Powder overlay

Patent metadata

Field	Value
Publication number	US-9296191-B2
Application number	US-201313912587-A
Country	US
Kind code	B2
Filing date	Jun 7, 2013
Priority date	Apr 13, 2010
Publication date	Mar 29, 2016
Grant date	Mar 29, 2016

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 fibers, 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

The invention claimed is:

1. A method of manufacturing a building panel, wherein the method comprises the steps of:
applying a decorative layer on a carrier;
applying a dry powder layer, comprising a mix of a thermoplastic material and wear resistant particles, on the decorative layer; and
applying heat and pressure in order to form the dry powder layer on the decorative layer into a transparent wear resistant layer.

2. The method as claimed in claim 1 , wherein the wear resistant particles comprise aluminium oxide and/or silica.

3. The method as claimed in claim 1 , wherein the mix further comprises processed wood fibres.

4. The method as claimed in claim 1 , wherein the thermoplastic material comprises vinyl particles.

5. The method as claimed in claim 1 , wherein the panel is a floor panel.

6. The method as claimed in claim 1 , wherein the carrier is a wood based board.

7. The method as claimed in claim 1 , wherein the carrier is an HDF or MDF board.

8. The method as claimed in claim 1 , wherein the decorative layer is a printed paper.

9. The method as claimed in claim 1 , wherein the decorative layer is a decorative powder mix including wood fibres and a binder.

10. The method as claimed in claim 1 , wherein the curing step comprises pressing the mix against an embossed matrix.

11. The method as claimed in claim 10 , wherein the pressing against the embossed matrix creates an embossing depth that exceeds a thickness of the decorative layer.

12. The method as claimed in claim 10 , wherein the pressing against the embossed matrix creates an embossing depth that exceeds the combined thickness of the decorative layer and the transparent wear layer.

13. A method of manufacturing a building panel, wherein the method comprises the steps of:
applying a decorative layer on a carrier;
applying a dry powder layer, comprising a mix of a thermoplastic material and wear resistant particles, on the decorative layer; and
applying heat and pressure on the powder layer to obtain a decorative surface layer comprising a transparent wear resistant layer, wherein the decorative layer comprises a transparent paper based overlay comprising aluminium oxide.

14. The method as claimed in claim 13 , wherein the transparent paper based overlay comprising aluminium oxide is applied over a lower powder layer, the lower powder layer comprising wood fibres and a binder.

15. A method of manufacturing a building panel, wherein the method consists of:
applying a decorative layer on a carrier;
applying a dry powder layer, comprising a mix of a thermoplastic material and wear resistant particles, on the decorative layer; and
applying heat and pressure on the dry powder layer to obtain a decorative surface layer comprising a transparent wear resistant layer.

Assignees

• Valinge Innovation Ab

Inventors

• Pervan Darko
• Ziegler Goran

Classifications

• B32B2317/02

  Cork · CPC title

• B32B2307/554

  Wear resistance · CPC title

• B32B2305/30

  Fillers, e.g. particles, powders, beads, flakes, spheres, chips · CPC title

• B32B2471/00

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

• B05D2401/32

  applied as powders · CPC title