Powder mix and a method for producing a building panel
View Patent ↗A powder mix layer for a building panel and a method for producing a building panel with a decorative surface produced from a powder mix layer with a controlled loss on cure.
1. A method of producing a building panel comprising the steps of:
applying a powder mix layer on a substrate, the powder mix layer comprising a fiber and a binder; and
applying heat and pressure to the powder mix layer and curing the powder mix layer having a loss on cure in the range of about 2 to about 7 wt-%, and thereby obtaining a layer of the building panel formed by the powder mix layer.
2. The method according to claim 1 , wherein the powder mix layer comprises wood fibres and a binder.
3. The method according to claim 2 , wherein the substrate is a wood-based core and the substrate is a core of the building panel.
4. The method of claim 3 , the method further comprising determining the loss on cure for the powder mix layer.
5. The method of claim 4 , the method further comprising adjusting the loss on cure of the powder mix layer by a step of applying a stabilisation fluid, or a step of drying, or a combination thereof, such that the powder mix layer obtains the loss on cure in said range.
6. The method according to claim 3 , wherein the powder mix layer has a loss on cure in the range of about 3.5 to about 5.5 wt-%.
7. The method according to claim 1 , comprising the further step of applying a stabilisation fluid on the powder mix layer.
8. The method according to claim 7 , further comprising adjusting the loss on cure of the powder mix layer by a step of applying the stabilisation fluid, or a step of drying, or a combination thereof such that the powder mix layer obtains the loss on cure in said range.
9. The method of claim 7 , the method further comprising determining the loss on cure for the powder mix layer.
10. The method of claim 9 , the method further comprising adjusting the loss on cure of the powder mix layer by a step of applying the stabilisation fluid, or a step of drying, or a combination thereof, such that the powder mix layer obtains the loss on cure in said range.
11. The method according to claim 1 , comprising the further step of drying the powder mix layer.
12. The method according to claim 11 , wherein the step of drying comprises applying heat with an effect of about 15-25 kW/m and a feeding speed of the substrate in the range of about 1-4 m/min.
13. The method according to claim 1 , comprising the further step of fixing the powder mix layer to the substrate.
14. The method according to claim 13 , wherein the step of fixing comprises applying stabilisation fluid and drying with an effect of about 15-25 kW/m and a feeding speed of the substrate in the range of about 1-4 m/min.
15. The method according to claim 1 , wherein the powder mix layer is applied by scattering.
16. The method according to claim 1 , wherein the powder mix layer is applied as a continuous powder mix sheet.
17. The method according to claim 1 , wherein the substrate is a core of the building panel.
18. The method according to claim 17 , wherein the layer forms a decorative surface layer arranged on the core.
19. The method according to claim 17 , wherein the substrate is a wood-based core.
20. The method according to claim 1 , wherein the powder mix layer has a loss on cure in the range of about 2.5 to about 7 wt-%.
21. The method according to claim 1 , wherein the powder mix layer has a loss on cure in the range of about 3 to about 6 wt-%.
22. A method of producing a building panel comprising the steps of:
applying a powder mix layer on a substrate, the powder mix layer comprising a fiber and a binder;
determining the loss on cure for the powder mix layer and, if outside the range of about 2 to about 7 wt-%, adjusting the loss on cure of the powder mix layer by a step of applying a stabilisation fluid, or a step of drying, or a combination thereof, such that the powder mix layer obtains the loss on cure in said range; and
applying heat and pressure to the powder mix layer and curing the powder mix layer having a loss on cure in the range of about 2 to about 7 wt-%, and thereby obtaining a layer of the building panel formed by the powder mix layer.