Granted Patent B2

US 12,532,987 · App. 18/409,984 · Granted Jan 27, 2026

Inventor: Darko Pervan (Viken, SE)

Assignee: CERALOC INNOVATION AB

A47J41/028A47G19/2288A47J41/0072A47J41/02A47J41/022B65D25/2817B65D81/3806B65D81/3869B65D81/3881B65D85/72F16L59/06

Abstract

Claims (28)

1 . A method of forming a surface layer of a building panel, the method comprising:

forming a binder layer comprising at least 80% by weight of particles of a thermoplastic binder;

forming a wear resistant layer comprising at least 50% by weight of wear resistant particles; and

pressing, under heat and pressure, the wear resistant layer and the binder layer to combine and mix the wear resistant particles of the wear resistant layer and the thermoplastic binder of the binder layer to form the surface layer.

2 . The method as claimed in claim 1 , further comprising forming a fibre layer comprising at least 50% by weight of fibres.

3 . The method as claimed in claim 2 , wherein the fibres are wood fibres.

4 . The method as claimed in claim 2 , wherein the wear resistant layer, the binder layer, and the fibre layer are applied on a substrate prior to pressing.

5 . The method as claimed in claim 2 , wherein the wear resistant layer, the binder layer, and the fibre layer are applied on a core prior to pressing.

6 . The method as claimed in claim 2 , wherein the wear resistant layer is applied on the fibre layer.

7 . The method as claimed in claim 6 , wherein the binder layer is applied on the wear resistant layer.

8 . The method as claimed in claim 2 , wherein the fibre layer comprises essentially one material with a material content of at least about 80% of the total weight of the layer.

9 . The method as claimed in claim 2 , wherein the fibre layer comprises colour pigments and at least about 80% by weight wood fibres.

10 . The method as claimed in claim 1 , wherein the wear resistant layer and the binder layer are applied on a substrate prior to pressing.

11 . The method as claimed in claim 1 , wherein the wear resistant layer and the binder layer are applied on a core prior to pressing.

12 . The method as claimed in claim 11 , wherein the core is a wood fibre-based board.

13 . The method as claimed in claim 11 , wherein the core is a high-density fibre (HDF) board.

14 . The method as claimed in claim 11 , wherein the surface layer and the core form the building panel.

15 . The method as claimed in claim 11 , wherein the surface layer and the core form the building panel, wherein the building panel is a floor panel.

16 . The method as claimed in claim 1 , wherein the thermoplastic binder is provided in powder form or as a granular material.

17 . The method as claimed in claim 1 , wherein the wear resistant particles are aluminium oxide particles.

18 . The method as claimed in claim 1 , wherein the binder layer is applied on the wear resistant layer.

19 . The method as claimed in claim 1 , wherein the wear resistant layer and/or the binder layer further comprises colour pigments.

20 . The method as claimed in claim 1 , wherein the wear resistant layer and the binder layer each comprises essentially one material with a material content of at least about 80% of the total weight of the layer.

21 . The method as claimed in claim 1 , wherein the surface layer is a paper-free surface layer.

22 . A method of forming a building panel, the method comprising:

providing a digital print; and

forming a surface layer by the method of claim 1 ,

wherein the surface layer covers the digital print.

Assignments (3)

Continuity (5)

References Cited (314)