Wood fibre based panel with a surface layer

Patent metadata

Field	Value
Publication number	US-10100535-B2
Application number	US-201514593521-A
Country	US
Kind code	B2
Filing date	Jan 9, 2015
Priority date	Jan 10, 2014
Publication date	Oct 16, 2018
Grant date	Oct 16, 2018

Abstract

A building panel with a surface layer (1) including a wood veneer, a wood fibre based core (2) and a sub-layer (3) between the surface layer (1) and the core (2). The sub-layer (3) includes wood fibres (4) and a binder (5). The surface layer (1) has surface portions (6) including material from the sub-layer (3). The surface portions (6) including material from the sub-layer (3) extend into the wood veneer.

First claim

The invention claimed is:

1. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core,
wherein the sub-layer comprises wood fibres and a binder,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and
wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions.

2. The building panel as claimed in claim 1 , wherein the surface portions comprising material from the sub-layer are flush with at least a portion of the surface layer.

3. The building panel as claimed in claim 1 , wherein the sub-layer comprises colour pigments and/or a colorant.

4. The building panel as claimed in claim 1 , wherein the sub-layer comprises wear resistant particles.

5. The building panel as claimed in claim 1 , further comprising a powder-based balancing layer.

6. The building panel as claimed in claim 1 , wherein the wood veneer comprises holes and/or cracks, wherein the sub-layer fills the holes and/or cracks of the wood veneer.

7. The building panel as claimed in claim 1 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.

8. The building panel as claimed in claim 1 , wherein the binder is liquid.

9. The building panel as claimed in claim 1 , wherein the binder in the sub-layer is a thermosetting resin.

10. The building panel as claimed in claim 1 , wherein the binder in the sub-layer is a melamine formaldehyde resin.

11. The building panel as claimed in claim 1 , wherein the sub-layer comprises a foaming agent.

12. The building panel as claimed in claim 11 , wherein the foaming agent includes a chemical blowing agent additive.

13. The building panel as claimed in claim 1 , further comprising:
a second surface layer comprising a second wood veneer, the second surface layer being arranged on an opposite side of the core from the surface layer; and
a second sub-layer arranged between the second surface layer and the core,
wherein the second surface layer has surface portions comprising material from the second sub-layer extending into the second wood veneer.

14. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core,
wherein the sub-layer comprises wood fibres, a binder and colour pigments and/or a colorant,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and
wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the non-porous portions of the wood veneer form the protrusions by containing less of the binder than the porous portions.

15. The building panel as claimed in claim 14 , further comprising a powder-based balancing layer.

16. The building panel as claimed in claim 15 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.

17. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core,
wherein the sub-layer comprises wood fibres, a binder and wear resistant particles,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer,
wherein the binder is between 40-60 wt-% of the sub-layer, and
wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions.

18. The building panel as claimed in claim 17 , wherein the binder is liquid.

19. The building panel as claimed in claim 17 , wherein the sub-layer comprises a foaming agent.

20. The building panel as claimed in claim 17 , further comprising a powder-based balancing layer.

21. The building panel as claimed in claim 20 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.

22. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising relatively high-density portions and relatively low-density portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core,
wherein the sub-layer comprises wood fibres and a binder,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and
wherein the surface layer comprises embossed portions and protrusions, wherein the binder of the sub-layer bonds the relatively low-density portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the relatively high-density portions of the wood veneer in the compressed position so that the relatively high-density portions of the wood veneer form the protrusions.

Assignees

• Vaelinge Innovation Ab
• Valinge Innovation Ab

Inventors

• Pervan Darko
• Ziegler Goran

Classifications

• Y10T428/249925

  Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.] · CPC title

• Y10T428/31989

  Of wood · CPC title

• B27N3/005

  and foam · CPC title

• Y10T428/24339

  Keyed · CPC title

• B32B2307/4026

  within the layer by addition of a colorant, e.g. pigments, dyes · CPC title