IP Library › Granted Patent US 11,318,726
Granted Patent B2
US 11,318,726 · App. 16/132,977 · Granted May 3, 2022

Wood fibre based panel with a surface layer

Inventors: Darko Pervan (Viken, SE); Goran Ziegler (Viken, SE)
Assignee: VALINGE INNOVATION AB
B32B37/10B27G1/00B27N3/02B27N3/04B27N7/005B32B3/30B32B5/142B32B21/02B32B21/08B32B21/14B32B27/20B32B27/42B32B37/1284B32B37/18B44C1/24B44C5/043B44C5/0438E04F15/042E04F15/045E04F15/082E04F15/085B27N3/005B27N3/08B32B38/06B32B2262/067B32B2264/062B32B2266/0214B32B2266/0285B32B2266/14B32B2305/073B32B2307/4026B32B2307/554B32B2317/02B32B2317/16B32B2471/00B32B2607/00Y10T156/10Y10T156/1039Y10T428/24132Y10T428/24298Y10T428/24314Y10T428/24322Y10T428/24331Y10T428/24339Y10T428/24521Y10T428/24603Y10T428/24612Y10T428/24802Y10T428/24893Y10T428/24992Y10T428/24994Y10T428/24995Y10T428/249925Y10T428/249959Y10T428/249982Y10T428/249985Y10T428/249986Y10T428/249987Y10T428/25Y10T428/253Y10T428/256Y10T428/257Y10T428/3167Y10T428/31862Y10T428/31866Y10T428/31957Y10T428/31989
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Quick Facts
Patent No.
US 11,318,726
App. No.
16/132,977
Granted
May 3, 2022
Kind
B2
Abstract

A building panel with a surface layer including a wood veneer, a wood fibre based core and a sub-layer between the surface layer and the core. The sub-layer includes wood fibres and a binder. The surface layer has surface portions including material from the sub-layer. The surface portions including material from the sub-layer extend into the wood veneer.

Claims (19)

1. A method to produce a building panel, the method comprising:

applying a wood fibre powder and a binder on a first side of a wood fibre based core, to obtain a first sub-layer;

applying a first wood veneer, comprising holes through the first wood veneer, on the first sub-layer; and

applying heat and pressure to bond the first wood veneer, the first sub-layer and the wood fibre based core together, thereby material from the first sub-layer is pressed into the holes of the first wood veneer, to form a first surface layer,

wherein the building panel comprises a second surface layer, wherein the second surface layer is on a second side opposite the first side of the wood fibre based core, wherein the second surface layer comprises a second sub-layer of a wood fibre powder and a binder, and a second wood veneer on the second sub-layer, and

the method further comprising, prior to applying heat and pressure to form the first surface layer, pre-pressing the first sublayer, wherein the binder of the first sub-layer is partially cured during the pre-pressing.

2. The method as claimed in claim 1 , further comprising applying a foaming agent in the first sub-layer.

3. The method as claimed in claim 2 , wherein the wood fibre powder comprises lignocellulosic particles or cellulose particles.

4. The method as claimed in claim 1 , further comprising applying different colour pigments, wherein portions of the first sub-layer are visible in the holes of the first veneer, wherein the colour of the visible first sub-layer portion varies along the building panel, or such that the portion of the first sub-layer in the holes forms a pattern.

5. The method as claimed in claim 1 , further comprising applying a protective overlay with wear resistant particles on the first wood veneer.

6. The method as claimed in claim 1 , wherein the first sub-layer comprises colour pigments and/or a colorant.

7. The method as claimed in claim 1 , wherein the first sub-layer comprises wear resistant particles.

8. The method as claimed in claim 1 , further comprising applying a protective overlay with wear resistant particles on the first wood veneer prior to pressing.

9. The method as claimed in claim 1 , further comprising pre-treating the first veneer, prior to applying heat and pressure.

10. The method as claimed in claim 9 , further comprising pre-treating the first veneer, prior to applying heat and pressure, by brushing.

11. The method as claimed in claim 1 , wherein after applying pressure, the first wood veneer comprises embossed portions, and wherein a part of the first sub-layer is more compressed under an embossed surface portion than under a non-embossed surface portion.

12. The method as claimed in claim 1 , wherein the first surface layer comprises embossed portions and protrusions, wherein the binder of the first sub-layer bonds porous portions of the first wood veneer in a compressed position to form the embossed portions, and wherein the binder does not bond non-porous portions of the first wood veneer in the compressed position so that non-porous portions of the first wood veneer form the protrusions.

13. The method as claimed in claim 1 , the method further comprising applying a protective overlay with wear resistant particles on the first wood veneer prior to pressing,

wherein the first sub-layer comprises wear resistant particles, wherein the panel comprises, after pressing, the first surface layer with surface portions comprising material from the first sub-layer, wherein the surface portions comprising material from the first sub-layer are flush with a remainder of the first surface layer, to obtain an entire surface layer with wear resistant particles.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Sep 17, 2018
From: PERVAN, DARKO; ZIEGLER, GORAN
To: VALINGE INNOVATION AB
Reel/Frame 046890/0191 →
Priority Claims (3)
SE 1450023-5 · Jan 10, 2014 · national
SE 1450552-3 · May 12, 2014 · national
SE 1451154-7 · Sep 29, 2014 · national
Continuity (2)
Continuation 14593521 · Jan 9, 2015
Related Publication 20190010711A1 · Jan 10, 2019
Cited By (6)
US 12,330,445 US 12,350,917 US 12,454,123 US 12,532,987 US 12,577,778 US 12,623,372