Method of producing a veneered element and such a veneered element

Patent metadata

Field	Value
Publication number	US-10286633-B2
Application number	US-201515308737-A
Country	US
Kind code	B2
Filing date	May 11, 2015
Priority date	May 12, 2014
Publication date	May 14, 2019
Grant date	May 14, 2019

Abstract

A method of producing a veneered element, the method including providing a substrate, applying a sub-layer on a surface of the substrate, applying a veneer layer on the sub-layer, and applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer. Also, such a veneered element.

First claim

The invention claimed is:

1. A method of producing a veneered element, the method comprising
providing a substrate,
applying a sub-layer on a surface of the substrate,
applying a veneer layer on the sub-layer,
applying a protective layer comprising a thermoplastic material on the veneer layer, and
applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer.

2. The method according to claim 1 , wherein the thermoplastic material comprises polyvinyl chloride, polyester, polypropylene, polyethylene, polystyrene, polyurethane, polyethylene terephthalate, polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

3. The method according to claim 1 , wherein the protective layer comprises at least one thermoplastic foil.

4. The method according to claim 1 , wherein applying the protective layer comprises applying a first foil comprising a first thermoplastic material, on the veneer layer, and applying a second foil comprising a second thermoplastic material, on the first foil.

5. The method according to claim 1 , wherein applying the protective layer comprises applying the thermoplastic material in powder form on the veneer layer.

6. The method according to claim 1 , wherein the protective layer further comprises wear resistant particles.

7. The method according to claim 1 , wherein the sub-layer further comprises pigments.

8. The method according to claim 1 , wherein the substrate is a wood-based board.

9. The method according to claim 1 , further comprising controlling a design of the veneer layer by controlling permeation of the sub-layer through the veneer layer.

10. The method according to claim 9 , wherein controlling permeation of the sub-layer through the veneer layer comprises controlling a fluid pressure of the sub-layer.

11. The method according to claim 10 , wherein controlling the fluid pressure of the sub-layer when applying pressure includes adjusting one or more of the following parameters:
concentration of a binder in the sub-layer;
type of binder in the sub-layer;
formulation of the binder in the sub-layer;
moisture content of the sub-layer;
the pressure applied to the veneer layer and/or the substrate;
a gas pressure in the sub-layer;
concentration of fillers in the sub-layer; and
thickness of the veneer layer.

12. The method according to claim 11 , wherein generating the gas pressure comprises including chemical and/or physical blowing agents in the sub-layer.

13. The method according to claim 9 , wherein controlling permeation of the sub-layer through the veneer layer comprises abrasive machining of the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

14. The method according to claim 13 , wherein the abrasive machining comprises brushing the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

15. The method according to claim 9 , wherein controlling permeation of the sub-layer through the veneer layer comprises forming holes, cavities and/or cracks in the veneer layer.

16. The method according to claim 1 , wherein said at least a portion of the sub-layer permeates through pores of the veneer layer.

17. The method according to claim 1 , wherein said at least a portion of the sub-layer permeates through cracks and/or holes of the veneer layer.

18. The method according to claim 1 , wherein the veneer layer comprises a wood veneer, a cork veneer, or a stone veneer.

19. The method according to claim 1 , wherein the sub-layer comprises a binder.

20. The method according to claim 19 , wherein the binder is a thermosetting binder or a thermoplastic binder.

21. The method according to claim 1 , wherein the sub-layer comprises wear resistant particles.

22. The method according to claim 1 , wherein after pressure has been applied, the veneer layer comprises embossed portions, wherein a portion of the sub-layer is more compressed under an embossed portion than under a non-embossed surface portion.

23. A veneered element, comprising
a substrate,
a sub-layer arranged on the substrate, and
a veneer layer arranged on the sub-layer,
a protective layer comprising a thermoplastic material arranged on the veneer layer, and
wherein at least a portion of the sub-layer is permeated through the veneer layer such that at least a portion of the sub-layer is visible at the surface of the veneer layer facing away from the substrate.

24. The veneered element according to claim 23 , wherein the protective layer further comprises wear resistant particles.

25. The veneered element according to claim 23 , wherein the thermoplastic material comprises polyvinyl chloride, polyester, polypropylene, polyethylene, polystyrene, polyurethane, polyethylene terephthalate, polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

26. The veneered element according to claim 23 , wherein the protective layer comprises at least one thermoplastic foil.

27. The veneered element according to claim 23 , the protective layer comprises a first foil comprising a first thermoplastic material, preferably polyvinylchloride (PVC), and a second foil comprising a second thermoplastic material, preferably polyurethane (PU).

28. The veneered element according to claim 23 , wherein the sub-layer comprises pigments.

29. The veneered element according to claim 23 , wherein the sub-layer comprises wear resistant particles.

30. The veneered element according to claim 23 , wherein the sub-layer comprises fillers.

31. The veneered element according to claim 23 , wherein said at least a portion of the sub-layer is permeated through pores of the veneer layer.

32. The veneered element according to claim 23 , wherein the veneer layer comprises embossed portions, wherein a portion of the sub-layer is more compressed under an embossed portion than under a non-embossed surface portion.

Assignees

• Vaelinge Innovation Ab
• Valinge Innovation Ab

Inventors

• Lundblad Christer
• Nygren Per
• Meijer Thomas
• Ziegler Göran

Classifications

• B32B3/30

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title

• B32B27/20

  using fillers, pigments, thixotroping agents · CPC title

• B32B27/36

  comprising polyesters · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title

• B32B27/304

  comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF · CPC title