Fibre based panels with a wear resistance surface

• US 9,556,622 B2
• Filed: 02/27/2014
• Issued: 01/31/2017
• Est. Priority Date: 11/19/2007
• Status: Active Grant

• Current Assignee: Valinge Innovation AB
• Original Assignee: Valinge Innovation AB
• Inventors: Bouck, Eddy, Pervan, Darko, Lindgren, Kent, Jacobsson, Jan, Ziegler, Gran, Hkansson, Niclas
• Primary Examiner(s): Dodds, Scott W
• Application Number:
  US14/192,169
• Publication Number:
  US 20140178630A1
• Time in Patent Office: 1,069 Days
• Field of Search: 427189-195, 427/201, 156/307.1, 156/307.3, 156/307.4, 156/307.5, 156/307.7, 156/283, 156/279, 156/326
• US Class Current: 1/1
• 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 layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• 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 walls, panels B32B2607/00
• 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 method of producing a panel, comprising:

providing a core,

applying a sub-layer on a first surface of the core, wherein the sub-layer comprises pigments and fibres mixed with a binder, the sub-layer being uncured,

applying a wood veneer layer on the sub-layer while the sub-layer is uncured, and

pressing the core, the sub-layer and the wood veneer layer together to cure the sub-layer to form the panel.

2. The method according to claim 1, wherein applying the sub-layer comprises mixing the fibres with the binder, and subsequently applying the fibres mixed with the binder on the core.

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

4. The method according to claim 1, wherein the fibres are cork or wood fibres.

5. The method according to claim 1, wherein the sub-layer is applied on the core in powder form.

6. The method according to claim 1, further comprising applying a balancing layer on a second surface of the core, opposite the first surface of the core.

7. The method according to claim 6, wherein the balancing layer comprises wood fibres and a binder.

8. The method according to claim 1, wherein the core is a wood fibre based core.

9. The method according to claim 8, wherein the core is a HDF core.

10. The method according to claim 1, wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.

11. The method according to claim 1, wherein the wood veneer layer has a thickness of 0.3-1.0 mm.

12. The method according to claim 1, wherein the step of pressing comprises pressing with an embossed pressure matrix.

13. The method according to claim 1, wherein the panel is a floorboard.

14. The method according to claim 1, wherein the step of pressing further comprises applying heat, wherein the sub-layer mixture is cured under heat and pressure to form the panel.

15. A method of producing a panel, comprising:

providing a core,

applying a sub-layer on a first surface of the core, wherein the sub-layer is a dry powder mix which comprises pigments and fibres mixed with a binder,

applying a wood veneer layer on the sub-layer while the sub-layer is the dry powder mix, and

pressing the core, the sub-layer and the wood veneer layer together to form the panel.

16. A method of producing a panel, comprising:

providing a core, the core possessing a first surface and a second surface facing opposite of the first surface,

applying a sub-layer on the first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, and wherein the core is a wood fibre based core,

applying a balancing layer on the second surface of the core,

applying a wood veneer layer on the sub-layer, and

pressing the core, the sub-layer, the wood veneer layer, and the balancing layer together to form the panel,

wherein the core is a pre-fabricated core selected from the group of high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, oriented strand board (OSB), and plywood,

wherein the sub-layer is applied on the core in a dry powder form, and

wherein the fibres are cork or wood fibres.

17. The method according to claim 16, wherein the sub-layer comprises pigments.

18. The method according to claim 16, wherein the core is a HDF core.

19. A method of producing a panel, comprising:

providing a core,

applying a sub-layer on a first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, the sub-layer being applied on the first surface of the core in a dry powder form,

applying a wood veneer layer directly on the sub-layer while the sub-layer is in the dry powder form, and

pressing the core, the sub-layer, and the wood veneer layer together to form the panel,

wherein the core is a pre-fabricated core selected from the group of high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, oriented strand board (OSB), and plywood,

wherein the panel is a floorboard and

wherein the fibres are cork or wood fibres.

20. The method according to claim 19, wherein applying the sub-layer comprises mixing the fibres with the binder, and subsequently applying the fibres mixed with the binder on the core.

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

22. The method according to claim 19, further comprising applying a balancing layer on a second surface of the core, opposite the first surface of the core.

23. The method according to claim 22, wherein the balancing layer comprises wood fibres and a binder.

24. The method according to claim 19, wherein the core is a HDF core.

25. The method according to claim 19, wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.

26. The method according to claim 19, wherein the wood veneer layer has a thickness of 0.3-1.0 mm.

27. The method according to claim 19, wherein the step of pressing comprises pressing with an embossed pressure matrix.

28. The method according to claim 19, wherein the sub-layer in the dry powder form is an uncured mixture comprising the fibres mixed with the binder, and the step of pressing the core, the sub-layer and the wood veneer layer together cures the sub-layer mixture to form a panel.

29. The method according to claim 28, wherein the step of pressing further comprises applying heat, wherein the sub-layer mixture is cured under heat and pressure to form the panel.

30. The method according to claim 19, wherein the sub-layer comprises pigments.

31. A method of producing a panel, comprising:

providing a core,

applying a sub-layer on a first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, the sub-layer being applied on the first surface of the core in a dry powder form,

applying a wood veneer layer directly on the sub-layer while the sub-layer is in the dry powder form, and

pressing the core, the sub-layer, and the wood veneer layer together to form the panel,

wherein the panel is a floorboard

wherein the fibres are cork or wood fibres and

wherein the sub-layer comprises pigments.