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FIBER BASED PANELS WITH A WEAR RESISTANCE SURFACE

IP.com Disclosure Number: IPCOM000176590D
Publication Date: 2008-Nov-17
Document File: 75 page(s) / 1M

Publishing Venue

The IP.com Prior Art Database

Related People

Ola Engstrand: CONTACT

Abstract

Building panels with a homogeneous decorative surface having a wear layer comprising fibers, binders and wear resistant particles.

This text was extracted from a PDF file.
This is the abbreviated version, containing approximately 5% of the total text.

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FIBRE BASED PANELS WITH A WEAR RESISTANCE SURFACE

Technical field

The disclosure generally relates to the field of fibre-based panels with wear resistant surfaces for building panels, preferably floor panels. The disclosure relates to building panels with such wear resistance surface and to production

methods to produce such panels.

Field of Application

The present disclosure is particularly suitable for use in floating floors, which are formed of floor panels with a wood fibre core and a decorative wear resistant surface. The following description of technique, problems of known systems and

objects and features of the invention will therefore, as a non-restrictive example, be aimed above all at this field of application and in particular at floorings which are similar to traditional floating wood fibre based laminate floorings. The disclosure does not exclude floors that are glued down to a sub floor.

It should be emphasized that the disclosure can be used as a panel or as a

surface layer, which is for example glued to a core. The disclosure can also be used in applications as for example wall panels, ceilings, and furniture components and similar. It is even possible to produce components that could for example replace metal or plastic components generally used in the industry, for example automotive components. Such components could be produced with

an advanced shape and properties. Wear resistance, impact resistance, friction and cost structure could be comparable or better than for other conventional materials.

Background

Wood fibre based direct pressed laminated flooring usually comprises a core of a

6-12 mm fibre board, a 0.2 mm thick upper decorative surface layer of laminate and a 0.1-0.2 mm thick lower balancing layer of laminate, plastic, paper or like material.

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A laminate surface generally comprise two paper sheets, a 0.1 mm thick printed decorative paper and a transparent 0.05-0.1 mm thick overlay paper applied over the decorative paper and intended to protect the decorative paper from abrasion. The print on the decorative non-transparent paper is only some 0.01 mm thick. The transparent overlay, which is made of refined α-cellulose fibres,

comprises small hard and transparent aluminium oxide particles. The refined fibres are rather long, about 2-5 mm and this gives the overlay paper the required strength. In order to obtain the transparency, all natural resins that are present in the virgin wood fibres, have been removed and the aluminium oxide particles are applies as a very thin layer over the decorative paper. The surface

layer of a laminate floor is characterized in that the decorative and wear properties are generally obtained with two separate layers one over the other.

The printed decorative paper and the overlay are impregnated with melamine resin and laminated to a wood fibre based core under heat and pressure.

The small aluminium oxid...