Production method

Patent metadata

Field	Value
Publication number	US-11040371-B2
Application number	US-201916395289-A
Country	US
Kind code	B2
Filing date	Apr 26, 2019
Priority date	May 31, 2010
Publication date	Jun 22, 2021
Grant date	Jun 22, 2021

Abstract

A method for producing a panel including a core and a decorative surface layer is disclosed. The method includes the step of applying a dry powder layer on the core. The method includes the step of applying steam on a dry powder layer on the core. Thereafter heat and pressure are applied to the powder layer in order to bond the powder together.

First claim

The invention claimed is:

1. A method comprising:
applying a dry powder layer on a core, the dry powder layer comprising a mix of wood fibers and a binder;
subsequently applying steam directly onto the dry powder layer while the dry powder layer is on the core to form a stabilized powder layer on the core; and
subsequently bonding the powder in the stabilized powder layer together into a cured layer by applying heat and pressure, and thereby forming a panel comprising the core and the cured layer.

2. The method as claimed in claim 1 , wherein the steam is a saturated vapour consisting essentially of water.

3. The method as claimed in claim 1 , wherein the steam comprises one or more additives.

4. The method as claimed in claim 1 , wherein the core is a wood fibre based core.

5. The method as claimed in claim 1 , wherein the core is an HDF panel.

6. The method as claimed in claim 1 , wherein the formed panel is a building panel.

7. The method as claimed in claim 1 , wherein the formed panel is a floor panel.

8. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises wear resistant particles.

9. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises aluminium oxide.

10. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises pigments.

11. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises wear resistant particles and pigments, and wherein the binder is a thermosetting resin.

12. The method as claimed in claim 1 , wherein the binder is a thermosetting resin.

13. The method as claimed in claim 1 , wherein a thickness of the cured layer is less than about 1 mm.

14. The method as claimed in claim 1 , wherein a thickness of the cured layer is less than about 0.3 mm.

15. The method as claimed in claim 1 , wherein the cured layer is a surface layer of the panel.

16. The method as claimed in claim 1 , wherein the cured layer is a decorative surface layer of the panel.

17. The method as claimed in claim 1 , wherein the steam is applied with a steam box.

18. The method as claimed in claim 1 , wherein the dry powder layer is applied by scattering.

19. The method as claimed in claim 1 , wherein heat and pressure are applied by a press.

20. The method as claimed in claim 1 , wherein the press is operated with the following parameters: 8-60 seconds of pressing time; 30-60 bars of applied pressure; and 150-220° C. of pressing temperature.

21. The method as claimed in claim 1 , wherein the steam is applied to the dry powder layer when the core is moving at a speed of 1 to 10 meters per minute.

22. The method as claimed in claim 1 , wherein the steam is substantially uniformly applied over the dry powder layer.

23. A method comprising:
applying a dry powder layer on a core, the dry powder layer comprising a mix of wood fibers and a binder;
subsequently applying steam directly onto the dry powder layer while the dry powder layer is on the core to form a stabilized powder layer on the core; and
subsequently bonding the powder in the stabilized powder layer together into a cured layer by applying heat and pressure, and thereby forming a panel comprising the core and the cured layer,
wherein the steam comprises one or more additives selected from the group consisting of wetting agents, releasing agents, and colour additives.

24. A floor panel produced according to the method in claim 1 .

25. A floor panel produced according to the method in claim 11 .

26. A floor panel produced according to the method in claim 22 .

Assignees

• Valinge Innovation Ab

Inventors

• Jacobsson Jan

Classifications

• B32B2310/049

  using steam or damp · CPC title

• B32B37/24

  with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) · CPC title

• B05D3/12

  by mechanical means · CPC title

• B32B2317/16

  Wood, e.g. woodboard, fibreboard, woodchips · CPC title

• B32B2307/554

  Wear resistance · CPC title