Fibre based panels with a wear resistance surface
Building panels with a homogenous decorative surface having a wear layer comprising fibers, binders and wear resistant particles.
1. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer comprises pigments and fibres mixed with a binder, the sub-layer being uncured,
applying a wood veneer layer on the sub-layer while the sub-layer is uncured, and
pressing the core, the sub-layer and the wood veneer layer together to cure the sub-layer to form the panel.
2. The method according to claim 1 , wherein applying the sub-layer comprises mixing the fibres with the binder, and subsequently applying the fibres mixed with the binder on the core.
3. The method according to claim 1 , wherein the binder is a thermosetting binder.
4. The method according to claim 1 , wherein the fibres are cork or wood fibres.
5. The method according to claim 1 , wherein the sub-layer is applied on the core in powder form.
6. The method according to claim 1 , further comprising applying a balancing layer on a second surface of the core, opposite the first surface of the core.
7. The method according to claim 6 , wherein the balancing layer comprises wood fibres and a binder.
8. The method according to claim 1 , wherein the core is a wood fibre based core.
9. The method according to claim 8 , wherein the core is a HDF core.
10. The method according to claim 1 , wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.
11. The method according to claim 1 , wherein the wood veneer layer has a thickness of 0.3-1.0 mm.
12. The method according to claim 1 , wherein the step of pressing comprises pressing with an embossed pressure matrix.
13. The method according to claim 1 , wherein the panel is a floorboard.
14. The method according to claim 1 , wherein the step of pressing further comprises applying heat, wherein the sub-layer mixture is cured under heat and pressure to form the panel.
15. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer is a dry powder mix which comprises pigments and fibres mixed with a binder,
applying a wood veneer layer on the sub-layer while the sub-layer is the dry powder mix, and
pressing the core, the sub-layer and the wood veneer layer together to form the panel.
16. A method of producing a panel, comprising:
providing a core, the core possessing a first surface and a second surface facing opposite of the first surface,
applying a sub-layer on the first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, and wherein the core is a wood fibre based core,
applying a balancing layer on the second surface of the core,
applying a wood veneer layer on the sub-layer, and
pressing the core, the sub-layer, the wood veneer layer, and the balancing layer together to form the panel,
wherein the core is a pre-fabricated core selected from the group of high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, oriented strand board (OSB), and plywood,
wherein the sub-layer is applied on the core in a dry powder form, and
wherein the fibres are cork or wood fibres.
17. The method according to claim 16 , wherein the sub-layer comprises pigments.
18. The method according to claim 16 , wherein the core is a HDF core.
19. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, the sub-layer being applied on the first surface of the core in a dry powder form,
applying a wood veneer layer directly on the sub-layer while the sub-layer is in the dry powder form, and
pressing the core, the sub-layer, and the wood veneer layer together to form the panel,
wherein the core is a pre-fabricated core selected from the group of high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, oriented strand board (OSB), and plywood,
wherein the panel is a floorboard and
wherein the fibres are cork or wood fibres.
20. The method according to claim 19 , wherein applying the sub-layer comprises mixing the fibres with the binder, and subsequently applying the fibres mixed with the binder on the core.
21. The method according to claim 19 , wherein the binder is a thermosetting binder.
22. The method according to claim 19 , further comprising applying a balancing layer on a second surface of the core, opposite the first surface of the core.
23. The method according to claim 22 , wherein the balancing layer comprises wood fibres and a binder.
24. The method according to claim 19 , wherein the core is a HDF core.
25. The method according to claim 19 , wherein the core material is particleboard, plywood, plastic material, or non-woven impregnated materials of natural fibres.
26. The method according to claim 19 , wherein the wood veneer layer has a thickness of 0.3-1.0 mm.
27. The method according to claim 19 , wherein the step of pressing comprises pressing with an embossed pressure matrix.
28. The method according to claim 19 , wherein the sub-layer in the dry powder form is an uncured mixture comprising the fibres mixed with the binder, and the step of pressing the core, the sub-layer and the wood veneer layer together cures the sub-layer mixture to form a panel.
29. The method according to claim 28 , wherein the step of pressing further comprises applying heat, wherein the sub-layer mixture is cured under heat and pressure to form the panel.
30. The method according to claim 19 , wherein the sub-layer comprises pigments.
31. A method of producing a panel, comprising:
providing a core,
applying a sub-layer on a first surface of the core, wherein the sub-layer comprises fibres mixed with a binder, the sub-layer being applied on the first surface of the core in a dry powder form,
applying a wood veneer layer directly on the sub-layer while the sub-layer is in the dry powder form, and
pressing the core, the sub-layer, and the wood veneer layer together to form the panel,
wherein the panel is a floorboard
wherein the fibres are cork or wood fibres and
wherein the sub-layer comprises pigments.