# US 12,179,392 B2 · Method of manufacturing a layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,179,392 B2 - Document ID: US12179392B2 - Status: Granted - Kind: B2 - Application number: 18/189,324 - Filed: 2023-03-24 - Published: 2023-11-02 - Granted: 2024-12-31 - Earliest claimed: 2011-04-12 - Assignees: Välinge Innovation AB - Applicants: Välinge Innovation AB - Inventors: Göran Ziegler; Marcus Bergelin; Jan Jacobsson; Melker Ryberg - Web page: https://patentgrep.com/patent/US12179392B2 ## CPC - B29C 41/28: by depositing flowable material on an endless belt - B27N 1/00: Pretreatment of moulding material - B27N 3/04: from fibres - B27N 3/18: Auxiliary operations, e.g. preheating, humidifying, cutting-off - B27N 7/005: {Coating boards, e.g. with a finishing or decorating layer} - C08L 61/28: with melamine - E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins} - B29K 2101/10: Thermosetting resins - B29K 2105/246: {Uncured, e.g. green} - B29L 2007/008: {Wide strips, e.g. films, webs} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## 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. ## Claims ### Claim 1 A method of manufacturing a powder mix layer being essentially uncured, comprising: applying a powder mix comprising fibres and a thermosetting binder on a carrier; forming a powder mix layer, wherein forming the powder mix layer comprises applying heat, wherein the powder mix is connected together in the powder mix layer, and wherein the powder mix layer is essentially uncured; and releasing the powder mix layer from the carrier, wherein the released powder mix layer is a separate and continuous layer, wherein the step of forming the powder mix layer includes heating the powder mix by means of IR radiation such that the powder mix is connected together. ### Claim 2 (depends on 1) The method according to claim 1, wherein the released powder mix layer is flexible. ### Claim 3 (depends on 1) The method according to claim 1, wherein the powder mix includes moisture, wherein the step of forming the powder mix layer includes drying the powder mix such that the powder mix is connected together. ### Claim 4 (depends on 1) The method according to claim 1, wherein the step of forming the powder mix layer further includes applying pressure on the powder mix such that the powder mix is connected together. ### Claim 5 (depends on 1) The method according to claim 1, wherein the fibres are wood fibres, plastic fibres, mineral fibres, vegetable fibres, or a mixture thereof. ### Claim 6 (depends on 1) The method according to claim 1, wherein the thermosetting binder is a melamine resin. ### Claim 7 (depends on 1) The method according to claim 1, wherein the step of applying the powder mix on the carrier comprises applying the powder mix directly on said carrier without any intermediate layer. ### Claim 8 (depends on 1) The method according to claim 1, further comprising arranging a reinforcement structure in the powder mix. ### Claim 9 (depends on 1) The method according to claim 1, further comprising printing a print in the powder mix and/or in the powder mix layer. ### Claim 10 (depends on 9) The method according to claim 9, further comprising printing a print on both sides of the powder mix layer. ### Claim 11 (depends on 1) The method according to claim 1, further comprising applying liquid in a pattern on the powder mix. ### Claim 12 (depends on 1) The method according to claim 1, further comprising tearing the released powder mix layer into smaller portions forming decorative elements. ### Claim 13 (depends on 1) The method according to claim 1, wherein the powder mix layer is a protective layer. ### Claim 14 (depends on 1) A method comprising: manufacturing an essentially uncured powder mix layer according to claim 1, and curing the released powder mix layer. ### Claim 15 A method of manufacturing a powder mix layer being essentially uncured, comprising: applying a powder mix comprising fibres and a thermosetting binder on a carrier; forming a powder mix layer; and releasing the powder mix layer from the carrier, wherein the released powder mix layer is a separate and continuous layer, wherein the step of forming the powder mix layer includes applying heat and moisture on the powder mix such that the powder mix is connected together in the powder mix layer. ### Claim 16 (depends on 15) The method according to claim 15, wherein a liquid forming the moisture is water, an alcohol, an ink, a binder, or a mixture thereof. ### Claim 17 (depends on 15) The method according to claim 15, wherein the released powder mix layer is flexible. ### Claim 18 (depends on 15) The method according to claim 15, wherein the step of forming the powder mix layer includes heating the powder mix by means of IR radiation such that the powder mix is connected together. ### Claim 19 (depends on 15) The method according to claim 15, wherein the step of applying the powder mix on the carrier comprises applying the powder mix directly on said carrier without any intermediate layer. ### Claim 20 (depends on 15) A method comprising: manufacturing an essentially uncured powder mix layer according to claim 15, and curing the released powder mix layer.