Fibre based panels with a wear resistance surface

Patent metadata

Field	Value
Publication number	US-9556622-B2
Application number	US-201414192169-A
Country	US
Kind code	B2
Filing date	Feb 27, 2014
Priority date	Nov 19, 2007
Publication date	Jan 31, 2017
Grant date	Jan 31, 2017

Abstract

Building panels with a homogenous decorative surface having a wear layer comprising fibers, binders and wear resistant particles.

First claim

The invention claimed is:

1. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer comprises pigments and fibres mixed with a binder, the sub-layer being uncured,
applying a wood veneer layer on the sub-layer while the sub-layer is uncured, and
pressing the core, the sub-layer and the wood veneer layer together to cure the sub-layer to form the panel.

2. The method according to claim 1 , wherein applying the sub-layer comprises mixing the fibres with the binder, and subsequently applying the fibres mixed with the binder on the core.

3. The method according to claim 1 , wherein the binder is a thermosetting binder.

4. The method according to claim 1 , wherein the fibres are cork or wood fibres.

5. The method according to claim 1 , wherein the sub-layer is applied on the core in powder form.

6. The method according to claim 1 , further comprising applying a balancing layer on a second surface of the core, opposite the first surface of the core.

7. The method according to claim 6 , wherein the balancing layer comprises wood fibres and a binder.

8. The method according to claim 1 , wherein the core is a wood fibre based core.

9. The method according to claim 8 , wherein the core is a HDF core.

10. The method according to claim 1 , wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.

11. The method according to claim 1 , wherein the wood veneer layer has a thickness of 0.3-1.0 mm.

12. The method according to claim 1 , wherein the step of pressing comprises pressing with an embossed pressure matrix.

13. The method according to claim 1 , wherein the panel is a floorboard.

14. The method according to claim 1 , wherein the step of pressing further comprises applying heat, wherein the sub-layer mixture is cured under heat and pressure to form the panel.

15. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer is a dry powder mix which comprises pigments and fibres mixed with a binder,
applying a wood veneer layer on the sub-layer while the sub-layer is the dry powder mix, and
pressing the core, the sub-layer and the wood veneer layer together to form the panel.

16. A method of producing a panel, comprising:
providing a core, the core possessing a first surface and a second surface facing opposite of the first surface,
applying a sub-layer on the first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, and wherein the core is a wood fibre based core,
applying a balancing layer on the second surface of the core,
applying a wood veneer layer on the sub-layer, and
pressing the core, the sub-layer, the wood veneer layer, and the balancing layer together to form the panel,
wherein the core is a pre-fabricated core selected from the group of high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, oriented strand board (OSB), and plywood,
wherein the sub-layer is applied on the core in a dry powder form, and
wherein the fibres are cork or wood fibres.

17. The method according to claim 16 , wherein the sub-layer comprises pigments.

18. The method according to claim 16 , wherein the core is a HDF core.

19. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, the sub-layer being applied on the first surface of the core in a dry powder form,
applying a wood veneer layer directly on the sub-layer while the sub-layer is in the dry powder form, and
pressing the core, the sub-layer, and the wood veneer layer together to form the panel,
wherein the core is a pre-fabricated core selected from the group of high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, oriented strand board (OSB), and plywood,
wherein the panel is a floorboard and
wherein the fibres are cork or wood fibres.

20. The method according to claim 19 , wherein applying the sub-layer comprises mixing the fibres with the binder, and subsequently applying the fibres mixed with the binder on the core.

21. The method according to claim 19 , wherein the binder is a thermosetting binder.

22. The method according to claim 19 , further comprising applying a balancing layer on a second surface of the core, opposite the first surface of the core.

23. The method according to claim 22 , wherein the balancing layer comprises wood fibres and a binder.

24. The method according to claim 19 , wherein the core is a HDF core.

25. The method according to claim 19 , wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.

26. The method according to claim 19 , wherein the wood veneer layer has a thickness of 0.3-1.0 mm.

27. The method according to claim 19 , wherein the step of pressing comprises pressing with an embossed pressure matrix.

28. The method according to claim 19 , wherein the sub-layer in the dry powder form is an uncured mixture comprising the fibres mixed with the binder, and the step of pressing the core, the sub-layer and the wood veneer layer together cures the sub-layer mixture to form a panel.

29. The method according to claim 28 , wherein the step of pressing further comprises applying heat, wherein the sub-layer mixture is cured under heat and pressure to form the panel.

30. The method according to claim 19 , wherein the sub-layer comprises pigments.

31. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, the sub-layer being applied on the first surface of the core in a dry powder form,
applying a wood veneer layer directly on the sub-layer while the sub-layer is in the dry powder form, and
pressing the core, the sub-layer, and the wood veneer layer together to form the panel,
wherein the panel is a floorboard
wherein the fibres are cork or wood fibres and
wherein the sub-layer comprises pigments.

Assignees

• Vaelinge Innovation Ab
• Valinge Innovation Ab

Inventors

• Pervan Darko
• Lindgren Kent
• Jacobsson Jan
• Boucké Eddy
• Ziegler Göran
• Håkansson Niclas

Classifications

• E04F2201/0541

  adapted to be moved along the joint edge · CPC title

• B32B2307/75

  Printability · CPC title

• B32B37/153

  at least one layer is extruded and immediately laminated while in semi-molten state · CPC title

• B32B2260/046

  Synthetic resin · CPC title

• B32B2307/102

  Insulating · CPC title