Wooden material panel, in particular in the form of a wood-plastic composite material, and a method for producing the same

Patent metadata

Field	Value
Publication number	US-11072087-B2
Application number	US-201916452031-A
Country	US
Kind code	B2
Filing date	Jun 25, 2019
Priority date	Nov 6, 2014
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

The present invention relates to a wooden material panel, in particular a wood-plastic composite material, including particles of wood and at least one plastic that is functionalized with at least one organic compound. At least one decorative layer is provided on at least one side of the wooden material panel.

First claim

The invention claimed is:

1. A floor panel made from a wood-based material board, producible from a mixture of wood fibers and polymer fibers, comprising:
wood fibers having a length of 1.0 mm to 10 mm and polymer fibers, wherein the polymer fibers have been functionalized with at least one organic compound,
wherein the mixing ratio of wood fibers and polymer fibers is between 70% by weight of wood fibers/30% by weight of polymer fibers and 40% by weight of wood fibers/60% by weight of polymer fibers,
wherein at least one decorative layer has been provided on at least one side of the wood-based material board, and
wherein the at least one decorative layer comprises at least one decorative film consisting of at least one thermoplastic carrier layer comprising polyethylene, polypropylene, or polyurethane, of at least one decoration printed onto the carrier layer, and at least one polymer seal comprising a polypropylene film or a polyurethane film.

2. The floor panel of claim 1 , wherein the decorative film has been laminated onto the wood-based material board using at least one adhesive.

3. The floor panel made of claim 1 , wherein the decorative film, during the process for producing the wood-based material board, is placed onto a pre-consolidated mat and subjected to further consolidation together with the pre-consolidated mat to give the wood-based material board.

4. The floor panel of claim 1 , wherein the polymer fibers comprises a thermoplastic polymer, selected from the group consisting of polyethylene (PE), polypropylene (PP), polyesters and mixtures thereof.

5. The floor panel of claim 4 , wherein the polyester is polyethylene terephthalate.

6. The floor panel of claim 4 , wherein the polymer fibers comprise polypropylene (PP) and polyethylene (PE).

7. The floor panel of claim 1 , wherein the at least one organic compound has at least one functional group, where the functional group is selected from the group consisting of —CO 2 H, —CONH 2 , —COO—, maleic acid, phthalic acid, succinic acid, glutaric acid, adipic acid or the anhydrides thereof, succinimide.

8. The floor panel of claim 1 , wherein the at least one organic compound is present in the polymer fibers in an amount between 0.1% and 5% by weight.

9. The floor panel of claim 8 , wherein the at least one organic compound is present in the polymer fibers in an amount between 0.5 and 3% by weight.

10. The floor panel of claim 8 , wherein the at least one organic compound is present in the polymer fibers in an amount between 1 and 2% by weight.

11. The floor panel of claim 1 , wherein an at least one backing paper has been applied on at least one side.

12. The floor panel of claim 11 , wherein an at least one backing paper has been applied on the opposite side from the decorative layer.

13. The floor panel of claim 1 , wherein profiling has been provided on an edge region of the panel for introduction of a groove profile and/or tongue profile into an edge of the panel.

14. The floor panel of claim 1 , wherein the floor panel has a thickness between 2 and 15 mm and an apparent density between 500 and 1500 kg/m 3 .

15. The floor panel of claim 14 , wherein the floor panel has a thickness between 3 and 12 mm and an apparent density between 650 and 1300 kg/m 3 .

16. The floor panel of claim 14 , wherein the floor panel has a thickness between 4 and 10 mm and an apparent density between 800 and 1100 kg/m 3 .

17. The floor panel of claim 1 , used as a floor panel for a laminate floor.

18. A process for producing a wood-based material board, comprising the steps of:
applying a mixture of wood fibers having a wood fiber moisture content between 6% and 15% and a polymer functionalized with at least one organic compound, in a mixing ratio between 70% by weight of wood fibers/30% by weight of polymer and 40% by weight of wood fibers/60% by weight of polymer, to a first transport belt to form a preliminary mat and introducing the preliminary mat into at least one first heat treatment oven for pre-consolidation;
transferring the pre-consolidated mat into at least one double belt press for further consolidation to a wood-based material board; and
chilling the consolidated wood-based material board in at least one chill press to temperatures between 10° C. and 70° C. wherein at least one decorative layer has been provided on at least one side of the wood-based board material, and wherein the at least one decorative layer comprises at least one decorative film consisting of at least one thermoplastic carrier layer comprising polyethylene, polypropylene, or polyurethane, of at least one decoration printed onto the carrier layer, and at least one polymer seal comprising a polypropylene film or a polyurethane film.

Assignees

• Flooring Technologies Ltd

Inventors

• Kalwa Norbert
• Siems Jens
• Lehnhoff Ingo

Classifications

• B27N3/002 Primary

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

• B29C43/02

  of articles of definite length, i.e. discrete articles {(B29C35/0227 takes precedence)} · CPC title

• B29C43/006

  Pressing and sintering powders, granules or fibres · CPC title

• B29C43/003

  characterised by the choice of material · CPC title

• B27N3/04 Primary

  from fibres · CPC title