Method of manufacturing a surface layer of building panels
View Patent ↗A method of manufacturing a surface layer is provided. The method includes applying a sublayer having a mix of wood fibers and a resin on a carrier, applying a powder layer having a mix of refined fibers and a binder on the sublayer, with the sublayer being arranged between the carrier and the powder layer, and curing the powder layer by applying heat and pressure.
1. A method of manufacturing a surface layer comprising the steps of:
applying a sublayer comprising a mix of wood fibres and a resin on a carrier;
applying a powder layer comprising a mix of refined fibres and a binder on the sublayer, wherein the sublayer is arranged between the carrier and the powder layer; and
curing the powder layer by applying heat and pressure on the powder layer, wherein the powder layer is cured to a surface layer.
2. The method as claimed in claim 1 , wherein the mix forming the powder layer further comprises wear resistant particles.
3. The method as claimed in claim 2 , wherein the wear resistant particles are aluminium oxide.
4. The method as claimed in claim 1 , wherein the mix forming the powder layer further comprises pigments.
5. The method as claimed in claim 1 , wherein the powder layer is a dry powder layer.
6. The method as claimed in claim 1 , wherein the carrier is a wood fibre based core, and the surface layer is attached to the wood fibre based core to obtain a panel, wherein the core comprises a major part of the panel.
7. The method as claimed in claim 6 , wherein the panel is a floor panel.
8. The method as claimed in claim 6 , wherein the carrier is an HDF panel.
9. The method as claimed in claim 1 , wherein the thickness of the surface layer is less than about 1 mm.
10. The method as claimed in claim 1 , wherein the binder is a resin and the weight ratio of resin compared to refined fibres is higher than about 120%.
11. The method as claimed in claim 1 , 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%.
12. The method as claimed in claim 1 , wherein the step of applying the sublayer on the carrier comprises scattering the mix of wood fibres and resin on the carrier.
13. The method as claimed in claim 1 , further comprising a step of scattering a top layer above the powder layer.
14. The method as claimed in claim 6 , wherein a balancing layer is applied to a surface of the wood fibre based core that is opposite the sublayer and the surface layer.
15. A method of manufacturing a surface layer comprising the steps of:
applying a powder layer comprising a mix of refined fibres and a resin on a carrier, wherein the weight ratio of resin to refined fibres is higher than about 120%; and
curing the powder layer to a wear resistant layer by applying heat and pressure on the powder layer.
16. The method as claimed in claim 15 , wherein the mix forming the powder layer further comprises wear resistant particles.
17. The method as claimed in claim 16 , wherein the wear resistant particles are aluminium oxide.
18. The method as claimed in claim 15 , wherein the mix forming the powder layer further comprises pigments.
19. The method as claimed in claim 15 , wherein the powder layer is a dry powder layer.
20. The method as claimed in claim 15 , wherein the carrier is a wood fibre based core, and the surface layer is attached to the wood fibre based core to obtain a panel.
21. The method as claimed in claim 20 , wherein the panel is a floor panel.
22. The method as claimed in claim 15 , wherein the thickness of the surface layer is less than about 1 mm.
23. The method as claimed in claim 20 , wherein the carrier is an HDF panel.
24. The method as claimed in claim 15 , wherein the weight ratio of resin compared to refined fibres is in the range of about 120% to about 180%.
25. The method as claimed in claim 15 , further comprising a step of scattering a sublayer on the carrier.
26. The method as claimed in claim 15 , further comprising a step of scattering a top layer above the powder layer.
27. A method of manufacturing a surface layer comprising the steps of:
applying a powder layer comprising a mix of refined fibres and a binder on a carrier,
applying a top layer comprising refined fibres on the powder layer, and
curing the powder layer to a surface layer by applying heat and pressure on the powder layer.
28. The method as claimed in claim 27 , wherein the mix further comprises wear resistant particles.