Fibre based panels with a wear resistance surface

Patent metadata

Field	Value
Publication number	US-9783996-B2
Application number	US-27025708-A
Country	US
Kind code	B2
Filing date	Nov 13, 2008
Priority date	Nov 19, 2007
Publication date	Oct 10, 2017
Grant date	Oct 10, 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 building panel comprising a surface layer and a core,
the core comprising wood fibres, and
the surface layer comprising a substantially uniformly dispersed mix of wood fibres, a binder and wear resistant particles,
the wood fibres in the mix comprising unrefined wood fibers,
wherein the mix is in direct contact with the wood fibers of an upper part of the core.

2. The building panel as claimed in claim 1 , wherein the panel is a floor panel comprising a balancing layer.

3. The building panel as claimed in claim 2 , wherein the binder is a thermosetting or thermoplastic resin.

4. The building panel as claimed in claim 3 wherein the binder is a thermosetting resin.

5. The building panel as claimed in claim 4 , wherein the wear resistant particles comprise aluminium oxide.

6. The building panel as claimed in claim 5 , wherein the core is HDF or particleboard, wherein the surface layer further comprises colour pigments, and wherein the wood fibres in the surface layer comprise fibres of the same material type as in the core.

7. The building panel as claimed in claim 4 , wherein the binder comprises a melamine formaldehyde resin.

8. The building panel as claimed in claim 7 , wherein the wear resistant particles are bonded to the wood fibres with the melamine formaldehyde resin.

9. The building panel as claimed in claim 5 , wherein the surface layer comprises a vertical portion with three horizontal planes extending parallel with the main plane of the panel wherein a first upper plane located in an upper part of the surface layer comprises a first aluminium oxide particle, a second intermediate plane located under the first aluminium oxide particle comprising wood particles and a third lower plane under the second plane comprising a second aluminium oxide particle and wherein aluminium oxide particles are in direct contact with an upper part of the core.

10. The building panel as claimed in claim 5 , wherein the weight content of the aluminium oxide particles in the surface layer is in the range of about 5% to about 30% of the total weight of the surface layer.

11. The building panel as claimed in claim 5 , wherein the weight content of the aluminium oxide particles in the surface layer is at least 100 gr/m2.

12. The building panel as claimed in claim 1 , wherein the core is HDF.

13. The building panel as claimed in claim 1 , wherein the core is a particleboard.

14. The building panel as claimed in claim 1 , wherein the surface layer further comprises a print that extends into the surface below upper wear resistant particles.

15. The building panel as claimed in claim 1 , wherein the surface layer comprises brushed portions with different fibre structures.

16. The building panel as claimed in claim 1 , wherein the surface layer comprises brushed portions with different wear resistance.

17. The building panel as claimed in claim 1 , wherein the surface layer comprises wood fibres that comprise lignin.

18. The building panel as claimed in claim 1 , wherein the surface layer wood fibres are essentially smaller than 1 mm.

19. The building panel as claimed in claim 1 , wherein the surface layer wood fibres are in powder form and essentially smaller than 0.5 mm.

20. The building panel as claimed in claim 1 , wherein a panel edge comprises a mechanical locking system for locking of the panel with similar other panels and wherein such locking system is formed in the core.

21. A building panel comprising a surface layer connected to a core,
the core comprising wood fibres,
wherein the surface layer, which gives the panel decorative effect and wear resistance, is a substantially uniformly dispersed layer comprising a mix of wood fibres, colour pigments, binders and wear resistant particles, and
wherein the mix is in direct contact with the wood fibers of an upper part of the core.

22. The building panel as claimed in claim 21 , wherein all parts of the surface layer are present at an outer surface of the surface layer and at an inner lower part which is connected to the core.

23. The building panel as claimed in claim 21 , wherein the panel is a floor panel comprising a balancing layer.

24. The building panel as claimed in claim 21 , wherein the binder is a thermosetting or thermoplastic resin.

25. The building panel as claimed in claim 24 wherein the binder is a thermosetting resin.

26. The building panel as claimed in claimed in claim 21 , wherein the wear resistant particles comprise aluminium oxide.

27. The building panel as claimed in claim 24 , wherein the binder comprises a melamine formaldehyde resin.

28. The building panel as claimed in claim 27 , wherein the wear resistant particles are bonded to the fibres with the melamine formaldehyde resin.

29. The building panel as claimed claim 21 , wherein the surface layer comprises a vertical portion with three horizontal planes extending parallel with the main plane of the panel wherein a first upper plane located in an upper part of the surface layer comprises a first aluminium oxide particle, a second intermediate plane located under the first aluminium oxide particle comprising wood particles and a third lower plane under the second plane comprising a second aluminium oxide particle and wherein aluminium oxide particles are in direct contact with an upper part of the core.

30. The building panel as claimed in claim 26 , wherein the weight content of the aluminium oxide particles in the surface layer is in the range of about 5% to about 30% of the total weight of the surface layer.

31. The building panel as claimed in claim 26 , wherein the weight content of the aluminium oxide particles in the surface layer is at least 100 gr/m2.

32. The building panel as claimed in claim 21 , wherein the core is HDF.

33. The building panel as claimed in claim 21 , wherein the core is a particleboard.

34. The building panel as claimed in claim 21 , wherein the surface layer further comprises a print that extends into the surface below upper wear resistant particles.

35. The building panel as claimed in claim 21 , wherein the surface layer comprises brushed portions with different fibre structures.

36. The building panel as claimed in claim 21 , wherein the surface layer comprises brushed portions with different wear resistance.

37. The building panel as claimed in claim 21 , wherein the surface layer comprises mineral fibres.

38. The building panel as claimed in claim 37 , wherein the surface layer wood fibres are essentially smaller than 1 mm.

39. The building panel as claimed in claim 34 , wherein the surface layer wood fibres are in powder form and essentially smaller than 0.5 mm.

40. The building panel as claimed in claim 21 , wherein a panel edge comprises a mechanical locking system for locking of the panel with similar other panels and wherein such locking system is formed in the core.

41. A building panel comprising a surface layer and a core,
the core comprising wood fibres, and
the surface layer comprising a substantially uniformly dispersed mix of wood fibres, a binder and wear resistant particles,
the wood fibres in the mix

Assignees

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

Inventors

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

Classifications

• Y10T428/24901

  including coloring matter · CPC title

• E04F2201/0138

  by moving the sheets, plates or panels perpendicular to the main plane · CPC title

• B32B2307/102

  Insulating · CPC title

• B32B2260/021

  Fibrous or filamentary layer · CPC title

• Y10T442/695

  Including a wood containing layer · CPC title