Production method
A method for producing a panel including a core and a decorative surface layer is disclosed. The method includes the step of applying a dry powder layer on the core. The method includes the step of applying steam on a dry powder layer on the core. Thereafter heat and pressure are applied to the powder layer in order to bond the powder together.
1. A method comprising:
applying a dry powder layer on a core, the dry powder layer comprising a mix of wood fibers and a binder;
subsequently applying steam directly onto the dry powder layer while the dry powder layer is on the core to form a stabilized powder layer on the core; and
subsequently bonding the powder in the stabilized powder layer together into a cured layer by applying heat and pressure, and thereby forming a panel comprising the core and the cured layer.
2. The method as claimed in claim 1 , wherein the steam is a saturated vapour consisting essentially of water.
3. The method as claimed in claim 1 , wherein the steam comprises one or more additives.
4. The method as claimed in claim 1 , wherein the core is a wood fibre based core.
5. The method as claimed in claim 1 , wherein the core is an HDF panel.
6. The method as claimed in claim 1 , wherein the formed panel is a building panel.
7. The method as claimed in claim 1 , wherein the formed panel is a floor panel.
8. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises wear resistant particles.
9. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises aluminium oxide.
10. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises pigments.
11. The method as claimed in claim 1 , wherein the mix of the dry powder layer further comprises wear resistant particles and pigments, and wherein the binder is a thermosetting resin.
12. The method as claimed in claim 1 , wherein the binder is a thermosetting resin.
13. The method as claimed in claim 1 , wherein a thickness of the cured layer is less than about 1 mm.
14. The method as claimed in claim 1 , wherein a thickness of the cured layer is less than about 0.3 mm.
15. The method as claimed in claim 1 , wherein the cured layer is a surface layer of the panel.
16. The method as claimed in claim 1 , wherein the cured layer is a decorative surface layer of the panel.
17. The method as claimed in claim 1 , wherein the steam is applied with a steam box.
18. The method as claimed in claim 1 , wherein the dry powder layer is applied by scattering.
19. The method as claimed in claim 1 , wherein heat and pressure are applied by a press.
20. The method as claimed in claim 1 , wherein the press is operated with the following parameters: 8-60 seconds of pressing time; 30-60 bars of applied pressure; and 150-220° C. of pressing temperature.
21. The method as claimed in claim 1 , wherein the steam is applied to the dry powder layer when the core is moving at a speed of 1 to 10 meters per minute.
22. The method as claimed in claim 1 , wherein the steam is substantially uniformly applied over the dry powder layer.
23. A method comprising:
applying a dry powder layer on a core, the dry powder layer comprising a mix of wood fibers and a binder;
subsequently applying steam directly onto the dry powder layer while the dry powder layer is on the core to form a stabilized powder layer on the core; and
subsequently bonding the powder in the stabilized powder layer together into a cured layer by applying heat and pressure, and thereby forming a panel comprising the core and the cured layer,
wherein the steam comprises one or more additives selected from the group consisting of wetting agents, releasing agents, and colour additives.
24. A floor panel produced according to the method in claim 1 .
25. A floor panel produced according to the method in claim 11 .
26. A floor panel produced according to the method in claim 22 .