Powder overlay
A method is disclosed of manufacturing a transparent wear resistant surface layer ( 1 ). The method may include the steps of, applying a decorative material on a carrier, applying a dry powder layer comprising a mix of processed wood fibers, binder and wear resistant particles above the decorative layer, curing the mix to a decorative surface, including the transparent wear resistant layer, by applying heat and pressure on the mix. In a preferred embodiment the method includes the step of pressing the mix against an embossed matrix to create an embossed decorative surface with high wear resistance.
1. A method of manufacturing a building panel, wherein the method comprises the steps of:
applying a decorative layer on a carrier;
applying a dry powder layer, comprising a mix of a thermoplastic material and wear resistant particles, on the decorative layer; and
applying heat and pressure in order to form the dry powder layer on the decorative layer into a transparent wear resistant layer.
2. The method as claimed in claim 1 , wherein the wear resistant particles comprise aluminium oxide and/or silica.
3. The method as claimed in claim 1 , wherein the mix further comprises processed wood fibres.
4. The method as claimed in claim 1 , wherein the thermoplastic material comprises vinyl particles.
5. The method as claimed in claim 1 , wherein the panel is a floor panel.
6. The method as claimed in claim 1 , wherein the carrier is a wood based board.
7. The method as claimed in claim 1 , wherein the carrier is an HDF or MDF board.
8. The method as claimed in claim 1 , wherein the decorative layer is a printed paper.
9. The method as claimed in claim 1 , wherein the decorative layer is a decorative powder mix including wood fibres and a binder.
10. The method as claimed in claim 1 , wherein the curing step comprises pressing the mix against an embossed matrix.
11. The method as claimed in claim 10 , wherein the pressing against the embossed matrix creates an embossing depth that exceeds a thickness of the decorative layer.
12. The method as claimed in claim 10 , wherein the pressing against the embossed matrix creates an embossing depth that exceeds the combined thickness of the decorative layer and the transparent wear layer.
13. A method of manufacturing a building panel, wherein the method comprises the steps of:
applying a decorative layer on a carrier;
applying a dry powder layer, comprising a mix of a thermoplastic material and wear resistant particles, on the decorative layer; and
applying heat and pressure on the powder layer to obtain a decorative surface layer comprising a transparent wear resistant layer, wherein the decorative layer comprises a transparent paper based overlay comprising aluminium oxide.
14. The method as claimed in claim 13 , wherein the transparent paper based overlay comprising aluminium oxide is applied over a lower powder layer, the lower powder layer comprising wood fibres and a binder.
15. A method of manufacturing a building panel, wherein the method consists of:
applying a decorative layer on a carrier;
applying a dry powder layer, comprising a mix of a thermoplastic material and wear resistant particles, on the decorative layer; and
applying heat and pressure on the dry powder layer to obtain a decorative surface layer comprising a transparent wear resistant layer.