Panel coating

Patent metadata

Field	Value
Publication number	US-10017950-B2
Application number	US-201214237617-A
Country	US
Kind code	B2
Filing date	Aug 23, 2012
Priority date	Aug 26, 2011
Publication date	Jul 10, 2018
Grant date	Jul 10, 2018

Abstract

The disclosure relates to a method for coating of a floor panel and a floor panel produced by the method. The disclosure relates to a method for producing a laminated product, for example a building panel, preferably a floor panel. The method comprises applying a paper on one side of a wood fiber based core, e.g. an HDF panel, creating a décor on the paper by a digital printing process, applying a resin, preferably a melamine formaldehyde resin, on the paper, heating the décor and the paper with the resin, preferably by using an IR lamp; and applying heat and pressure in order to cure the resin and thereby obtain a laminated product. The disclosure also relates to alternative methods for producing a laminated product, and such a laminated product.

First claim

The invention claimed is:

1. A method for producing a laminated building panel, wherein the method comprises:
applying a paper on one side of a wood fiber based core,
after applying the paper on the core creating a décor on the paper by a digital printing process while paper is on core,
applying a resin in powder form on the paper;
heating the décor and the paper with the resin; and
applying heat and pressure in order to cure the resin and thereby obtain a laminated product.

2. The method as claimed in claim 1 , wherein the method further comprises applying a powder based sub layer on the core before the paper is applied on the core, said powder based sub layer comprising wood fibers and a powder resin.

3. The method as claimed in claim 2 , wherein the method further comprises applying moisture on the powder based sub layer and thereafter applying heat in order to dry the powder based sub layer.

4. The method as claimed in claim 1 , wherein the method further comprises:
applying a liquid resin on the core; and
drying the liquid resin before the paper is applied on the core.

5. The method as claimed in claim 1 , wherein the method further comprises applying moisture on the resin, where the resin is in powder form.

6. The method as claimed in claim 1 , wherein the method further comprises applying wear resistant particles on the paper before the heating of the décor and the paper with the resin.

7. The method as claimed in claim 1 , wherein the method further comprises applying cellulose fibers on the paper, before the heating of the décor and the paper with the resin.

8. The method as claimed in claim 1 , wherein the method further comprises applying a balancing layer on an opposite side of the core, before the applying of heat and pressure, to obtain a balancing layer.

9. The method as claimed in claim 8 , wherein the balancing layer is a powder layer comprising wood fibers and a resin or the balancing layer is a paper.

10. The method as claimed in claim 2 , wherein the paper is a thin raw paper with a weight of about 40-60 g/m 2 .

11. The method as claimed in claim 2 , wherein the paper is a thin raw paper with a weight of about 40-50 g/m 2 .

12. The method as claimed in claim 1 , wherein a digital non-contact process is used comprising a Piezo print head that applies water based drops.

13. The method as claimed in claim 12 , wherein color pigments are applied in a separate step in dry form and bonded by the water based drops.

14. The method as claimed in claim 1 , wherein the heating of the décor and the paper is performed by an IR lamp prior to the applying of heat and pressure to cure the resin.

15. The method as claimed in claim 1 , wherein the paper is a raw paper when the paper is applied on the one side of the wood fiber based core and when the décor is created on the paper by the digital printing process.

16. The method as claimed in claim 1 , wherein
the paper, the resin, and the décor on the one side of the wood fibre based core possess a thickness, and
the thickness of the paper, the resin, and the décor on the one side of the wood fibre based core after the applying of the heat and pressure is less than 80% of the thickness of the paper, the resin, and the décor on the one side of the wood fiber based core before the applying of the heat and pressure.

17. The method as claimed in claim 16 , wherein the thickness of the paper, the resin, and the décor on the one side of the wood fiber based core after the applying of the heat and pressure is less than 50% of the thickness of the paper, the resin, and the décor on the one side of the wood fiber based core before the applying of the heat and pressure.

18. A method for producing a laminated building panel, wherein the method comprises:
applying a powder based sub layer comprising wood fibers and a thermosetting resin on a wood fiber based core,
applying a raw paper on the powder based sub layer,
applying a powder comprising a melamine formaldehyde resin and aluminum oxide on said raw paper to form a protective overlay on said raw paper;
applying heat and pressure in order to impregnate the raw paper, to cure the resin and thereby obtain a laminated product.

19. The method as claimed in claim 18 , wherein a powder based balancing layer comprising wood fibers and a thermosetting resin is applied on a rear side of the core.

20. The method as claimed in claim 18 , wherein a paper overlay is applied directly on top of the powder protective overlay before the applying of the heat and pressure.

21. A method for producing a laminated building panel, wherein the method comprises:
applying a paper on one side of a wood fiber based core, the paper being unimpregnated when the paper is applied on the core;
digitally printing a décor directly onto the paper using a digital printer while paper is on the core;
applying a resin directly on the paper while the paper is on the core and the paper remains unimpregnated;
heating the paper, the décor, and the resin while the paper, the décor, and the resin are on the core; and
simultaneously applying heat and pressure to cure the resin and thereby obtain a laminated product, the simultaneously applying heat and pressure being after the heating of the paper, the décor and the resin.

Assignees

• Pervan Darko
• Ceraloc Innovation Ab

Inventors

• Pervan Darko

Classifications

• B32B2309/12

  Pressure · CPC title

• B32B2260/046

  Synthetic resin · CPC title

• B32B2255/26

  Polymeric coating · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title

• B32B2260/028

  Paper layer · CPC title