Method of manufacturing a building panel and a building panel

Patent metadata

Field	Value
Publication number	US-10913176-B2
Application number	US-201414321288-A
Country	US
Kind code	B2
Filing date	Jul 1, 2014
Priority date	Jul 2, 2013
Publication date	Feb 9, 2021
Grant date	Feb 9, 2021

Abstract

A method of manufacturing a building panel (10). The method includes applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a carrier for forming a first layer (11), applying a second binder and free lignocellulosic or cellulosic particles on the first layer (11) for forming a second layer (12), wherein the first binder is different from the second binder, and applying heat and pressure to the first and second layers (11, 12) to form a building panel. Also, such a building panel (10).

First claim

The invention claimed is:

1. A method of manufacturing a building panel, comprising
applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a core for forming a first layer, the core being a wood based board, the core possessing a second surface opposite to the first surface,
applying a second binder and free lignocellulosic or cellulosic particles on the first layer for forming a second layer,
wherein the first binder is different from the second binder,
applying heat and pressure to the first and second layers to form the building panel, and
applying a balancing layer on the second surface of the core opposite to the first surface,
wherein the first binder is urea formaldehyde resin and the second binder is melamine formaldehyde resin.

2. A method according to claim 1 , wherein applying the first binder and said free lignocellulosic or cellulosic particles comprises applying a first mix comprising the first binder and said free lignocellulosic or cellulosic particles.

3. A method according to claim 2 , wherein the first mix is a first powder mix.

4. The method according to claim 2 , wherein
applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles,
the first binder is 45-60% of the first mix by weight, and
the second binder is 45-60% of the second mix by weight.

5. The method according to claim 2 , wherein
applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles, and
a binder concentration of the first binder in the first mix is equal to the binder concentration of the second binder in the second mix.

6. A method according to claim 1 , wherein said first binder is applied in liquid form.

7. A method according to claim 6 , wherein said free lignocellulosic or cellulosic particles are applied onto the liquid first binder.

8. A method according to claim 1 , wherein applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles.

9. A method according to claim 8 , wherein the second mix is a second powder mix.

10. A method according to claim 1 , wherein said second binder is applied in liquid form.

11. A method according to claim 10 , wherein said free lignocellulosic or cellulosic particles are applied onto the liquid second binder.

12. A method according to claim 1 , wherein the second layer further comprises wear resistant particles.

13. A method according to claim 1 , wherein the binder concentration of the first layer substantially correspond to the binder concentration of the second layer.

14. A method according to claim 1 , wherein the building panel is a floor panel.

15. The method according to claim 1 , wherein the balancing layer is applied to the core before the applying of the first binder and the free lignocellulosic or cellulosic particles.

16. The method according to claim 1 , wherein
the applying of the first binder and the free lignocellulosic or cellulosic particles consists of applying a first dry powder of urea formaldehyde resin and free lignocellulosic or cellulosic particles, and
the applying of the second binder and the free lignocellulosic or cellulosic particles on the first layer for forming the second layer consists of applying a second dry powder of melamine formaldehyde resin and free lignocellulosic or cellulosic particles on the first layer.

17. A method of manufacturing a building panel, comprising:
applying a first layer comprising a first binder and free lignocellulosic or cellulosic particles on a first surface of a board,
applying a second layer comprising a second binder and free lignocellulosic or cellulosic particles on the first layer, the first binder being uncured when the second layer is applied, and
applying heat and pressure to the board, the first layer, and the second layer to cure the first and second layers thereby forming the building panel,
wherein the first binder is different from the second binder,
wherein the first binder is urea formaldehyde resin, a mixture comprising urea formaldehyde resin, or a co-polymer comprising urea formaldehyde resin, and
wherein the second binder is melamine formaldehyde resin, a mixture comprising melamine formaldehyde resin, or a co-polymer comprising melamine formaldehyde resin.

18. The method according to claim 17 , wherein
the first binder and the free lignocellulosic or cellulosic particles of the first layer are applied as a first mix on the first surface of the board,
the second binder and the free lignocellulosic or cellulosic particles of the second layer are applied as a second mix on the first mix, and
the first and second mixes are substantially homogenous such that the first and second layers of the building panel each possess a substantially uniform composition after the first and second mixes are formed into the building panel.

19. The method according to claim 18 , wherein the first and second mixes are each a dry powder.

20. The method according to claim 17 , wherein the first mix cures faster than the second mix when the heat and pressure are applied.

21. A method of manufacturing a building panel, comprising:
applying a first layer comprising a first binder and free lignocellulosic or cellulosic particles on a first surface of a core, the first layer being applied as a dry powder mix in an amount of 100-700 g/m 2 ,
applying a second layer comprising a second binder and free lignocellulosic or cellulosic particles on the first layer, the first binder being uncured when the second layer is applied, the second layer being applied as a dry powder mix in an amount of 100-700 g/m 2 , and
applying heat and pressure to the board, the first layer, and the second layer to cure the first and second layers thereby forming the building panel,
wherein the first binder is different from the second binder, the first binder comprising urea formaldehyde resin and the second binder comprising melamine formaldehyde resin.

22. The method according to claim 21 , wherein a ratio of the amount of the dry powder mix of the first layer to the amount of the dry powder mix of the second layer is 1:1.

Assignees

• Valinge Innovation Ab

Inventors

• Lindgren Kent
• Persson Hans
• Ziegler Göran

Classifications

• E04F15/107

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title

• B27N3/06 Primary

  Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation · CPC title

• B27N3/02

  from particles · CPC title

• B27N3/002 Primary

  characterised by the type of binder (compositions of macromolecular compounds C08L) · CPC title