Method of manufacturing a building panel

Patent metadata

Field	Value
Publication number	US-2015111055-A1
Application number	US-201414516957-A
Country	US
Kind code	A1
Filing date	Oct 17, 2014
Priority date	Oct 18, 2013
Publication date	Apr 23, 2015
Grant date	—

Abstract

A method of manufacturing a building panel including a core, a decorative layer and a balancing layer, including mechanically processing production waste including a resin impregnated paper to processed production waste, applying a first mix including said processed production waste and a thermosetting binder on a first surface of a core, applying a decorative layer on a second surface of the core, and curing the first mix to a balancing layer of the building panel. Also, a building panel formed by such a method.

First claim

1 . A method of manufacturing a building panel comprising a core, a decorative layer and a balancing layer, comprising
applying a first mix comprising a thermosetting binder and particles formed from production waste comprising resin impregnated paper on a first surface of a core, applying a decorative layer on a second surface of the core, and curing the first mix to form the balancing layer of the building panel.

2 . A method according to claim 1 , wherein the particles formed from production waste comprise lignocellulosic material or cellulosic material.

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

4 . A method according to claim 1 , wherein the thermosetting binder is applied on the core in dry powder form.

5 . A method according to claim 1 , wherein the thermosetting binder is in powder form when mixed with the particles formed from production waste.

6 . A method according to claim 1 , wherein the particles formed from production waste comprise wear resistant particles.

7 . A method according to claim 1 , wherein the particles formed from production waste are formed by mechanically processing production waste comprising resin impregnated paper.

8 . A method according to claim 1 , wherein the resin impregnated paper is a resin impregnated décor paper, a resin impregnated backing paper or a resin impregnated overlay paper.

9 . A method according to claim 1 , wherein the resin impregnated paper comprises a substantially uncured thermosetting binder.

10 . A method according to claim 1 , wherein the resin impregnated paper comprises a substantially cured thermosetting binder.

11 . A method according to claim 1 , further comprising:
applying a stabilization fluid on the first mix, turning the core having the first mix applied thereto such that the first mix is directed downwards from a surface of the core before applying the decorative layer.

12 . A method according to claim 11 , further comprising drying the first mix before turning the core.

13 . A method according to claim 1 , wherein the first mix further comprises lignocellulosic or cellulosic particles separate from the particles formed from product waste.

14 . A method according to claim 13 , wherein the first mix is formed by adding the particles formed from product waste to a mix comprising the thermosetting binder and said lignocellulosic or cellulosic particles.

15 . A method according to claim 13 , wherein the first mix comprises 1-50% by weight of said particles formed from production waste.

16 . A method according to claim 1 , wherein the decorative layer comprises a décor paper.

17 . A method according to claim 1 , wherein the decorative layer comprises a second mix comprising lignocellulosic or cellulosic particles and a thermosetting binder.

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

19 . A method according to claim 1 , wherein the decorative layer comprises wear resistant particles.

20 . A building panel comprising:
a core having a first and a second surface, a balancing layer arranged on a first surface of the core, a decorative layer arranged on the second surface of the core, and wherein the balancing layer comprises a thermosetting binder and particles formed from production waste comprising resin impregnated paper.

21 . A building panel according to claim 20 , wherein the particles formed from production waste comprises lignocellulosic material or cellulosic material.

Assignees

• Vaelinge Innovation Ab
• Vaelinge Innovation Ab

Inventors

• Persson Hans
• Wingårdh Peter

Classifications

• B32B2607/02

  Wall papers, wall coverings · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B2307/4026

  within the layer by addition of a colorant, e.g. pigments, dyes · CPC title

• B32B37/24

  with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) · CPC title

• E04C2/24

  laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 · CPC title