Powder overlay

Patent metadata

Field	Value
Publication number	US-2016186318-A1
Application number	US-201615061303-A
Country	US
Kind code	A1
Filing date	Mar 4, 2016
Priority date	Apr 13, 2010
Publication date	Jun 30, 2016
Grant date	—

Abstract

A method is disclosed of manufacturing a transparent wear resistant surface layer ( 1 ). The method may include the steps of, applying a decorative material on a carrier, applying a dry powder layer comprising a mix of processed wood fibres, binder and wear resistant particles above the decorative layer, curing the mix to a decorative surface, including the transparent wear resistant layer, by applying heat and pressure on the mix. In a preferred embodiment the method includes the step of pressing the mix against an embossed matrix to create an embossed decorative surface with high wear resistance.

First claim

1 . (canceled)

2 . A method of manufacturing a building panel, wherein the method comprises the steps of:
applying a first layer on a carrier; applying a dry powder layer, comprising a binder and wear resistant particles, on the first layer; and applying heat on the dry powder layer to obtain a transparent wear resistant layer.

3 . The method according to claim 2 , wherein the step of applying heat further comprises applying pressure.

4 . The method according to claim 2 , wherein the wear resistant particles comprise aluminum oxide and/or silica.

5 . The method according to claim 2 , wherein the dry powder layer further comprises processed wood fibres.

6 . The method according to claim 2 , wherein the first layer is a decorative layer.

7 . The method according to claim 6 , wherein the decorative layer is a printed paper.

8 . The method according to claim 6 , wherein the decorative layer is wood veneer.

9 . The method according to claim 2 , wherein the binder is a thermosetting resin.

10 . The method according to claim 2 , wherein the binder is a thermoplastic material.

11 . The method according to claim 10 , wherein the thermoplastic material comprises vinyl particles.

12 . The method according to claim 10 , wherein the thermoplastic material comprises E-PVC, S-PVC, PVA, PET, PS, SAN, or PMMA.

13 . The method as claimed in claim 2 , wherein the carrier is a wood based board.

14 . The method as claimed in claim 2 , wherein the carrier is an HDF or MDF board.

15 . The method as claimed in claim 3 , wherein the pressings step comprises pressing the dry powder layer against an embossed matrix.

16 . The method as claimed in claim 15 , wherein the pressing against the embossed matrix creates an embossing depth that exceeds the combined thickness of the first layer and the transparent wear layer.

17 . The method as claimed in claim 2 , wherein the first layer is applied on the carrier before the dry powder layer is applied on the first layer.

18 . A method of manufacturing a building panel, wherein the method comprises the steps of:
applying a wood veneer layer on a carrier; applying a dry powder layer, comprising a binder and wear resistant particles, on the first layer; and applying heat on the dry powder layer to obtain a transparent wear resistant layer.

19 . The method according to claim 18 , wherein the wood veneer layer is placed on powder mix comprising wood fibres and a binder.

20 . The method according to claim 19 , wherein the powder mix further comprises pigments.

21 . The method according to claim 19 , wherein the powder mix further comprises wear resistant particles.

22 . The method according to claim 18 , wherein the binder is a thermosetting resin.

23 . The method according to claim 18 , wherein the binder is a thermoplastic material.

24 . The method according to claim 18 , wherein the step of applying heat further comprises applying pressure.

25 . A method of manufacturing a building panel, wherein the method comprises the steps of:
applying a first layer on a carrier; applying a dry powder layer, comprising a binder and wear resistant particles, on the first layer; and applying pressure on the dry powder layer to obtain a transparent wear resistant layer.

Assignees

• Valinge Innovation Ab

Inventors

• Pervan Darko
• Ziegler Goran

Classifications

• B32B38/145

  Printing · CPC title

• B05D3/12

  by mechanical means · CPC title

• B05D5/02 Primary

  to obtain a matt or rough surface · CPC title

• B32B38/06

  Embossing · CPC title

• B32B2307/554

  Wear resistance · CPC title