Method of manufacturing a building panel and a building panel

Patent metadata

Field	Value
Publication number	US-12070873-B2
Application number	US-202017125199-A
Country	US
Kind code	B2
Filing date	Dec 17, 2020
Priority date	Jul 2, 2013
Publication date	Aug 27, 2024
Grant date	Aug 27, 2024

Abstract

A method of manufacturing a building panel. The method includes applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a carrier for forming a first layer, applying a second binder and free lignocellulosic or cellulosic particles on the first layer for forming a second layer, wherein the first binder is different from the second binder, and applying heat and pressure to the first and second layers to form a building panel. Also, such a building panel.

First claim

The invention claimed is:

1. A method of manufacturing a building panel, comprising
applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a solid core for forming a first layer,
applying a second binder and free lignocellulosic or cellulosic particles on the first layer for forming a second layer,
wherein the first binder is different from the second binder, wherein the first binder comprises a thermoplastic binder or a mixture comprising a thermoplastic binder and a thermosetting resin, and the second binder comprises a thermosetting binder, and
applying heat and pressure to the first and second layers to form a building panel,
wherein applying the first binder and said free lignocellulosic or cellulosic particles comprises applying a first mix comprising the first binder and said free lignocellulosic or cellulosic particles,
wherein the first mix is free of cork particles.

2. A method according to claim 1 , wherein the first mix is a first powder mix.

3. A method according to claim 1 , wherein applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles.

4. A method according to claim 3 , wherein the second mix is a second powder mix.

5. A method according to claim 1 , wherein said second binder is applied in liquid form.

6. A method according to claim 5 , wherein said free lignocellulosic or cellulosic particles are applied onto the liquid second binder.

7. A method according to claim 1 , wherein the second layer further comprises wear resistant particles.

8. A method according to claim 1 , wherein the core is a wood based board.

9. A method according to claim 1 , further comprising applying a balancing layer on a second surface of the core being opposite to said first surface.

10. A method according to claim 1 , wherein the binder concentration of the first layer substantially correspond to the binder concentration of the second layer.

11. A method according to claim 1 , wherein the thermoplastic binder is polyvinyl acetate, a mixture comprising polyvinyl acetate, or a co-polymer comprising polyvinyl acetate.

12. A method according to claim 1 , wherein the second binder is an amino resin.

13. A method according to claim 1 , wherein the thermosetting resin of the mixture of the first binder is an amino resin.

Assignees

• Vaelinge Innovation Ab

Inventors

• Lindgren Kent
• Persson Hans
• Ziegler Göran

Classifications

• E04F15/107

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title

• B27N7/005

  Coating boards, e.g. with a finishing or decorating layer · CPC title

• Y10T428/31957

  Wood · CPC title

• Y10T428/31982

  Wood or paper · CPC title