Method of manufacturing a layer
AssigneeVälinge Innovation AB
InventorsGöran Ziegler, Marcus Bergelin, Jan Jacobsson, Melker Ryberg
Life of this patent
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Abstract
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.
Claims30
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.
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.
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.
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.
Dependencies are inferred from the claim text.