Method for producing a panel with a wood based core and a surface layer comprising a thermosetting resin

Patent metadata

Field	Value
Publication number	US-9757928-B2
Application number	US-201213606878-A
Country	US
Kind code	B2
Filing date	Sep 7, 2012
Priority date	Sep 9, 2011
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

A method for forming of a building panel with a surface including a thermosetting resin such that tension created during curing of the surface is reduced or eliminated.

First claim

The invention claimed is:

1. Method for producing a panel with a wood based core and a surface layer comprising a thermosetting resin, wherein the method comprises the steps of:
curing and connecting the surface layer to the core while applying heat and pressure in a first main pressing step, thus raising a temperature of the surface layer above an initial temperature;
while the panel is still above the initial temperature from the first pressing step, applying a bending force on the panel in a second pressing step to bend the panel such that an uppermost surface of the panel is convex and a lowermost surface of the panel is concave; and
releasing the bending force such that the panel springs back to an essentially flat shape.

2. The method as claimed in claim 1 , wherein the method further comprises the step of decreasing the surface temperature while applying the bending force.

3. The method as claimed in claim 2 , wherein the surface temperature decrease is about 20° C.

4. The method as claimed in claim 2 , wherein the surface temperature decrease is more than 20° C.

5. The method as claimed in claim 1 , wherein the thermosetting resin is a melamine formaldehyde resin.

6. The method as claimed in claim 1 , wherein the bending is at least about 3 cm/m.

7. The method as claimed in claim 1 , wherein the surface layer comprises wood fibres and wear resistant particles.

8. The method as claimed in claim 1 , wherein the surface layer comprises impregnated paper, the wood based core comprises a high-density fibreboard (HDF) core, and the impregnated paper is bonded to the HDF core.

9. The method as claimed in claim 1 , wherein the surface layer comprises wood fibres, wear resistant particles and colour pigments.

10. The method as claimed in claim 1 , wherein the surface layer comprises a powder based layer, the powder comprising wood fibers, wear resistant particle and colour pigments.

11. The method as claimed in claim 1 , wherein the panel is a building panel.

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

13. The method as claimed in claim 1 , wherein the bending force is applied to at least two opposite edge portions of the panel.

14. The method as claimed in claim 1 , wherein the panel is rectangular and the bending force is applied to both sets of opposite edge portions of the panel.

15. The method as claimed in claim 1 , wherein the bending force is applied with a first press table on the uppermost surface of the panel and a second press table on the lowermost surface of the panel.

16. The method as claimed in claim 15 , wherein the first and second press tables are curved in two perpendicular directions, such that bending is made along and across the panel.

Assignees

• Pervan Darko
• Pervan Tony
• Ceraloc Innovation Ab

Inventors

• Pervan Darko
• Pervan Tony

Classifications

• E04F15/107

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title

• B32B2038/0076

  Curing, vulcanising, cross-linking · CPC title

• B32B37/0015 Primary

  to avoid warp or curl · CPC title

• B29B13/02

  by heating (B29B13/06, B29B13/08 take precedence) · CPC title

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title