Powder based balancing layer

Abstract
A method to produce a building panel comprising a decorative surface layer, a core and a balancing and/or protective layer is disclosed.
Description
TECHNICAL FIELD

The disclosure generally relates to the field of panels with a decorative surface layer and a balancing and/or protective layer, preferably floor and wall panels. The disclosure relates to production 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 comprising a core and a decorative wear resistant solid surface layer comprising fibres, binders and wear resistant particles that have been applied on the core as a powder as described in WO 2009/065769. 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 laminate and a 0.1-0.2 mm thick lower balancing and/or protective 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 aluminium 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 resistant particles.


The wear resistant particles are preferably aluminium oxide particles, the binders 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 pressure to a 0.1-1.0 mm solid layer.


Several advantages over known technology and especially over conventional laminate floorings can be obtained:

    • 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.
    • New and very advanced decorative effects can be obtained with deep embossing and by separate decorative materials, which can be incorporated into the homogenous surface layer and coordinated with the embossing.
    • An increased impact resistance can be reached with a homogenous surface layer, which is thicker 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 materials 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 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 surface 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, optionally, 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 example HDF, and cured under heat and pressure.


Known Technique 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, i.e. treated in a way that the lignin content is essentially 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 semi-transparent, and are preferably transparent in a cured binder.


A preferred binder is melamine or urea formaldehyde resin. Any other binder, preferably synthetic thermosetting or thermoplastic 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 backside 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.


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 direction either in the production direction or perpendicular to the production direction. The shrinkage during curing is always higher in the transverse 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 balance the decorative layer, which may as an example comprise a powder mix with random fibre direction, the consequence is that an optimised 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 surface 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 WO 2009/065769 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.


OBJECTS AND SUMMARY

An objective 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.


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:

    • 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, wherein the first layer forms the balancing and/or protective layer and the second layer forms the decorative surface layer in 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 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 scattering units and into a press. A paper based balancing or protective layer can be replaced 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 embodiment, the second layer forming the decorative surface layer is a laminate 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 thermosetting binder, and wear resistant particles. Thereby, 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 comprise 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 thickness that does not exceed the thickness of the decorative surface layer;
    • placing the core material on the first powder based mix;
    • 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 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 transport to the device that applies the surface layer and finally 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 comprise 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 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 thermosetting binder, and wear resistant particles. 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 essentially uncured. The method comprises the steps below and is preferably performed in the listed sequence:

    • 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 connected together to an essential uncured balancing and/or protective layer; and
    • releasing the uncured balancing and/or protective layer from the carrier.


The separate 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:

    • placing the uncured balancing and/or protective layer under a core material;
    • applying a surface layer on the core material; and
    • curing the surface 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., IR heating, thereby removing the moisture and connecting the fibres in the mix. A powder based uncured balancing or protective layer may be formed as a flexible thin sheet and a core material 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 connected fibres and an essentially uncured thermosetting binder.


The powder based balancing or protective layer is preferably produced according to the method of the third aspect.


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, wherein the balancing layer is formed of a powder based mix comprising 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 reference to the appended exemplary drawings, wherein,



FIGS. 1
a-e illustrate a method to form a balancing and/or protective layer.



FIGS. 2
a-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 protective 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 FIG. 1a. FIG. 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-line 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 FIG. 1c, such that it may be transported further along the production line or be stacked on a pallet for intermediate storage before further production takes place.


Oversized or undersized fibres from the hammer mill that produces the fibres for the surface layer may be used in the balancing or protective layer mix. The fibre size is not as critical 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 0.1-1.0 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 binders 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. α-cellulose fibres or holocellulose. A mixture 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 laminate, 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 comprises 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 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 directions 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 dominating fibre direction.


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 comprise 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 comprise a curable lacquer layer applied 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 décor layers may also be used as a second layer, such as cork, rubber, plastics, especially a thermoplastic décor 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 surface layer. The fibre orientation in the layers may be essentially the same.


Recycled fibres from the machining of the panels, 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 fibre content may vary from 30-70%, most preferably between 40-55%.


If needed the powder formulation can be modified 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 sealing against moisture penetration into the core.


The core of an HDF board preferably has a moisture content of 0-8%.


The scattering 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 100×100 mm cross- and length wise the board. The amount of stabilization fluid may vary from 0 up to 200 g/m2.


The scattering unit 11 may comprise a needle belt and a scattering roller 12. The scattering roller is provided with needles in the range of about 30-120, preferably about 50-100, and most preferably about 70-90 needles per cm2. 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 10 may be used to stabilize the surface layer 1 and/or the balancing 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 comprise 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 preferred is water.


The stabilization fluid can further comprise additives such as wetting agents, defoamers, release agents, anti-slip agents and catalysts.



FIGS. 2
a-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 carrier 5. The core is applied on the mix (FIG. 2c) 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 FIG. 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 without the carrier 5 as shown in FIG. 2b. Such a separate and continuous 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 thermosetting binder.


EXAMPLES

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 Compression of Product Produced 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 stabilisation fluid with 5 w-% wetting agent, 6 w-% release agent and 3 w-% 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 2.7 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 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/cm2, 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 degrees 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 balancing 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 Balancing 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 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 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/cm2, 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 by the appended claims.


For example, it is contemplated that the balancing 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 properties as the decorative surface layer, an orientation may be formed in the balancing layer. Such orientation may be provided with by means of scattering the powder in a specific pattern, by a pattern in the press plate, or by means of a rake forming a pattern.


The steps of the method claims 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 applied, 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
  • 1. A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method comprises the steps: applying a first layer of a first powder based mix, comprising wood fibers and a thermosetting binder, on a core;applying a liquid substance on the first powder based mix;drying the first powder based mix by infrared heating;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; andcuring 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.
  • 2. The method as claimed in claim 1, wherein the building panel is a floor panel.
  • 3. The method as claimed in claim 1, wherein the core is a HDF or MDF board.
  • 4. The method as claimed in claim 1, wherein the step of applying said second layer comprises applying a veneer layer.
  • 5. The method as claimed in claim 1, 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.
  • 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 fiber direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fiber direction of the second paper sheet is extending in a second direction, said second direction being transverse to the first direction.
  • 8. The method as claimed in claim 1, wherein the step of applying the second layer comprises applying a second powder based mix comprising wood fibers, binders, and wear resistant particles.
  • 9. The method as claimed in claim 8, wherein the method comprises the further step of applying a print or a color substance into the second mix.
  • 10. A method of manufacturing a building panel with a decorative surface layer, a core and a balancing and/or protective layer, wherein the method comprises the steps of: applying a first layer of a first powder based mix, comprising wood fibers and a thermosetting binder, on a carrier;applying a liquid substance on the first powder based mix;drying the first powder based mix by infrared heating;placing the core on the first powder based mix;applying a second layer on the upper part of the core; andcuring 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 of the building panel.
  • 11. The method as claimed in claim 10, wherein the building panel is a floor panel.
  • 12. The method as claimed in claim 10, wherein the core is a HDF or MDF board.
  • 13. The method as claimed in claim 10, wherein the carrier is a fiber based material.
  • 14. The method as claimed in claim 10, wherein the step of applying said second layer comprises applying a veneer layer.
  • 15. The method as claimed in claim 10, wherein the step of applying said second layer comprises applying a first paper sheet.
  • 16. The method as claimed in claim 15, wherein the step of applying said second layer further comprising 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 fiber direction of the first paper sheet is extending in a first direction, and arranging said second paper sheet such that the fiber direction of the second paper sheet is extending in a second direction, said second direction being transverse to the first direction.
  • 18. The method as claimed in claim 10, wherein the step of applying said second layer comprises applying a second powder based mix comprising wood fibers, binders, and wear resistant particles.
  • 19. A method of manufacturing a separate and continuous powder based balancing and/or protective layer, which is essentially uncured, wherein the method comprises the steps of: applying a powder mix, comprising fibers and a thermosetting binder, on a carrier;applying moisture on the powder mix such that the powder mix is connected together to form an uncured balancing and/or protective layer;drying the uncured balancing and/or protective layer by infrared heating; andreleasing the uncured balancing and/or protective layer from the carrier.
  • 20. The method as claimed in claim 19, wherein the fibers are wood fibers and the binder a melamine resin.
  • 21. The method as claimed in claim 10, wherein the carrier is of a thin material with a thickness that does not exceed the thickness of the decorative surface layer.
CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of Swedish Application No. 1150320-8, filed on Apr. 12, 2011, Swedish Application No. 1151058-3, filed on Nov. 9, 2011, U.S. Provisional Application No. 61/474,498, filed on Apr. 12, 2011, and U.S. Provisional Application No. 61/557,734, filed on Nov. 9, 2011. The entire contents of each of Swedish Application No. 1150320-8, Swedish Application No. 1151058-3, U.S. Provisional Application No. 61/474,498, and U.S. Provisional Application No. 61/557,734 are hereby incorporated herein by reference.

US Referenced Citations (136)
Number Name Date Kind
2587064 Rapson Feb 1952 A
2962081 Dobry et al. Nov 1960 A
3032820 Johnson May 1962 A
3135643 Michl Jun 1964 A
3308013 Bryant Mar 1967 A
3325302 Hosfeld Jun 1967 A
3342621 Point et al. Sep 1967 A
3345234 Jecker et al. Oct 1967 A
3426730 Lawson et al. Feb 1969 A
3463653 Letter Aug 1969 A
3486484 Bullough Dec 1969 A
3533725 Bridgeford Oct 1970 A
3540978 Ames Nov 1970 A
3565665 Stranch et al. Feb 1971 A
3673020 De Jaeger Jun 1972 A
3846219 Kunz Nov 1974 A
3880687 Elmendorf et al. Apr 1975 A
3897185 Beyer Jul 1975 A
3897588 Nohtomi Jul 1975 A
3914359 Bevan Oct 1975 A
3961108 Rosner et al. Jun 1976 A
4052739 Wada et al. Oct 1977 A
4093766 Scher et al. Jun 1978 A
4131705 Kubinsky Dec 1978 A
4313857 Blount Feb 1982 A
4337290 Kelly et al. Jun 1982 A
4430375 Scher et al. Feb 1984 A
4474920 Kyminas et al. Oct 1984 A
5034272 Lindgren et al. Jul 1991 A
5206066 Horacek Apr 1993 A
5246765 Lussi et al. Sep 1993 A
5258216 Von Bonin et al. Nov 1993 A
5422170 Iwata et al. Jun 1995 A
5543193 Tesch Aug 1996 A
5569424 Amour Oct 1996 A
5601930 Mehta et al. Feb 1997 A
5604025 Tesch Feb 1997 A
5609966 Perrin et al. Mar 1997 A
5855832 Clausi Jan 1999 A
5925296 Leese Jul 1999 A
5942072 McKinnon Aug 1999 A
6036137 Myren Mar 2000 A
6103377 Clausi Aug 2000 A
6238750 Correll et al. May 2001 B1
6468645 Clausi Oct 2002 B1
6521326 Fischer et al. Feb 2003 B1
6537610 Springer et al. Mar 2003 B1
6773799 Persson et al. Aug 2004 B1
6803110 Drees et al. Oct 2004 B2
6926954 Schueren et al. Aug 2005 B2
6991830 Hansson et al. Jan 2006 B1
7022756 Singer Apr 2006 B2
7485693 Matsuda et al. Feb 2009 B2
7811489 Pervan et al. Oct 2010 B2
8349234 Ziegler et al. Jan 2013 B2
8349235 Pervan et al. Jan 2013 B2
8419877 Pervan et al. Apr 2013 B2
8431054 Pervan et al. Apr 2013 B2
8480841 Pervan et al. Jul 2013 B2
8481111 Ziegler et al. Jul 2013 B2
8617439 Pervan et al. Dec 2013 B2
8663785 Ziegler et al. Mar 2014 B2
20010006704 Chen et al. Jul 2001 A1
20010009309 Taguchi et al. Jul 2001 A1
20020054994 Dupre et al. May 2002 A1
20020100231 Miller Aug 2002 A1
20030056873 Nakos et al. Mar 2003 A1
20030102094 Tirri et al. Jun 2003 A1
20030208980 Miller et al. Nov 2003 A1
20040123542 Grafenauer Jul 2004 A1
20040191547 Oldorff Sep 2004 A1
20040202857 Singer Oct 2004 A1
20040206036 Pervan Oct 2004 A1
20040237436 Zuber et al. Dec 2004 A1
20040250911 Vogel Dec 2004 A1
20050003099 Quist et al. Jan 2005 A1
20050079780 Rowe et al. Apr 2005 A1
20050193677 Vogel Sep 2005 A1
20050252130 Martensson Nov 2005 A1
20060008630 Thiers et al. Jan 2006 A1
20060024465 Briere Feb 2006 A1
20060032175 Chen et al. Feb 2006 A1
20060070321 Au Apr 2006 A1
20060145384 Singer Jul 2006 A1
20060182938 Oldorff Aug 2006 A1
20060183853 Sczepan Aug 2006 A1
20070166516 Kim et al. Jul 2007 A1
20070184244 Doehring Aug 2007 A1
20070207296 Eisermann Sep 2007 A1
20070218260 Miclo et al. Sep 2007 A1
20070224438 Van Benthem et al. Sep 2007 A1
20070256804 Garcis Espino et al. Nov 2007 A1
20080000417 Pervan et al. Jan 2008 A1
20080032120 Braun Feb 2008 A1
20080090032 Perrin et al. Apr 2008 A1
20080176039 Chen et al. Jul 2008 A1
20080263985 Hasch et al. Oct 2008 A1
20090124704 Jenkins May 2009 A1
20090155612 Pervan et al. Jun 2009 A1
20090208646 Kreuder et al. Aug 2009 A1
20090294037 Oldorff Dec 2009 A1
20090311433 Wittmann Dec 2009 A1
20100092731 Pervan et al. Apr 2010 A1
20100196678 Vermeulen Aug 2010 A1
20100223881 Kalwa Sep 2010 A1
20100239820 Buhlmann Sep 2010 A1
20100291397 Pervan et al. Nov 2010 A1
20100300030 Pervan et al. Dec 2010 A1
20100307675 Buhlmann Dec 2010 A1
20100307677 Buhlmann Dec 2010 A1
20100319282 Ruland Dec 2010 A1
20100323187 Kalwa Dec 2010 A1
20100330376 Trksak Dec 2010 A1
20110175251 Ziegler et al. Jul 2011 A1
20110177319 Ziegler et al. Jul 2011 A1
20110177354 Ziegler et al. Jul 2011 A1
20110189448 Lindgren et al. Aug 2011 A1
20110247748 Pervan et al. Oct 2011 A1
20110250404 Pervan et al. Oct 2011 A1
20110283642 Meirlaen et al. Nov 2011 A1
20110283650 Pervan et al. Nov 2011 A1
20110293823 Bruderer et al. Dec 2011 A1
20110293906 Jacobsson Dec 2011 A1
20120263878 Ziegler et al. Oct 2012 A1
20120263965 Persson et al. Oct 2012 A1
20120264853 Ziegler et al. Oct 2012 A1
20120288689 Hansson et al. Nov 2012 A1
20120308774 Persson et al. Dec 2012 A1
20130092314 Ziegler et al. Apr 2013 A1
20130095315 Pervan et al. Apr 2013 A1
20130111845 Pervan et al. May 2013 A1
20130189534 Pervan et al. Jul 2013 A1
20130269863 Pervan et al. Oct 2013 A1
20130273244 Vetter et al. Oct 2013 A1
20130273245 Ziegler et al. Oct 2013 A1
20140075874 Pervan et al. Mar 2014 A1
Foreign Referenced Citations (112)
Number Date Country
8028475 Jun 1975 AU
2 557 096 Jul 2005 CA
298894 May 1954 CH
298 894 Aug 1954 CH
1 815 312 Jul 1969 DE
7148789 Apr 1972 DE
7148789 Apr 1972 DE
29 39 828 Apr 1981 DE
33 34 921 Apr 1985 DE
42 36 266 May 1993 DE
202 14 532 Feb 2004 DE
103 31 657 Feb 2005 DE
20 2004 003 061 Jul 2005 DE
10 2004 050 278 Apr 2006 DE
20 2006 007 797 Aug 2006 DE
10 2005 046 264 Apr 2007 DE
10 2006 024 593 Dec 2007 DE
10 2010 045 266 Mar 2012 DE
0 129 430 Dec 1984 EP
0 129 430 Jan 1990 EP
0 355 829 Feb 1990 EP
0 611 408 Dec 1993 EP
0 592 013 Apr 1994 EP
0 656 443 Jun 1995 EP
0 611 408 Sep 1996 EP
0 732 449 Sep 1996 EP
0 744 477 Nov 1996 EP
0 914 914 May 1999 EP
0 732 449 Aug 1999 EP
0 744 477 Jan 2000 EP
1 035 255 Sep 2000 EP
1 193 288 Apr 2002 EP
1 209 199 May 2002 EP
1 249 322 Oct 2002 EP
1 454 763 Sep 2004 EP
1 498 241 Jan 2005 EP
1 507 664 Feb 2005 EP
1 507 664 Feb 2005 EP
1 584 378 Oct 2005 EP
1 681 103 Jul 2006 EP
1 690 603 Aug 2006 EP
1 847 385 Oct 2007 EP
1 961 556 Aug 2008 EP
1 985 464 Oct 2008 EP
1 997 623 Dec 2008 EP
2 025 484 Feb 2009 EP
1 454 763 Aug 2009 EP
2 105 320 Sep 2009 EP
2 213 476 Aug 2010 EP
2 226 201 Sep 2010 EP
2 246 500 Nov 2010 EP
2 264 259 Dec 2010 EP
2 272 667 Jan 2011 EP
2 272 668 Jan 2011 EP
2 305 462 Apr 2011 EP
1 847 385 Sep 2011 EP
2 873 953 Feb 2006 FR
984 170 Feb 1965 GB
1090450 Nov 1967 GB
2 248 246 Apr 1992 GB
2-229002 Sep 1990 JP
11-291203 Oct 1999 JP
2001-287208 Oct 2001 JP
2003-311717 Nov 2003 JP
2003-311718 Nov 2003 JP
2005-034815 Feb 2005 JP
2005-074682 Mar 2005 JP
2005-170016 Jun 2005 JP
2005-219215 Aug 2005 JP
3705482 Oct 2005 JP
2005-307582 Nov 2005 JP
2007-216692 Aug 2007 JP
2007-268843 Oct 2007 JP
2008-188826 Aug 2008 JP
469 326 Jun 1993 SE
WO 9206832 Apr 1992 WO
WO 9400280 Jan 1994 WO
WO 9506568 Mar 1995 WO
WO 0022225 Apr 2000 WO
WO 0044576 Aug 2000 WO
WO 0148333 Jul 2001 WO
WO 0164408 Sep 2001 WO
WO 0192037 Dec 2001 WO
WO 0242167 May 2002 WO
WO 03078761 Sep 2003 WO
WO 03095202 Nov 2003 WO
WO 2004042168 May 2004 WO
WO 2004050359 Jun 2004 WO
WO 2005054600 Jun 2005 WO
WO 2005066431 Jul 2005 WO
WO 2005097874 Oct 2005 WO
WO 2006007413 Jan 2006 WO
WO 2006013469 Feb 2006 WO
WO 2006015313 Feb 2006 WO
WO 2006043893 Apr 2006 WO
WO 2007015669 Feb 2007 WO
WO 2007042258 Apr 2007 WO
WO 2007059294 May 2007 WO
WO 2008148771 Dec 2008 WO
WO 2009065768 May 2009 WO
WO 2009065769 May 2009 WO
WO 2009065769 May 2009 WO
WO 2009080772 Jul 2009 WO
WO 2009080813 Jul 2009 WO
WO 2009124704 Oct 2009 WO
WO 2010084466 Jul 2010 WO
WO 2010094500 Aug 2010 WO
WO 2011087422 Jul 2011 WO
WO 2011087423 Jul 2011 WO
WO 2011141851 Nov 2011 WO
WO 2012004699 Jan 2012 WO
WO 2012141647 Oct 2012 WO
Non-Patent Literature Citations (31)
Entry
Pervan, Darko, et al., U.S. Appl. No. 13/693,979, entitled “Recycling of Laminate Floorings,” filed in the U.S. Patent and Trademark Office on Dec. 4, 2012.
Ziegler, Goran, et al., U.S. Appl. No. 13/705,310, entitled “Fibre Based Panels with a Decorative Wear Resistance Surface,” filed in the U.S. Patent and Trademark Office on Dec. 5, 2012.
Pervan, Darko, et al., U.S. Appl. No. 14/089,928 entitled “Recycling of Laminate Floors,” filed in the U.S. Patent and Trademark Office on Nov. 26, 2013.
Pervan, Darko, et al., U.S. Appl. No. 14/151,973 entitled “A Method of Producing a Building Panel and a Building Panel”, filed in the U.S. Patent and Trademark Office on Jan. 10, 2014.
BTLSR Toledo, Inc. website. http://www.bltresins.com/more.html. “Advantages to Using Powdered Resins,” May 26, 2007, 2 pages, per the Internet Archive WayBackMachine.
Nimz, H.H., “Wood,” Ullmann's Encyclopedia of Industrial Chemistry, published online Jun. 15, 2000, pp. 453-505, vol. 39, Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim, DE.
International Search Report (Form PCT/ISA/210) issued in corresponding PCT/SE2012/050386, mailed Jun. 27, 2012, 5 pages, ISA/SE, Stockholm, Sweden.
Pervan, Darko, et al., U.S. Appl. No. 61/751,393, entitled “Method of Producing a Building Panel and a Building Panel,” filed in the U.S. Patent and Trademark Office on Jan. 11, 2013.
Pervan, Darko, U.S. Appl. No. 14/237,617, entitled “Panel Coating,” filed in the U.S. Patent and Trademark Office on Feb. 7, 2014.
Ziegler, Göran, et al., U.S. Appl. No. 14/184,299, entitled “Heat and Pressure Generated Design”, filed in the U.S. Patent and Trademark Office on Feb. 19, 2014.
Pervan, Darko, et al., U.S. Appl. No. 14/192,169, entitled “Fibre Based Panels with a Wear Resistance Surface”, filed in the U.S. Patent and Trademark Office on Feb. 27, 2014.
Ziegler, Göran, U.S. Appl. No. 14/247,839, entitled A Powder Mix and a Method for Producing a Building Panel, filed in the U.S. Patent and Trademark Office on Apr. 8, 2014.
Ziegler, Göran, et al., U.S. Appl. No. 13/444,604, entitled “Powder Mix and a Method for Producing a Building Panel,” filed in the U.S. Patent and Trademark Office on Apr. 11, 2012.
Ziegler, Göran, et al., U.S. Appl. No. 13/445,379, entitled “Method of Manufacturing a Layer,” filed in the U. S. Patent and Trademark Office on Apr. 12, 2012.
Hakansson, Niclas, et al., U.S. Appl. No. 13/469,799, entitled “Method of Producing a Powder Layer or a Granular Layer,” filed in the U.S. Patent and Trademark Office on May 11, 2012.
Persson, Hans, et al., U.S. Appl. No. 61/557,643, entitled “Scattering,” filed in the U.S. Patent and Trademark Office on Nov. 9, 2011.
Håkansson, Niclas, et al., U.S. Appl. No. 61/557,734, entitled “Powder Based Balancing Layer,” filed in the U.S. Patent and Trademark Office on Nov. 9, 2011.
Vetter, Georg, et al., U.S. Appl. No. 61/612,672, entitled “Method for Producing a Building Panel,” filed in the U. S. Patent and Trademark Office on Mar. 19, 2012.
Parquet International, “Digital Printing is still an expensive process,” Mar. 2008, cover page/pp. 78-79, www.parkettmagazin.com.
Floor Daily, “Shaw Laminates: Green by Design,” Aug. 13, 2007, 1 pg, Dalton, GA.
Engstrand, Ola (Contact)Nalinge Innovation, Technical Disclosure entitled “Fibre Based Panels With a Wear Resistance Surface,” Nov. 17, 2008, IP.com No. IPCOM000176590D, IP.com PriorArtDatabase, 76 pages.
Engstrand, Ola (Contact)Nalinge Innovation, Technical Disclosure entitled “WFF Embossing,” May 15, 2009, IP.com No. IPCOM000183105D, IP.com PriorArtDatabase, 36 pages.
Engstrand, Ola (Contact)Nalinge Innovation, Technical Disclosure entitled “VA063 VA064 Scattering and Powder Backing,” Nov. 11, 2011, IP.com No. IPCOM000212422D, IP.com PriorArtDatabase, 34 pages.
Pervan, Darko, et al., U.S. Appl. No. 13/793,971, entitled “Wood Fibre Based Panels with a Thin Surface Layer,” filed in the U.S. Patent and Trademark Office on Mar. 11, 2013.
Vetter, Georg, et al., U.S. Appl. No. 13/804,355, entitled “Method for Producing a Building Panel,” filed in the U.S. Patent and Trademark Office on Mar. 14, 2013.
Ziegler, Göran, et al., U.S. Appl. No. 13/912,564, entitled “Bright Coloured Surface Layer,” filed in the U.S. Patent and Trademark Office on Jun. 7, 2013.
Pervan, Darko, et al., U.S. Appl. No. 13/912,587, entitled “Powder Overlay,” filed in the U.S. Patent and Trademark Office on Jun. 7, 2013.
Lindgren, Kent, et al., U.S. Appl. No. 14/321,288, entitled “A Method of Manufacturing Panel and a Building Panel,” filed in the U.S. Patent and Trademark Office on Jul. 1, 2014.
Persson, Hans, et al., U.S. Appl. No. 14/516,957, entitled “Method of Manufacturing a Building Panel,” filed in the U.S. Patent and Trademark Office on Oct. 17, 2014.
Vetter, Georg, et al., U.S. Appl. No. 14/553,196, entitled “Method for Producing a Building Panel,” filed in the U.S. Patent and Trademark Office on Nov. 25, 2014.
Ziegler, Göran, et al., U.S. Appl. No. 14/563,167, entitled “Bright Coloured Surface Layer,” filed in the U.S. Patent and Trademark Office on Dec. 8, 2014.
Related Publications (1)
Number Date Country
20120263965 A1 Oct 2012 US
Provisional Applications (2)
Number Date Country
61474498 Apr 2011 US
61557734 Nov 2011 US