
• Inventors: Vermeulen, Bruno Paul Louis
• Primary Examiner(s): Hess, Bruce H
• Assistant Examiner(s): POLLEY, CHRISTOPHER M
• Application Number:
  US12/594,989
• Publication Number:
  US 20100055420A1
• Time in Patent Office: 2,504 Days
• Field of Search: 428/195.1, 428/201, 428/206, 428/207, 428/211.1
• US Class Current: 428/201
• CPC Class Codes: B27N 3/06 Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
• 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 21/06 of paper or cardboard
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/048 Natural or synthetic rubber
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2264/067 Wood particles
• CPC Class Codes: B32B 2305/70 Scrap or recycled material
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• 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 37/04 characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 37/08 characterised by the cooling method
• CPC Class Codes: B32B 37/1027 Pressing using at least one press band
• 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 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24893 : including particulate material
• CPC Class Codes: Y10T 428/24901 : including coloring matter
• CPC Class Codes: Y10T 428/24934 : including paper layer

Abstract

The invention relates to a method of manufacturing laminate floor panels comprising at least a core containing wood/plastic composite (WPC) and a top layer of laminate. It includes the step of providing a granulate of WPC in which natural fibers are encapsulated in polymer plastics. There is provided a layer of granulate which is melted. The melted layer is pressed for forming the core of the panels. The top laminate is attached onto the core to form a sheet (S), and the sheet is finished to form one or more panels. The laminate panel comprises a core made of WPC, a basic layer melted to the core and a top laminate comprising at least one paper layer impregnated with impregnation material, such as melamine resin, and being attached to the basic layer through this impregnation material, or a plastic layer melted to a glass fiber basic layer.

Claims

1. A laminated panel, comprising:

a core comprising a pressed composite containing polymeric material,

a basic layer directly joined to a surface of the core,

wherein the surface of the core is melted to directly adhere the core and basic layer, and

a top laminate support by the basic layer, the top laminated comprising a plurality of layers, disposed on a top side of the basic layer opposite the core.

2. The laminate panel of claim 1, wherein the basic layer is made of a paper.

3. The laminate panel of claim 1, wherein the top laminate includes an anti-wear layer and a top layer.

4. The laminate panel of claim 1, wherein at least the top laminate is textured.

5. The laminate panel of claim 1, wherein the basic layer is one of a paper, glass fiber or foil layer.

6. The laminate panel of claim 1, wherein the polymeric material containing composite is wood/plastic composite (WPC).

7. The laminate panel according to claim 1, wherein the basic layer is made of an absorbing material.

8. The laminate panel according to claim 1, wherein a second layer of material is attached to a second surface of the core on a side of the core opposite to that of the top laminate.

9. The laminate panel according to claim 8, wherein the second layer of material is attached to the second surface of the core on the side of the core opposite to that of the top laminate without the use of a second separate adhesive.

10. The laminate panel of claim 9, wherein the second layer of material is bonded directly to the second surface of the core on the side of the core opposite to that of the top laminate without the use of the second separate adhesive, but rather with a bond exhibiting melting of a second layer of the core comprising the second surface of the core.

11. The laminate panel of claim 10, wherein the second layer of material comprises absorbing material.