Method of producing a panel with a facing and panel with a facing
By using binders and fillers to fill the openings during the pressing process in the production of wood veneer panels, the problem of ineffective filling of openings in wood veneer flooring has been solved, resulting in a more natural surface effect and reduced production costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- VÄLINGE INNOVATION AB
- Filing Date
- 2022-07-01
- Publication Date
- 2026-06-05
AI Technical Summary
In the production process of existing wood veneer flooring, openings such as knots, holes, and cracks cannot be effectively filled, resulting in additional production steps and increased costs. Furthermore, it cannot be sanded like solid wood or engineered wood flooring.
By placing first and second adhesive layers between the core and the wood veneer layer, pressing the first wood veneer layer into the opening structure of the second wood veneer layer, and filling the opening structure with filler and adhesive during the pressing process, a veneer panel is formed.
It reduces additional production steps and costs, improves the aesthetics and overall design of wood veneer panels, avoids the need for putty filling, and achieves a more natural surface effect.
Smart Images
Figure CN117615906B_ABST
Abstract
Description
Technical Field
[0001] Embodiments of this disclosure relate to a method of producing a veneered panel and such a veneered panel. Background Technology
[0002] There are several different types of floor coverings with a wood surface. Solid wood flooring is made from solid blocks of wood in the form of planks.
[0003] Engineered wood flooring can be formed from a wood surface layer glued to a core. The core can be a veneer core or a wood substrate, such as plywood, MDF, or HDF. As an example, the wood surface layer can have a thickness of 2.5-10 mm.
[0004] Wood flooring veneers can also be formed by gluing wood veneer panels to a core, which is, for example, a wood substrate such as particleboard, MDF, or HDF. The wood veneer panels are thin layers of wood, for example, with a thickness of 0.3-1 mm. Flooring with a separate surface layer glued to a core made of, for example, HDF or plywood has better moisture stability than solid wood flooring.
[0005] Compared to solid wood and engineered wood flooring, wood veneer flooring has lower production costs and consumes less timber resources because it uses only a thin layer of wood. However, wood veneer cannot be sanded like solid wood or engineered wood flooring.
[0006] To improve the impact resistance of wood veneer flooring, a sublayer can be provided between the wood veneer layer and the core. WO2009 / 065769 discloses a thin surface layer, such as a wood veneer layer, applied over a sublayer comprising, for example, cork or wood fibers mixed with a binder. The sublayer is applied over a wood fiber-based core.
[0007] Depending on the quality of the wood veneer, it may include open structures such as knots, holes, and cracks. These open structures may extend through the veneer or partially extend through it. In traditional engineered wood flooring, these open structures are filled with putty after the surface layer of the wood has been glued to the core. This additional production step is undesirable for streamlining manufacturing.
[0008] WO 2015 / 105456 discloses a method for producing a veneer element comprising a substrate, a veneer layer, and a sublayer disposed between the substrate and the veneer layer. The sublayer contains a binder and may be applied in powder, liquid, paste, or flake form. The sublayer may fill any cracks, holes, or knots in the veneer layer. The cracks, holes, or knots are filled with a material having the composition, properties, and appearance of the sublayer.
[0009] WO 2020 / 127556 discloses a method for producing wood-based materials in which high-quality veneer panels are combined with inexpensive veneer panels. For example, thin, expensive oak veneer panels (0.6 mm thick) are laid on top of thick, inexpensive poplar veneer panels (1.5 mm thick) to form a thick veneer surface on a support board. The veneer panels are attached to each other by an excess of synthetic resin. "Excess" refers to the amount of synthetic resin additionally applied to the support board and / or veneer panels based on the amount of synthetic resin required for bonding. During pressing, the synthetic resin liquefies and is pressed into a lower-density veneer panel. Summary of the Invention
[0010] The purpose of at least the embodiments disclosed herein is to provide improvements over the above-described and known technologies.
[0011] According to a first aspect, a method for producing a veneered panel is provided. The method includes:
[0012] Provide the core components;
[0013] Provide the first wood veneer layer;
[0014] Provide a second wood veneer layer having at least one open structure;
[0015] A first wood veneer layer is disposed on a first surface of the core using a first adhesive layer containing a first adhesive, the first adhesive layer being applied between the first surface of the core and the first wood veneer layer;
[0016] A second wood veneer layer is disposed on a first wood veneer layer using a second adhesive layer containing a second adhesive, the second adhesive layer being applied between the first wood veneer layer and the second wood veneer layer;
[0017] The core, the first wood veneer layer, and the second wood veneer layer are pressed together to form a veneered panel.
[0018] During pressing, the first wood veneer layer is pressed into at least one opening in the second wood veneer layer, and after pressing, the first wood veneer layer at least partially fills the at least one opening in the second wood veneer layer.
[0019] The first binder layer may comprise a first binder and at least one filler.
[0020] The opening structure can be an opening in the wood veneer layer, such as a knot, hole, or crack. The opening structure can have an extension from one surface of the second wood veneer layer to the opposite surface of the second wood veneer layer, or it can have an extension less than the thickness of the second wood veneer layer.
[0021] The opening structure can extend in a direction perpendicular to the first surface of the core.
[0022] "At least partially filled" is understood to mean that the upper surface of the first wood veneer layer is flush with the upper surface of the second wood veneer layer, or that the upper surface of the first wood veneer layer is located at a certain distance from the lower surface of the second wood veneer layer facing the first wood veneer layer. In one example, in an open structure, a portion of the upper surface of the first wood veneer layer is positioned closer to the upper surface of the second wood veneer layer than to the lower surface of the second wood veneer layer.
[0023] In an open structure, a portion of the first wood veneer layer may extend into the second wood veneer layer.
[0024] The second wood veneer layer can be formed as the top veneer layer of a veneered panel.
[0025] The second wood veneer layer can be formed as the top layer of the veneered panel. The second wood veneer layer can be formed as the top decorative layer of the veneered panel. The second wood veneer layer can be formed as the top wood base layer of the veneered panel.
[0026] The opening structure is visible from the top layer of the finished paneling. The opening structure is visible when the finished paneling is installed and used as architectural paneling.
[0027] The open structure may be filled only or at least partially filled with material derived from the first wood veneer layer.
[0028] The opening structure can be an opening on the upper surface of the second wood veneer layer. The opening structure may not be covered by any additional wood veneer layer.
[0029] When installed and used as architectural paneling, a second wood veneer layer can be used to form the visible surface.
[0030] Before pressing, a balancing layer may be arranged on a second surface of the core opposite to the first surface of the core.
[0031] After pressing, the veneered panel can consist of a core, a first wood veneer layer, a second wood veneer layer (which may optionally be coated), and a balancing layer.
[0032] The first wood veneer layer can be compressible. The first wood veneer layer can be more compressible than the second wood veneer layer. The first wood veneer layer can be compressed to approximately 80% of its original thickness, or compressed to less than 80% of its original thickness. For example, the original thickness is the thickness of the first wood veneer panel before pressing, such as when it was laid on the first veneer layer before pressing.
[0033] Before pressing, the thickness of the first wood veneer layer can be less than or equal to 1 mm. Before pressing, the thickness of the first wood veneer layer can be less than or equal to 0.6 mm.
[0034] After pressing, the first wood veneer layer and the second wood veneer layer together can have a thickness of less than or equal to 1.6 mm, such as less than or equal to 1.2 mm.
[0035] The first binder layer may also contain at least one filler. The filler may be organic, such as wood particles, and / or inorganic, such as barium sulfate. When applied, the first binder may be mixed with said at least one filler.
[0036] The first binder can be applied in powder form.
[0037] The first binder can be applied in liquid form and can be dried before pressing.
[0038] The second wood veneer layer can be a sliced wood veneer layer.
[0039] The first wood veneer layer can be a rotary-cut wood veneer layer.
[0040] The second wood veneer layer may be or may include oak veneer panels.
[0041] The first wood veneer layer may be or include birch veneer panels.
[0042] The method may further include brushing the first wood veneer layer and the second wood veneer layer to a brushing depth extending into the first wood veneer layer after pressing.
[0043] The first binder can be less than 100g / m³. 2 The amount applied.
[0044] The second binder can be less than 100g / m². 2 The amount applied.
[0045] The first binder can be less than 300 g / m³. 2 The amount applied.
[0046] The second binder can be less than 150 g / m². 2 The amount applied.
[0047] Compression may include applying a pressure of at least 20 bar, for example 20-100 bar, at a temperature of at least 160°C, for example 160-250°C, for a period of at least 10 seconds, for example 10-100 seconds.
[0048] Compression may include applying a pressure of at least 30 bar, for example 30-80 bar, at a temperature of at least 180°C, for example 180-250°C, for a period of at least 40 seconds, for example 40-100 seconds.
[0049] The core can be a wood-based panel, such as a wood fiber panel.
[0050] According to a second aspect, a finished panel is provided. The finished panel includes:
[0051] Core;
[0052] A first wood veneer layer disposed on a first surface of the core, wherein the first wood veneer layer is attached to the core by a first adhesive layer disposed between the first surface of the core and the first wood veneer layer; and
[0053] A second wood veneer layer is disposed on a first wood veneer layer, wherein the second wood veneer layer is attached to the first wood veneer layer by a second adhesive layer disposed between the first and second wood veneer layers, wherein the second wood veneer layer has at least one opening structure.
[0054] The first wood veneer layer at least partially fills the at least one opening structure of the second wood veneer layer.
[0055] The first binder layer may comprise a first binder and at least one filler.
[0056] The opening structure can be an opening in the wood veneer layer, such as a knot hole, a hole, or a crack. The opening structure can have an extension from one surface of the second wood veneer layer to the opposite surface of the second wood veneer layer, or it can have an extension less than the thickness of the second wood veneer layer.
[0057] The opening structure can extend in a direction perpendicular to the first surface of the core.
[0058] "At least partially filled" is understood to mean that the upper surface of the first wood veneer layer is flush with the upper surface of the second wood veneer layer, or that the upper surface of the first wood veneer layer is located at a certain distance from the lower surface of the second wood veneer layer. In one example, in an open structure, a portion of the upper surface of the first wood veneer layer is positioned closer to the upper surface of the second wood veneer layer than to the lower surface of the second wood veneer layer.
[0059] In an open structure, a portion of the first wood veneer layer may extend into the second wood veneer layer.
[0060] The second wood veneer layer can be formed as the top veneer layer of a veneered panel.
[0061] The second wood veneer layer can be formed as the top layer of the veneered panel. The second wood veneer layer can be formed as the top decorative layer of the veneered panel. The second wood veneer layer can be formed as the top wood base layer of the veneered panel.
[0062] The opening structure is visible from the top layer of the finished paneling. The opening structure is visible when the finished paneling is installed and used as architectural paneling.
[0063] The open structure may be filled only or at least partially filled with material derived from the first wood veneer layer.
[0064] The opening structure can be an opening on the upper surface of the second wood veneer layer. The opening structure may not be covered by any additional wood veneer layer.
[0065] When installed and used as architectural paneling, a second wood veneer layer can be used to form the visible surface.
[0066] Before pressing, a balancing layer may be arranged on a second surface of the core opposite to the first surface of the core.
[0067] After pressing, the veneered panel can consist of a core, a first wood veneer layer, a second wood veneer layer (which may optionally be coated), and a balancing layer.
[0068] The first wood veneer layer can be compressible. The first wood veneer layer can be more compressible than the second wood veneer layer. The first wood veneer layer can be compressed to approximately 80% of its original thickness, or compressed to less than 80% of its original thickness. For example, the original thickness is the thickness of the first wood veneer panel before pressing, such as when it was laid on the first veneer layer before pressing.
[0069] The thickness of the first wood veneer layer can be less than 1 mm. The thickness of the first wood veneer layer can be less than or equal to 0.6 mm.
[0070] The first and second wood veneer layers may have a total thickness of less than or equal to 1.6 mm, for example, less than or equal to 1.2 mm.
[0071] The first binder layer may also contain at least one filler. The filler may be an organic filler such as wood particles, and / or an inorganic filler such as barium sulfate. The first binder may be mixed with said at least one filler.
[0072] The second wood veneer layer can be sliced wood veneer panels.
[0073] The first wood veneer layer can be rotary-cut wood veneer panels.
[0074] The second wood veneer layer may be or may include oak veneer panels.
[0075] The first wood veneer layer may be or include birch veneer panels. Attached Figure Description
[0076] The present disclosure will be described in more detail by way of example with reference to the schematic drawings, which illustrate examples of the present disclosure.
[0077] Figure 1 The method of producing veneered panels is illustrated schematically.
[0078] Figure 2 The method of producing veneered panels is illustrated schematically.
[0079] Figure 3 It shows according to Figure 1 or Figure 2 The method disclosed in the paper produces a decorative panel.
[0080] Figure 4 The brushing device is shown. Detailed Implementation
[0081] Figure 1 A method for producing a finished panel 10 is shown. The finished panel 10 can be adapted to form architectural panels, such as floor panels, wall panels, furniture components, architectural components, worktops, etc. The finished panel 10 can be divided into individual panels and can be provided with a mechanical locking system configured to connect one panel to an adjacent panel.
[0082] A core 1 is provided. Core 1 can be a wood substrate, such as MDF or HDF board. Core 1 can be plywood. Core 1 can be a thin-sheet core. Core 1 can be particleboard. Core 1 can be thermoplastic board. Core 1 is preferably produced prior to this method.
[0083] The core 1 can be based on wood fiber. The core 1 may contain binders and fillers, such as organic and / or inorganic fillers.
[0084] In one example, core 1 is a single-layer core, not a multi-layer core, such as plywood. In one example, core 1 differs from the finish layer, for example, in material or construction. In one example, the thickness of core 1 is at least twice the total thickness of the first and second finish layers, for example, 2-20 times, or 3-10 times. Core 1 may not have a finish layer.
[0085] The thickness of core 1 can be 3-40mm, for example 3-12mm.
[0086] A first binder layer 3 is applied to the first surface 11 of the core 1. Figure 1 In the example shown, the first binder layer 3 is applied in powder form. The first binder layer 3 comprises a first binder 3a. Figure 1In the example shown, the first binder 3a is applied in powder form. Powder form of binder is intended to also include various forms of particles. The first binder 3a can be a thermosetting binder, such as an amino resin, such as melamine-formaldehyde resin or urea-formaldehyde resin. Thermosetting binders can be urea-formaldehyde, phenolic, melamine-formaldehyde, polyurethane, polyester, emulsion polymer isocyanate (EPI), or combinations thereof. Alternatively, the first binder 3a can be a thermoplastic binder. Thermoplastic binders can be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), polyvinyl alcohol (PVOH), polyvinyl butyral (PVB), and / or polyvinyl acetate (PVAc), or combinations thereof. The first binder 3a can include a hot melt or pressure-sensitive adhesive. The first binder 3a can be an acrylic resin or a methacrylic resin.
[0087] The first binder 3a can be less than 100g / m 2 For example, 50-100g / m 2 The amount applied. In one example, the first binder 3a can be less than 300 g / m. 2 For example, 50-300g / m 2 For example, 100-250g / m 2 The first binder 3a is applied in the amount required to attach the first wood veneer layer 2 to the first surface 11 of the core 1. No excess of the first binder 3a is applied.
[0088] The first binder layer 3 may also contain one or more fillers 3b, such as organic fillers and / or inorganic fillers. The fillers may be organic fillers, such as wood particles, or other types of lignocellulose or cellulose particles. The fillers may be inorganic fillers, such as barium sulfate, calcium carbonate, limestone, kaolin, etc. Organic and inorganic fillers may be used in combination.
[0089] The amount of filler used can be 75-150 g / m³. 2 In one example, it can be 75-300g / m³. 2 The amount of filler applied shall be specified. If more than one type of filler is used, the specified quantity refers to the total amount of filler. The amount of filler applied may be similar to the amount of the first binder 3a applied.
[0090] exist Figure 1 In the example shown, the first binder 3a and filler 3b are applied as a mixture. This mixture can be applied via, for example... Figure 1 The filler 3b is applied by an application device 20, which may be, for example, a distributing device. In several other examples, the filler 3b may be applied separately from the first binder 3a.
[0091] The mixture containing the first binder 3a and filler 3b may also contain additives and pigments. For example, the pigment can be 0-50 g / m³. 2 The amount applied is specific. For example, the additive can be applied in quantities of 0-100 g / m³. 2 The amount applied.
[0092] The mixture can contain a total of 200-600 g / m³. 2 The mixture may contain 30-70% by weight of a first binder 3a, 10-60% by weight of filler, 0-30% by weight of optional additives and 0-10% by weight of optional pigment.
[0093] When applied to the first surface 11 of the core 1, the first binder 3a and the filler 3b form a first binder layer 3.
[0094] After the first adhesive layer 3 is applied to the core 1, the first wood veneer layer 2 is applied to the first adhesive layer 3. The first adhesive layer 3 is located between the first surface 11 of the core 1 and the first wood veneer layer 2.
[0095] As an alternative or supplement, the first adhesive layer 3 of the above type can be applied to the surface of the first wood veneer layer 2. Thereafter, the first wood veneer layer 2 can be applied to the first surface 11 of the core 1, such that the first adhesive layer 3 is disposed between the first surface 11 of the core 1 and the first wood veneer layer 2.
[0096] The first wood veneer layer 2 may have a thickness of less than 1.5 mm as measured before pressing. In one example, the first wood veneer layer 2 has a thickness of less than or equal to 1 mm as measured before pressing, such as less than or equal to 0.6 mm as measured before pressing. For example, the thickness may be 0.3-1.5 mm. The first wood veneer layer 2 may be a sliced wood veneer panel. The surface of the first wood veneer layer 2 may be substantially free of open structures such as knots, holes, and cracks. In one example, the first wood veneer layer 2 may be a birch veneer panel. In another example, the first wood veneer layer 2 may be a pine veneer panel.
[0097] As described above, the first adhesive 3a is applied in the amount required to attach the first wood veneer layer 2 to the core 1. In one example, the first adhesive 3a is not applied in excess, and the first adhesive 3a does not penetrate the first wood veneer layer 2, or at least does not completely penetrate the first wood veneer layer 2.
[0098] The first wood veneer layer 2 can be compressible. By being compressible, the first wood veneer layer 2 can be pressed into any opening in the second wood veneer layer applied above the first wood veneer layer 4. For example, after pressing, the portion of the first wood veneer layer within the opening in the second wood veneer layer may not be compressed, or may be compressed less than the remaining portion of the first wood veneer layer not below the opening in the second wood veneer layer.
[0099] The second wood veneer layer 4 is applied over the first wood veneer layer 2. A second adhesive layer 5 is disposed between the first wood veneer layer 2 and the second wood veneer layer 4.
[0100] The first wood veneer layer 2 and the second wood veneer layer 4 may be the only veneer layers. The first wood veneer layer 2 may not have an opening structure extending from the lower surface to the upper surface through the first wood veneer layer 2.
[0101] The second binder layer 5 includes a second binder 5a. The second binder 5a may be of the same type as the first binder 3a. The second binder 5a may be a thermosetting binder, such as an amino resin, melamine-formaldehyde resin, or urea-formaldehyde resin. Thermosetting binders may be urea-formaldehyde, phenolic, melamine-formaldehyde, polyurethane, polyester, emulsion polymer isocyanate (EPI), or combinations thereof. Alternatively, the second binder 5a may be a thermoplastic binder. Thermoplastic binders may be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), polyvinyl alcohol (PVOH), polyvinyl butyral (PVB), and / or polyvinyl acetate (PVAc), or combinations thereof. The second binder 5a may include a hot melt or pressure-sensitive adhesive. The second binder 5a may be an acrylic resin or a methacrylic resin.
[0102] exist Figure 1 In the example shown, the second binder 5a is applied in liquid form. Furthermore, in Figure 1 In the example, the second binder 5a is applied to the first wood veneer layer 2. Figure 1 In this process, the second binder 5a is applied to the surface of the first wood veneer layer 2 that is intended to face the second wood veneer layer 4.
[0103] In an alternative example, the second binder 5a of the second binder layer 5 may be applied to the surface of the second wood veneer layer 4 that is intended to face the first wood veneer layer 2.
[0104] The second binder 5a can be less than 100g / m 2 The amount applied. In one example, the second binder 5a can be less than 150 g / m. 2 The amount applied, for example, at 50-150 g / m³ 2The second adhesive 5a is applied in the amount required to attach the second wood veneer layer 4 to the first wood veneer layer 2. In one example, the second adhesive 5a is not applied in excess, and the second adhesive 5a does not penetrate the second wood veneer layer 4, or at least does not completely penetrate the second wood veneer layer 4.
[0105] For example, if the second binder layer 5 is applied as a solution of approximately 50 / 50, comprising approximately 50% by weight of the second binder 5a and approximately 50% by weight of water, then the second binder layer 5 can be less than 200 g / m³. 2 The amount applied.
[0106] In one example, the second binder layer 5 is applied as a solution containing 30-70% by weight of water (e.g., 50% by weight of water) and 30-70% by weight of a second binder (e.g., 50% by weight of the second binder).
[0107] After application, the second binder layer 5 is dried before pressing.
[0108] The second wood veneer layer 4 includes at least one opening structure 8. The opening structure 8 may be naturally present in the wood veneer panel or may be formed in the second wood veneer layer 4. The opening structure may be an opening on the surface of the wood veneer panel, such as a hole, knot, crack, or other opening. At least one opening structure may extend from the lower surface to the upper surface through the second wood veneer layer 4.
[0109] The second wood veneer layer 4 may have a thickness of 1 mm or less, measured before pressing, for example, a thickness of 0.6 mm or less, measured before pressing. For example, the thickness may be 0.3-1 mm. The second wood veneer layer 4 may be an oak veneer panel. The second wood veneer layer 4 may be a rotary-cut wood veneer panel.
[0110] Balance layer ( Figure 1 (Not shown) can be applied to a second surface 12 of the core 1, which is opposite to the first surface 11 and opposite to the first wood veneer layer 2.
[0111] After applying the first wood veneer layer 2, the second wood veneer layer 4, and optionally a balancing layer, pressure, and preferably heat, is applied to press the components together to form the veneered panel 10. The first wood veneer layer 2 and the second wood veneer layer 4 are pressed and attached to each other while being pressed and attached to the core 1. Preferably, no pre-pressing is performed to attach the first wood veneer layer 2 to the second wood veneer layer 4.
[0112] Pressure can be applied in press 40. The press can be a static or continuous press.
[0113] The applied pressure can be in the range of 30-60 bar. The pressurization time can be 10-60 seconds. The applied temperature can be in the range of 120-250°C. In one example, the applied pressure is about 50 bar, the pressing temperature is about 190°C, and the pressing time is about 45 seconds.
[0114] During pressing, the first wood veneer layer 2 is attached to the core 1, and the second wood veneer layer 4 is attached to the first wood veneer layer 2.
[0115] After pressing, the first wood veneer layer 2 and the second wood veneer layer 4 may have a total thickness of less than 2.5 mm. In one example, the first wood veneer layer 2 and the second wood veneer layer 4 may have a total thickness of less than or equal to 2 mm after pressing. In one example, the first wood veneer layer 2 and the second wood veneer layer 4 may have a total thickness of less than or equal to 1.6 mm after pressing. In one example, the first wood veneer layer 2 and the second wood veneer layer 4 may have a total thickness of less than or equal to 1.2 mm after pressing. For example, the first wood veneer layer 2 and the second wood veneer layer 4 may have a total thickness of 0.6-2.5 mm, such as 0.8-1.5 mm.
[0116] During pressing, the first wood veneer layer 2 is pressed into at least one opening structure 8 in the second wood veneer layer 4. After pressing, the opening structure 8 is at least partially filled with the first wood veneer layer 2, which... Figure 3 It is shown in more detail below.
[0117] In one example, at this opening structure 8, the upper surface of the first wood veneer layer 2 may be flush with the upper surface of the second wood veneer layer 4, such that the opening structure 8 is completely filled. In another example, at this opening structure 8, at least a portion of the upper surface of the first wood veneer layer 2 may be flush with the upper surface of the second wood veneer layer 4. In yet another example, the opening structure 8 is at least partially filled, such that the upper surface of the first wood veneer layer 2 is located at a certain distance from the lower surface of the second wood veneer layer 4. Preferably, in the opening structure 8, a portion of the upper surface of the first wood veneer layer 2 is closer to the upper surface of the second wood veneer layer 4 than to the lower surface of the second wood veneer layer 4.
[0118] Therefore, the need to fill the opening structure 8 of the second wood veneer layer 4 with putty or the like after pressing is eliminated or at least reduced. The opening structure 8 of the second wood veneer layer 4 is filled with wood veneer panels, which produces the aesthetic impression of a finished panel. A more natural impression of the finished panel 10 can be obtained compared to filling the opening structure with putty. In addition, the first wood veneer layer 2 can contribute to the overall design of the finished panel 10.
[0119] Due to the thinness of the first wood veneer layer 2, it can fill or at least partially fill the opening structure 8 in the second wood veneer layer 4 during pressing. After pressing, the opening structure 8 remains at least partially filled by a portion of the first wood veneer layer 2. Before pressing, the first wood veneer layer 2 may have a thickness of less than 1.5 mm, for example, less than or equal to 1 mm, or for example, less than or equal to 0.6 mm. In such an example, the thinness of the first wood veneer layer 2 allows it to fill the opening structure in the second wood veneer layer 4. During pressing, the portion of the first wood veneer layer 2 below the opening structure in the second wood veneer layer 4 is not compressed. During pressing, a portion of the first wood veneer layer 2 is allowed to fill the opening structure.
[0120] In another example, by including at least one filler in the first binder layer 3, during pressing, the first wood veneer layer 2 will follow the first binder layer 3 filled with one or more fillers, and may not be compressed at an opening in the second wood veneer layer 4, but rather forced to fill the opening in the second veneer layer 4 by the at least one filler. Furthermore, a thinner wood veneer layer, such as the first wood veneer layer 2, is more likely to follow the first binder layer 3 than a thicker wood veneer layer.
[0121] For example, softwood species such as pine or birch are more likely to fill open structures. Because the first wood veneer layer 2, made of pine or birch, is compressed more under the solid portion of the second wood veneer layer 4 compared to a less soft veneer layer, the first wood veneer layer made of pine or birch fills open structures to a greater extent than a less soft veneer panel.
[0122] In one example, the first wood veneer layer 2 is compressible, for example, compressed to approximately 80% of its original thickness during a pressing operation at 160°C and 50 bar over a period of 30 seconds, or compressed to less than 80% of its original thickness as measured before pressing; wherein only the upper pressure plate applies heat during pressing. In Example 4, compression of several different wood species is listed. The first wood veneer layer 2 can be compressed to at least 20% of its original thickness, which was measured before pressing.
[0123] The first wood veneer layer 2 may be more compressible than the second wood veneer layer 4. The second wood veneer layer 4 may be compressed to 90% of its original thickness after pressing, or to a thickness less than 90% of its original thickness, which was measured before pressing during the pressing operation, as described above with reference to the compression of the first wood veneer layer 2.
[0124] Adding filler to the first binder layer 3 improves the filling of the opening structure 8 in the second wood veneer layer 4. Compared to the first binder layer 3 without filler, by adding filler to the first binder layer 3, the first wood veneer layer 2 can fill the opening structure to a height closer to the upper surface of the second wood veneer layer 4.
[0125] Furthermore, after suppression, such as Figure 4 As shown, the veneered panel 10 can be brushed. The veneered panel 10 can be brushed using a brushing device 50 including a roller brush 51. The roller brush 51 can rotate. The veneered panel 10 can be brushed deeply. The veneer element 10 can be brushed to a depth extending into the first wood veneer layer 2. The veneer layer 10, comprising two wood veneer layers 2, 4, can be brushed deeply to create a rougher appearance without exposing the underlying core 1. After brushing, the first wood veneer layer 2 can be partially visible.
[0126] A protective layer or coating may be applied to the upper surface of the second wood veneer layer 2. In one example, the protective layer may include at least one lacquer layer, which may be applied after pressing. In another example, a protective layer in the form of a resin-impregnated coating may be applied to the upper surface of the second wood veneer layer 2 before pressing.
[0127] Figure 2 It shows the relationship with Figure 1 A similar process. However, the application of the first binder layer 3 differs from the above reference. Figure 1 Application of the first binder layer 3 disclosed.
[0128] Similar to Figure 1 , Figure 2 A method for producing a finished panel 10 is shown. The finished panel 10 can be adapted to be formed as an architectural panel, such as a floor panel, wall panel, furniture component, architectural component, work surface, etc. The finished panel 10 can be divided into individual panels and can be provided with a mechanical locking system configured to connect one panel to an adjacent panel.
[0129] As per the above reference Figure 1 As described above, a core 1 is provided. Core 1 is the referenced above. Figure 1 The type.
[0130] exist Figure 2In the example shown, the first binder 3a is applied in liquid form to the first surface 11 of the core 1. The first binder 3a can be a thermosetting binder, such as an amino resin, melamine-formaldehyde resin, or urea-formaldehyde resin. Thermosetting binders can be urea-formaldehyde, phenolic, melamine-formaldehyde, polyurethane, polyester, emulsion polymer isocyanate (EPI), or combinations thereof. Alternatively, the first binder 3a can be a thermoplastic binder. Thermoplastic binders can be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), polyvinyl alcohol (PVOH), polyvinyl butyral (PVB), and / or polyvinyl acetate (PVAc), or combinations thereof. The first binder 3a can include a hot melt or pressure-sensitive adhesive. The first binder 3a can be an acrylic resin or a methacrylic resin.
[0131] The first binder 3a is applied by an application device, such as a... Figure 2 Roller 21 is shown.
[0132] The first binder 3a can be less than 100g / m 2 The amount applied. In one example, the first binder 3a can be less than 300 g / m. 2 For example, 50-300g / m 2 For example, 100-250g / m 2 The first binder 3a is applied in the amount required to attach the first wood veneer layer 2 to the first surface 11 of the core. Excessive amounts of the first binder 3a are not necessary.
[0133] In one example, the first binder 3a is applied as a 50 / 50 solution, comprising 50% first binder 3a and 50% water, and the first binder 3a may be less than 200 g / m³. 2 The amount applied.
[0134] After applying the first binder 3a, one or more fillers 3b are applied to the first binder 3a. The filler can be applied using an application device such as a distributing device 22. The filler 3b can be an organic filler and / or an inorganic filler. Organic and inorganic fillers can be used in combination. The filler 3b can be an organic filler, such as wood particles, or other types of lignocellulose or cellulose particles. The filler can be an inorganic filler, such as barium sulfate, calcium carbonate, limestone, kaolin, etc., or combinations thereof. The filler concentration can be 50-150 g / m³. 2 The amount applied. In one example, it can be 75-300 g / m³. 2 The specified amount refers to the total amount of packing material applied. If more than one type of packing material is used, the specified amount refers to the total amount of packing material.
[0135] As a supplement or alternative, the fillers of the above type can be mixed with the first binder 3a.
[0136] The first binder 3a can be dried before the application of the second wood veneer layer 4. IR can be used to dry the first binder 3a. The first binder 3a can be dried before or after the application of filler 3b.
[0137] A first binder 3a and one or more fillers 3b are formed as a first binder layer 3 disposed on a first surface 11 of the core.
[0138] In addition to the first binder 3a and filler 3b, the first binder layer 3 may also contain additives and pigments.
[0139] After the first adhesive layer 3 has been applied to the core 1, the first wood veneer layer 2 is applied to the first adhesive layer 3, as shown in the reference above. Figure 1 The first adhesive layer 3 is located between the first surface 11 of the core 1 and the first wood veneer layer 2. The first wood veneer layer 2 is the one mentioned above. Figure 1 The type of description.
[0140] Before pressing, the first wood veneer layer may have a thickness of less than 1.5 mm. Before pressing, the thickness of the first wood veneer layer may be less than or equal to 1 mm, for example, less than or equal to 0.6 mm.
[0141] As an alternative or supplement, the first binder 3a may be applied to the surface of the first wood veneer layer 2 that is intended to face the first surface 11 of the core 1. Thereafter, the first wood veneer layer 2 is applied to the first surface 11 of the core 1, such that the first binder layer 3 is disposed between the first surface 11 of the core 1 and the first wood veneer layer 2.
[0142] As referenced above Figure 1 The second binder layer 5, comprising the second binder 5a, is applied. The second binder 5a and the second binder layer 5 are as described above. Figure 1 The type described, therefore not referenced. Figure 2 Detailed description.
[0143] As per the above reference Figure 1 The second wood veneer layer is applied onto the second adhesive layer 5. The second wood veneer layer is as described above. Figure 1 The type of description.
[0144] The second binder 5a can be applied to the surface of the first wood veneer layer 2 that faces the second wood veneer layer 4, such as... Figure 2 As shown, and refer to the above. Figure 1 The description is more detailed. Alternatively or as an addition, as described above, the second binder 5 may be applied to the surface of the second wood veneer layer 4 that is intended to face the first wood veneer layer 2.
[0145] After applying the first wood veneer layer 2, the second wood veneer layer 4, and an optional balancing layer ( Figure 2 (Not shown in the image) Afterwards, pressure and preferably heat are applied in press 40 to press the components together, thereby forming the veneered panel 10. The first wood veneer layer 2 and the second wood veneer layer 4 are pressed and attached to each other while being pressed and attached to the core 1. Preferably, no pre-pressing is performed for attaching the first wood veneer layer 2 to the second wood veneer layer 4.
[0146] The press 40 and pressing parameters can be referenced above. Figure 1 The description is the same. Pressure can be applied in either a continuous press or a static press.
[0147] During pressing, the first wood veneer layer 2 is attached to the core 1, and the second wood veneer layer 4 is attached to the first wood veneer layer 2.
[0148] The first wood veneer layer 2 and the second wood veneer layer 4 together may have a thickness of less than 2.5 mm. The first wood veneer layer 2 and the second wood veneer layer 4 may have a total thickness of less than or equal to 2 mm. After pressing, the first wood veneer layer 2 and the second wood veneer layer 4 may have a total thickness of less than or equal to 1.6 mm, for example, a total thickness of less than or equal to 1.2 mm.
[0149] As per the above reference Figure 1 During pressing, the first wood veneer layer 2 is pressed into at least one opening structure 8 in the second wood veneer layer 4. After pressing, the opening structure 8 is at least partially filled with the first wood veneer layer 2, which... Figure 3 It is shown in more detail below.
[0150] The above discussion regarding the opening structure 8 for filling the second wood veneer layer 4 also applies to... Figure 2 The method shown produces a decorative panel 10.
[0151] Furthermore, after pressing, the veneered panel 10 can be brushed. The veneered panel 10 can be brushed deeply. The veneer element 10 can be brushed to a depth extending into the first wood veneer layer 2. The veneer layer 10, comprising two wood veneer layers 2 and 4, can be brushed deeply to create a rougher appearance without exposing the underlying core 1. After brushing, the first wood veneer layer 2 is partially visible through the second wood veneer layer 4.
[0152] A protective layer or coating may be applied to the upper surface of the second wood veneer layer 2. In one example, the protective layer may include at least one lacquer layer, which may be applied after pressing. In another example, a protective layer in the form of a resin-impregnated coating may be applied to the upper surface of the second wood veneer layer 2 before pressing.
[0153] Figure 3 It shows the reference Figure 1or Figure 2 The described method produces a veneered panel 10. The veneered panel 10 includes a core 1, a first wood veneer layer 2 attached to the upper surface 11 of the core 1 via a first adhesive layer 3, a second wood veneer layer 4 attached to the first wood veneer layer 2 via a second adhesive layer 5, and a balancing layer 13 attached to the lower surface 12 of the core 1. The core 1, the first wood veneer layer 2, the second wood veneer layer 4, the first adhesive 3a, the first adhesive layer 3, the second adhesive 5a, and the second adhesive layer 5 are of the type described above and will not be described in detail further.
[0154] Figure 3 The opening structure 8 of the pressed second wood veneer panel 4 is shown in more detail. (As shown...) Figure 3 As shown, a portion of the first wood veneer layer 2 at least partially fills the opening structure 8 of the second wood veneer layer 4. Figure 3 As shown, the first wood veneer layer 2 can substantially fill the opening structure 8 of the second wood veneer layer 2. In Figure 3 In the open structure 8, the upper surface of the first wood veneer layer 2 is flush with the upper surface of the second wood veneer layer 4. In another example, the upper surface of the first wood veneer layer 2 may be located between the upper and lower surfaces of the second wood veneer layer 4. Preferably, the upper surface of the wood veneer layer 2 is closer to the upper surface of the second wood veneer layer 4 than to the lower surface of the second wood veneer layer 4.
[0155] The core 1, the first wood veneer layer 2, and the second wood veneer layer 4 all have planar extensions in the horizontal plane. The planar extensions of the core 1, the first wood veneer layer 2, and the second wood veneer layer 4 are parallel to each other.
[0156] In the above method, the first adhesive layer 3 can be applied to the core 1 and / or to the first wood veneer layer 2. The second adhesive layer 5 can be applied to the first wood veneer layer 2 and / or to the second wood veneer layer 4.
[0157] Example
[0158] Refer to Example 1:
[0159] The 400g / m³ of product contains 40% by weight wood fiber, 10% by weight alumina, 49.5% by weight melamine-formaldehyde resin, and 0.5% by weight carbon black. 2 The powder mixture was dispersed on a 10.0 mm HDF plate to form a sublayer. Using 20 g / m²... 2 An aqueous release agent solution was sprayed to form a powder layer for the sublayer. A 0.6 mm oak veneer layer was placed on the sublayer, and the assembly was then pressed for 30 seconds in a short-cycle press at 40 bar and a platen temperature of 160°C. The resulting product is HDF with a veneer, which has pores and cracks in the veneer layer filled with the cured powder mixture of the sublayer.
[0160] Example 2:
[0161] By approximately 150g / m 2 The amount of the first liquid binder, in the form of 50% by weight of melamine-formaldehyde dissolved in water, is applied by rolling on the first surface of the HDF board forming the core.
[0162] A first wood veneer layer is provided in the form of rotary-cut birch veneer panels with a thickness of 0.55 mm.
[0163] The second binder is applied to the first wood veneer panel. The second binder is in the form of 50% by weight melamine formaldehyde dissolved in water, which is applied by rolling at approximately 150 g / m². 2 The amount is applied.
[0164] A second wood veneer is provided in the form of a 0.57mm thick natural-grade sliced oak veneer. The second wood veneer layer includes an open structure in the form of holes, knots, and cracks.
[0165] The first and second binders are air-dried at low temperature to a moisture content of approximately 6-10% by weight.
[0166] A first wood veneer layer is applied to an HDF board, wherein a dried first adhesive is disposed between the HDF board and the first wood veneer layer. A second wood veneer layer is applied to the first wood veneer layer, wherein a dried second adhesive is disposed between the first wood veneer layer and the second wood veneer layer.
[0167] The components are pressed in a static press with the following pressing parameters:
[0168] Temperature: 190℃
[0169] - Pressure: 50 bar
[0170] - Compression time: 45 seconds
[0171] Heat transfer is sufficient to cure the first and second adhesives, achieving complete adhesion between the HDF board, the first wood veneer layer, and the second wood veneer layer. The first wood veneer layer partially fills the openings in the second wood veneer layer.
[0172] Example 3:
[0173] A powder mixture containing a first binder in the form of melamine-formaldehyde powder, as specified in the table below, is dispersed on the surface of the HDF board forming the core. The amount of powder mixture applied is approximately 300 g / m². 2 .
[0174] A first wood veneer layer is provided in the form of rotary-cut birch veneer panels with a thickness of 0.55 mm.
[0175] The second binder is applied to the first wood veneer panel. The second binder is in the form of 50% by weight melamine formaldehyde dissolved in water, which is applied by rolling at approximately 150 g / m². 2 The amount applied.
[0176] The second binder is air-dried at low temperature until the moisture content is about 6-10% by weight.
[0177] A second wood veneer is provided in the form of a 0.57mm thick natural-grade sliced oak veneer. The second wood veneer layer includes an open structure in the form of holes, knots, and cracks.
[0178] A first wood veneer layer is applied to the HDF board, wherein a dried first adhesive is disposed between the core and the first wood veneer layer. A second wood veneer layer is applied on top of the first wood veneer layer, wherein a dried second adhesive is disposed between the first wood veneer layer and the second wood veneer layer.
[0179] The components are pressed in a static press with the following pressing parameters:
[0180] Temperature: 190℃
[0181] - Pressure: 50 bar
[0182] - Compression time: 45 seconds
[0183] The heat transfer is sufficient to cure the binder of the powder mixture layer and achieve complete adhesion between the powder mixture, the HDF board, and the first wood veneer layer. Complete adhesion is also achieved between the first and second wood veneer layers. Supported by the powder layer, the first wood veneer layer fills the openings in the second wood veneer layer.
[0184] Powder mixture weight% Binder: Melamine-formaldehyde 52 Organic filler: wood fiber 33.5 Inorganic filler: calcium carbonate 9.5 pigment 5
[0185] Example 4: Compression
[0186] Press the wood veneer layers from the timber species listed in the table below at 50 bar for 30 seconds. The temperature of the upper press plate is 160°C. The lower press plate is not heated. Measure the thickness of the wood veneer layers before and after pressing, and calculate the compression ratio as a percentage by dividing the pressed thickness by the original thickness.
[0187]
Claims
1. A method for producing a veneered panel (10), comprising: Provide core (1); Provide the first wood veneer layer (2); Provide a second wood veneer layer (4) having at least one open structure (8); The first wood veneer layer (2) is disposed on the first surface (11) of the core (1) using a first binder layer (3) comprising a first binder (3a) and at least one filler (3b), the first binder layer being applied between the first surface (11) of the core (1) and the first wood veneer layer (2); The second wood veneer layer (4) is disposed on the first wood veneer layer (2) using a second binder layer (5) containing a second binder (5a), and the second binder layer is applied between the first wood veneer layer (2) and the second wood veneer layer (4); The core (1), the first wood veneer layer (2), and the second wood veneer layer (4) are pressed together to form a veneered panel (10). During pressing, the first wood veneer layer (2) is pressed into at least one opening structure (8) of the second wood veneer layer (4), and after pressing, the first wood veneer layer (2) at least partially fills the at least one opening structure (8) of the second wood veneer layer (4).
2. The method according to claim 1, wherein, The second wood veneer layer (4) is formed as the uppermost veneer layer of the veneered panel (10).
3. The method according to claim 1, wherein, The first wood veneer layer (2) has a thickness of less than or equal to 1 mm before pressing.
4. The method according to claim 1, wherein, The first wood veneer layer (2) has a thickness of less than or equal to 0.6 mm before pressing.
5. The method according to any one of claims 1 to 4, wherein, The first wood veneer layer (2) and the second wood veneer layer (4) have a total thickness of less than or equal to 1.6 mm after pressing.
6. The method according to claim 5, wherein, The first wood veneer layer (2) and the second wood veneer layer (4) have a total thickness of less than or equal to 1.2 mm after pressing.
7. The method according to any one of claims 1 to 4, wherein, The first binder (3a) is applied in powder form.
8. The method according to any one of claims 1 to 4, wherein, The first binder (3a) is applied in liquid form and dried before pressing.
9. The method according to any one of claims 1 to 4, wherein, The second wood veneer layer (4) is a sliced wood veneer layer.
10. The method according to any one of claims 1 to 4, wherein, The first wood veneer layer (2) is a rotary-cut wood veneer layer.
11. The method according to any one of claims 1 to 4, wherein, The second wood veneer layer (4) includes oak veneer panels.
12. The method according to any one of claims 1 to 4, wherein, The first wood veneer layer (2) includes birch veneer panels.
13. The method according to any one of claims 1 to 4, further comprising brushing the first wood veneer layer (2) and the second wood veneer layer (4) after pressing to a brushing depth extending into the first wood veneer layer (2).
14. The method according to any one of claims 1 to 4, wherein, The first binder (3a) is less than 300 g / m 2 The amount applied.
15. The method according to any one of claims 1 to 4, wherein, The first binder (3a) is at less than 100 g / m 2 The amount applied.
16. The method according to any one of claims 1 to 4, wherein, The second binder (5a) is less than 150 g / m 2 The amount applied.
17. The method according to any one of claims 1 to 4, wherein, The second binder (5a) is less than 100 g / m 2 The amount applied.
18. The method according to any one of claims 1 to 4, wherein, Suppression involves applying a pressure of at least 20 bar at a temperature of at least 160°C for a period of at least 10 seconds.
19. The method according to any one of claims 1 to 4, wherein, Compression involves applying 20-100 bar of pressure at a temperature of 160-250°C for a period of 10-100 seconds.
20. A panel (10) with a decorative finish produced using the method according to claim 1, comprising: Core (1); A first wood veneer layer (2) disposed on a first surface (11) of the core (1), wherein the first wood veneer layer (2) is attached to the core (1) by a first adhesive layer (3) disposed between the first surface (11) of the core (1) and the first wood veneer layer (2), the first adhesive layer (3) comprising a first adhesive (3a) and at least one filler (3b); and A second wood veneer layer (4) is disposed on the first wood veneer layer (2), wherein the second wood veneer layer (4) is attached to the first wood veneer layer (2) by a second adhesive layer (5) disposed between the first wood veneer layer (2) and the second wood veneer layer (4), wherein the second wood veneer layer (4) has at least one opening structure (8). The first wood veneer layer (2) at least partially fills the at least one opening structure (8) of the second wood veneer layer (4).
21. The panel with a decorative finish according to claim 20, wherein, The second wood veneer layer (4) is formed as the uppermost veneer layer of the veneered panel (10).
22. The panel with a decorative finish according to claim 20, wherein, The first wood veneer layer (2) has a thickness of less than 1 mm.
23. The veneered panel according to any one of claims 20 to 22, wherein, The total thickness of the first wood veneer layer (2) and the second wood veneer layer (4) is less than or equal to 1.6 mm.
24. The panel with a decorative finish according to any one of claims 20 to 22, wherein, The total thickness of the first wood veneer layer (2) and the second wood veneer layer (4) is less than or equal to 1.2 mm.
25. The panel with a decorative finish according to any one of claims 20 to 22, wherein, The second wood veneer layer (4) is a sliced wood veneer layer.
26. The panel with a decorative finish according to any one of claims 20 to 22, wherein, The first wood veneer layer (2) is a rotary-cut wood veneer layer.
27. The panel with a decorative finish according to any one of claims 20 to 22, wherein, The second wood veneer layer (4) includes oak veneer panels.
28. The veneered panel according to any one of claims 20 to 22, wherein, The first wood veneer layer (2) includes birch veneer panels.