Bright coloured surface layer
View Patent ↗A method to produce a pale and/or plain colored wear resistant surface layer by using a dry powder layer comprising a mix of refined fibers binder, pigment and wear resistant particles.
1. A method of manufacturing a wear resistant surface layer comprising the steps of:
applying a sublayer comprising a mix of wood fibres and a resin on a carrier;
applying a dry powder layer comprising a mix of refined fibres, binder, pigments and wear resistant particles on the sublayer, wherein the sublayer is arranged between the carrier and the dry powder layer; and
curing the sublayer and the dry powder layer by applying heat and pressure on the layers, wherein the dry powder layer is cured to a wear resistant surface layer.
2. The method as claimed in claim 1 , wherein the carrier is a wood fibre based core, and the wear resistant surface layer is attached to the wood fibre based core to obtain a panel, wherein the core comprises a major part of the panel.
3. The method as claimed in claim 2 , wherein the panel is a floor panel.
4. The method as claimed in claim 1 , wherein the wear resistant particles are aluminium oxide.
5. The method as claimed in claim 1 , wherein the thickness of the wear resistant surface layer is less than about 1 mm.
6. The method as claimed in claim 1 , wherein the wear resistant surface layer is white or red.
7. The method as claimed in claim 2 , wherein the carrier is an HDF panel.
8. The method as claimed in claim 2 , wherein the wear resistant particles are aluminium oxide.
9. The method as claimed in claim 2 , wherein the thickness of the wear resistant surface layer is less than about 1 mm.
10. The method as claimed in claim 5 , wherein the thickness of the wear resistant surface layer is less than about 0.3 mm.
11. The method as claimed in claim 2 , wherein the thickness of the wear resistant surface layer is less than about 0.3 mm.
12. The method as claimed in claim 2 , wherein the wear resistant surface layer is white or red.
13. The method as claimed in claim 2 , wherein the binder is a resin and the weight ratio of resin compared to refined fibres is higher than about 100%.
14. The method as claimed in claim 2 , wherein the binder is a resin and the weight ratio of resin compared to refined fibres is higher than about 120%.
15. The method as claimed in claim 2 , wherein the binder is a resin and the weight ratio of resin compared to refined fibres is in the range of about 120% to about 180%.
16. The method as claimed in claim 2 , wherein the step of applying the sublayer on the core comprises scattering the mix of wood fibres and resin on the core.
17. The method as claimed in claim 2 , further comprising a step of scattering a top layer above the dry powder layer.
18. The method as claimed in claim 2 , wherein a balancing layer is applied to a surface of the wood fibre based core that is opposite that sublayer and the wear resistant surface layer.
19. The method as claimed in claim 1 , wherein the wood fibres in the sublayer layer are refined fibres.
20. The method as claimed in claim 1 , wherein the wood fibres in the sublayer layer are HDF fibres.
21. A method of manufacturing a wear resistant surface layer comprising the steps of:
applying a dry powder layer comprising a mix of refined fibres, resin, pigments and wear resistant particles on a carrier, wherein the weight ratio of resin to refined fibres is higher than about 120%; and
curing the dry powder layer to a wear resistant layer by applying heat and pressure on the dry powder layer.
22. The method as claimed in claim 21 , wherein the carrier is a wood fibre based core, and the wear resistant surface layer is attached to the wood fibre based core to obtain a panel.
23. The method as claimed in claim 22 , wherein the panel is a floor panel.
24. The method as claimed in claim 21 , wherein the wear resistant particles are aluminium oxide.
25. The method as claimed in claim 21 , wherein the thickness of the wear resistant surface layer is less than about 1 mm.
26. The method as claimed in claim 21 , wherein the wear resistant surface layer is white or red.
27. The method as claimed in claim 22 , wherein the carrier is an HDF panel.
28. The method as claimed in claim 22 , wherein the wear resistant particles are aluminium oxide.
29. The method as claimed in claim 22 , wherein the thickness of the wear resistant surface layer is less than about 1 mm.
30. The method as claimed in claim 25 , wherein the thickness of the wear resistant surface layer is less than about 0.3 mm.
31. The method as claimed in claim 22 , wherein the thickness of the wear resistant surface layer is less than about 0.3 mm.
32. The method as claimed in claim 22 , wherein the wear resistant surface layer is white or red.
33. The method as claimed in claim 22 , wherein the weight ratio of resin compared to refined fibres is in the range of about 120% to about 180%.
34. The method as claimed in claim 32 , further comprising a step of scattering a sublayer on the wood fibre based core.
35. The method as claimed in claim 22 , further comprising a step of scattering a top layer above the dry powder layer.
36. A floor panel produced by a method comprising:
applying a sublayer comprising a mix of wood fibres and a resin on a carrier, wherein the carrier is a wood fibre based core, and the wood fibre based core comprises a major part of the floor panel;
applying a dry powder layer comprising a mix of refined fibres, binder, pigments and wear resistant particles on the sublayer to form a wear resistant surface layer; and
curing the sublayer and the dry powder layer by applying heat and pressure on the layers, wherein the dry powder layer is cured to a wear resistant surface layer.
37. A floor panel produced according to the method in claim 23 .