Powder based balancing layer

Patent metadata

Field	Value
Publication number	US-2019277039-A1
Application number	US-201816210493-A
Country	US
Kind code	A1
Filing date	Dec 5, 2018
Priority date	Apr 12, 2011
Publication date	Sep 12, 2019
Grant date	—

Abstract

A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method includes applying a first layer of a first powder based mix, including wood fibres and a thermosetting binder, on a core; applying a liquid substance on the first powder based mix; drying the first powder based mix; turning the core with the dried first powder based mix such that the first powder based mix points downwards; applying a second layer on the upper part of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel.

First claim

1 - 26 . (canceled)

27 . A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method comprises the steps:
applying a first layer of a first powder based mix, comprising wood fibres and a thermosetting binder, on a first surface of a core; applying a liquid substance on the first powder based mix; applying a second layer on a second surface of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel, wherein the first layer comprises wood fibres with random fibre direction that has similar shrinkage properties as the decorative surface layer.

28 . The method as claimed in claim 27 , wherein the building panel is a floor panel.

29 . The method as claimed in claim 27 , wherein the core is a HDF or MDF board.

30 . The method as claimed in claim 27 , wherein the step of applying said second layer comprises applying a veneer layer.

31 . The method as claimed in claim 27 , wherein the step of applying said second layer comprises applying a first paper sheet.

32 . The method as claimed in claim 31 , wherein the step of applying said second layer further comprising applying a second paper sheet.

33 . The method as claimed in claim 32 , wherein the step of applying said first and second paper sheets comprises arranging said first paper sheet such that the fibre direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fibre direction of the second paper sheet is extending in a second direction, said second direction being transverse to the first direction.

34 . The method as claimed in claim 27 , wherein the step of applying the second layer comprises applying a second powder based mix comprising wood fibres, binders, and wear resistant particles.

35 . The method as claimed in claim 34 , wherein the method comprises the further step of applying a print or a colour substance into the second mix.

36 . The method as claimed in claim 27 , wherein the step of applying the first layer of the first powder based mix is done by scattering.

37 . The method as claimed in claim 27 , wherein the step of drying the first powder based mix comprises applying heat, the heat being applied before the step of turning the core.

38 . The method as claimed in claim 27 , wherein the wood fibres of the first powder mixture possesses a moisture content of between 3-8 weight-%.

39 . The method as claimed in claim 27 , wherein a stabilization device applies the liquid substance on the first powder based mix.

40 . The method as claimed in claim 39 , wherein the stabilization device uses at least one of steam, nozzle spray coating, and ultrasonic coating to apply the liquid substance on the first powder mixture.

41 . The method as claimed in claim 27 , wherein the liquid substance further comprises an additive, the additive comprising at least one of a wetting agent, a release agent, a defoamer, an anti-slip agent, and a catalyst.

42 . A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method comprises the steps of:
applying a first layer of a first powder based mix, comprising wood fibres and a thermosetting binder, on a carrier; applying a liquid substance on the first powder based mix; placing a lower surface of the core on the first powder based mix after the liquid substance has been applied on the first powder based mix; applying a second layer on an upper surface of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer of the building panel, wherein the first layer comprises wood fibres with random fibre direction that has similar shrinkage properties as the decorative surface layer.

43 . The method as claimed in claim 42 , wherein the building panel is a floor panel.

44 . The method as claimed in claim 42 , wherein the core is a HDF or MDF board.

45 . The method as claimed in claim 42 , wherein the carrier is a fibre based material.

46 . The method as claimed in claim 42 , wherein the step of applying said second layer comprises applying a veneer layer.

47 . The method as claimed in claim 42 , wherein the step of applying said second layer comprises applying a first paper sheet.

48 . The method as claimed in claim 47 , wherein the step of applying said second layer further comprising applying a second paper sheet.

49 . The method as claimed in claim 48 , wherein the step of applying said first and second paper sheet comprises arranging said first paper sheet such that the fibre direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fibre direction of the second paper sheet is extending in a second direction, said second direction being transverse to the first direction.

50 . The method as claimed in claim 42 , wherein the step of applying said second layer comprises applying a second powder based mix comprising wood fibres, binders, and wear resistant particles.

51 . The method as claimed in claim 42 , wherein the carrier is of a thin material with a thickness that does not exceed the thickness of the decorative surface layer.

Assignees

• Valinge Innovation Ab

Inventors

• Persson Han
• Hakansson Niclas
• Jacobsson Jan

Classifications

• B32B38/145

  Printing · 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

• C09D161/28

  with melamine · CPC title

• B27N7/005

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

• B27N3/04

  from fibres · CPC title