Publication Date: 2009-May-15
The IP.com Prior Art Database
Building panels with a thin and embossed surface layer and a sub layer between a surface layer and a core.
WOOD FIBRE BASED PAN
ELS WITH A THIN SURF
The invention generally relates but is not limited to the field of wood fibre
based building panels with a thin surface layer, preferably floor panels. The
invention relates but is not li
mited to building panels with such surface layer
and to equipment and methods to produce such panels.
Field of Application of the Invention
The present invention is particularly suitable for use in floating floors, which
are formed of floor panels with a w
ood fibre core and a thin decorative wear
resistant surface. The following description of prior
art technique, problems of
known systems and objects and features of the invention will therefore, as a
restrictive example, be aimed above all at this fiel
d of application and in
particular at floorings which are similar to traditional wood fibre based
It should be
emphasized that the invention can also be used in other
applications as for example wall panels, ceilings, and furniture com
Wood fibre based direct pressed laminated flooring usually comprises a core
of a 6
mm fibre board, a 0.2 mm thick upper decorative surface layer of
laminate and a 0.1
mm thick lower balancing layer of laminate, plast
paper or like material.
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
intended to protect the decorative paper from abrasion. The transparent
is made of
cellulose fibres, comprises small hard and
oxide particles, which gives the thin surface layer a
high wear resistance.
The printed decorative paper and the overlay are impregnated with melamine
resin and laminated to a w
ood fibre based core under heat and pressure. The
two papers have prior to pressing a total thickness of about 0.3 mm and they
are after pressing compressed to about 0.2 mm.
Other common thin surface materials are wood veneer and foils, which are
The most common core material is fibreboard with high density and good
stability usually called HDF
High Density Fibreboard with a density
exceeding 800 kg/cm
2. Sometimes also MDF
Medium Density Fibreboard
with a density of 600
2used as core.
Other core materials could
also be used such as particleboard, plywood, and plastic
A balancing layer is generally applied on the rear side of the board in order to
keep the panel flat when humidity changes.
HDF is prod
uced as follows: Roundwood such as for example pine, larch or
spruce are reduced to wood chips and then broken down into individual fibres
in a refiner. The fibres are thereafter mixed with binders and then subjected to
high pressure and temperature to for
m a board.
Floor panels with such thin surface layer are very cost...