Method for producing a material plate provided with a decorative layer

Patent metadata

Field	Value
Publication number	US-9757974-B2
Application number	US-201314651280-A
Country	US
Kind code	B2
Filing date	Dec 12, 2013
Priority date	Dec 12, 2012
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

Provided is a method for producing a wood based board including a support board and a decor paper disposed on the support board. The method includes the steps of a) providing a support board, b) applying at least one layer of at least one impregnating resin onto the at least one side of the support board, c) providing the decor paper, d) applying at least one resin as impregnating agent onto the side of the decor paper opposite from the decor, and e) placing the decor paper with the side impregnated opposite from the decor onto the side of the support board provided with the impregnating resin.

First claim

The invention claimed is:

1. A method for producing a board of wood based material including a support board and a decor paper disposed on the support board, the method comprising the steps of:
a) providing the decor paper, the decor paper having a decoration on a side thereof,
b) applying at least one resin as an impregnating agent solely onto a side of the decor paper opposite from the decoration, wherein the amount of resin applied is between 30% and 70%, based on a paper weight of the decor paper, and wherein the impregnating agent used is a melamine-formaldehyde resin, a melamine-phenol-formaldehyde resin, a melamine-urea resin, a polyurethane resin or an acrylate resin having a solid content between 30% and 50%,
c) providing the support board,
d) applying at least one layer of impregnating resin to at least one side of the support board, and
e) placing the side of the decor paper opposite from the decoration onto the at least one side of the support board provided with the at least one layer of the at least one impregnating resin,
wherein the decor paper impregnated on the side opposite from the decor has a swelling in length in a range between 0.2% and 0.4% and a swelling in width in a range between 0.5% to 0.9%.

2. The method according to claim 1 , wherein the decor paper impregnated on the side opposite from the decoration is dried to a moisture of 3-10 wt %.

3. The method according to claim 1 , wherein the amount of liquid resin applied to the side of the decor paper opposite from the decoration is between 40 and 60% based on the paper weight of the decor paper.

4. The method according to claim 1 , wherein the decor paper impregnated on the side opposite from the decor is rolled up before being placed onto the support board.

5. The method according to claim 1 , wherein the decor paper impregnated on the side opposite from the decor is placed onto the support board immediately following the impregnation.

6. The method according to claim 1 , wherein the impregnation agent applied to the decor paper comprises the solid content between 40% to 50%.

7. The method according to claim 1 , wherein the impregnating resin applied to the at least one side of the support board is a melamine-formaldehyde-resin, melamine-phenol-formaldehyde resin, a melamine-urea resin, a polyurethane resin or an acrylate resin with a solid content between 55% to 80%.

8. The method according to claim 1 , wherein following the placement of the decor paper onto the support board at least one further layer of a resin is applied.

9. The method according to claim 8 , wherein the resin to be applied onto the decor paper further comprises natural and/or synthetic fibers, abrasion resistant particles and optionally further additives.

10. The method according to claim 8 , wherein after an interim drying at least one further application of a mixture of liquid resin, natural and/or synthetic fibers, abrasion resistant particles and optionally further additives takes place or at least one overlay is applied.

11. The method according to claim 1 , wherein after the placement of the decor paper impregnated on the side opposite from the decor onto the support board at least one resin impregnated overlay is applied.

12. The method according to claim 1 , wherein at least one backing paper is applied to the opposite side of the support board, which is not provided with the decor paper.

13. The method according to claim 1 , wherein the support board, the decor paper, and the impregnating resin are compressed.

14. The method according to claim 1 , wherein the support board is made of a wood based material, a plastic material, or a mixture of wood based and plastic materials.

15. The method according to claim 2 , wherein the decor paper impregnated on the side opposite from the decoration is dried to the moisture of 5-7%.

16. The method according to claim 2 , wherein the decor paper impregnated on the side opposite from the decoration is dried to the moisture of 6 wt %.

17. The method according to claim 3 , wherein the amount of liquid resin applied to the side of the decor paper opposite from the decoration is 50% based on the paper weight of the decor paper.

18. The method according to claim 6 , wherein the impregnation agent applied to the decor paper comprises the solid content of 50%.

19. The method according to claim 7 , wherein the impregnating resin applied to the at least one side of the support board comprises the solid content between 60% to 70%.

Assignees

• Flooring Technologies Ltd

Inventors

• Kalwa Norbert

Classifications

• B44C5/0469 Primary

  comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper · CPC title

• E04F15/00

  Flooring (stair treads E04F11/104; coverings not specially adapted for floors E04F13/00; borders, skirtings E04F19/02; {implements for laying flooring E04F21/20;} gratings for cleaning soles of footwear A47L23/24; {built-in gratings E04F19/10; removing floor coverings E04G23/00; carpets A47G27/00;} of similar materials to roads E01C; basic or rough floors {, structural floors} E04B5/00) · CPC title

• B44C5/04 Primary

  Ornamental plaques, e.g. decorative panels, decorative veneers · CPC title