A method of producing a veneered element and such a veneered element

Patent metadata

Field	Value
Publication number	US-2017190156-A1
Application number	US-201515308737-A
Country	US
Kind code	A1
Filing date	May 11, 2015
Priority date	May 12, 2014
Publication date	Jul 6, 2017
Grant date	—

Abstract

A method of producing a veneered element, the method including providing a substrate, applying a sub-layer on a surface of the substrate, applying a veneer layer on the sub-layer, and applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer. Also, such a veneered element.

First claim

1 . A method of producing a veneered element, the method comprising
providing a substrate, applying a sub-layer on a surface of the substrate, applying a veneer layer on the sub-layer, applying a protective layer comprising a thermoplastic material on the veneer layer, and applying pressure to the veneer layer and/or the substrate, such that at least a portion of the sub-layer permeates through the veneer layer.

2 . The method according to claim 1 , wherein the thermoplastic material comprises polyvinyl chloride, polyester, polypropylene, polyethylene, polystyrene, polyurethane, polyethylene terephthalate, polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

3 . The method according to claim 1 , wherein the protective layer comprises at least one thermoplastic foil.

4 . The method according to claim 1 , wherein applying the protective layer comprises applying a first foil comprising a first thermoplastic material, on the veneer layer, and applying a second foil comprising a second thermoplastic material, on the first foil.

5 . The method according to claim 1 , wherein applying the protective layer comprises applying the thermoplastic material in powder form on the veneer layer.

6 . The method according to claim 1 , wherein the protective layer further comprises wear resistant particles.

7 . The method according to claim 1 , wherein the sub-layer further comprises pigments.

8 . The method according to claim 1 , wherein the substrate is a wood-based board.

9 . The method according to claim 1 , further comprising controlling a design of the veneer layer by controlling permeation of the sub-layer through the veneer layer.

10 . The method according to claim 9 , wherein controlling permeation of the sub-layer through the veneer layer comprises controlling a fluid pressure of the sub-layer.

11 . The method according to claim 10 , wherein controlling the fluid pressure of the sub-layer when applying pressure includes adjusting one or more of the following parameters:
concentration of a binder in the sub-layer; type of binder in the sub-layer; formulation of the binder in the sub-layer; moisture content of the sub-layer; the pressure applied to the veneer layer and/or the substrate; a gas pressure in the sub-layer; concentration of fillers in the sub-layer; and thickness of the veneer layer.

12 . The method according to claim 11 , wherein generating the gas pressure comprises including chemical and/or physical blowing agents in the sub-layer.

13 . The method according to claim 9 , wherein controlling permeation of the sub-layer through the veneer layer comprises abrasive machining of the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

14 . The method according to claim 13 , wherein the abrasive machining comprises brushing the veneer layer prior to applying pressure to the veneer layer and/or the substrate.

15 . The method according to claim 9 , wherein controlling permeation of the sub-layer through the veneer layer comprises forming holes, cavities and/or cracks in the veneer layer.

16 . The method according to claim 1 , wherein said at least a portion of the sub-layer permeates through pores of the veneer layer.

17 . The method according to claim 1 , wherein said at least a portion of the sub-layer permeates through cracks and/or holes of the veneer layer.

18 . The method according to claim 1 , wherein the veneer layer comprises a wood veneer, a cork veneer, or a stone veneer.

19 . The method according to claim 1 , wherein the sub-layer comprises a binder.

20 . The method according to claim 19 , wherein the binder is a thermosetting binder or a thermoplastic binder.

21 . The method according to claim 1 , wherein the sub-layer comprises wear resistant particles.

22 . The method according to claim 1 , wherein after pressure has been applied, the veneer layer comprises embossed portions, wherein a portion of the sub-layer is more compressed under an embossed portion than under a non-embossed surface portion.

23 . A veneered element, comprising
a substrate, a sub-layer arranged on the substrate, and a veneer layer arranged on the sub-layer, a protective layer comprising a thermoplastic material arranged on the veneer layer, and wherein at least a portion of the sub-layer is permeated through the veneer layer such that at least a portion of the sub-layer is visible at the surface of the veneer layer facing away from the substrate.

24 . The veneered element according to claim 23 , wherein the protective layer further comprises wear resistant particles.

25 . The veneered element according to claim 23 , wherein the thermoplastic material comprises polyvinyl chloride, polyester, polypropylene, polyethylene, polystyrene, polyurethane, polyethylene terephthalate, polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

26 . The veneered element according to claim 23 , wherein the protective layer comprises at least one thermoplastic foil.

27 . The veneered element according to claim 23 , the protective layer comprises a first foil comprising a first thermoplastic material, preferably polyvinylchloride (PVC), and a second foil comprising a second thermoplastic material, preferably polyurethane (PU).

28 . The veneered element according to claim 23 , wherein the sub-layer comprises pigments.

29 . The veneered element according to claim 23 , wherein the sub-layer comprises wear resistant particles.

30 . The veneered element according to claim 23 , wherein the sub-layer comprises fillers.

31 . The veneered element according to claim 23 , wherein said at least a portion of the sub-layer is permeated through pores of the veneer layer.

32 . The veneered element according to claim 23 , wherein the veneer layer comprises embossed portions, wherein a portion of the sub-layer is more compressed under an embossed portion than under a non-embossed surface portion.

Assignees

• Vaelinge Innovation Ab

Inventors

• Lundblad Christer
• Nygren Per
• Meijer Thomas
• Ziegler Göran

Classifications

• B32B27/36

  comprising polyesters · CPC title

• B27D1/00

  Joining wood veneer with any material; Forming articles thereby (in conjunction with moulding of wood particles or fibres B27N3/06); Preparatory processing of surfaces to be joined, e.g. scoring · CPC title

• B44C5/043

  containing wooden elements · CPC title

• B32B2307/102

  Insulating · CPC title

• B27D1/06

  Manufacture of central layers; Form of central layers {(see also B27M3/002 and B27M3/0026)} · CPC title