Method for finishing a large-size supplied building panel

Patent metadata

Field	Value
Publication number	US-11220130-B2
Application number	US-201916972837-A
Country	US
Kind code	B2
Filing date	Jun 7, 2019
Priority date	Jun 8, 2018
Publication date	Jan 11, 2022
Grant date	Jan 11, 2022

Abstract

The disclosure relates to a method for finishing a panel, the method includes a) a relief embossed into the upper side in the form of at least one strip-shaped depression with a depth (T), b) a decorative paper applied to the upper side, c) an overlay paper applied to the decorative paper as an abrasion-resistant layer, d) the lower side provided with a backing layer, e) the structure pressed at a high pressure and temperature, and f) during the pressing, at least one strip-shaped depression again embossed in a second embossing without changing the depth (T). Also, the upper side features a press skin that has a thickness of 0.3 to 0.5 mm, the bulk density of the panel in a top layer is between 950 and 1,000 kg/m3, and an aqueous melamine resin is applied to the upper side as a tempering agent before or after embossing.

First claim

The invention claimed is:

1. A method for finishing a supplied building panel with an upper side and a lower side, the method comprises:
a) in a first embossing step, embossing a relief at least into the upper side in a form of at least one strip-shaped depression comprising a bottom wall with a depth (T),
b) applying a decorative paper to the upper side;
c) applying an overlay paper to the decorative paper an abrasion-resistant layer;
d) feeding the thus-prepared structure to a press and pressing the structure;
e) during the pressing, at least one strip-shaped depression is again embossed in a second embossing step without changing the depth (T),
f) the upper side includes a press skin that has a thickness of 0.3 to 0.5 mm;
g) a bulk density of the building panel the top layer that forms the upper side is between 950 and 1.000 kg/m 3 ,
h) the lower side includes a backing layer prior to pressing; and further comprising:
i) heating the building panel using steam prior to the embossing until it reaches a surface temperature of 30 to 50° C.,
j) applying an aqueous melamine resin to the upper side as a tempering agent before or immediately after the embossing; and
k) the press is a short-cycle press with pressure and temperature.

2. The method according to claim 1 , wherein at least one further depression is embossed at an angle (α) transverse to the at least one depression.

3. The method according to claim 1 , wherein the first embossing step is carried out with at least one embossing calender roll which operates under application of a pressure of up to 300 N/mm 2 and a surface temperature of up to 220° C.

4. The method according to claim 1 , wherein the first embossing step is carried out in a short-cycle press with a deeply structured press plate.

5. The method according to claim 1 , wherein the depth (T) is up to 0.7 mm.

6. The method according to claim 1 , wherein the depth (T) is in a form of steps, so that the bottom wall is designed in the form of the steps.

7. The method according to claim 1 , further comprising embossing markings on a region of the bottom wall.

8. The method according to claim 7 , wherein the markings, which comprises lines, circles, dots, crosses or other graphic characters, are printed on the decorative paper where it reaches the base walls of the at least one depression.

9. The method according to claim 4 , wherein re-embossing in the depression in the second embossing step is conducted by strip-shaped elevations the press plate of the short-cycle press.

10. The method according to claim 1 , wherein a structure is embossed into the upper side which is at least partially synchronous with the decorative pattern.

11. The method according to claim 1 , further comprising dividing up the large size building panel into individual panels by carrying out a saw cut in and along each of the depressions.

12. The method according to claim 4 , wherein the first embossing step is carried out in the short-cycle press by means of strip-shaped elevations on the press plate.

13. The method according to claim 1 , wherein the supplied building panel is made of HDF.

Assignees

• Flooring Technologies Ltd

Inventors

• Braun Roger
• Oldorff Frank
• Lehnhoff Ingo
• Kalwa Norbert
• Klupsch Rüdiger

Classifications

• B44C1/24 Primary

  Pressing or stamping ornamental designs on surfaces · CPC title

• E04F13/105

  with an outer layer imitating natural stone, brick work, tiled surface or the like · CPC title

• E04F13/0871

  having an ornamental or specially shaped visible surface (E04F13/0867 takes precedence) · CPC title

• B32B2451/00

  Decorative or ornamental articles · CPC title

• B32B21/02

  the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard · CPC title