Method of producing a veneered element

Patent metadata

Field	Value
Publication number	US-10988941-B2
Application number	US-201514593458-A
Country	US
Kind code	B2
Filing date	Jan 9, 2015
Priority date	Jan 10, 2014
Publication date	Apr 27, 2021
Grant date	Apr 27, 2021

Abstract

A method of producing a veneered element (10), including providing a substrate (1), applying a sub-layer (2) on a surface of the substrate (1), applying a veneer layer (3) on the sub-layer (2), and applying pressure to the veneer layer (3) and/or the substrate (1), such that at least a portion of the sub-layer (2) permeates through the veneer layer (3). Also, such a veneered element (10).

First claim

The invention claimed is:

1. A method of producing a veneered element, comprising:
providing a substrate,
applying a sub-layer on a surface of the substrate, the sub-layer comprising a binder selected from the group of melamine formaldehyde, urea formaldehyde, phenol formaldehyde, and a combination thereof,
applying a wood veneer on the sub-layer,
applying pressure to the wood veneer and/or the substrate, such that at least a portion of the sub-layer permeates through the wood veneer, wherein the method further comprises:
controlling a decorative design of a surface of the veneered element by determining a level of partial permeation of the sub-layer through the wood veneer, and forming new holes and/or cracks in the wood veneer to achieve the level of partial permeation of the sub-layer through the wood veneer.

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

3. The method according to claim 1 , wherein the determining of the level of permeation of the sublayer through the wood veneer comprises adjusting the thickness of the wood veneer.

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

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

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

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

8. A method of producing a veneered element, comprising:
providing a substrate,
applying a sub-layer on a surface of the substrate, the sub-layer being applied as a dry powder,
applying a veneer layer on the sub-layer,
applying heat and pressure to the veneer layer and/or the substrate to cause the sub-layer to melt and to then partially permeate at least a portion of the sub-layer through the veneer layer, and
controlling a decorative design of the veneer layer by determining a level of partial permeation of the sub-layer through the veneer layer, and forming new holes and/or cracks in the veneer layer to achieve the level of partial permeation of the sub-layer through the veneer layer,
wherein the new holes and/or cracks in the veneer layer are caused by abrasive machining the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

9. The method according to claim 8 , wherein the abrasive machining comprises brushing the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

10. The method according to claim 8 , wherein the abrasive machining comprises processing the veneer layer to enlarge existing holes and/or cracks in the veneer layer before the applying pressure.

11. The method according to claim 8 , wherein the abrasive machining includes brushing, sanding, grinding, blasting, locally compressing, tearing or splitting the veneer layer.

12. The method according to claim 8 , further comprising abrasive machining the veneer layer after pressure has been applied.

13. The method of claim 8 , wherein abrasive machining is applied to the upper surface of the veneer layer.

14. The method of claim 8 , wherein abrasive machining is applied to the lower surface of the veneer layer.

15. A method of producing a veneered element, comprising: providing a substrate,
applying a sub-layer on a surface of the substrate, the sub-layer being applied as a dry powder, the sub-layer comprising a binder, pigments, wood fibers, and wear resistant particles,
applying a veneer on the sub-layer, the veneer being one of a wood veneer, a cork veneer, and a stone veneer, the veneer comprising a hole extending from the top surface through the bottom surface so that the sub-layer is visible through the hole of the veneer,
controlling a decorative design of the veneer by determining a level of partial permeation of the sub-layer through the veneer,
applying heat and pressure to the veneer and/or the substrate, the heat and pressure causing the sub-layer to melt and causing at least a portion of the sub-layer to permeate partially through the veneer.

16. A method of producing a veneered element, comprising
providing a substrate,
applying a sub-layer on a surface of the substrate, the sub-layer comprising a binder,
applying a veneer on the sub-layer, the veneer possessing a top surface and a bottom surface, the veneer being one of a wood veneer, a cork veneer, and a stone veneer,
applying pressure to the veneer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer, wherein the method further comprises
controlling a decorative design of the veneer by
before applying pressure to the veneer and/or substrate, determining a level of partial permeation of the sub-layer through the veneer, and
forming new holes and/or cracks in the veneer to achieve the level of partial permeation of the sub-layer through the veneer.

17. A method of producing a veneered element, comprising:
providing a substrate,
applying a sub-layer on a surface of the substrate, the sub-layer comprising a binder,
applying a wood veneer on the sub-layer,
processing the wood veneer by abrasive machining with an abrasive tool,
applying pressure to the wood veneer and/or the substrate, such that at least a portion of the sub-layer permeates through the wood veneer, wherein the method further comprises:
controlling a decorative design of a surface of the veneered element by
before applying pressure to the wood veneer and/or substrate, determining a level of partial permeation of the sub-layer through the wood veneer, and
forming new holes and/or cracks in the wood veneer to achieve the level of partial permeation of the sub-layer through the wood veneer,
wherein the new holes and/or cracks in the wood veneer are caused by abrasive machining the wood veneer prior to applying pressure to the wood veneer and/or the substrate.

18. The method according to claim 17 , wherein the abrasive machining comprises brushing.

19. The method according to claim 17 , wherein the abrasive tool is brush filaments, abrasive strips, sanding belts, sanding disks, grinding wheels or a water jet.

20. The method according to claim 17 , wherein the wood veneer is processed by the abrasive tool such that veneer material with low density is removed while veneer material with higher density remains.

21. A method of producing a veneered element, comprising:
providing a substrate,
applying a sub-layer on a surface of the substrate, the sub-layer comprising a binder,
applying a wood veneer on the sub-layer,
applying pressure to the wood veneer and/or the substrate, such that at least a portion of the sub-layer permeates through the wood veneer, wherein the method further comprises:
controlling a decorative design of a surface of the veneered element by
before applying pressure to the wood veneer and/or substrate, determining a level of partial permeation of the sub-layer through the wood veneer,
forming new holes and/or cracks in the wood veneer to achieve the level of partial permeation of the sub-layer through the wood veneer, and
generating a gas pressure in the sub-layer by including a chemical and/or physical blowing agent in the sub-layer to achieve the level of partial permeation of the sublayer through the wood veneer.

Assignees

• Vaelinge Innovation Ab
• Valinge Innovation Ab

Inventors

• Ziegler Göran
• Nygren Per
• Meijer Thomas

Classifications

• E04F15/042 Primary

  the lower layer being of fibrous or chipped material, e.g. bonded with synthetic resins · CPC title

• B32B37/10 Primary

  characterised by the pressing technique, e.g. using action of vacuum or fluid pressure · CPC title

• E04F15/082

  with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass in combination with a lower layer of other material · CPC title

• B32B2305/073

  partially · CPC title

• B32B38/06

  Embossing · CPC title