Method of manufacturing a layer
A method of manufacturing a separate and continuous layer being essentially uncured. The method includes applying a powder mix including fibres and a thermosetting binder on a carrier, forming a powder mix layer, wherein the powder mix is connected together such that the powder mix layer is obtained and wherein the powder mix layer is essentially uncured, and releasing the powder mix layer from the carrier. Also, a layer and a method for manufacturing a building panel.
1. A method of manufacturing a layer, comprising
applying a powder mix comprising fibres and a binder on a surface of a supporting layer, wherein the fibres and binder are mixed to form the powder mix prior to the powder mix being applied to the surface of the supporting layer, and wherein the supporting layer is arranged on a carrier,
permanently connecting the powder mix to the supporting layer by applying moisture on the powder mix such that the powder mix is connected together by the binder to thereby create an essentially uncured layer comprised of the powder mix and the supporting layer, and
releasing the essentially uncured layer from the carrier to thereby manufacture a separate, semi-finished and continuous layer.
2. The method according to claim 1 , wherein the supporting layer is a paper sheet.
3. The method according to claim 2 , wherein the paper sheet is impregnated.
4. The method according to claim 1 , wherein the supporting layer is a non-woven sheet.
5. The method according to claim 1 , wherein the supporting layer is one of a rice sheet, a sugar paper, a netting, mineral fibres, carbon fibres, textile fibres or nylon fibres.
6. The method according to claim 1 , wherein the binder is a thermosetting binder.
7. The method according to claim 1 , wherein the binder is a thermoplastic binder.
8. The method according to claim 1 , wherein the step of permanently connecting the powder mix includes drying the powder mix such that the powder mix is connected together.
9. The method according to claim 1 , wherein the powder mix layer is flexible.
10. The method according to claim 1 , further comprising curing the separate, semi-finished and continuous layer before being applied to a core.
11. The method according to claim 1 , further comprising applying the separate, semi-finished and continuous layer to a core.
12. The method according to claim 11 , wherein the separate, semi-finished and continuous layer is attached to the core by an adhesive.
13. The method according to claim 1 , wherein the fibres are wood fibres, plastic fibres, mineral fibre or vegetable fibres, or a mixture thereof.
14. The method according to claim 1 , further comprising printing a print in the powder mix and/or powder mix layer.
15. The method according to claim 14 , wherein the printing is by digital printing.
16. The method according to claim 1 , wherein the connecting of the powder mix to the supporting layer further comprises applying heat and/or pressure.
17. The method according to claim 1 , wherein the binder is a combination binder including both thermoplastic and thermosetting properties.
18. The method according to claim 1 , wherein the moisture is applied to a predetermined portion of the powder mix to create a predetermined shape in the powder mix, and wherein the method further comprises separating the portion of the powder mix exposed to the moisture from those not exposed to the moisture.
19. A method of manufacturing a layer attached to a wood-based core, comprising
applying uncured particles on a surface of a supporting layer, wherein the supporting layer is an impregnated paper sheet and arranged on a carrier,
applying moisture on the particles or on the supporting layer such that the particles are connected together and are permanently connected to the supporting layer, thereby forming an essentially uncured layer comprised of the uncured particles and the impregnated paper sheet,
removing the essentially uncured layer from the carrier to thereby manufacture a separate, semi-finished and continuous layer, and
attaching the separate, semi-finished and continuous layer to a wood-based core selected from the group consisting of MDF, HDF, OSB, WPC and particleboard.
20. The method according to claim 19 , wherein the particles comprises wood particles.
21. The method according to claim 19 , wherein the particles comprises a binder.
22. The method according to claim 21 , wherein the binder is a thermosetting binder.
23. The method according to claim 21 , wherein the binder is thermoplastic binder.
24. A method of manufacturing a layer, comprising
applying a powder mix comprising fibres and a thermosetting binder on a surface of a supporting layer, wherein the supporting layer is arranged on a carrier,
applying moisture on the powder mix such that the powder mix is connected together, forming a powder mix layer, the powder mix layer being permanently connected to the supporting layer,
removing the powder mix layer and the supporting layer from the carrier to create a separate, semi-finished and continuous layer,
curing the separate, semi-finished and continuous layer to create a cured powder mix layer on the supporting layer, and
after curing, attaching the cured powder mix layer on the supporting layer to a core, thereby manufacturing a layer which is comprised of the cured powder mix layer, the supporting layer, and the core,
wherein the fibres and thermosetting binder are mixed to form the powder mix prior to the powder mix being applied to the surface of the supporting layer.
25. The method according to claim 24 , wherein the supporting layer is a paper sheet.
26. The method according to claim 25 , wherein the paper sheet is impregnated.
27. The method according to claim 24 , wherein the supporting layer is a non-woven sheet.
28. A method of manufacturing a layer, comprising
applying a powder mix comprising fibres and a binder on a surface of a supporting layer, wherein the supporting layer is arranged on a carrier,
applying moisture on the powder mix such that the powder mix is connected together by the binder to thereby create a layer comprised of the powder mix and the supporting layer,
applying heat to the layer comprised of the powder mix and the supporting layer at a temperature below the curing temperature of the binder to form a heated layer that is continuous, flexible and comprised of the powder mix and supporting layer, and
removing the heated layer from the carrier to create a separate, continuous and flexible layer,
wherein the fibres and binder are mixed to form the powder mix prior to the powder mix being applied to the surface of the supporting layer.
29. The method according to claim 28 , wherein the fibres comprise wood fibres.
30. The method according to claim 28 , wherein the binder is a thermosetting binder.