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WFF Embossing

IP.com Disclosure Number: IPCOM000183105D
Publication Date: 2009-May-15

Publishing Venue

The IP.com Prior Art Database

Related People

Ola Engstrand: CONTACT

Abstract

Building panels with a thin and embossed surface layer and a sub layer between a surface layer and a core.

This text was extracted from a PDF file.
This is the abbreviated version, containing approximately 11% of the total text.

Page 1 of 35

1

WOOD FIBRE BASED PAN

ELS WITH A THIN SURF

ACE LAYER

Technical field

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.

5

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

10

non

-

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

laminate floorings.

It should be

emphasized that the invention can also be used in other

applications as for example wall panels, ceilings, and furniture com

15

ponents

and similar.

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

20

-

0.2

mm thick lower balancing layer of laminate, plast

ic,

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

Page 2 of 35

2

overlay, which

is made of

α

-

cellulose fibres, comprises small hard and

transparent

aluminium

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

5

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

glued to

a core.

10

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

-

800 kg/cm

is

2used as core.

Other core materials could

also be used such as particleboard, plywood, and plastic

m

aterials and

15

similar.

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

20

high pressure and temperature to for

m a board.

Floor panels with such thin surface layer are very cost...