Method to produce a building panel and a semi-finished product

Patent metadata

Field	Value
Publication number	US-12330445-B2
Application number	US-202117375046-A
Country	US
Kind code	B2
Filing date	Jul 14, 2021
Priority date	Dec 21, 2015
Publication date	Jun 17, 2025
Grant date	Jun 17, 2025

Abstract

A method to produce a building panel, including: providing a substrate, applying a thermosetting binder in dry form on the substrate for forming a sub-layer, applying a sheet on the sub-layer, and pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet from below. Also, a semi-finished product.

First claim

The invention claimed is:

1. A method to produce a building panel, comprising
providing a substrate,
applying a thermosetting binder in dry form on the substrate for forming a sub-layer,
controlling the moisture content of the sub-layer when arranged on the substrate,
applying a sheet on the sub-layer, while the sub-layer is sticky from applied moisture, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and wherein the sheet further comprises pigments and/or fillers, and
pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet,
wherein controlling the moisture content of the sub-layer comprises:
controlling adhesion of the sheet to sub-layer by applying moisture to the sub layer; and
controlling flow of the thermosetting binder of the sub-layer.

2. The method according to claim 1 , wherein controlling the moisture content of the sub-layer comprises one or more of the following:
applying steam on the substrate prior to applying the sub-layer,
applying steam on the sub-layer when arranged on the substrate,
applying steam on the sheet,
applying liquid on the substrate prior to applying the sub-layer,
applying liquid on the sub-layer when arranged on the substrate,
applying liquid on the sheet, and/or
drying the sub-layer and/or the sheet.

3. The method according to claim 1 , wherein the moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.

4. The method according to claim 1 , wherein the sheet being applied on the sub-layer is unimpregnated or impregnated by a fluid comprising less than 20 wt % of a thermosetting binder.

5. The method according to claim 1 , wherein the sub-layer consists essentially of the thermosetting binder.

6. The method according to claim 1 , further comprising printing a décor on the sheet when arranged on the sub-layer.

7. The method according to claim 6 , wherein the sheet is adhered to the sub-layer prior to printing.

8. A method to produce a building panel, comprising
providing a substrate,
controlling relative humidity (RH) of ambient air enclosing an application device adapted to apply a thermosetting binder in dry form,
applying a thermosetting binder in dry form on the substrate by said application device for forming a sub-layer,
applying a sheet on the sub-layer, wherein the sheet comprises pigments and/or fillers, and
pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet,
wherein the relative humidity (RH) is 35-60% RH.

9. The method according to claim 8 , wherein the sheet being applied on the sub-layer is unimpregnated or impregnated by a fluid comprising less than 20 wt % of a thermosetting binder.

10. The method according to claim 8 , wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet.

11. The method according to claim 8 , wherein the sub-layer consists essentially of the thermosetting binder.

12. The method according to claim 8 , further comprising printing a décor on the sheet when arranged on the sub-layer.

13. The method according to claim 12 , wherein the sheet is adhered to the sub-layer prior to printing.

14. The method according to claim 8 , further comprising applying moisture to the thermosetting binder, the sub-layer, the sheet, and/or the substrate prior to pressing.

15. The method according to claim 8 , wherein a moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.

16. A method to produce a building panel, comprising
providing a substrate,
applying a thermosetting binder in dry form on the substrate for forming a sub-layer,
controlling the moisture content of the sub-layer when arranged on the substrate,
applying a sheet on the sub-layer, while the sub-layer is sticky from applied moisture, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and wherein the sheet further comprises pigments and/or fillers,
pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet,
wherein the sub-layer comprises the thermosetting binder and non-absorbing fillers,
wherein the sheet comprises a print,
wherein controlling the moisture content of the sub-layer comprises:
controlling adhesion of the sheet to sub-layer by applying moisture to the sub- layer; and
controlling flow of the thermosetting binder of the sub-layer.

17. The method according to claim 16 , wherein the sheet being applied on the sub-layer is unimpregnated or impregnated by a fluid comprising less than 20 wt % of a thermosetting binder.

18. The method according to claim 16 , wherein the sub-layer consists essentially of the thermosetting binder.

19. The method according to claim 16 , further comprising applying moisture to the thermosetting binder, the sub-layer, the sheet, and/or the substrate prior to pressing.

20. The method according to claim 16 , wherein a moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.

21. The method according to claim 16 , further comprising printing the print on the sheet when arranged on the sub-layer, wherein the print is a décor.

22. The method according to claim 16 , wherein the sheet is adhered to the sub-layer prior to printing.

23. The method according to claim 16 , wherein a moisture content of the sub-layer when arranged on the substrate is 15-35 wt. %.

Assignees

• Vaelinge Innovation Ab

Inventors

• Persson Hans
• Bergelin Marcus

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

• B44C5/0476

  with abrasion resistant properties · CPC title

• B32B2471/00

  Floor coverings (B32B2419/04 takes precedence) · CPC title

• B32B38/145

  Printing · CPC title

• B32B5/022

  Non-woven fabric · CPC title