Wood fibre based panel with a surface layer

Patent metadata

Field	Value
Publication number	US-11318726-B2
Application number	US-201816132977-A
Country	US
Kind code	B2
Filing date	Sep 17, 2018
Priority date	Jan 10, 2014
Publication date	May 3, 2022
Grant date	May 3, 2022

Abstract

A building panel with a surface layer including a wood veneer, a wood fibre based core and a sub-layer between the surface layer and the core. The sub-layer includes wood fibres and a binder. The surface layer has surface portions including material from the sub-layer. The surface portions including material from the sub-layer extend into the wood veneer.

First claim

The invention claimed is:

1. A method to produce a building panel, the method comprising:
applying a wood fibre powder and a binder on a first side of a wood fibre based core, to obtain a first sub-layer;
applying a first wood veneer, comprising holes through the first wood veneer, on the first sub-layer; and
applying heat and pressure to bond the first wood veneer, the first sub-layer and the wood fibre based core together, thereby material from the first sub-layer is pressed into the holes of the first wood veneer, to form a first surface layer,
wherein the building panel comprises a second surface layer, wherein the second surface layer is on a second side opposite the first side of the wood fibre based core, wherein the second surface layer comprises a second sub-layer of a wood fibre powder and a binder, and a second wood veneer on the second sub-layer, and
the method further comprising, prior to applying heat and pressure to form the first surface layer, pre-pressing the first sublayer, wherein the binder of the first sub-layer is partially cured during the pre-pressing.

2. The method as claimed in claim 1 , further comprising applying a foaming agent in the first sub-layer.

3. The method as claimed in claim 2 , wherein the wood fibre powder comprises lignocellulosic particles or cellulose particles.

4. The method as claimed in claim 1 , further comprising applying different colour pigments, wherein portions of the first sub-layer are visible in the holes of the first veneer, wherein the colour of the visible first sub-layer portion varies along the building panel, or such that the portion of the first sub-layer in the holes forms a pattern.

5. The method as claimed in claim 1 , further comprising applying a protective overlay with wear resistant particles on the first wood veneer.

6. The method as claimed in claim 1 , wherein the first sub-layer comprises colour pigments and/or a colorant.

7. The method as claimed in claim 1 , wherein the first sub-layer comprises wear resistant particles.

8. The method as claimed in claim 1 , further comprising applying a protective overlay with wear resistant particles on the first wood veneer prior to pressing.

9. The method as claimed in claim 1 , further comprising pre-treating the first veneer, prior to applying heat and pressure.

10. The method as claimed in claim 9 , further comprising pre-treating the first veneer, prior to applying heat and pressure, by brushing.

11. The method as claimed in claim 1 , wherein after applying pressure, the first wood veneer comprises embossed portions, and wherein a part of the first sub-layer is more compressed under an embossed surface portion than under a non-embossed surface portion.

12. The method as claimed in claim 1 , wherein the first surface layer comprises embossed portions and protrusions, wherein the binder of the first sub-layer bonds porous portions of the first wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond non-porous portions of the first wood veneer in the compressed position so that non-porous portions of the first wood veneer form the protrusions.

13. The method as claimed in claim 1 , the method further comprising applying a protective overlay with wear resistant particles on the first wood veneer prior to pressing,
wherein the first sub-layer comprises wear resistant particles, wherein the panel comprises, after pressing, the first surface layer with surface portions comprising material from the first sub-layer, wherein the surface portions comprising material from the first sub-layer are flush with a remainder of the first surface layer, to obtain an entire surface layer with wear resistant particles.

Assignees

• Vaelinge Innovation Ab
• Valinge Innovation Ab

Inventors

• Pervan Darko
• Ziegler Goran

Classifications

• B44C5/043

  containing wooden elements · CPC title

• E04F15/042 Primary

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

• Y10T428/3167

  Of cork · CPC title

• B32B3/30

  characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)} · CPC title

• B32B2262/067

  Wood fibres · CPC title