Method for producing building component and building component

Abstract

The present disclosure relates to a method of manufacturing a building component (10) comprising applying a first layer (1) on a first surface of a substrate (2), the first layer (1) comprising a mixture of a binder, at least one filler, and fine non-pigment cohesive particles wherein the amount of fine non-pigment cohesive particles in the mixture may be 0.05 to 9 wt% of the mixture, and applying heat and / or pressure to the first layer (1) and / or the substrate (2), thereby forming the building element (10). The disclosure further relates to such a building element (10).

Description

[0001] This application is a divisional application of the Chinese invention patent application entitled “Method for Manufacturing Building Components and Building Components”, with an application date of January 9, 2020, application number 202080007885.1, and international application number PCT / SE2020 / 050010. Technical Field

[0002] Embodiments of the present invention relate to a method of manufacturing a building element and a building element. Technical Background

[0003] There are several different types of floor coverings with a wooden surface. Solid wood flooring consists of solid wooden planks. Engineered wood flooring consists of a wooden surface layer glued to a core layer. The core layer can be a lamella core or a wood-based panel such as plywood, MDF, or HDF. As an example, the wooden surface layer can have a thickness of 2-10 mm.

[0004] Wooden floor coverings can also be formed by gluing a wood veneer to a substrate, for example a wood-based panel such as particleboard, MDF, or HDF. A wood veneer is a thin layer of wood, for example with a thickness of 0.2-1 mm. Floors with a separate surface layer glued to a core layer of, for example, HDF or plywood are more resistant to moisture than solid wood floors.

[0005] Compared to solid wood flooring and engineered wood flooring, wood veneer flooring can be produced at a lower cost because only thin layers of wood are used.

[0006] A new type of floor covering has recently been developed which has a solid surface comprising a substantially homogeneous mixture of wood particles, a binder and wear resistant particles. Such floor coverings and building panels are marketed under the trade mark sell.

[0007] The panels are produced using a method in which a mixture comprising wood flour, a binder such as melamine formaldehyde, and optionally wear-resistant particles is applied in powder form to a core layer. Such a method is disclosed in WO 2009 / 065769. A method for controlling curing loss in such a method is disclosed in US 2012 / 0263878.

[0008] The mixture is spread as a dry powder over a wood core layer, such as HDF. It has been shown that wood flour has a relatively low flowability in low-stress environments (e.g., from large bags, air conveyed, and spread). For example, it is difficult to evenly spread wood flour over a substrate without leaving bare areas without wood flour, areas with less powder, or areas with too much powder applied. This is due to the fact that wood flour forms bridges and ratholing during low-stress processes. Rattling refers to the emptying of material from the center of a hopper or silo, leaving material at the periphery.

[0009] Both behaviors are attributed to the particle texture, shape and density, which in the case of wood flour increase the risk of mechanical interlocking, bridging or voiding. Wood flour particles or fibers are rough, have kinks and fibrils, are fibrous and therefore far from spherical, and the particles are not dense enough to induce gravity to break bridges.

[0010] The binder, which is the other main component of the mixture, generally comprises particles that are at least more free-flowing than the wood flour.

[0011] After the mixture has been applied to the core layer, it is then cured under heat and pressure into a 0.1-1.0 mm thick surface layer arranged on the core layer. When the melamine formaldehyde resin is cured, the shrinkage of the melamine formaldehyde resin causes tension in this layer. The internal stresses formed in this layer can cause warping of the panel. The tension on the front of the panel must be compensated by counter-tension on the back of the panel. Therefore, a balancing layer is usually arranged on the back of the core layer opposite to this layer. The balancing layer is suitable for balancing the shrinkage and expansion caused by pressing, cooling and climate changes. The balancing layer can be resin-impregnated paper or a powder formed from a mixture containing wood flour and a thermosetting binder.

[0012] US2005 / 0250879 relates to powder coating films formed by melting or flowing powder coating particles into a cohesive layer, followed by solidification of the components to form a continuous film. The powder composition comprises a mixture of ingredients as unbound discrete particles having an average particle size of 1 to 25 μm in a raw mix. The raw mix comprises a film-forming (co)polymer or resin.

[0013] Overview

[0014] It is an object of at least some embodiments of the present invention to provide improvements over the above-described techniques and known techniques.

[0015] It is another object of at least some embodiments of the present invention to optimize methods of producing building elements.

[0016] It is another object of at least some embodiments of the present invention to make the method more cost-effective and thereby reduce the cost of the building element while maintaining good quality.

[0017] It is another object of at least some embodiments of the present invention to apply a layer having a uniform thickness.

[0018] It is another object of at least some embodiments of the present invention to improve the shape of building elements.

[0019] At least some of these and other objects and advantages apparent from the specification are achieved by at least some of the aspects disclosed below.

[0020] In a first aspect, a method of making a building element is disclosed, comprising applying a first layer on a first surface of a substrate, the first layer comprising a mixture of a binder, at least one filler, and cohesive particles, and applying heat and / or pressure to the first layer and / or the substrate, thereby forming the building element.

[0021] The cohesive particles may be fine cohesive particles.Fine particles may be defined as at least 70% of the particles having a length in their largest dimension of 2.5 μm or less, such as a length in their largest dimension of 0.1 μm to 2.5 μm.

[0022] The amount of cohesive particles in the mixture may be between 0.05 wt% and 9 wt%.

[0023] Cohesive particles can be non-pigment cohesive particles. Non-pigment cohesive particles can mean that particles are not conventional pigments, such as titanium pigments, carbon black, iron oxide pigments, copper pigments, etc. An example of conventionally used titanium pigments is titanium dioxide. Non-pigment cohesive particles can be particles with a low ability to change the color of reflected light or transmitted light due to wavelength selective absorption. Therefore, cohesive particles are not used in the sense of pigments as a rule in this industry. Conventional pigments can have a size less than 500nm. Reflective pigments, such as white pigments, have a size (such as 300-400nm) larger than absorbing pigments.

[0024] The cohesive particles may be fine non-pigment cohesive particles.

[0025] It should be understood that cohesive particles are particles that exhibit cohesive attraction or cohesion. Cohesion is the action or property of particles sticking together, attracting each other, or the like. This is an inherent property of matter caused by the shape and structure of at least one particle, forming an electrical attraction that maintains the microstructure. In other words, cohesion can reduce surface energy by creating a bulk-like atmosphere for the molecules on the particle surface.

[0026] One advantage of the first aspect is that the fine cohesive particles, due to their cohesive nature, tend to coat fillers, such as wood flour, including wood fibers or wood particles, to fill cavities, pores, kinks, and fibrils. Thus, the cohesive particles make the wood particles smoother and less prone to mechanical interlocking. Thus, the risk of bridging and / or cavitation, as explained above, is at least reduced.

[0027] When bridging and / or cavitation is reduced, the risk of uneven application of the mixture to the substrate is at least reduced. Thus, the first layer can have a uniform thickness throughout its entire extent. This uniform thickness is aesthetically desirable and also contributes to the balance of the first layer. If the first layer has a uniform thickness, the force required by the balancing layer to counteract the forces generated by the first layer during and / or after curing is reduced. This allows the amount of binder in the balancing layer to be reduced.

[0028] Due to their high cohesive behavior, cohesive particles usually exhibit poor flowability. Fillers, such as wood flour, exhibit poor flowability due to the high risk of mechanical interlocking. However, it has been surprisingly found and shown in this article that, by a specific concentration of the cohesive particles in the mixture, these two different properties can be balanced to surprisingly improve flowability. If the amount of the cohesive particles in the mixture is too low, the mechanical interlocking properties of the wood flour will prevail, resulting in low flowability. If the amount of the cohesive particles in the mixture is too high, the cohesive properties of the cohesive particles will prevail, resulting in low flowability. The amount of cohesive particles should be balanced to improve flowability. The amount of the fine non-pigment cohesive particles in the mixture can be from 0.05% by weight to 9% by weight of the mixture.

[0029] One advantage is that the heat and / or pressure treated first layer has substantially the same thickness throughout its extension, preferably in its longitudinal and transverse extension.

[0030] One advantage of increased flowability is that the mixture is more evenly distributed on the substrate.

[0031] The cohesion force of the cohesive particles, such as fine non-pigment cohesive particles, may exceed the cohesive force of the at least one filler. Thus, the cohesive particles tend to coat the filler.

[0032] The cohesive force of the cohesive particles, such as fine non-pigment cohesive particles, can be at least 0.25 kPa, such as 0.25 to 3 kPa, as measured using a standard Shear Cell Program, 50 mm shear, 6 kPa (FT4 Powder Rheometer). The standard Shear Cell Program is a standard program for a Freeman Technology FT4 Powder Rheometer. When wood flour is used as a filler, the cohesive force of the wood flour containing wood fibers can be 0.25 kPa when measured using the standard Shear Cell Program.

[0033] The mixture may be provided in dry form.

[0034] The mixture can be applied to the substrate in dry form.

[0035] The mixture may be a dry powder.

[0036] The amount of cohesive particles, such as fine non-pigment cohesive particles, in the mixture may be between 0.2% and 4.5% by weight.

[0037] The amount of cohesive particles, such as fine non-pigment cohesive particles, in the mixture may be between 0.5 wt% and 5 wt%, such as between 2 wt% and 4 wt%.

[0038] At least 70% of the cohesive particles, such as fine non-pigment cohesive particles, may have a length in their largest dimension of 2.5 μm or less, preferably a length in their largest dimension of 0.1 μm to 2.5 μm.

[0039] Cohesive particles, such as fine non-pigment cohesive particles, may have a length in their largest dimension of 2.5 μm or less, preferably a length in their largest dimension of 0.1 μm to 2.5 μm.

[0040] Cohesive particles, such as fine non-pigment cohesive particles, may have a refractive index (RI) of less than 1.9.

[0041] Cohesive particles, such as fine non-pigmentary cohesive particles, may be selected from silicates, such as aluminum silicate or silicon oxides, such as SiO2.

[0042] SiO2 can be provided as fumed silica.

[0043] The cohesive particles, for example the fine non-pigment cohesive particles may be calcium carbonate.

[0044] The cohesive particles, for example the fine non-pigment cohesive particles may be barium sulfate.

[0045] The cohesive particles, for example the fine non-pigment cohesive particles may be polytetrafluoreten.

[0046] The at least one filler may be or comprise fibers.

[0047] The at least one filler may comprise wood flour. The wood flour may comprise wood fibers or wood particles. The wood fiber particle size may be 0-300 μm, such as 0-150 μm. The wood fiber particle size may be 10-300 μm, such as 10-150 μm.

[0048] The adhesive may be a thermosetting adhesive or a thermoplastic adhesive.

[0049] The binder may be a urea-formaldehyde resin, a mixture comprising a urea-formaldehyde resin, or a copolymer comprising a urea-formaldehyde resin, a phenol-formaldehyde resin, a mixture comprising a phenol-formaldehyde resin, or a copolymer comprising a phenol-formaldehyde resin, a melamine-formaldehyde resin, a mixture comprising a melamine-formaldehyde resin, or a copolymer comprising a melamine-formaldehyde resin, or a mixture thereof.

[0050] The first layer may further comprise wear resistant particles.

[0051] The first layer may further comprise pigment particles.

[0052] The substrate may be selected from wood-based board, particle board, thermoplastic board, plywood, veneer core, veneer layer.

[0053] The first layer may be permanently attached to the substrate, thereby forming a building panel.

[0054] Building panels can be floor or wall panels.

[0055] The method may further comprise applying a surface layer as a second layer on the first layer.

[0056] The method may further comprise applying a balancing layer on a second surface of the substrate, the second surface being opposite the first surface of the substrate.

[0057] In a second aspect, a building element is provided. The building element comprises a first layer disposed on a substrate, the first layer being formed from a mixture comprising a binder, at least one filler, and cohesive particles, wherein the building element is formed by applying heat and / or pressure.

[0058] The building element may be cured by application of heat and / or pressure.

[0059] The cohesive particles may be fine cohesive particles.Fine particles may be defined as at least 70% of the particles having a length in their largest dimension of 2.5 μm or less, such as a length in their largest dimension of 0.1 μm to 2.5 μm.

[0060] The amount of cohesive particles in the mixture may be between 0.05 wt% and 9 wt%.

[0061] Cohesive particles can be non-pigment cohesive particles. Non-pigment cohesive particles can mean that particles are not conventional pigments, such as titanium pigments, carbon black, iron oxide pigments, copper pigments, etc. An example of conventionally used titanium pigments is titanium dioxide. Non-pigment cohesive particles can be particles with a low ability to change the color of reflected light, absorbed light, or transmitted light due to wavelength selective absorption. Therefore, cohesive particles are not used in the sense of pigments as a rule in this industry. Conventional pigments can have a size less than 500nm. Reflective pigments, such as white pigments, have a size (such as 300-400nm) larger than absorbing pigments.

[0062] The cohesive particles may be fine non-pigment cohesive particles.

[0063] It should be understood that cohesive particles are particles that exhibit cohesive attraction or force. Cohesion is the action or property of particles sticking together, attracting each other, or the like. This is an inherent property of matter caused by the shape and structure of at least one particle, creating an electrical attraction that maintains the microstructure. In other words, cohesion can reduce surface energy by creating a packing-like environment for molecules on the particle surface.

[0064] The second aspect comprises all the advantages of the first aspect discussed previously, whereby the previous discussion also applies to the building element.

[0065] The cohesion of the cohesive particles, such as fine non-pigment cohesive particles, may exceed the cohesion of the at least filler.

[0066] The cohesive force of the cohesive particles, such as fine non-pigment cohesive particles, may be at least 0.25 kPa, such as 0.25 to 3 kPa, as measured using a Standard Shear Cell Program, 50 mm shear 6 kPa (FT4 Powder Rheometer). The Standard Shear Cell Program is a standard program for a Freeman Technology FT4 Powder Rheometer.

[0067] The mixture may be provided in dry form.

[0068] The mixture can be applied to the substrate in dry form.

[0069] The mixture may be a dry powder.

[0070] The amount of cohesive particles, such as fine non-pigment cohesive particles, in the mixture may be between 0.2% and 4.5% by weight.

[0071] The amount of cohesive particles, such as fine non-pigment cohesive particles, in the mixture may be between 0.5 wt% and 5 wt%, such as between 2 wt% and 4 wt%.

[0072] At least 70% of the cohesive particles, such as fine non-pigment cohesive particles, may have a length in their largest dimension of 2.5 μm or less, preferably a length in their largest dimension of 0.1 μm to 2.5 μm.

[0073] Cohesive particles, such as fine non-pigment cohesive particles, may have a length in their largest dimension of 2.5 μm or less, preferably a length in their largest dimension of 0.1 μm to 2.5 μm.

[0074] Cohesive particles, such as fine non-pigment cohesive particles, may have a refractive index (RI) of less than 1.9.

[0075] Cohesive particles, such as fine non-pigmentary cohesive particles, may be selected from silicates, such as aluminum silicate or silicon oxides, such as SiO2.

[0076] SiO2 can be provided as fumed silica.

[0077] The cohesive particles, for example the fine non-pigment cohesive particles may be calcium carbonate.

[0078] The cohesive particles, for example the fine non-pigment cohesive particles may be barium sulfate.

[0079] The cohesive particles, for example the fine non-pigment cohesive particles may be polytetrafluoreten.

[0080] The at least one filler may comprise wood flour. The wood flour may comprise wood fibers or wood particles.

[0081] The adhesive may be a thermosetting adhesive or a thermoplastic adhesive.

[0082] The binder may be a urea-formaldehyde resin, a mixture comprising a urea-formaldehyde resin, or a copolymer comprising a urea-formaldehyde resin, a phenol-formaldehyde resin, a mixture comprising a phenol-formaldehyde resin, or a copolymer comprising a phenol-formaldehyde resin, a melamine-formaldehyde resin, a mixture comprising a melamine-formaldehyde resin, or a copolymer comprising a melamine-formaldehyde resin, or a mixture thereof.

[0083] The first layer may further comprise wear resistant particles.

[0084] The first layer may further comprise pigment particles.

[0085] The substrate may be selected from wood board, particle board, thermoplastic board, plywood, veneer core, veneer layer.

[0086] The first layer may be permanently attached to the substrate, thereby forming a building panel.

[0087] Building panels can be floor or wall panels.

[0088] The building panel may further comprise a surface layer on the first layer as a second layer.

[0089] The building panel may further comprise a balancing layer disposed on a second surface of the substrate, the second surface being opposite the first surface of the substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0090] Embodiments of the present invention are described in more detail by way of example with reference to the accompanying schematic drawings which show embodiments of the invention.

[0091] Figure 1A A method of producing a building element is shown.

[0092] Figure 1B One embodiment of a building element is shown.

[0093] Figure 1C One embodiment of a building element is shown.

[0094] Figure 1D One embodiment of a building element is shown.

[0095] Figure 2A Reference powder compositions are shown.

[0096] Figure 2B An exemplary powder composition according to one embodiment of the present invention is shown.

[0097] Figure 3A The results of the free-fall test of Sample A and Sample F in Example 1 are shown.

[0098] Figure 3B The results of the spreading experiment of Sample A and Sample F in Example 2 are shown.

[0099] Figure 4A Shows the permeability results for selected fine non-pigment cohesive particles compared to a reference sample.

[0100] Figure 4B Display depends on Mikhart Permeability results are represented by the concentration of calcium carbonate.

[0101] Figure 4C Display depends on Polygloss Permeability results for the concentration of representative fine high-brightness aluminum silicate.

[0102] Details

[0103] Disclosed herein is a method of making a building element 10 comprising applying a first layer 1 comprising a mixture of a binder, at least one filler, and cohesive particles 4 to a first surface of a substrate 2, applying heat and / or pressure to the first layer and / or the substrate, thereby forming the building element 10.

[0104] Now refer to Figure 1A -D describes a method of manufacturing a building element 10 and the building element 10 formed thereby.

[0105] The building element 10 may be a building panel, such as a floor, ceiling, wall panel, door panel, countertop, furniture component or part of a furniture component, skirting board, molding, trim profile, or the like.

[0106] The method includes providing a substrate 2. The substrate is preferably a prefabricated substrate produced prior to the method for manufacturing building element 10. The substrate may include at least one wood veneer layer. The substrate may include several wood veneer layers, such as plywood. Preferably, the veneered element includes an odd number of wood veneer layers. The substrate may include a wood-based panel. The wood-based panel may be selected from HDF, MDF, OSB, veneer core, and solid wood. The substrate may be a thermoplastic board. The substrate may include a thermoplastic material. The substrate may be a mineral composite board. The substrate may be a fiber cement board. The substrate may include a sheet material, such as a sheet of paper or nonwoven material, or a conveyor. The substrate is preferably a prefabricated substrate produced prior to the method for manufacturing building element 10. The wood-based panel may be a wood fiber-based board, such as MDF, HDF, particleboard, or plywood. The substrate may be a wood plastic composite (WPC). The substrate may be a mineral composite board. The substrate may be a magnesium oxide cement board. The substrate may be a ceramic board. The substrate may be a plastic board, such as a thermoplastic board.

[0107] The substrate 2 may be a carrier such as paper, a nonwoven sheet or a wood veneer.

[0108] The building element 10 is a building panel when the first layer 1 is permanently attached to the substrate 2. Permanently means that the substrate cannot be separated from at least the first layer after they have been attached to the substrate by application of heat and / or pressure.

[0109] When the substrate is a temporary carrier, such as paper or a nonwoven sheet or a conveyor belt, the first layer is reversibly attached to the substrate 10. Reversible means that at least the first layer 1 can be separated from the substrate 2 after application of heat and / or pressure.

[0110] The substrate 2 has two surfaces. The first surface faces the first layer 1. The second surface is the surface of the substrate 2 opposite the first surface. If a balancing layer 5 is optionally applied to the substrate, the second surface of the substrate 2 faces the balancing layer 5.

[0111] According to another aspect, the method further comprises applying a balancing layer 5 on a second surface of the substrate 2 , the second surface being opposite to the first surface of the substrate 2 .

[0112] The balancing layer 5 may be a powder-based balancing layer applied as a powder. The powder-based balancing layer may comprise wood particles, such as lignocellulose and / or cellulose particles, and a binder, preferably a thermosetting binder, such as an amino resin. The balancing layer may be a resin-impregnated paper, preferably impregnated with a thermosetting binder. The balancing layer may have the same composition as the first layer 1.

[0113] A first layer 1 is applied to a first surface of a substrate 2. Figure 1A The first layer 1 is shown in FIG. 1 as being applied by spreading.

[0114] The first layer 1 is formed from a mixture comprising a binder, at least one filler and cohesive particles.

[0115] The mixture is applied in dry form. The mixture is preferably applied in dry powder form.

[0116] The at least one filler can be particles or fibers, such as wood fibers or particles, or mineral particles or fibers. The wood particles can be lignocellulose particles and / or cellulose particles. The wood particles can be at least partially bleached or have a natural wood color. The particles can also be colored before they are added to the mixture. The filler can be rice, straw, corn, jute, linen, cotton, hemp, bamboo particles or fibers. The filler can be metal, ceramic filler, composite filler, etc.; for example, silicate or silicon oxide.

[0117] In the following, particles and fibers will be used as an alternative.

[0118] More than one filler may be present in the mixture.The mixture may comprise a combination of two or more of the fillers discussed above.

[0119] The adhesive may be a thermosetting or thermoplastic adhesive.

[0120] The first layer 1 may comprise a thermosetting binder. The thermosetting binder may be an amino resin, such as melamine formaldehyde, urea formaldehyde or a combination thereof. The thermosetting binder may be phenol formaldehyde.

[0121] The first layer 1 may include a thermoplastic adhesive. The thermoplastic adhesive may be polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), polyvinyl alcohol (PVOH), polyvinyl butyral (PVB), and / or polyvinyl acetate (PVAc), or a combination thereof. The thermoplastic adhesive simultaneously bonds the first surface of the substrate 2 to the first layer 1.

[0122] According to another aspect, the first layer 1 may comprise as thermosetting binder a urea-formaldehyde resin, a mixture comprising a urea-formaldehyde resin or a copolymer comprising a urea-formaldehyde resin, a phenol-formaldehyde resin, a mixture comprising a phenol-formaldehyde resin or a copolymer comprising a phenol-formaldehyde resin, a melamine-formaldehyde resin, a mixture comprising a melamine-formaldehyde resin or a copolymer comprising a melamine-formaldehyde resin, or a mixture thereof.

[0123] The mixture may further comprise cohesive particles, such as fine non-pigment cohesive particles.

[0124] A particle is a powder component having a discrete amount of matter and a surface relative to the surrounding environment, meaning a single discrete component or two or more such components chemically or physically bound together by a coupling agent to form one solid unit of greater mass and / or size.

[0125] The cohesive particles may be fine cohesive particles.

[0126] The cohesive particles may be non-pigment particles, such as fine non-pigment cohesive particles.

[0127] Cohesive particles, such as fine non-pigment cohesive particles, may be selected from silicates, silicon oxides, calcium carbonate, barium sulfate, polytetrafluoreten.

[0128] The cohesive particles, such as fine non-pigmentary cohesive particles, may be selected from silicates, such as aluminum silicate, magnesium silicate or silicon oxide, preferably SiO2, preferably as fumed silica.

[0129] Cohesive particles, such as fine non-pigmented cohesive particles, may be selected from calcium carbonate (CaCO3, such as Mikhart ), barium sulfate such as BaSO4BB30EX, aluminum silicate such as Polygloss Hydrated magnesium silicate, calcined aluminum silicate (fired raw kaolin with reduced water of crystallization content), polytetrafluoreten such as and fumed silica such as HDK

[0130] It should be understood that cohesive particles are particles that exhibit cohesive attraction or force. Cohesion is the action or property of particles sticking together, attracting each other, or the like. This is an inherent property of matter caused by the shape and structure of at least one particle, creating an electrical attraction that maintains the microstructure. In other words, cohesion can reduce surface energy by creating a packing-like environment for molecules on the particle surface.

[0131] Fine particles are generally understood to mean that at least 70% of the particles have a length in their largest dimension of 2.5 μm or less, preferably the particles have a length in their largest dimension of 2.5 μm or less.

[0132] Fine cohesive particles, such as fine non-pigment cohesive particles, are therefore particles in which at least 70% of the particles have a particle size of 0.1 μm to 2.5 μm, preferably a length in their largest dimension, so that the particles have a particle size of 0.1 μm to 2.5 μm, preferably a length in their largest dimension.

[0133] The cohesion of the cohesive particles may exceed the cohesion of the at least one filler so that the cohesive particles coat the filler. The cohesion of the cohesive particles may be at least 0.25 kPa, such as 0.25-3 kPa, as measured using a standard Shear Cell Program, 50 mm shear 6 kPa (FT4 Powder Rheometer).

[0134] According to one aspect, the cohesive particles, such as fine non-pigment cohesive particles, in the first layer are present in the mixture in an amount of 0.05% to 9% by weight.

[0135] Preferably, the amount of cohesive particles, such as fine non-pigment cohesive particles, in the mixture may be between 0.3 wt% and 8.5 wt%, preferably between 1 wt% and 7 wt%, preferably between 2 wt% and 6 wt%, preferably between 4 wt% and 5 wt%.

[0136] In one embodiment, the amount of non-pigment cohesive particles in the mixture may be about 7.5% by weight.

[0137] In one embodiment, the amount of non-pigment cohesive particles in the mixture may be about 2.5% by weight.

[0138] In one aspect, the amount of cohesive particles, such as fine non-pigment cohesive particles, in the mixture can be between 0.2 wt% and 4.5 wt%, preferably between 0.2 wt% and 2.5 wt%.

[0139] In one aspect, the amount of cohesive particles, such as fine non-pigment cohesive particles, in the mixture may be between 0.3 wt% and 5 wt%, preferably between 0.5 wt% and 5 wt%, more preferably between 2 wt% and 4 wt%.

[0140] In one embodiment, the amount of non-pigment cohesive particles in the mixture may be about 0.1 wt%.

[0141] According to another aspect, the fine non-pigmentary cohesive particles are selected from silicates, such as aluminum silicates or silicon oxides, preferably SiO2, preferably as fumed silica.

[0142] In particular, if aluminum silicate is used as the fine non-pigment cohesive particles, the amount of aluminum silicate in the mixture may be between 0.5% and 9% by weight, such as between 0.5% and 5% by weight, and preferably between 2% and 4% by weight. In one aspect, the amount of aluminum silicate in the mixture may be between 0.3% and 5% by weight.

[0143] If fumed silica, such as SiO2, is used as the fine non-pigmentary cohesive particles, the amount of silicon oxide in the mixture may be between 0.05% and 3% by weight, preferably between 0.05% and 0.7% by weight, such as between 0.1% and 0.7% by weight, preferably between 0.3% and 0.7% by weight.

[0144] Preferably, the fine non-pigment cohesive particles may be selected from calcium carbonate (CaCO3, such as Mikhart C), BaSO4 BB30EX, Polygloss (aluminum silicate), hydrated magnesium silicate, calcined aluminum silicate (fired raw kaolin with reduced water of crystallization content), (polytetrafluoreten) and HDK (fumed silica).

[0145] If calcium carbonate is used as the fine non-pigment cohesive particles, the amount of calcium carbonate in the mixture can be between 0.3% and 9% by weight, preferably between 0.3% and 5% by weight, such as between 0.5% and 5% by weight, preferably between 2% and 4% by weight. In one aspect, the amount of calcium carbonate in the mixture can be between 0.5% and 9% by weight.

[0146] If barium sulfate is used as the fine non-pigment cohesive particles, the amount of calcium carbonate in the mixture can be between 0.3% and 9% by weight, preferably between 0.3% and 5% by weight, such as between 0.5% and 5% by weight, and preferably between 2% and 4% by weight. In one aspect, the amount of barium sulfate in the mixture can be between 0.5% and 9% by weight.

[0147] If polytetrafluoreten is used as the fine non-pigment cohesive particles, the amount of calcium carbonate in the mixture can be between 0.3% and 9% by weight, preferably between 0.3% and 5% by weight, such as between 0.5% and 5% by weight, and preferably between 2% and 4% by weight. In one aspect, the amount of polytetrafluoreten in the mixture can be between 0.5% and 9% by weight.

[0148] According to another aspect, SiO2 is fumed silicon dioxide.

[0149] In one aspect, the first layer may further comprise a pigment.

[0150] In another aspect, the first layer can be substantially free of pigment.

[0151] Preferably, the cohesive particles, such as fine non-pigment cohesive particles, have a refractive index (RI) of less than 1.9, such as 1.0-1.9. When the refractive index is equal to or less than 1.9, the fine non-pigment cohesive particles are less likely to discolor the first layer than particles having a refractive index greater than 1.9. Thus, the fine non-pigment cohesive particles according to certain embodiments of the present invention do not significantly affect certain properties of the first layer, such as color.

[0152] Preferably, the cohesive particles, such as fine non-pigment cohesive particles, have a refractive index of about 1.56, such as the cohesive particles are aluminum silicate.

[0153] Preferably, the cohesive particles, such as fine non-pigmented cohesive particles, have a refractive index of about 1.46, such as when the cohesive particles are fumed silica (e.g. ).

[0154] The refractive index of a cohesive pigment particle is a value that describes how fast light travels through the material and is defined as:

[0155] Refractive index (RI) = speed of light / phase velocity of light in medium. The refractive index can be measured using a refractometer, such as the OPTi Digital Range refractometer from Bellingham and Stanley.

[0156] The dry mixture preferably comprises 30 to 47 wt% filler, such as wood flour, preferably 33-45 wt%, more preferably 35 or 44 wt%.

[0157] The dry mixture preferably comprises 44% to 70% by weight of at least one binder (or mixture of binders), such as 49-54% or 60-75% by weight.

[0158] The dry mixture preferably comprises 0.05% to 9% by weight of cohesive particles, such as fine non-pigment cohesive particles. For example, when aluminum silicate is used, the mixture preferably comprises aluminum silicate in an amount of 2-4% by weight. For example, when fumed silica is used, it is preferably included in the dry mixture in an amount of 0.2-0.7% by weight.

[0159] The mixture can be 200-600g / m 2 , preferably 300-500g / m 2 , such as about 400g / m 2 The amount of adhesive in the applied mixture may be 100-300 g / m 2 , preferably 150-250g / m 2 , such as about 200g / m 2 .

[0160] The mixture of binder, at least one filler and fine non-pigment cohesive particles can be prepared as Figure 1A The first layer 1 is shown distributed on the first surface of the substrate 2 to form the first layer 1 , or may be mixed with additional additives and / or wear resistant particles and / or pigments or dyes to be distributed on the first surface of the substrate 2 .

[0161] The present inventors have surprisingly found that fine non-pigment cohesive particles added within the range disclosed above to a dry mixture comprising a binder and at least one filler enhance the free flow of the dry mixture of the first layer.

[0162] At the same time, the addition of such particles to the balanced composition has no substantial negative impact on the other properties of the mixture.The process parameters for producing the building element, such as pressure, temperature and time, remain essentially unchanged.

[0163] The inventors have found that fine non-pigment cohesive particles are suitable for this purpose and do not substantially affect any other parameters of the mixture and the first surface layer in a negative manner. Thus, a mixture comprising a binder, at least one filler and fine non-pigment cohesive particles can form the first layer of a building element as defined herein.

[0164] Including non-pigment cohesive particles in the mixture improves the free flow of the first layer, thereby achieving better distribution of the layer. It also improves the adhesion of the first layer 1 to the substrate 2 after pressing.

[0165] The first layer 1 may also have other properties, such as wear resistance, provided by additives, such as wear-resistant particles. The wear-resistant particles may be aluminum oxide particles, such as corundum.

[0166] The first layer 1 may contain additional additives, such as wetting agents, antistatic agents and / or thermally conductive additives, such as aluminum, catalysts.

[0167] The flowability of the dry mixture resulting from the addition of fine non-pigment cohesive particles improves the curing of the building element upon application of heat and / or pressure, since the board leaving the press has an improved shape.

[0168] The balance of the product is thereby improved. If a balancing layer 5 is present, it may be thinner than conventionally used in the industry.

[0169] It is possible to arrange additional layers or intermediate layers on the first layer 1 or on the first surface of the substrate 2, not shown. Figure 1A -D. The middle layer may be, but is not limited to, a cork layer or a cork veneer layer having sound absorbing properties.

[0170] Moisture may be applied to the first layer 1 before pressing. The first layer 1 may be dried and or stabilized by applying heat, for example by IR or NIR.

[0171] like Figure 1A As shown in FIG, the mixture is applied to a substrate 2 to form a first layer 1 and pressed together by applying heat and / or pressure to the first layer 1 and / or substrate 2. If the first layer 1 comprises a thermosetting adhesive, the first layer 1 is cured by applying heat and / or pressure. Preferably, pressure is applied. The applied pressure may be between 20 and 60 bar. Pressure may be applied to the first layer by a continuous press or a discontinuous press. When the press is discontinuous, the pressure is preferably between 40 and 60 bar, or when the press is continuous, between 20 and 60 bar. The temperature is preferably between 150°C and 250°C.

[0172] Preferably before pressing, a surface layer 3 may optionally be applied to the first layer 1. The first layer 1 may be pre-pressed before applying the surface layer 1 or may preferably be spread onto the substrate 2 before pressing.

[0173] A surface layer 3 may be applied to the first layer 1, thereby forming a second layer on the first layer 1. The surface layer 1 may be such as Figure 1C The surface layer may be or include a wood veneer or a softwood veneer. The density of the wood veneer may be at least 1000 kg / m 3 , for example 1000 to 5000 kg / m 3 The wood veneer layer may be formed by compressing the wood veneer. By making the wood veneer have a density of at least 1000 kg / m 3 Density or compressed to 1000kg / m 3 The density of the wood veneer is increased, thereby improving the hardness of the wood veneer. The wood veneer is a thin wood layer, for example, with a thickness of 0.2-1 mm. The surface layer 3 can be continuous or discontinuous. The surface layer 3 can be formed from several veneer segments. The surface layers can be overlapping or non-overlapping. Gaps can be formed between the veneer segments.

[0174] When the surface layer 3 is applied to the first layer 1, an adhesive, such as a thermosetting adhesive of the type described above, simultaneously bonds the surface layer 3 to the first layer 1 during the pressing process. When heat and / or pressure are applied to the first layer 1, the thermosetting adhesive becomes fluid before crosslinking occurs. The applied heat and pressure simultaneously causes the thermosetting adhesive of the first layer 1 to cure while bonding the surface layer 3 to the first layer 1.

[0175] In one embodiment, the finished building element may be 6-25 mm thick, preferably 8-15 mm thick, after pressing, and the substrate may be 5-22 mm thick, preferably 7-14 mm thick. The first layer may be 0.1-2 mm thick after pressing.

[0176] An exemplary building element 10 made by an embodiment of the above-described method is shown in FIG. Figure 1B -D.

[0177] exist Figure 1B In the embodiment shown in FIG, the building element 10 is a building panel. The building element comprises a first layer 1 as described above, a substrate 2 of the type described above, and a balancing layer 5.

[0178] exist Figure 1C In the embodiment shown in , the building element is a building panel. The building element comprises a first layer 1 as described above, a substrate 2 of the type described above and a balancing layer 5. Figure 1C In the embodiment shown in , the building element 10 further comprises a surface layer 3 comprising a wood veneer.

[0179] exist Figure 1D In the embodiment shown in , the building element 10 comprises a first layer 1 as described above, the surface layer 3 comprises a first wood veneer arranged on the first layer 1 , and the substrate 2 comprises a second wood veneer arranged below the first layer 1 .

[0180] The first layer may be applied in powder form.

[0181] According to one aspect, the building panel is a floor or wall panel.

[0182] According to one aspect, a building element 10 may comprise a first layer 1 disposed on a substrate 2, the first layer comprising a mixture of a binder, at least one filler and fine non-pigment cohesive particles, wherein the building element is assembled by applying heat and / or pressure to the first layer 1 and / or substrate 2.

[0183] The building element according to the above aspect may comprise all the advantages of the method which have been discussed previously, whereby the previous discussion also applies to the building element.

[0184] Numerous modifications are contemplated for the embodiments described herein which remain within the scope of the invention as defined by the appended claims.For example, it is contemplated that more than one wear resistant foil may be arranged on a core layer used to form a building panel. Example

[0185] Example 1

[0186] With increasing concentration Different powder formulations containing wood fiber and melamine-formaldehyde resin were made from G90 fine particle aluminum silicate to study the powder free flow and The relationship between the concentration of G90 and the amount of the powder was determined. The powder formulations were placed in glass jars to approximately half their volume and visually evaluated while applying force to the jar to allow the powder to flow. Typical powders considered were fluid, did not form aggregates, and did not exhibit thick dust formation that was readily partially adsorbed to the jar walls. Acceptable formulations had a greater Figure 2A )Uniform particle size distribution ( Figure 2B ).

[0187] Table 1. Use of different concentrations of G90's free-flow experiment

[0188] preparation ASP G90 (weight %) MF (weight %) Wood fiber (weight %) A(Ref) 0 54 46 B 1 53.5 45.5 C 2 53 45 D 3 52.5 44.5 E 5 51.5 42.5

[0189] As visually assessed, Formulations BE exhibited significantly greater free flow than Reference Powder A (Ref). There was a visually noticeable improvement between Formulations B and C, but no significant differences between Samples C, D, and E.

[0190] Example 2

[0191] With increasing concentration Different powder formulations containing wood fiber and melamine-formaldehyde resin were prepared using 200 ultra-fine fumed silica to study the free flow and The relationship between the concentrations of 200 and 200 is shown in Table 2. The mixture compositions are shown in Table 2. The powder formulations were evaluated as described in Example 1.

[0192] Table 2. Use of different concentrations of 200 free flow experiment

[0193]

[0194] Formulations F and G exhibited visually significantly higher free flow than Reference A (Ref), which was further visually demonstrated in Figures 3A-3B , where sample F is shown in comparison with reference sample A.

[0195] When formulations BE and FG were further used in a method for producing a building element, the formulations were easily distributed without forming aggregates. The formulations provided a uniform layer, thereby improving the properties of the first layer and the adhesion of the first layer to the substrate.

[0196] Example 3

[0197] Four standardized formulations (AD in Table 3 below) were prepared in which only the additive portion was switched between different inorganic non-pigment fine cohesive particles. These formulations were then run using a Freeman Technology FT4 Powder Rheometer permeability program, where air is forced through the powder bed at different pressures. Pressure drop is directly inversely proportional to permeability. A graph of pressure drop vs. applied normal stress was obtained, where high pressure drop was attributed to low permeability, meaning higher cohesion in the powder. All powders were then visually inspected and flowability was compared using the glass jar method mentioned in Example 1.

[0198] Table 3. Standardized formulations.

[0199]

[0200]

[0201] exist Figure 4A The permeability results are shown in Figure 2, which show that all samples behaved more cohesively than the reference, as expected. All samples also visually appeared freer flowing than the reference in the glass jar experiments. However, Figure 4B As can be seen in the Figure 1 , when certain additives are added, powder cohesion increases, while free flow does not. The reference material tends to exhibit bridging (mechanical interlocking), which is alleviated with the addition of any given additive until a certain concentration, at which point free flow begins to decrease again due to cohesive forces. The optimal free-flow agent concentration for the additives given in this example is 0.5-5% by weight, highly dependent on the type of additive.

[0202] Figure 4B show C, where B, C, and D represent different formulations in Table 3. Figure 4C show 90 permeability results, where A and C represent different formulations in Table 3.

[0203] When the word "about" or "substantially" is used in this specification with respect to a numerical value, the relevant numerical value is intended to include a tolerance of + / - 10% around the specified numerical value.

Claims

1. A method of manufacturing a building element (10), comprising A first layer (1) is applied on a first surface of a substrate (2), the first layer (1) comprising a mixture of a binder, at least one filler and non-pigment cohesive particles, wherein the fine non-pigment cohesive particles are selected from calcium carbonate and barium sulfate, wherein the amount of fine non-pigment cohesive particles in the mixture is from 0.05% to 9% by weight of the mixture, wherein at least 70% of the fine non-pigment cohesive particles have a length in their largest dimension of 2.5 μm or less, and wherein the non-pigment cohesive particles are configured to increase the flowability of a mixture of the first layer (1) when the first layer (1) is applied to the first surface of the substrate (2), applying heat and / or pressure to the first layer (1) and / or the substrate (2), thereby forming a building element (10).

2. The method according to claim 1, wherein the cohesion of the cohesive particles exceeds the cohesion of the at least one filler.

3. A method according to claim 1 or 2, wherein the cohesion of the cohesive particles is at least 0.25 kPa as measured using a standard Shear Cell Program, 50 mm shear 6 kPa (FT4 Powder Rheometer).

4. A method according to any one of the preceding claims, wherein the mixture is applied in dry form.

5. A method according to any one of the preceding claims, wherein the mixture is applied by spreading.

6. A method according to any one of the preceding claims, wherein the fine non-pigment cohesive particles have a refractive index (RI) of less than 1.

9.

7. The method according to any one of the preceding claims, wherein the at least one filler comprises wood flour.

8. A method according to any preceding claim, wherein the adhesive is a thermosetting adhesive.

9. The method according to any of the preceding claims, wherein the first layer (1) further comprises wear resistant particles.

10. The method according to any of the preceding claims, wherein the first layer (1) further comprises pigment particles.

11. Method according to any of the preceding claims, wherein the substrate (2) is a wood board, particle board, thermoplastic board, plywood, veneer core, veneer layer.

12. A building element (10) comprising a first layer (1) arranged on a substrate (2), the first layer (1) being formed from a mixture comprising a binder, at least one filler and non-pigment cohesive particles, wherein the fine non-pigment cohesive particles are selected from calcium carbonate and barium sulfate, wherein the amount of fine non-pigment cohesive particles in the mixture is from 0.05% to 9% by weight of the mixture, wherein at least 70% of the fine non-pigment cohesive particles have a length in their largest dimension of 2.5 μm or less, and The building element (10) is formed by applying heat and / or pressure.

13. The building element according to claim 12, wherein the cohesion of the cohesive particles exceeds the cohesion of the at least filler.

14. A building element according to claim 12 or 13, wherein the cohesion of the cohesive particles is at least 0.25 kPa as measured using a standard Shear Cell Program, 50 mm shear 6 kPa (FT4 Powder Rheometer).

15. The construction element according to any one of claims 12 to 14, wherein the at least one filler comprises wood flour.

16. The construction element according to any one of claims 12 to 15, wherein the adhesive is a thermosetting adhesive.

17. The building element according to any one of claims 12 to 16, wherein the first layer (1) further comprises wear resistant particles.

18. The building element according to any one of claims 12 to 17, wherein the first layer (1) further comprises pigment particles.

19. Building element according to any of claims 12 to 18, wherein the substrate (2) is a wood board, a particle board, a thermoplastic board, a plywood, a veneer core, a veneer layer.

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