Method to produce a building panel and a semi-finished product
A method to produce a building panel, including: providing a substrate, applying a thermosetting binder in dry form on the substrate for forming a sub-layer, applying a sheet on the sub-layer, and pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet from below. Also, a semi-finished product.
1. A method to produce a building panel, comprising
providing a substrate,
applying a thermosetting binder in dry form on the substrate for forming a sub-layer,
controlling the moisture content of the sub-layer when arranged on the substrate,
applying a sheet on the sub-layer, while the sub-layer is sticky from applied moisture, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and wherein the sheet further comprises pigments and/or fillers, and
pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet,
wherein controlling the moisture content of the sub-layer comprises:
controlling adhesion of the sheet to sub-layer by applying moisture to the sub layer; and
controlling flow of the thermosetting binder of the sub-layer.
2. The method according to claim 1 , wherein controlling the moisture content of the sub-layer comprises one or more of the following:
applying steam on the substrate prior to applying the sub-layer,
applying steam on the sub-layer when arranged on the substrate,
applying steam on the sheet,
applying liquid on the substrate prior to applying the sub-layer,
applying liquid on the sub-layer when arranged on the substrate,
applying liquid on the sheet, and/or
drying the sub-layer and/or the sheet.
3. The method according to claim 1 , wherein the moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.
4. The method according to claim 1 , wherein the sheet being applied on the sub-layer is unimpregnated or impregnated by a fluid comprising less than 20 wt % of a thermosetting binder.
5. The method according to claim 1 , wherein the sub-layer consists essentially of the thermosetting binder.
6. The method according to claim 1 , further comprising printing a décor on the sheet when arranged on the sub-layer.
7. The method according to claim 6 , wherein the sheet is adhered to the sub-layer prior to printing.
8. A method to produce a building panel, comprising
providing a substrate,
controlling relative humidity (RH) of ambient air enclosing an application device adapted to apply a thermosetting binder in dry form,
applying a thermosetting binder in dry form on the substrate by said application device for forming a sub-layer,
applying a sheet on the sub-layer, wherein the sheet comprises pigments and/or fillers, and
pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet,
wherein the relative humidity (RH) is 35-60% RH.
9. The method according to claim 8 , wherein the sheet being applied on the sub-layer is unimpregnated or impregnated by a fluid comprising less than 20 wt % of a thermosetting binder.
10. The method according to claim 8 , wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet.
11. The method according to claim 8 , wherein the sub-layer consists essentially of the thermosetting binder.
12. The method according to claim 8 , further comprising printing a décor on the sheet when arranged on the sub-layer.
13. The method according to claim 12 , wherein the sheet is adhered to the sub-layer prior to printing.
14. The method according to claim 8 , further comprising applying moisture to the thermosetting binder, the sub-layer, the sheet, and/or the substrate prior to pressing.
15. The method according to claim 8 , wherein a moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.
16. A method to produce a building panel, comprising
providing a substrate,
applying a thermosetting binder in dry form on the substrate for forming a sub-layer,
controlling the moisture content of the sub-layer when arranged on the substrate,
applying a sheet on the sub-layer, while the sub-layer is sticky from applied moisture, wherein the sheet comprises one or more of a paper sheet, a non-woven, a woven fibre sheet, or a fibre sheet, and wherein the sheet further comprises pigments and/or fillers,
pressing the substrate, the sub-layer and the sheet together to form a building panel, thereby the thermosetting binder of the sub-layer impregnates the sheet,
wherein the sub-layer comprises the thermosetting binder and non-absorbing fillers,
wherein the sheet comprises a print,
wherein controlling the moisture content of the sub-layer comprises:
controlling adhesion of the sheet to sub-layer by applying moisture to the sub- layer; and
controlling flow of the thermosetting binder of the sub-layer.
17. The method according to claim 16 , wherein the sheet being applied on the sub-layer is unimpregnated or impregnated by a fluid comprising less than 20 wt % of a thermosetting binder.
18. The method according to claim 16 , wherein the sub-layer consists essentially of the thermosetting binder.
19. The method according to claim 16 , further comprising applying moisture to the thermosetting binder, the sub-layer, the sheet, and/or the substrate prior to pressing.
20. The method according to claim 16 , wherein a moisture content of the sub-layer when arranged on the substrate is 5-35 wt %.
21. The method according to claim 16 , further comprising printing the print on the sheet when arranged on the sub-layer, wherein the print is a décor.
22. The method according to claim 16 , wherein the sheet is adhered to the sub-layer prior to printing.
23. The method according to claim 16 , wherein a moisture content of the sub-layer when arranged on the substrate is 15-35 wt. %.