NZ615287B2 - Powder based balancing layer - Google Patents
Powder based balancing layer Download PDFInfo
- Publication number
- NZ615287B2 NZ615287B2 NZ615287A NZ61528712A NZ615287B2 NZ 615287 B2 NZ615287 B2 NZ 615287B2 NZ 615287 A NZ615287 A NZ 615287A NZ 61528712 A NZ61528712 A NZ 61528712A NZ 615287 B2 NZ615287 B2 NZ 615287B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- layer
- core
- applying
- paper sheet
- balancing
- Prior art date
Links
- 239000000843 powder Substances 0.000 title claims abstract description 110
- 239000010410 layer Substances 0.000 claims abstract description 159
- 239000000203 mixture Substances 0.000 claims abstract description 68
- 239000002344 surface layer Substances 0.000 claims abstract description 53
- 239000011241 protective layer Substances 0.000 claims abstract description 46
- 239000011230 binding agent Substances 0.000 claims abstract description 25
- 229920002522 Wood fibre Polymers 0.000 claims abstract description 23
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 19
- 239000000126 substance Substances 0.000 claims abstract description 10
- 238000001035 drying Methods 0.000 claims abstract description 7
- 239000007788 liquid Substances 0.000 claims abstract description 5
- 238000007514 turning Methods 0.000 claims abstract description 4
- 239000000835 fiber Substances 0.000 claims description 29
- 239000002245 particle Substances 0.000 claims description 18
- 238000004519 manufacturing process Methods 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 15
- 239000000969 carrier Substances 0.000 claims description 12
- 239000002023 wood Substances 0.000 claims description 7
- 239000011162 core material Substances 0.000 description 61
- 229920000877 Melamine resin Polymers 0.000 description 15
- PNEYBMLMFCGWSK-UHFFFAOYSA-N al2o3 Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 12
- 239000012530 fluid Substances 0.000 description 10
- 229920005989 resin Polymers 0.000 description 10
- 239000011347 resin Substances 0.000 description 10
- 239000007787 solid Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 239000003795 chemical substances by application Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 229910001884 aluminium oxide Inorganic materials 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 4
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 4
- 150000002500 ions Chemical class 0.000 description 4
- 239000004922 lacquer Substances 0.000 description 4
- 229920005610 lignin Polymers 0.000 description 4
- 238000005507 spraying Methods 0.000 description 4
- 238000011105 stabilization Methods 0.000 description 4
- 239000004640 Melamine resin Substances 0.000 description 3
- 239000003054 catalyst Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 239000000049 pigment Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 230000003019 stabilising Effects 0.000 description 3
- 230000000087 stabilizing Effects 0.000 description 3
- 239000000080 wetting agent Substances 0.000 description 3
- 229940035295 Ting Drugs 0.000 description 2
- 238000004049 embossing Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 238000007667 floating Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000002633 protecting Effects 0.000 description 2
- 239000003586 protic polar solvent Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 240000005337 Agave sisalana Species 0.000 description 1
- 241000609240 Ambelania acida Species 0.000 description 1
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
- 240000003917 Bambusa tulda Species 0.000 description 1
- 235000017491 Bambusa tulda Nutrition 0.000 description 1
- 240000000218 Cannabis sativa Species 0.000 description 1
- 240000000491 Corchorus aestuans Species 0.000 description 1
- 235000011777 Corchorus aestuans Nutrition 0.000 description 1
- 235000010862 Corchorus capsularis Nutrition 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 240000006962 Gossypium hirsutum Species 0.000 description 1
- 241000229754 Iva xanthiifolia Species 0.000 description 1
- 240000006240 Linum usitatissimum Species 0.000 description 1
- 235000004431 Linum usitatissimum Nutrition 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- ODGAOXROABLFNM-UHFFFAOYSA-N Polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N Silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 229920003180 amino resin Polymers 0.000 description 1
- 239000010905 bagasse Substances 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000007799 cork Substances 0.000 description 1
- 238000010192 crystallographic characterization Methods 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 235000012765 hemp Nutrition 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- KFZMGEQAYNKOFK-UHFFFAOYSA-N iso-propanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 235000012766 marijuana Nutrition 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000006011 modification reaction Methods 0.000 description 1
- 239000000025 natural resin Substances 0.000 description 1
- 239000012454 non-polar solvent Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000003880 polar aprotic solvent Substances 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 235000013311 vegetables Nutrition 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27K—PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR; CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
- B27K2200/00—Wooden materials to be treated
- B27K2200/10—Articles made of particles or fibres consisting of wood or other lignocellulosic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27K—PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR; CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
- B27K3/00—Impregnating wood, e.g. impregnation pretreatment, for example puncturing; Wood impregnation aids not directly involved in the impregnation process
- B27K3/02—Processes; Apparatus
- B27K3/15—Impregnating involving polymerisation including use of polymer-containing impregnating agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27K—PROCESSES, APPARATUS OR SELECTION OF SUBSTANCES FOR IMPREGNATING, STAINING, DYEING, BLEACHING OF WOOD OR SIMILAR MATERIALS, OR TREATING OF WOOD OR SIMILAR MATERIALS WITH PERMEANT LIQUIDS, NOT OTHERWISE PROVIDED FOR; CHEMICAL OR PHYSICAL TREATMENT OF CORK, CANE, REED, STRAW OR SIMILAR MATERIALS
- B27K5/00—Treating of wood not provided for in groups B27K1/00, B27K3/00
- B27K5/02—Staining or dyeing wood; Bleaching wood
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
- B27N3/06—Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
- B27N7/005—Coating boards, e.g. with a finishing or decorating layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/042—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/08—Coating on the layer surface on wood layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/24—Organic non-macromolecular coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/06—Vegetal fibres
- B32B2262/062—Cellulose fibres, e.g. cotton
- B32B2262/067—Wood fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/07—Parts immersed or impregnated in a matrix
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/20—Fibres of continuous length in the form of a non-woven mat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/30—Fillers, e.g. particles, powders, beads, flakes, spheres, chips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/70—Scrap or recycled material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2310/00—Treatment by energy or chemical effects
- B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
- B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
- B32B2310/0825—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using IR radiation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2607/00—Walls, panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/14—Printing or colouring
- B32B38/145—Printing
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2397/00—Characterised by the use of lignin-containing materials
- C08J2397/02—Lignocellulosic material, e.g. wood, straw or bagasse
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2461/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
- C08J2461/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
- C08J2461/26—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
- C08J2461/28—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2497/00—Characterised by the use of lignin-containing materials
- C08J2497/02—Lignocellulosic material, e.g. wood, straw or bagasse
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/042—Coating with two or more layers, where at least one layer of a composition contains a polymer binder
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D161/00—Coating compositions based on condensation polymers of aldehydes or ketones; Coating compositions based on derivatives of such polymers
- C09D161/20—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
- C09D161/26—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
- C09D161/28—Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
- C09D5/03—Powdery paints
- C09D5/033—Powdery paints characterised by the additives
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/70—Additives characterised by shape, e.g. fibres, flakes or microspheres
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/18—Paper- or board-based structures for surface covering
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/10—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of wood or with an outer layer of wood
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
- E04F15/045—Layered panels only of wood
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31975—Of cellulosic next to another carbohydrate
- Y10T428/31978—Cellulosic next to another cellulosic
- Y10T428/31982—Wood or paper
Abstract
Disclosed herein is a method to produce a building panel comprising a decorative surface layer, a core and a balancing and/or protective layer, the method comprising; applying a first layer of a first powder based mix, comprising wood fibres and a thermosetting binder on a core; applying a liquid substance on the first powder based mix; drying the first powder based mix; turning the core with the dried first powder based mix such that the first powder based mix points downwards; applying a second layer on the upper part of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel. Also disclosed are the panels produced by the method. bstance on the first powder based mix; drying the first powder based mix; turning the core with the dried first powder based mix such that the first powder based mix points downwards; applying a second layer on the upper part of the core; and curing the first and second layers by providing heat and pressure, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in the building panel. Also disclosed are the panels produced by the method.
Description
W0 41647
POWDER BASED BALANCING LAYER
cal field
The disclosure generally relates to the field of panels with a decorative surface
layer and a ing and/or protective layer, preferably floor and wall panels.
The disclosure relates to tion methods to produce such panels.
Field of Application
Embodiments of the present invention are particularly suitable for use in
production of floating floors, which are formed of floor panels sing a core
and a decorative wear resistant solid surface layer sing fibres, binders
and wear ant particles that have been applied on the core as a powder as
described in . The field of application comprises products with
other types of decorative layers such as paper based, laminated panels (DPL),
where a balancing and/or a protecting layer is used. The following description of
technique, problems of known systems and objects and features of the
embodiments of the invention will therefore, as a non-restrictive example, be
aimed above all at this field of application and in particular at floorings which are
similar to traditional floating wood fibre based laminate floorings. The invention
does not exclude floors that are glued down to a sub floor. Embodiments of the
invention can also be used in building panels such as for example wall panels,
ceilings, and furniture components and similar.
Background
Wood fibre based direct pressed laminated flooring (DPL) usually comprises a
core of a 6-12 mm fibre board, a 0.2 mm thick upper decorative surface layer of
te and a 0.1—0.2 mm thick lower balancing and/or tive layer of
laminate, plastic, paper or like material.
The surface layer of a laminate floor is characterized in that the decorative and
wear properties are generally obtained with two separate layers one over the
other. The decorative layer is generally a printed paper and the wear layer is a
transparent overlay paper, which comprises small ium oxide particles.
The printed decorative paper and the overlay are impregnated with melamine
formaldehyde resin and laminated to a wood fibre based core under heat and
pressure. The balancing layer is used to keep the panel flat after production and
when the panel is exposed to variations in moisture conditions that cause the
surface layer to swell and shrink.
Recently new “paper free” Wood Fibre Floor (WFF) types have been developed
with solid surfaces comprising a substantially homogenous mix of fibres, binders
and wear ant particles.
The wear resistant particles are preferably aluminium oxide les, the s
are preferably thermosetting resins such as amino resins and the fibres are
preferably wood based. Other suitable wear resistant materials are for example
silica or silicon carbide. in most applications decorative particles such as for
example colour pigments are included in the homogenous mix. In general all
these materials are preferably applied in dry form as a mixed powder on a HDF
core and cured under heat and re to a 0.1 — 1.0 mm solid layer.
Several advantages over known technology and especially over conventional
laminate floorings can be obtained:
0 The wear resistant surface layer, which is a homogenous mix, can be
made much thicker and a wear resistance is achieved, which is
considerably higher.
0 New and very advanced decorative effects can be obtained with deep
embossing and by te decorative materials, which can be
incorporated into the homogenous e layer and nated with the
embossing.
. An increased impact resistance can be d with a homogenous
surface layer, which is r and has a higher density.
. The homogenous surface layer can comprise particles that have a
positive impact on sound and moisture properties.
. Production costs can be reduced since low cost and even recycled
als can be used and several production steps can be eliminated.
Powder technology is very suitable to produce solid decorative surface layer,
which are much thicker than conventional laminate surface layers. Such solid
powder based layers create a much higher tension on the panel when they
WC 2012/141647 3
shrink (or swell) during curing and balancing is a problem. It is therefore difficult
to produce a panel with a thick and a high quality surface, which is also well
balanced after pressing as well as stable and flat in variable moisture conditions.
Definition of Some Terms
By "surface layer" is meant all types of e layers, which give the panel its
decorative properties and its wear resistance. By a “WFF mix” is meant a mix of
materials comprising fibres, binders, wear resistant particles and, ally, a
colour substance, which is preferably applied as powder on a carrier.
By “WFF floor” is meant a floor panel comprising a solid surface, which is
obtained by a WFF mix that is preferably applied as dry powder on a core, such
as for e HDF, and cured under heat and pressure.
Known Technigue and Problems thereof
The new “paper free” WFF floors with a solid surface comprising a WFF mix of
fibres, preferably wood fibres, small hard wear resistant particles and a binder
are produced according to a production method where the WFF mix is applied in
powder form on a core. The wood fibres are generally refined, mechanically
worked, and of the same type as used in HDF and particleboard, l.e. treated in a
way that the lignin t is ially unchanged. They comprise natural
resins such as lignin. The wear resistant particles are preferably aluminium oxide
particles. The surface layer comprises preferably also colour pigments or other
decorative materials or chemicals. Processed fibres e.g. bleached wood fibres
may also be used. Processed fibres may be ransparent, and are
preferably transparent in a cured binder.
A preferred binder is melamine or urea formaldehyde resin. Any other ,
preferably synthetic thermosetting or plastic resins, may be used. The
WFF layer is generally scattered in dry powder form on a wood based core, such
as for example HDF.
The de of the core is covered by a balancing layer, which comprises one
or several papers impregnated with melamine resin in order to get a balanced
product after pressing. The panel is generally produced with a surface that is
slightly convex in order to be able to stay flat even in very dry conditions.
W0 41647
The total build up with decorative layer, core and balancing or protective layer is
transferred into a press, where the decorative layer and the balancing or
protective layer are cured, under the influence of heat and pressure.
By a protective layer is meant a layer adapted to protect the backside of the
core.
The curing of a melamine formaldehyde (MF) resin involves shrinkage of the MF
resin matrix and the balancing layer is needed to balance the shrinkage forces
from the decorative layer.
Paper based backer materials can create problems as the paper always has a
dominating fibre ion either in the production direction or perpendicular to
the production ion. The shrinkage during curing is always higher in the
erse direction of the fibres as the fibres can be packed together closer in
this direction. The implication of this behaviour is that the balancing layer has
different shrinkage in the production direction compared with the transverse
direction.
As the backer is used to e the decorative layer, which may as an example
comprise a powder mix with random fibre direction, the consequence is that an
sed balancing only can be obtained in one direction, either along or
perpendicular to the production direction. It is also complicated to adapt the
thickness of the paper to different thicknesses of the e layer.
However, the paper based balancing layer offer the advantages that the paper is
rather easy to transport together with the core under the scattering units and into
a press.
it is known from that the balancing layer can be created with a
powder layer that is applied on the backside of the core. This known disclosure
does not show how a powder layer on a back side of a core should be handled in
order to allow a cost efficient production, especially when discontinuous presses
are used which require that the core with its powder based layers can be fed in
high speed with clamping devices into a press.
The above description of various known aspects is the applicants'
characterization of such, and is not an admission that any of the description is
prior art.
Obiects and Summary
An ive of certain embodiments of the invention is to provide a building
panel, preferably a floor panel with a decorative surface layer and a balancing
and/or protective layer which can be produced in a cost efficient way, or to at
least provide the public with a useful alternative.
A first aspect of the invention is a method of manufacturing a building panel with
a decorative surface layer, a core and a balancing and/or protective layer. The
method comprises the steps below and preferably performed in the listed
sequence:
0 applying a first layer of a first powder based mix, comprising wood fibres
and a thermosetting binder on a core;
. applying a liquid substance on the first powder based mix;
. drying the first powder based mix;
. turning the core with the dried first powder based mix such that the first
powder based mix points downwards;
. applying a second layer on the upper part of the core; and
. curing the first and second layers simultaneously by providing heat and
pressure, n the first layer forms the balancing and/or tive
layer and the second layer forms the decorative surface layer in the
building panel.
The method offers the ages that a powder based ing or
protective layer can be applied in a cost efficient way by scattering on a core.
The powder may be fixed to the core with a liquid substance that swells,
partly dissolves or dissolves the resin, thereby making the powder tacky and
stick together. A drying step removes part of the water thus leaving the
powder glued not only to itself but also to the core. The attachment makes
the first layer stable such that the core with the first layer can be turned and
fed under ring units and into a press. A paper based balancing or
WO 41647 6
protective layer can be ed in a cost efficient way by a wood fibre based
layer with random fibre direction that has similar shrinkage properties as the
decorative surface layer.
The building panel may be a floor panel.
The core may be a HDF or MDF board.
The second layer may comprise a veneer layer. Thereby, the veneer layer forms
the decorative surface layer. The second layer may comprise a sheet—shaped
layer of wood. A curable lacquer may be applied on top of the veneer layer.
The second layer may comprise a first paper sheet. in this ment, the
second layer forming the decorative surface layer is a te such as a DPL
(direct pressed laminate) or HPL (high pressure laminate).
The second layer may further comprise a second paper sheet.
The first and/or the second paper sheet may be impregnated with a
thermosetting resin such as melamine formaldehyde.
The first paper sheet may be arranged such that the fibre direction of the first
paper sheet is extending in a first direction, and the second paper sheet may be
arranged such that the fibre direction of the second paper sheet is extending in a
second direction, said second direction being transverse to the first direction.
The second layer may comprise a second powder based mix comprising wood
fibres, binders, preferably a setting binder, and wear ant particles.
y, the second layer can be applied in the same way as the powder based
balance or protective layer by scattering on the core.
The method may se the further step of applying a print or a colour
substance into the second mix.
A second aspect of the invention is a method of manufacturing a building panel
with a decorative surface layer, a core and a balancing and/or protective layer.
The method comprises the steps below and is preferably performed in the listed
sequence:
. applying a first layer of a first powder based mix, comprising wood fibres
and a thermosetting binder on a carrier, preferably of a thin material with
a ess that does not exceed the thickness of the decorative surface
layen
o placing the core material on the first powder based mix;
. applying a second layer comprising a first paper sheet on the upper part of
the core; and
o curing the first and second layers by providing heat and pressure wherein the
first layer forms the balancing and/or protective layer and the second layer
forms the tive surface layer of the building panel.
The method offers the advantages that a powder based balancing or protective layer
can be applied in a cost efficient way by scattering on a carrier that keeps the
powder based balancing or protective layer connected to the core during ort to
the device that applies the surface layer and y when the core is fed into the
press.
The building panel may be a floor panel.
The core may be a HDF or MDF board.
The carrier may be a fibre based material.
The second layer may se a veneer layer. Thereby, the veneer layer forms the
decorative surface layer. A curable lacquer or powder mix layer may be applied on
top of the veneer layer.
The second layer may comprise a first paper sheet. In this embodiment, the second
layer forming the decorative layer is a laminate such as a DPL (direct d
laminate) or HPL (high pressure laminate).
The second layer may further comprise a second paper sheet.
The first and/or the second paper sheet may be impregnated with a thermosetting
resin such as melamine formaldehyde.
The first paper sheet may be arranged such that the fibre direction of the first paper
sheet is extending in a first direction, and the second paper sheet may be arranged
such that the fibre direction of the second paper sheet is extending in a second
direction, said second direction being erse to the first direction.
The second layer may comprise a second powder based mix comprising wood
fibres, binders, preferably a thermosetting binder, and wear resistant particles.
W0 2012/141647 8
Thereby, the second layer can be applied in the same way as the powder based
balance or protective layer by scattering on a core.
The method may comprise the further step of applying a print or a colour
substance into the second mix.
A third aspect of the invention is a method of manufacturing a separate and
continuous powder based balancing and/or protective layer, which is ially
uncured. The method ses the steps below and is preferably performed in
the listed sequence:
0 applying a powder mix comprising fibres and a thermosetting binder on a
carrier;
. applying moisture on the powder mix such that the powder mix is
ted together to an ial uncured balancing and/or protective
layer; and
. releasing the uncured balancing and/or protective layer from the carrier.
The te and continuous powder based balancing or protective layer may
be used in a method for producing a building panel which method comprises the
steps below and is preferably performed in the listed sequence:
0 placing the uncured balancing and/or protective layer under a core
material;
. applying a surface layer on the core material; and
. curing the e layer and the uncured balancing and/or protective layer
under heat and pressure.
The method offers the advantages that a powder based balancing or protective
layer can be produced as a separate uncured layer that can be handled as a
conventional paper based balancing or protective layer. The moisture, that
preferably comprises water, may be sprayed on the powder such that the binder,
preferably a melamine resin, moisture swells, partly dissolves or dissolve the
resin, thereby making the powder tacky and stick together. The fibres in the mix
will be connected to each other when the water dries. The fibres may also be
connected by applying heat, e.g., lR heating, thereby removing the moisture and
ting the fibres in the mix. A powder based uncured balancing or protective
layer may be formed as a flexible thin sheet and a core al may be placed
over the balancing or protective layer.
The surface layer may comprise a powder based surface layer, at least one
paper sheet or a veneer layer.
A fourth aspect of the invention is a separate and continuous powder based
balancing and/or protective layer, which is essentially uncured. The separate
layer comprises powder mix comprising ted fibres and an essentially
uncured thermosetting binder.
The powder based balancing or protective layer is preferably produced
according to the method of the third .
A fifth aspect of the invention is a building panel, comprising a core, preferably a
wood—based core such as MDF or HDF board, a decorative surface layer
arranged on a first surface of said core, the decorative surface layer comprising
at least one paper layer, and a balancing layer arranged on a second surface of
said core, said second surface being opposite to said first surface, n the
balancing layer is formed of a powder based mix sing wood fibres and a
thermosetting binder.
The building panel is preferably produced according to the first or second aspect
of the invention.
Brief Description of the Drawings
The invention will in the following be described in connection to preferred
embodiments and in greater detail with nce to the appended exemplary
gs, wherein,
Figs 1a-e rate a method to form a balancing and/or protective layer.
Figs 2a-e Illustrate a method to form a balancing and/or protective layer.
Fig 3 illustrates a building panel wherein the decorative layer is laminate.
Fig 4 illustrates a building panel wherein the decorative layer is a veneer layer.
Detailed Description of Embodiments
The powder intended to be used as a balancing and/or tive layer 3 is
applied as a first powder mix on a core 2, preferably a MDF or HDF material,
preferably by one or several scattering units 11 as shown in figure 1a.
Figure 1b shows that the powder is thereafter pre-stabilized by a fluid 7,
preferable based on water, which is applied by a stabilizing device 9. The first
powder layer is thereafter dried. Such drying can be performed off-line in a
controlled environment or in-Iine by applying heat 8 with a heating device 10 on
the powder mix 3. The heating device 10 may comprise infrared light.
The water based fluid 7 and the following drying 8, attaches the powder layer 3
to the core 2, to such an extent that the core 2 with the powder can be turned
180° to bring the powder based balancing or protective layer 3 downwards, as
shown in figure 10, such that it may be transported further along the production
line or be stacked on a pallet for intermediate storage before further tion
takes place.
Oversized or ized fibres from the hammer mill that es the fibres for
the e layer may be used in the balancing or protective layer mix. The fibre
size is not as al as in a powder based surface layer and may vary from a
fibre length of several mm to less than 0.1 mm. The most preferred average fibre
length is O,1-1,0 mm.
A second powder based surface layer mix 1 is thereafter applied on the upper
side of the core 2 as showed in fig. 1d. A digital print 4 may be printed into the
surface layer 1. The surface layer 1 preferably also comprises wood fibres, a
colour substance, thermosetting s and aluminium oxide particles.
The wood fibres in both the first and second powder mixes in all embodiments of
the invention may be virgin, unrefined, refined and/or processed, comprising
lignin and without lignin, e.g. or-ceilulose fibres or holocellulose. A e of
refined and unrefined fibres may also be used. It is also contemplated that
vegetable fibres as jute, linen, flax, cotton, hemp, bamboo, bagasse and sisal
may be used. Also mineral fibres and carbon fibres may be used.
As an alternative to the second powder based surface layer mix, the second
layer forming the decorative surface layer may comprise at least one paper
sheet 21 adapted to form a te, which is shown in fig. 3. Said at least one
paper sheet 21 may be arranged on the upper side of the core. Preferably, the
second layer ses a first paper sheet 21 and a second paper sheet 22. The
first and second paper sheets 21, 22 may be arranged such that the fibre
direction of the first paper sheet 21 is extending in a first direction, and the fibre
W0 2012/141647
direction of the second paper sheet 22 is extending in a second direction being
opposite to the first direction. By arranging the fibre direction of the sheets
transversely, the second layer has fibre ions in more than one direction.
Thereby, during shrinkage, the second layer obtains properties more similar to
the balancing or protective layer having a random fibre direction compared to a
surface layer having only one ting fibre ion.
The first paper sheet 21 may be a printed paper. The second paper sheet 22
may be a transparent overlay paper. The second paper sheet 22 may form a
wear layer and may comprise small aluminium oxide particles. The first and
second paper sheets 21, 22 may be impregnated with melamine resin such that
they can be laminated to the core under heat and pressure simultaneously as
curing the balancing and/or protective layer. The second paper sheet 22 may be
arranged on top of the first paper sheet 21.
Alternatively, the second layer may se a veneer layer 23 or sheet-shaped
layer of wood arranged on the upper side of the core, which is shown in fig. 4.
The second layer may further se a curable lacquer layer d on top of
the veneer layer or sheet—shaped layer of wood. The curable lacquer layer may
be cured simultaneously as curing the balancing and/or protective layer.
Other decor layers may also be used as a second layer, such as cork, rubber,
plastics, especially a thermoplastic decor layer.
The core 2 with the surface layer 1 and the balancing or protective layer 3 is
thereafter fed into a press where the layers are cured under heat and pressure.
The balancing layer may be optimized in thickness and material composition in
order to create a perfect balancing of the e layer. The fibre orientation in
the layers may be essentially the same.
Recycled fibres from the machining of the , for example when a
mechanical locking system is formed, may be used in the balancing or protective
layer mix.
The balancing or protective layer 3 may preferably comprise a homogenous
powder mixture comprising about 50 weight % recycled MDF fibres with a
moisture content of preferably 3—8 % and about 50 weight % Melamine
Formaldehyde (MF) resin (Prefere 4865, Dynea). The MF resin amount can vary
between 30—70 w—%, preferably 40-65 w—% and most preferably 45—60 w—%. The
WO 41647 12
fibre content may vary from 30 — 70%, most preferably between 40-55%.
If needed the powder formulation can be ed such that thermosetting
particles, pigments, hard particles, release agents, wetting agents and similar
materials are included into the mix. The thermosetting plastic particles may be
mixed at random into the powder or applied as a separate thin layer and may be
used to provide a g against moisture penetration into the core.
The core of an HDF board preferably has a moisture content of 0—8 %.
The ring unit 11 may have capacity of scattering of 100-1000 g/m2 with a
tolerance of +/- 5% as measured using a calibration cup with an area of 100x100
mm cross- and length wise the board. The amount of stabilization fluid may vary
between 0 up to 200 g/m2.
The scattering unit 11 may comprise a needle belt and a scattering roller 12. The
ring roller is provided with needles in the range of about 30-120, preferably
about 50-100, and most preferably about 70-90 needles per cmz. The needle
length is about 0.5—2.5 mm, preferably about 1-2 mm and most preferably about
1.5 mm. Several scattering units 11 may be used to even out differences in the
applied powder mixture.
Furthermore, the scattering unit may be provided with a needle belt with needles
with a preferred length of about 15-20 mm, a preferred frequency in the range of
about 500-1000 rpm preferably about 1000 rpm, and a stroke length of about +/—
3 mm.
The stabilizing device 9 and the heating device 8 may be used to stabilize the
surface layer 1 and/or the ing or protective layer 3.
The stabilization device 9 may stabilize the powder using steam, nozzle spray
coating or ultra sonic spray coating.
Stabilization fluid may se solvents such as non—polar solvents, polar
aprotic solvents and polar protic solvents or mixtures thereof. Preferred solvents
are polar protic solvents such as isopropanol, ethanol and water. Most red
is water.
The stabilization fluid can further comprise ves such as wetting ,
defoamers, release agents, anti~slip agents and catalysts.
Figures 2a-2e show how a powder based balancing or protective layer can be
applied by applying the powder based balancing or protective layer as a first mix
3 on a r 5. The core is applied on the mix (fig 20) and a powder based
surface layer 1 is applied on the core 2. Alternatively, a surface layer of at least
one paper sheet 21 or veneer layer 23 is applied to the core for forming a
decorative surface layer, as described above with reference to figs. 3 and 4.
Stabilizing and/or heating of the balancing and/or surface layers may be made
as described above. The core and layers are fed into a press and cured under
heat and pressure to a building panel as shown in figure 2e.
The carrier may be a paper with a weight of for example 100 —— 200 gr. It may
also be a non woven fibre based material or a foil.
Powder may also be applied on a carrier that preferably is a conveyor belt 11
and stabilized with fluid and dried such that it can be released from the conveyor
11 and handled as a separate sheet t the carrier 5 as shown in figure 2b.
Such a separate and uous sheet or layer is essentially uncured. The sheet
or layer may be flexible such that it may be bent. The powder may comprise
fibres, preferably wood fibres, and a setting binder.
EXAMPLE
In example 1 below the powder formulation for the balancing layer used
comprising 50 weight—% recycled MDF fibre (valinge Innovation Sweden), 50
weight—% Melamine Formaldehyde resin (Prefere 4865, Dynea).
Example 1: Powder based product obtained through heat ssion of
product ed with powder based balancing layer and a treated powder as
decorative layer.
A balancing layer was formed by scattering 500 g/m2 of powder on a 9.7 mm
HDF core.
40 g/m2 of isation fluid with 5 w—% wetting agent, 6 w-% e agent and
3 w-% catalyst was d by spraying on the powder based balancing layer
The powder and the stabilisation fluid were applied at a line speed of 2.7 m/min.
The powder based balancing layer was dried at the same line speed with IR with
an effect of 19 kW.
The resulting intermediate product with a stabilized powder based balancing
layer was turned 180° and stacked on a pallet before use in the next operation
where a decorative surface layer of 500 gr/m2 was d in powder form on the
core.
The core with the e and balancing layers was pressed in a press with a
pressure of 40 kg/cmz, during 25 seconds. The upper press table applied a heat
of 170 degrees C on the surface layer and the lower press table applied a heat
of 175 s C on balancing layer.
A panel with a small pre tension backwards and a slightly convex surface was
obtained.
In example 2 below the powder formulation for the ing layer used
comprising 42 weight-% recycled MDF fibre (valinge Innovation Sweden), 58
weight-% Melamine Formaldehyde resin (Prefere 4865, Dynea).
Example 2: Powder based product obtained through heat compression of
product produced with powder based ing layer and a treated powder as
decorative layer.
A balancing layer was formed by scattering 320 g/m2 of powder on a 9.7 mm
HDF core.
40 g/m2 of stabilisation fluid with 1 wt-% wetting agent, 6 wt-% rerelease agent
and 1 wt—% catalyst was applied by spraying on the powder based balancing
layer mix
The powder and the stabilisation fluid were applied at a line speed of 2.0 m/min.
The powder based ing layer was dried at the same line speed with IR with
an effect of 19 kW.
The resulting intermediate product with a stabilized powder based balancing
layer was turned 180° and feed into the next operation where a decorative
surface layer of 550 gr/m2 was applied in powder form on the core.
The core with the surface and balancing layers was pressed in a press with a
pressure of 40 kg/cmz, during 37 seconds. The upper press table applied a heat
of 184°C on the surface layer and the lower press table applied a heat of 175°C
on balancing layer.
A panel with a small pre tension backwards and a slightly convex surface was
obtained.
It is contemplated that there are numerous modifications of the embodiments
described herein, which are still within the scOpe of the invention as defined
herein.
For example, it is contemplated that the ing layer may be provided with an
orientation in some embodiments. The wood fibres based the balancing layer
generally has a random fibre direction. However, in order to form a balancing
layer having similar ties as the decorative surface layer, an ation
may be formed in the balancing layer. Such orientation may be provided with by
means of scattering the powder in a specific n, by a pattern in the press
plate, or by means of a rake forming a pattern.
The steps of the method of the invention do not necessarily have to be
performed in the above described order. it is for example contemplated that the
second layer may be applied before the first layer, and that the core is turned
after the second layer has been applied. Thereafter the first layer is d,
liquid is applied, the first powder based mix is dried and the core is turned with
the dried first powder based mix such that the first powder based mix points
downwards.
Claims (21)
1. A method of manufacturing a building panel with a decorative e layer, a core and a balancing and/or protective layer, wherein the method comprises the steps: 0 applying a first layer of a first powder based mix, comprising wood fibres and a thermosetting binder on a core; . ng a liquid substance on the first powder based mix; 0 drying the first powder based mix; 10 . turning the core with the dried first powder based mix such that the first powder based mix points downwards; o applying a second layer on the upper part of the core; and . curing the first and second layers by providing heat and re, wherein the first layer forms the balancing and/or protective layer and the second 15 layer forms the decorative surface layer in the building panel.
2. The method as claimed in claim 1, wherein the building panel is a floor panel.
3._ The method as claimed in claim 1 or 2, wherein the core is a HDF or MDF board.
4. The method as claimed in any one of claims 1-3, n the step of ng 20 said second layer comprises applying a veneer layer.
5. The method as claimed in any one of claims 1-3, wherein the step of applying said second layer comprises applying a first paper sheet.
6. The method as claimed in claim 5, wherein the step of applying said second layer further comprising applying a second paper sheet. 25
7. The method as claimed in claim 6, wherein the step of applying said first and second paper sheets comprises arranging said first paper sheet such that the fibre direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fibre direction of the second paper sheet is extending in a second direction, said second direction being 30 transverse to the first direction.
8. The method as claimed in any one of claims 1—3, wherein the step of applying the second layer comprises applying a second powder based mix sing wood fibres, binders, and wear ant particles.
9. The method as claimed in claim 8, wherein the binder is a thermosetting binder.
10. The method as claimed in claim 8 or 9, wherein the method comprises the further step of ng a print or a colour substance into the second mix.
11. A method of cturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method comprises 10 the steps of: . applying a first layer of a first powder based mix, comprising wood fibres and a thermosetting binder on a carrier; . placing the core on the first powder based mix; 0 applying a second layer comprising a first paper sheet on the upper part 15 of the core; and . curing the first and second layers by providing heat and pressure, n the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer of the building panel.
12. The method as claimed in claim 11, wherein the first layer of the first powder 20 based mix, comprising wood fibres and the thermosetting binder on the carrier, is of a thin material with a thickness that does not exceed the thickness of the decorative surface layer.
13. The method as claimed in claim 11 or 12, wherein the building panel is a floorpaneL 25
14. The method as claimed in any one of claims 11-13, wherein the core is a HDF or MDF board.
15. The method as claimed in any one of the claims 11-14, wherein the carrier is a fibre based material.
16. The method as claimed in any one of claims 11-15, wherein the step of 30 applying said second layer r comprises applying a second paper sheet.
17. The method as claimed in claim 16, wherein the step of applying said first and second paper sheet comprises arranging said first paper sheet such that the fibre direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fibre direction of the second paper sheet is extending in a second direction, said second direction being transverse to the first direction.
18. A building panel, comprising a core, a decorative e layer arranged on a first e of said core, the 10 decorative surface layer comprising at least one paper layer, and a balancing layer ed on a second surface of said core, said second surface being opposite to said first surface, wherein the ing layer is formed of a powder based mix comprising wood fibres and a thermosetting binder. 15
19. A building panel as claimed in claim 18, wherein the core is a ased core.
20. A building panel as claimed in claim 19, wherein the wood—based core is MDF or HDF board.
21. The method as claimed in claim 1, substantially as herein described with 20 nce to any one of the es and/or
Applications Claiming Priority (9)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161474498P | 2011-04-12 | 2011-04-12 | |
US61/474,498 | 2011-04-12 | ||
SE1150320-8 | 2011-04-12 | ||
SE1150320 | 2011-04-12 | ||
US201161557734P | 2011-11-09 | 2011-11-09 | |
SE1151058-3 | 2011-11-09 | ||
US61/557,734 | 2011-11-09 | ||
SE1151058 | 2011-11-09 | ||
PCT/SE2012/050386 WO2012141647A1 (en) | 2011-04-12 | 2012-04-11 | Powder based balancing layer |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ615287A NZ615287A (en) | 2015-09-25 |
NZ615287B2 true NZ615287B2 (en) | 2016-01-06 |
Family
ID=
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11046063B2 (en) | Powder based balancing layer | |
EP2697060B1 (en) | Method of manufacturing a building panel | |
US11135814B2 (en) | Method of producing a building panel and a building panel | |
EP3057806B1 (en) | A method of manufacturing a building panel | |
EP2697065B1 (en) | A powder mix and a method for producing a building panel | |
US9352499B2 (en) | Method of manufacturing a layer | |
KR101850921B1 (en) | Method for manufacturing a building panel comprising a powder overlay | |
JP2019038267A (en) | Woody material panel, in particular, woody material panel in the form of wood-plastic composite material, and method of producing woody material panel | |
US10828874B2 (en) | Composite board composed of wood material with a middle layer made of plywood | |
CA2897156C (en) | A method of producing a building panel | |
NZ615287B2 (en) | Powder based balancing layer |