Wood fibre based panel with a surface layer
A building panel with a surface layer ( 1 ) including a wood veneer, a wood fibre based core ( 2 ) and a sub-layer ( 3 ) between the surface layer ( 1 ) and the core ( 2 ). The sub-layer ( 3 ) includes wood fibres ( 4 ) and a binder ( 5 ). The surface layer ( 1 ) has surface portions ( 6 ) including material from the sub-layer ( 3 ). The surface portions ( 6 ) including material from the sub-layer ( 3 ) extend into the wood veneer.
1. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core,
wherein the sub-layer comprises wood fibres and a binder,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and
wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions.
2. The building panel as claimed in claim 1 , wherein the surface portions comprising material from the sub-layer are flush with at least a portion of the surface layer.
3. The building panel as claimed in claim 1 , wherein the sub-layer comprises colour pigments and/or a colorant.
4. The building panel as claimed in claim 1 , wherein the sub-layer comprises wear resistant particles.
5. The building panel as claimed in claim 1 , further comprising a powder-based balancing layer.
6. The building panel as claimed in claim 1 , wherein the wood veneer comprises holes and/or cracks, wherein the sub-layer fills the holes and/or cracks of the wood veneer.
7. The building panel as claimed in claim 1 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.
8. The building panel as claimed in claim 1 , wherein the binder is liquid.
9. The building panel as claimed in claim 1 , wherein the binder in the sub-layer is a thermosetting resin.
10. The building panel as claimed in claim 1 , wherein the binder in the sub-layer is a melamine formaldehyde resin.
11. The building panel as claimed in claim 1 , wherein the sub-layer comprises a foaming agent.
12. The building panel as claimed in claim 11 , wherein the foaming agent includes a chemical blowing agent additive.
13. The building panel as claimed in claim 1 , further comprising:
a second surface layer comprising a second wood veneer, the second surface layer being arranged on an opposite side of the core from the surface layer; and
a second sub-layer arranged between the second surface layer and the core,
wherein the second surface layer has surface portions comprising material from the second sub-layer extending into the second wood veneer.
14. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core,
wherein the sub-layer comprises wood fibres, a binder and colour pigments and/or a colorant,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and
wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the non-porous portions of the wood veneer form the protrusions by containing less of the binder than the porous portions.
15. The building panel as claimed in claim 14 , further comprising a powder-based balancing layer.
16. The building panel as claimed in claim 15 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.
17. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising porous portions and non-porous portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core,
wherein the sub-layer comprises wood fibres, a binder and wear resistant particles,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer,
wherein the binder is between 40-60 wt-% of the sub-layer, and
wherein the surface layer comprising embossed portions and protrusions, wherein the binder of the sub-layer bonds the porous portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the non-porous portions of the wood veneer in the compressed position so that the non-porous portions of the wood veneer form the protrusions.
18. The building panel as claimed in claim 17 , wherein the binder is liquid.
19. The building panel as claimed in claim 17 , wherein the sub-layer comprises a foaming agent.
20. The building panel as claimed in claim 17 , further comprising a powder-based balancing layer.
21. The building panel as claimed in claim 20 , further comprising a protective overlay comprising wear resistant particles arranged on the surface layer.
22. A building panel comprising:
a surface layer comprising a wood veneer, the wood veneer comprising relatively high-density portions and relatively low-density portions,
a wood fibre based core, and
a sub-layer arranged between the surface layer and the wood fibre based core, the sub-layer being a separate discrete layer from the core,
wherein the sub-layer comprises wood fibres and a binder,
wherein the surface layer has surface portions comprising material from the sub-layer extending into the wood veneer, and
wherein the surface layer comprises embossed portions and protrusions, wherein the binder of the sub-layer bonds the relatively low-density portions of the wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond the relatively high-density portions of the wood veneer in the compressed position so that the relatively high-density portions of the wood veneer form the protrusions.