Heat and pressure generated design

• US 9,410,319 B2
• Filed: 02/19/2014
• Issued: 08/09/2016
• Est. Priority Date: 01/15/2010
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Ziegler, Goran, Lindgren, Kent
• Primary Examiner(s): Quast, Elizabeth A
• Assistant Examiner(s): Walraed-Sullivan, Kyle
• Application Number:
  US14/184,299
• Publication Number:
  US 20140171554A1
• Time in Patent Office: 902 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B44C 5/0476 with abrasion resistant properties
• CPC Class Codes: E04C 2/246 combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04F 13/0871 having an ornamental or specially shaped visible surface E04F13/0867 takes precedence
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/24995 Two or more layers

Abstract

A wood fiber based panel with surfaces layer with lower parts which has less binders than the upper parts. Also, a method of manufacturing a building panel having a structured surface with a design that has color variation in register with the structure obtained by a varying pressure distribution applied on the surface.

Claims

1. A building panel comprising a decorative surface layer arranged on a core wherein

the surface layer comprises a lower part and an upper part disposed above the lower part with a binder concentration gradient between the lower part and the upper part;

the lower part of the surface layer comprises a first mix comprising fibres, coloring substance, a binder, and wear resistance particles; and

the upper part of the surface layer comprises a second mix comprising the fibres, the coloring substance, the binder, and the wear resistance particles;

wherein the first mix possesses a first homogenous binder concentration, and

wherein the second mix possesses a second homogenous binder concentration not equal to the first homogenous binder concentration.

2. The building panel according to claim 1, wherein the lower part comprises less binder than the upper part.

3. The building panel according to claim 1, wherein the upper part comprises less binder than the lower part.

4. The building panel according to claim 1, wherein the binder is a melamine resin.

5. The building panel according to claim 1, wherein the fibres are wood fibres.

6. The building panel according to claim 1, wherein the panel is a floor panel.

8. The building panel according to claim 1, wherein the weight content of the binder is at least 40% of the surface layer.

9. The building panel according to claim 1, wherein the binders in the mix of the upper part and the lower part of the surface layer are provided in a powder form.

10. The building panel according claim 1, wherein the surface layer has a substantially homogenous distribution of the wear resistant particles throughout a thickness of the surface layer.

11. The building panel according to claim 1, wherein the mass ratio between the binder and the fibres is in the range of 130-240%.

12. The building panel according to claim 1, wherein the mass ratio between the binder and the fibres is in the range of 180-200%.

7. A building panel produced according to a method of manufacturing a building panel having an evenly colored surface whereby the method comprises the steps of:

applying a layer comprising a mix of fibres, binder, wear resistant particles, and a coloring substance, on a carrier wherein the mix is floatable under heat and pressure; and

applying heat and pressure on the mix,

wherein the mass ratio between the binder and fibres is less than about 90%,

wherein the layer comprises an upper part comprising a first mix of the fibres, the binder, the wear resistant particles, and the coloring substance, and the layer comprises a lower part comprising a second mix of the fibres, the binder, the wear resistant particles, and the coloring substance, the upper part being disposed above the lower part,

wherein the first mix possesses a first homogenous binder concentration, and

wherein the second mix possesses a second homogenous binder concentration not equal to the first homogenous binder concentration.

13. The building panel according to claim 7, wherein the mass ratio between the binder and the sum of the mass of the fibres and the coloring substance is in the range of 100-130%.

14. A building panel comprising a decorative surface layer arranged on a core wherein the surface layer comprises two mixes, a first mix comprising fibres, coloring substance, a binder and wear resistant particles, and a second mix comprising fibres, coloring substance, a binder and wear resistant particles, wherein the first mix is applied on the second mix causing the first mix to be disposed above the second mix in the surface layer, and wherein a homogenous binder concentration of the first mix is different than a homogenous binder concentration of the second mix.

15. The building panel according to claim 14, wherein the content of binder in the first mix is less than the content of binder in the second mix.

16. The building panel according to claim 14, wherein the content of binder in the second mix is less than the content of binder in the first mix.

17. A building panel comprising a decorative surface layer connected to a core wherein the surface layer is a mix comprising fibres, coloring substance, a binder and wear resistant particles, and

wherein the surface layer comprises a lower part and an upper part disposed above the lower part with a binder concentration gradient between the lower part and the upper part;

the lower part of the surface layer comprising a first mix having a first homogenous binder concentration; and

the upper part of the surface layer comprising a second mix having a second homogenous binder concentration not equal to the first homogenous binder concentration.

18. The building panel according to claim 17, wherein the content of binder in the first mix is less than the content of binder in the second mix.

19. The building panel according to claim 17, wherein the content of binder in the second mix is less than the content of binder in the first mix.