A building panel and a method to produce a building panel

Abstract

The present disclosure relates to a building panel (1), comprising a substrate (10), an intermediate layer (12) arranged on a first surface (10a) of the substrate (10), a surface layer (14) arranged on a surface of the intermediate layer (12) opposite the substrate (10), wherein the surface layer (14) comprises a wood veneer layer, wherein the surface layer (14) is adhered to the intermediate layer (12) by an adhesive layer (13) arranged between the surface layer (14) and the intermediate layer (12), wherein the intermediate layer (12) is continuous in a longitudinal (L) and / or a transverse (T) direction extending along a first surface (10a) of the substrate (10), and wherein the intermediate layer (12) is more rigid and / or harder than the surface layer (14), such that the intermediate layer (12) is configured to at least partially convert pressure forces applied on a surface of the surface layer (14) opposite the intermediate layer (12) to tensile forces in the intermediate layer (12). The present disclosure also relates to a method of producing such a building panel (1).

Description

[0001] A BUILDING PANEL AND A METHOD TO PRODUCE A BUILDING PANEL

[0002] Field of the invention

[0003] The present disclosure relates to a building panel, such as a floor panel, wall panel or worktop, and a method to produce such a building panel.

[0004] Technical background

[0005] Floor coverings having a wooden surface may be of several different types. Solid wood floorings are formed of a solid piece of wood in form of a plank.

[0006] Engineered wood floorings are formed of a surface layer of wood glued to a core. The core may be a lamella core or a wood-based panel, such as plywood, MDF or HDF. The wooden surface layer may, as an example, have a thickness of 2.5 - 10 mm.

[0007] A wooden floor covering may also be formed by gluing a wood veneer to a core, for example, a wood-based panel, such as particleboard, MDF or HDF. Wood veneer is a thin wood layer, for example having a thickness of 0.3-1 mm. A flooring with a separate surface layer glued to a core of, for example, HDF or plywood, is more moisture stable than solid wood floorings.

[0008] Compared to solid wood and engineered wood floorings, wood veneer floorings can be produced to a lower cost and less wood resources are consumed since only a thin wood layer is used. Compared to engineered wood floorings, wood veneer floorings present a harder surface as measured by Brinell hardness.

[0009] In heavy use, known wood veneer floorings do not fulfil requirements put on floorings, in for example, commercial venues. Heavy use may be in high traffic applications such as airport terminals, shops, restaurants, and schools. To withstands such wear, hard and rigid lacquers are required. However, when such hard and rigid lacquers are applied to known wood veneer floorings, the lacquer cracks and delaminate when the flooring is exposed to wear and pressure forces in heavy use environments.

[0010] In order to improve impact resistance of a wood veneer flooring, a sublayer including a binder may be arranged between the wood veneer layer and the core prior to pressing the wood veneer layer to the core.

[0011] WO 2009 / 065769 discloses a thin surface layer, such as wood veneer layer, which is applied on a sub-layer comprising, for example, cork or wood fibres mixed with a binder. The binder is conventionally an amino resin such melamine formaldehyde resin. The sub-layer is applied on a wood fibre-based core. During pressing, the binder of the sub-layer impregnates the wood veneer layer and the binder cures, thereby forming a wood veneer surface having improved impact resistance.

[0012] However, adding a sub-layer comprising an uncured binder is a more complicated process compared to gluing a wood veneer to a substrate. For example, both the pressure applied and pressing temperature needs to be higher than in a process wherein a wood veneer is glued to a substrate. The higher pressure and temperature are required in order to press the binder into the wood veneer and thereafter cure the binder.

[0013] The sub-layer including the uncured binder is often applied in powder form. Handling of powders and application of powders requires substantial modifications compared to a conventional pressing line wherein the layers are adhered by glue.

[0014] Consequently, there has been found a need for an improved wood veneer flooring.

[0015] Summary

[0016] It is an object of at least embodiments of the present disclosure to provide an improved building panel including a wood veneer surface layer.

[0017] According to a first aspect, a building panel is provided. The building panel comprises a substrate, an intermediate layer arranged on a first surface of the substrate, a surface layer arranged on a surface of the intermediate layer opposite the substrate, wherein the surface layer comprises a wood veneer layer, wherein the surface layer is adhered to the intermediate layer by an adhesive layer arranged between the surface layer and the intermediate layer, and wherein the intermediate layer is more rigid and / or harder than the surface layer, such that the intermediate layer is configured to at least partially convert pressure forces applied on a surface of the surface layer opposite the intermediate layer to tensile forces in the intermediate layer.

[0018] In one example, the building panel comprises a substrate, an intermediate layer arranged on a first surface of the substrate, a surface layer arranged on a surface of the intermediate layer opposite the substrate, wherein the surface layer comprises a wood veneer layer, wherein the surface layer is adhered to the intermediate layer by an adhesive layer arranged between the surface layer and the intermediate layer, wherein the intermediate layer is continuous in a longitudinal (L) and / or a transverse (T) direction extending along a first surface of the substrate, and wherein the intermediate layer is more rigid and / or harder than the surface layer, preferably such that the intermediate layer is configured to at least partially convert pressure forces applied on a surface of the surface layer opposite the intermediate layer to tensile forces in the intermediate layer.

[0019] By being continuous, the intermediate layer may extend continuously between opposite edges of a first surface of the substrate, in a longitudinal (L) and / or transverse (T) direction. The intermediate layer may be extending without any interruptions, such as joints of individual building elements, from edge to edge of a first surface of the substrate. The intermediate layer may be pre-formed. The intermediate layer may be formed in one piece.

[0020] In one example, the intermediate layer is more rigid than the surface layer.

[0021] In one example, the intermediate layer is harder than the surface layer.

[0022] In one example, the intermediate layer is more rigid and harder than the surface layer.

[0023] The building panel may have a Brinell hardness exceeding 49 N / mm2, preferably exceeding 60 N / mm2, as measured in accordance with EN 1534. The building panel may have a Brinell hardness of 49-300 N / mm2, as measured in accordance with EN1534. The intermediate layer may have a Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN1534.

[0024] The intermediate layer may have a Brinell hardness exceeding 49 N / mm2, preferably exceeding 60 N / mm2, as measured in accordance with EN1534.

[0025] The intermediate layer may have a Brinell hardness of 49-300 N / mm2, as measured in accordance with EN1534.

[0026] The intermediate layer may have a bending moment exceeding a bending moment of the surface layer, for example as measured in accordance with ISO 2493-2.

[0027] The intermediate layer may have a bending moment exceeding 50 millinewton-meter as measured in accordance with ISO 2493-2.

[0028] The intermediate layer may have a bending moment of 50-500 millinewtonmeter as measured in accordance with ISO 2493-2. The intermediate layer may be more rigid and / or harder than the substrate.

[0029] The intermediate layer may have a Brinell hardness exceeding a Brinell hardness of the substrate, as measured in accordance with EN1534.

[0030] The intermediate layer may have a bending moment exceeding a bending moment of the substrate as measured in accordance with ISO 2493- 2.

[0031] The substrate and the intermediate layer may be adhered to each other by an adhesive layer arranged between the substrate and the intermediate layer.

[0032] The adhesive layer between the surface layer and the intermediate layer may be referred to as a first adhesive layer. The adhesive layer between the substrate and the intermediate layer may be referred to as a second adhesive layer.

[0033] The wood veneer layer may have a thickness between 0.1 mm and 1 mm. In one example, the wood veneer layer may have a thickness between 0.2 mm and 0.6 mm. The thickness of the surface layer may be less than the thickness of the intermediate layer.

[0034] The building panel may comprise a coating layer on the surface of the surface layer opposite the intermediate layer.

[0035] The intermediate layer may comprise at least one cured resin impregnated paper.

[0036] The intermediate layer may comprise at least one high pressure laminate (HPL) layer.

[0037] The intermediate layer may comprise at least 3 cured resin impregnated papers, for example the intermediate layer may comprise a high pressure laminate comprising at least 3 papers.

[0038] The intermediate layer may comprise at least 5 cured resin impregnated papers, for example the intermediate layer may comprise a high pressure laminate comprising at least 5 papers.

[0039] The intermediate layer may comprise at least 10 cured resin impregnated papers, for example the intermediate layer may comprise a high pressure laminate comprising at least 10 papers.

[0040] The intermediate layer may comprise a polymer-based material.

[0041] The intermediate layer may comprise a cured thermosetting binder.

[0042] The intermediate layer may comprise a thermoplastic binder.

[0043] The intermediate layer may comprise a polyester resin.

[0044] The intermediate layer may comprise an epoxy resin.

[0045] The intermediate layer may comprise polycarbonate.

[0046] The intermediate layer may comprise a fibre reinforcement. The fibre reinforcement may be included in a polymer-based material of the above disclosed type.

[0047] The intermediate layer may be reinforced by organic and / or inorganic fibres. The fibres may be chosen from the group of natural fibres, glass fibres, polymer fibres, mineral-based fibres, carbon fibres, and a combination thereof.

[0048] The fibre reinforcement may comprise glass fibres.

[0049] The intermediate layer may comprise a wood veneer layer. The wood veneer layer may have a thickness exceeding 0.6 mm, such as having a thickness of 0.6 - 1.5 mm. The wood veneer layer may be or comprise a birch veneer layer, a poplar veneer layer, a beech veneer layer, or a pine veneer layer.

[0050] The intermediate layer may comprise a wood veneer layer reinforced by a polymer-based material. The polymer-based material may be of the above disclosed type.

[0051] The adhesive may be present in the surface layer in a portion extending from a surface facing the adhesive layer into a thickness of the surface layer, said portion being less than 10 % of a thickness of the wood veneer layer, such that less than 5% of a thickness of the wood veneer layer.

[0052] The building panel may further comprise a backing layer adhered to a second surface of the substrate by an adhesive layer. The backing layer may comprise a wood veneer layer.

[0053] The adhesive layer between the backing layer may be referred to as a third adhesive layer.

[0054] According to a second aspect, a method to produce a building panel is provided. The method comprises: arranging an intermediate layer on a first surface of a substrate, applying an adhesive layer on a surface of the intermediate layer and / or on a surface of a surface layer, arranging the surface layer on the intermediate layer, wherein the adhesive layer is arranged between the intermediate layer and the surface layer, adhering the substrate, the intermediate layer, and the surface layer to each other, wherein the surface layer is adhered to the intermediate layer by the adhesive layer, wherein the intermediate layer is more rigid and / or harder than the surface layer, such that the intermediate layer is configured to convert pressure forces applied on a surface of the surface layer opposite the intermediate layer to tensile forces in the intermediate layer. In one example the method comprises: arranging an intermediate layer on a first surface of a substrate, applying an adhesive layer on a surface of the intermediate layer and / or on a surface of a surface layer, arranging the surface layer on the intermediate layer, wherein the adhesive layer is arranged between the intermediate layer and the surface layer, adhering the substrate, the intermediate layer, and the surface layer to each other, wherein the surface layer comprises a wood veneer layer, wherein the surface layer is adhered to the intermediate layer by the adhesive layer, wherein the intermediate layer (12) is continuous in a longitudinal (L) and / or a transverse (T) direction extending along a first surface (10a) of the substrate (10), and wherein the intermediate layer is more rigid and / or harder than the surface layer, preferably such that the intermediate layer is configured to convert pressure forces applied on a surface of the surface layer opposite the intermediate layer to tensile forces in the intermediate layer.

[0055] In one example, adhering the substrate, the intermediate layer and the surface layer to each other comprises thereby forming a board and the method further comprises dividing the board, thereby forming the building panel.

[0056] The board may be divided in a longitudinal (L) and / or transverse (T) direction, extending along a first surface (10a) of the substrate (10).

[0057] In one example, dividing the board comprises forming at least two building panels.

[0058] In one example, the intermediate layer is more rigid than the surface layer.

[0059] In one example, the intermediate layer is harder than the surface layer. In one example, the intermediate layer is more rigid and harder than the surface layer.

[0060] The intermediate layer may have a Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN1534.

[0061] The intermediate layer may have a Brinell hardness exceeding 49 N / mm2, preferably exceeding 60 N / mm2, as measured in accordance with EN1534.

[0062] The intermediate layer may have a Brinell hardness of 49-300 N / mm2, as measured in accordance with EN1534.

[0063] The intermediate layer may have a bending moment exceeding a bending moment of the surface layer as measured in accordance with ISO 2493-2.

[0064] The intermediate layer may have a bending moment exceeding 50 millinewton-meter as measured in accordance with ISO 2493-2.

[0065] The intermediate layer may have a bending moment of 50-500 millinewton-meter as measured in accordance with ISO 2493-2.

[0066] The intermediate layer may be more rigid and / or harder than the substrate.

[0067] The intermediate layer may have a Brinell hardness exceeding a Brinell hardness of the substrate, as measured in accordance with EN 1534.

[0068] The intermediate layer may have a bending moment exceeding a bending moment of the substrate as measured in accordance with ISO 2493- 2.

[0069] The thickness of the surface layer may be less than the thickness of the intermediate layer.

[0070] A pressure applied when adhering the substrate, the intermediate layer, and the surface layer to each other may be less than 30 bar, such as less than 20 bar, for example 5-10 bar.

[0071] A temperature applied when adhering the substrate, the intermediate layer, and the surface layer to each other may be 40-100 °C. The step of arranging the intermediate layer on the substrate may comprise applying an adhesive layer on the substrate and / or the intermediate layer, such that the intermediate layer is adhered to the substrate layer by the adhesive layer.

[0072] The intermediate layer may comprise a polymer-based material.

[0073] The intermediate layer may comprise a thermosetting binder, wherein the thermosetting binder is in a cured state when the surface layer is applied to the intermediate layer.

[0074] The intermediate layer may comprise a thermoplastic binder.

[0075] The intermediate layer may comprise a polyester resin.

[0076] The intermediate layer may comprise an epoxy resin.

[0077] The intermediate layer may comprise polycarbonate.

[0078] The intermediate layer may comprise a fibre reinforcement. The fibre reinforcement may be included in a polymer-based material of the above disclosed type.

[0079] The intermediate layer may be reinforced by organic and / or inorganic fibres. The fibres may be chosen from the group of natural fibres, glass fibres, polymer fibres, mineral-based fibres, carbon fibres, and a combination thereof.

[0080] The fibre reinforcement may comprise glass fibres.

[0081] The intermediate layer may comprise a wood veneer layer reinforced by a polymer-based material. The polymer-based material may be of the above disclosed type.

[0082] The intermediate layer may comprise a wood veneer layer reinforced by a thermosetting binder, wherein the thermosetting binder is in a cured state when the surface layer is applied to the intermediate layer.

[0083] The intermediate layer may comprise at least one cured resin impregnated paper. The resin impregnated paper may be in a cured state when the surface layer is applied on the intermediate layer.

[0084] The intermediate layer may comprise at least one high pressure laminate (HPL) layer. The intermediate layer may comprise at least 5 cured resin impregnated papers, for example may comprise a high pressure laminate comprising at least 5 papers.

[0085] The intermediate layer may comprise at least 10 cured resin impregnated papers, for example may comprise a high pressure laminate comprising at least 10 papers.

[0086] The wood veneer layer may have a thickness between 0.1 mm and 1 mm. In one example, the wood veneer layer may have a thickness between 0.2 mm and 0.6 mm.

[0087] The wood veneer layer may have been made from a plural of veneer sheets that have been joined together to form a larger sheet. The veneer sheets may for example have been joined by gluing the veneer edges.

[0088] The intermediate layer may extend continuously under a plural of veneer sheets.

[0089] The method may further comprise applying a coating layer on the surface of the surface layer opposite the intermediate layer.

[0090] The method may further comprise adhering a backing layer to a second surface of the substrate by an adhesive layer.

[0091] The backing layer may comprise a wood veneer layer.

[0092] The building panel may be a floor panel, a wall panel, a furniture component, a building component, or a worktop.

[0093] Brief description of the drawings

[0094] The present disclosure will by way of example be described in more detail with reference to the appended schematic drawings, which show examples of the present disclosure.

[0095] Fig. 1 discloses a method to produce a building panel according to a first example.

[0096] Fig. 2 discloses a method to produce a building panel according to a second example.

[0097] Fig. 3 discloses a method to produce a building panel according to a third example.

[0098] Fig. 4 discloses an example of a building panel in cross-section. Fig. 5 discloses an example of a building panel in cross-section.

[0099] Fig. 6 discloses an example of a building panel in cross-section.

[0100] Fig. 7 discloses a building panel with a backing layer according to a first example.

[0101] Fig. 8 discloses a building panel with a backing layer according to a second example.

[0102] Fig. 9 discloses an exploded view of an example of a building panel.

[0103] Fig. 10 is a schematic illustration of a board that is divided into several building panels, according to an example of the disclosed method.

[0104] Detailed description

[0105] Fig. 1 shows an example of a method to produce a building panel 1. The method comprises providing a substrate 10 having a first surface 10a and a second surface 10b. The substrate 10 may be a wood-based board such as MDF or HDF board. The substrate 10 may be a plywood board. The substrate 10 may be a lamella core. The substrate 10 may be a particleboard. The substrate 10 may be a thermoplastic board. The substrate 10 is preferably produced prior to the present method.

[0106] The substrate 10 is conveyed in a feeding direction F through the process.

[0107] An adhesive is applied on the first surface 10a of the substrate 10 in a first step. The adhesive may be a hot melt, spray adhesive or a pressure sensitive adhesive. The adhesive can be a one component glue or a two- component glue. The adhesive may be applied in an amount of 15-100 g / m2, such as 30-45 g / m2. In the method shown in fig. 1 , the adhesive is applied by an application device 20. The adhesive may be in liquid form when applied. In alternatives, the adhesive may be sprayed on the surface. When applied on the first surface 10a of the substrate, the adhesive forms an adhesive layer 11 on the first surface 10a of the substrate. The adhesive layer 11 on the first surface 10a of the substrate may be referred as a second adhesive layer 11 .

[0108] The adhesive may be dried, for example by IR (not shown).

[0109] An intermediate layer 12 is applied on the adhesive layer 11 . In the example shown in fig. 1 , the intermediate layer 12 comprises at least on resin impregnated paper. The resin of the resin impregnated paper is in a cured state when applied on the adhesive layer. Such a cured resin impregnated paper is referred to as a High Pressure Laminate (HPL). Consequently, the intermediate layer 12 may be an HPL. The intermediate layer may comprise more than one resin impregnated papers. For example, the intermediate layer 12 may comprise 3 resin impregnated papers, such as 5 resin impregnated papers. In other words, the intermediate layer 12 comprise an HPL comprising at 3 paper layers, such as 5 paper layers.

[0110] The resin of the intermediate layer 12 may be a thermosetting binder, such as amino resin, polyester, polyurethane, acrylic, epoxy, or a combination thereof.

[0111] In alternative examples, the intermediate layer 12 may comprise a thermoplastic binder. The intermediate layer 12 may comprise a thermoplastic film or thermoplastic sheet. The intermediate layer 12 may comprise a rigid thermoplastic material, for example a polycarbonate such as a polycarbonate sheet applied on the adhesive layer.

[0112] In alternative examples, the intermediate layer 12 comprises a fibre reinforcement, for example comprising a fibre reinforced sheet. The intermediate layer 12 may comprise a fibre reinforced plastic, such as a glass-fibre reinforced plastic which is also referred to as fibreglass. The fibre reinforced plastic comprises fibres, for example glass fibres or carbon fibres, embedded in a polymer matrix. The polymer matrix may comprise a thermosetting polymer such as epoxy, polyester, and / or vinyl ester. The polymer matrix may comprise a thermoplastic polymer. The fibres may be randomly arranged, such as in a chopped strand mat, or be woven into a cloth.

[0113] One or more fibre reinforced sheets may be applied on the substrate 10.

[0114] When applied on the first surface 10a of the substrate 10, the thermosetting polymer of the polymer matrix is in a cured state.

[0115] In alternative examples, the intermediate layer 12 comprises a metal layer, such as metal sheet or metal foil. The intermediate layer 12 may be provided in continuous form, for example as rolls, or in form of sheets.

[0116] In an alternative process, the adhesive of the above type is applied on a surface of the intermediate layer 12, which is intended to face the first surface 10a of the substrate 10.

[0117] In further step, an adhesive is applied on the intermediate layer 12. The adhesive may be a hot melt, spray adhesive or a pressure sensitive adhesive. The adhesive can be a one component glue or a two-component glue. The adhesive may be applied in an amount of 15-100 g / m2, such as SO- 45 g / m2. In the method shown in fig. 1 , the adhesive is applied by an application device 30. The adhesive may be in liquid form when applied. In alternatives, the adhesive may be sprayed on the surface. When applied on the intermediate layer 12, the adhesive forms an adhesive layer 13 on the intermediate layer 12. The adhesive layer 13 on the intermediate layer 12 may be referred to as a first adhesive layer 13.

[0118] In a further step, a surface layer 14 comprising a wood veneer layer is applied on the adhesive layer 13. In an alternative process, the adhesive of the above type is applied on a surface of the surface layer 14, which is intended to face the intermediate layer 12.

[0119] The wood veneer layer may be or comprise an oak veneer, maple veneer, birch veneer, walnut veneer, ash veneer, and / or pine veneer. The oak veneer may be American oak veneer. The wood veneer layer may have a thickness between 0.1 mm and 1 mm. In one example, the wood veneer layer has a thickness between 0.2 mm and 0.6 mm. In one example, the wood veneer layer has a thickness being equal or less than 0.6 mm.

[0120] The thickness of the surface layer 14 may be less than the thickness of the intermediate layer 12.

[0121] The surface layer 14 is bonded to the intermediate layer 12 by the adhesive layer 13. Heat and / or pressure may be applied in a pressing device 40, as in shown in the example in fig. 1 . The pressing device 30 is a glue press, and not a pressing device configured for a curing process. The pressing device 40 may be a double press device as shown in fig. 1 , comprising an upper press belt 41 and a lower press belt 42. The pressure applied may be less than be less than 30 bar, such as less than 20 bar, for example 5-10 bar. The temperature may be 40-100 °C. The press parameters and pressing technique may be as conventionally used for glue pressing.

[0122] The adhesive of the adhesive layer 13 do not substantially permeate into the surface layer 14. For example, if some permeation occurs, adhesive from the adhesive layer 13 is present in less than 10 % of the thickness of the surface layer 14.

[0123] As shown in fig. 1 , a backing layer 15 may be applied to the second surface 10b of the substrate 10 prior to the pressing device 40. The backing layer 15 may be adhered to the second surface 10b by an adhesive layer. The adhesive layer between the substrate 10 and the backing layer 15 may be referred to as a third adhesive layer. The backing layer 15 may for example comprise a wood veneer layer or a resin impregnated paper layer.

[0124] After the pressing device 40, a building panel 1 is provided. A surface of the building panel 1 may be provided with a coating, which may also be referred to as a lacquer. The coating may be a UV curable coating, such that a UV curing step is performed after application. The coating may be an electron beam (EB) curable coating, such that an EB curing step is performed after application. The coating may comprise an acrylate or methacrylate polymer. The coating may be applied in one or more layers.

[0125] The building panel 1 produced according to the method described above with reference to fig. 1 is shown in fig. 4, which will be described below. The method described in fig. 1 may produce a product having a size often referred to as a board, which may be divided into panels, having a size smaller than the board.

[0126] Fig. 2 shows another example of a method to produce a building panel. Similar to the method described above, the method comprises providing a substrate 10 having a first surface 10a and a second surface 10b. The substrate 10 may be a wood-based board such as MDF or HDF board. The substrate 10 may be a plywood board. The substrate 10 may be a lamella core. The substrate 10 may be a particleboard. The substrate 10 may be a thermoplastic board. The substrate 10 is preferably produced prior to the present method.

[0127] The substrate 10 is conveyed in a feeding direction F through the process.

[0128] A binder is applied by an application device 20 on the first surface 10a of the substrate 10. The binder may be applied in liquid form as shown in fig. 2. The binder may be or comprise a thermosetting binder, such as amino resins, epoxy resins, polyesters, polyurethane, acrylic, or a combination thereof .

[0129] A fibre reinforcement may be added to the binder, for example by an application device 50 applying fibres on the binder applied on the first surface 10a of the substrate 10. The application device 50 may be a scattering device. The fibres may be organic and / or inorganic fibres. The fibres may be chosen from the group of natural fibres, glass fibres, polymer fibres, mineralbased fibres, carbon fibres, and a combination thereof. The fibres may be randomly distributed.

[0130] The fibre reinforcement may also be in the form of a mesh, such as woven, or be a non-woven.

[0131] Depending on the type of binder used, the binder may be dried and / or cured. In the process shown in fig. 2, the binder is dried, for example by I R, by a heating device 60. After the binder has been dried and / or cured, the binder, reinforced by the fibres, forms an intermediate layer 12.

[0132] In a further step, an adhesive is applied on the intermediate layer 12. The adhesive may be a hot melt or a pressure sensitive adhesive. The adhesive can be a one component glue or a two-component glue. The adhesive may be applied in an amount of 15-100 g / m2, such as 30-45 g / m2. In the method shown in fig. 2, the adhesive is applied by an application device 30. The adhesive may be in liquid form when applied. In alternatives, the adhesive may be sprayed on the surface.

[0133] When applied on the intermediate layer 12, the adhesive forms an adhesive layer 13 on the intermediate layer 12. The adhesive layer 13 on the intermediate layer 12 may be referred as a first adhesive layer 13. In a further step, a surface layer 14 comprising a wood veneer layer is applied on the adhesive layer 13. In an alternative process, the adhesive of the above type is applied on a surface of the surface layer 14, which is intended to face the intermediate layer 12.

[0134] The wood veneer layer may be or comprise an oak veneer, maple veneer, birch veneer, walnut veneer, ash veneer, and / or pine veneer. The oak veneer may be American oak veneer. The wood veneer layer may have a thickness between 0.1 mm and 1 mm. In one example, the wood veneer layer has a thickness between 0.2 mm and 0.6 mm. In one example, the wood veneer layer has a thickness being equal or less than 0.6 mm.

[0135] The surface layer 14 is bonded to the intermediate layer 12 by the adhesive layer 13. Heat and / or pressure may be applied in a pressing device 40, as in shown in the example in fig. 2. The pressing device 30 is a glue press, and not a pressing device configured for a curing process. The pressing device 40 may be a double press device as shown in fig. 2, comprising an upper press belt 41 and a lower press belt 42.

[0136] The pressure applied may be less than 30 bar, such as less than 15 bar, for example 5-10 bar. The temperature may be 40-100 °C. The press parameters and pressing technique may be as conventionally used for glue pressing.

[0137] The adhesive of the adhesive layer 13 do not substantially permeate into the surface layer 14. For example, if some permeation occurs, adhesive from the adhesive layer 13 is present in less than 10 % of the thickness of the surface layer 14.

[0138] As shown in fig. 2, a backing layer 15 may be applied to the second surface 10b of the substrate 10 prior to the pressing device 40. The backing layer 15 may be adhered to the second surface 10b by an adhesive layer. The adhesive layer between the substrate 10 and the backing layer 15 may be referred to as a third adhesive layer. The backing layer 15 may for example comprise a wood veneer layer or a resin impregnated paper layer.

[0139] After the pressing device 40, a building panel 1 is provided. A surface of the building panel 1 may be provided with a coating, which may also be referred to as a lacquer. The coating may be a UV curable coating, such that a UV curing step is performed after application. The coating may be an EB curable coating, such that an EB curing step is performed after application. The coating may comprise an acrylate or methacrylate polymer. The coating may be applied in one or more layers.

[0140] The building panel 1 produced according to the method described above with reference to fig. 2 is shown in fig. 5, which will be described below. The method described in fig. 2 may produce a product having a size often referred to as a board, which may be dividing into panels, having a size smaller than the board.

[0141] Fig. 3 shows another example of a method to produce a building panel. Similar to the method described above, the method comprises providing a substrate 10 having a first surface 10a and a second surface 10b. The substrate 10 may be a wood-based board such as MDF or HDF board. The substrate 10 may be a plywood board. The substrate 10 may be a lamella core. The substrate 10 may be a particleboard. The substrate 10 may be a thermoplastic board. The substrate 10 is preferably produced prior to the present method.

[0142] The substrate 10 is conveyed in a feeding direction F through the process.

[0143] An adhesive layer 11 is applied by an application device 20 on the first surface 10a of the substrate 10. The adhesive layer comprises a binder. The binder may be applied in liquid form as shown in fig. 3. The binder may be or comprise a thermosetting binder, such as amino resins, epoxy resins, polyesters, polyurethanes, acrylics, or a combination thereof.

[0144] An intermediate layer 12 is applied on the adhesive layer 11. The intermediate layer 12 comprises a wood veneer layer. The wood veneer layer may have a thickness exceeding 0.6 mm, such as having a thickness of 0.6 - 1 .5 mm. The wood veneer layer may be or comprise a birch veneer layer, a poplar veneer layer, a beech veneer layer, or a pine wood veneer layer.

[0145] The intermediate layer may comprise a wood veneer layer reinforced by a polymer-based material. Pressure, and preferably also heat, is applied to the wood veneer layer of the intermediate layer in a pressing device 70. The pressing device 70 may be a double belt press comprising an upper press belt 71 and a lower press belt 72 as shown in fig. 3.

[0146] Pressure applied may be at least 30 bar, such as 30-60 bar. The pressure time may be 10-60 s. The temperature applied may be in the range of 120-250 °C.

[0147] After pressing, the wood veneer layer of the intermediate layer 12 is bonded to the substrate 10. The binder of the adhesive layer 11 has at least partly permeated into the wood veneer layer such that the wood veneer layer is reinforced by the binder after pressing. After pressing, the wood veneer layer reinforced by the binder of the adhesive layer 11 forms the intermediate layer 12.

[0148] In further step, an adhesive is applied on the intermediate layer 12. The adhesive may be a hot melt or a pressure sensitive adhesive. The adhesive can be a one component glue or a two-component glue. The adhesive may be applied in an amount of 15-100 g / m2, such as 30-45 g / m2. In the method shown in fig. 3, the adhesive is applied by an application device 30. The adhesive may be in liquid form when applied. In alternatives, the adhesive may be sprayed on the surface.

[0149] When applied on the intermediate layer 12, the adhesive forms an adhesive layer 13 on the intermediate layer 12. The adhesive layer 13 on the intermediate layer 12 may be referred as a first adhesive layer 13.

[0150] In a further step, a surface layer 14 comprising a wood veneer layer is applied on the adhesive layer 13. In an alternative process, the adhesive of the above type is applied on a surface of the surface layer 14, which is intended to face the intermediate layer 12.

[0151] The wood veneer layer of the surface layer 14 may be or comprise an oak veneer, maple veneer, birch veneer, walnut veneer, ash veneer, and pine veneer. The oak veneer may be American oak veneer. The second wood veneer layer 2 may have a thickness between 0.1 mm and 1 mm. In one example, the wood veneer layer of the surface layer 14 has a thickness between 0.2 mm and 0.6 mm. In one example, the wood veneer layer of the surface layer 14 has a thickness being equal or less than 0.6 mm.

[0152] The thickness of the wood veneer layer of the surface layer 14 may be less than the thickness of the wood veneer layer of the intermediate layer 12.

[0153] The surface layer 14 is bonded to the intermediate layer 12 by the adhesive layer 13. Heat and / or pressure may be applied in a pressing device 40, as in shown in the example in fig. 3. The pressing device 30 is a glue press, and not a pressing device configured for a curing process. The pressing device 40 may be a double press device as shown in fig. 3, comprising an upper press belt 41 and a lower press belt 42.

[0154] The pressure applied may be less than 30 bar, such as less than 15 bar, for example 5-10 bar. The temperature may be 40-100 °C. The press parameters and pressing technique may be as conventionally used for glue pressing. The pressure and / or temperature in the pressing device 40 may be less than the pressure and / or temperature of the pressing device 70.

[0155] The adhesive of the adhesive layer 13 do not substantially permeate into the surface layer 14. For example, if some permeation occurs, adhesive from the adhesive layer 13 is present in less than 10 % of the thickness of the surface layer 14.

[0156] As shown in fig. 3 a backing layer 15 may be applied to the second surface 10b of the substrate 10 prior to the pressing device 40. The backing layer 15 may be adhered to the second surface 10b by an adhesive layer. The adhesive layer between the substate 10 and the backing layer 15 may be referred to as a third adhesive layer. The backing layer 15 may for example comprise a wood veneer layer or a resin impregnated paper layer.

[0157] After the pressing device 40, a building panel 1 is provided. A surface of the building panel 1 may be provided with a coating, which may also be referred to as a lacquer. The coating may be a UV curable coating, such that a UV curing step is performed after application. The coating may be an EB curable coating, such that an EB curing step is performed after application. The coating may comprise an acrylate or methacrylate polymer. The coating may be applied in one or more layers. The coating may form an upper portion of the surface layer 14, above the wood veneer layer. The building panel 1 produced according to the method described above with reference to fig. 3 is shown in fig. 6, which will be described below. The method described in fig. 3 may produce a product having a size often referred to as a board, which may be dividing into panels, having a size smaller than the board.

[0158] Common for all examples disclosed above and below is that the intermediate layer 12 is harder and / or more rigid than the surface layer 14. Thereby, the intermediate layer 12 can, at least partially, convert pressure forces applied on the surface 14a of the surface layer 14 to tensile forces in the intermediate layer 12. In use, the surface 14a of the surface layer 14, facing away from the intermediate layer 12, may form an upper surface of the surface layer 14. Such pressure forces on the surface layer 14 may result from a static load applied on the building panel 1 , for example from a piece of furniture arranged on the building panel 1 in form of a floor panel. Such pressure forces on the surface layer may also be the result on dynamic loads applied on the building panels 1 , for example by a person walking on the building panel 1 in form of a floor panel. Such pressure forces are at least partially converted to tensile forces in the intermediate layer 12. Thereby, a harder building panel is obtained, compared to a conventional building panel having a surface layer of a wood veneer layer.

[0159] In a building panel 1 according to the present disclosure, any damage resulting from pressure forces applied on the surface layer 14 is restricted from being transferred into the intermediate layer 12. Thereby, the extension of the damage is limited to the surface layer 14. For example, a crack formed in the wood veneer layer is limited to the wood veneer layer and is not extending into the intermediate layer 12.

[0160] The thinner the surface layer 14 is, the less is the impact of the damage on the surface layer. 14 Thereby, a surface layer comprising a wood veneer layer having a thickness of, for example, less than 0.6 mm, can be used with advantageous results.

[0161] Further, as a result of the reinforcement formed by the intermediate layer 12, a coating layer being hard and / or rigid can be used by coating the wood veneer layer with a lacquer having a high degree of crosslinking. Lacquers having a high degree of crosslinking are more resistant to chemicals than a lacquer having a lower degree of crosslinking. In known solution, such hard and / or rigid coatings have not been used, since the hard and / or rigid coatings have resulted in delamination between the coating layer and the wood veneer layer and / or cracks in the coating layer. By providing the intermediate layer 12 of the above-described type, the above problems are at least reduced, such as the extension of cracks is at least reduced.

[0162] Consequently, an improved building panel 1 can be provided, where any kind of coating can be used, including hard and / or rigid coatings having improved chemical resistance.

[0163] The intermediate layer 12 can be harder than the surface layer 14, such as the intermediate layer 12 may have a Brinell hardness that is higher than a Brinell hardness of the wood specie of the surface layer 14. For example, the intermediate layer 12 may have a Brinell hardness (HB) exceeding 49 N / mm2, preferably exceeding 60 N / mm2. Brinell hardness (HB) is measured in accordance with EN1534. Thereby, the building panel 1 will obtain a higher Brinell hardness (HB), such as exceeding 49 N / mm2as measured in accordance with EN1534. For a conventional veneer flooring glued to a HDF, the Brinell hardness substantially corresponds to the Brinell hardness of the HDF, since the ball is pressed through the wood veneer layer to the HDF surface due to the thin wood veneer layer.

[0164] The intermediate layer 12 can be more rigid than the surface layer 14. For example, the intermediate layer 12 may have a bending moment exceeding a bending moment of the surface layer 14. For example, the intermediate layer 12 may have a bending moment exceeding 50 millinewtonmeter. Bending moment is measured in accordance with ISO 2493-2.

[0165] All the methods described in figs. 1-3 may produce a product having a size often referred to as a board, which may be divided into panels, having a size smaller than the board. Fig. 10 shows a board 2 that is divided into panels 1 . The board 2 may be divided in a longitudinal (L) and / or transverse (T) direction, extending along a first surface 10a of the substrate 10. An example of dividing lines is shown in fig 10 as dashed lines. Dividing the board 2 may comprise forming at least 2 building panels 1 . Dividing the board may comprise cutting, such as by a rotating cutting device, machining, sawing or other known principles in the art for dividing a board.

[0166] The building panel 1 will now be described with reference to figs. 4-9. The building panel 1 may be produced by any of the method described above with reference to figs. 1-3.

[0167] The building panel in fig. 4 may have been produced according to the method shown in fig. 1. The building panel 1 comprises the substrate 10. The substrate 10 may be a wood-based board such as MDF or HDF board. The substrate 10 may be a plywood board. The substrate 10 may be a lamella core. The substrate 10 may be a particleboard. The substrate 10 may be a thermoplastic board.

[0168] The intermediate layer 12 is arranged on the first surface of the substrate 10a. The intermediate layer 12 is attached to the substrate by an adhesive, which may form the adhesive layer 11 . In the final building panel 1 , the adhesive layer 11 may be more or less distinct, and may for example no longer be present as a distinct layer.

[0169] The intermediate layer 12 may comprise a polymer material.

[0170] The intermediate layer 12 may comprise at least one resin impregnated paper, such as an HPL. In other examples, the intermediate layer 12 comprises a fibre reinforcement, for example comprising a fibre reinforced sheet. The intermediate layer 12 may comprise a fibre reinforced plastic, such as a glass-fibre reinforced plastic which is also referred to as fibreglass. The fibre reinforced plastic comprises fibres, for example glass fibres or carbon fibres, embedded in a polymer matrix. The polymer matrix may comprise a thermosetting polymer such as epoxy, polyester, and / or vinyl ester. The polymer matrix may comprise a thermoplastic polymer. The fibres may be randomly arranged, such as in a chopped strand mat, or be woven into a cloth.

[0171] In alternative examples, the intermediate layer 12 may comprise a thermoplastic binder. The intermediate layer 12 may comprise a thermoplastic film or thermoplastic sheet. The intermediate layer 12 may comprise a rigid thermoplastic material, for example a polycarbonate such as a polycarbonate sheet applied on the adhesive layer. In other examples, the intermediate layer 12 comprises a metal layer, such as metal sheet or metal foil.

[0172] The surface layer 14 is attached to the intermediate layer 12 by an adhesive, which may form an adhesive layer 13. In the final building panel 1 , the adhesive layer 11 may be more or less distinct, and may for example no longer be present as a distinct layer.

[0173] The surface layer 14 comprises the wood veneer layer, which may have a thickness of 0.1 - 1 mm, such as 0.2 mm - 0.6 mm. The thickness of the surface layer 14 may be less than the thickness of the intermediate layer 12.

[0174] As discussed above, the intermediate layer is more rigid and / or harder than the surface layer.

[0175] For example, the intermediate layer 12 may have Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN1534. The intermediate layer 12 may have Brinell hardness exceeding 49 N / mm2as measured in accordance with EN1534.

[0176] Further, the intermediate layer 12 may have a bending moment exceeding a bending moment of the surface layer 14 as measured in accordance with ISO 2493-2. The intermediate layer 12 may have a bending moment exceeding 50 millinewton-meter as measured in accordance with ISO 2493-2.

[0177] A coating layer 16 is applied to the upper surface of the surface layer. The coating layer 16 may be applied on a surface of the wood veneer layer. The coating layer 16 may be a hard coating and / or a rigid coating. The coating may for example be an UV curable coating, or an EB curable coating.

[0178] The backing layer 15 is arranged on the second surface 10b of the substrate 10. The second surface 10b may be a lower surface of the substrate 10. The backing layer 15 may be attached to the second surface 10b of the substrate by an adhesive.

[0179] The backing layer 15 may include a wood veneer layer. In other examples, the backing layer may comprise a resin impregnated paper. The building panel in fig. 5 may have been produced according to the method shown in fig. 2. The building panel 1 comprises the substrate 10. The substrate 10 may be a wood-based board such as MDF or HDF board. The substrate 10 may be a plywood board. The substrate 10 may be a lamella core. The substrate 10 may be a particleboard. The substrate 10 may be a thermoplastic board.

[0180] The intermediate layer 12 of the building panel 1 shown in fig. 5 comprises a polymer material. The polymer material may be or comprise a thermosetting binder, such as amino resins, epoxy resins, polyurethanes, acrylics, polyesters, or a combination thereof.

[0181] The polymer material may be reinforced by fibres. The fibres may be organic and / or inorganic fibres. The fibres may be chosen from the group of natural fibres, glass fibres, polymer fibres, mineral-based fibres, carbon fibres, and a combination thereof. The fibres may be randomly distributed on the polymer material. The polymer material together with the fibres form the intermediate layer 12.

[0182] The surface layer 14 is attached to the intermediate layer 12 by an adhesive, which may form an adhesive layer 13. In the final building panel 1 , the adhesive layer 11 may be more or less distinct, and may in example no longer be present as a distinct layer.

[0183] The surface layer 14 comprises the wood veneer layer, which may have a thickness of 0.1 - 1 mm, such as 0.2 mm - 0.6 mm. The thickness of the surface layer 14 may be less than the thickness of the intermediate layer 12.

[0184] As discussed above, the intermediate layer 12 is more rigid and / or harder than the surface layer 14.

[0185] For example, the intermediate layer 12 may have Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN1534. The intermediate layer 12 may have Brinell hardness exceeding 49 N / mm2as measured in accordance with EN1534.

[0186] Further, the intermediate layer 12 may have a bending moment exceeding a bending moment of the surface layer 14 as measured in accordance with ISO 2493-2. The intermediate layer 12 may have a bending moment exceeding 50 millinewton-meter as measured in accordance with ISO 2493-2.

[0187] A coating layer 16 is applied to the upper surface of the surface layer. The coating layer 16 may be applied on a surface of the wood veneer layer. The coating layer 16 may be a hard coating and / or a rigid coating. The coating may be may for example be an UV curable coating, or an EB curable coating.

[0188] The backing layer 15 is arranged on the second surface 10b of the substrate 10. The second surface 10b may be a lower surface of the substrate 10. The backing layer 15 may be attached to the second surface 10b of the substrate by an adhesive.

[0189] The backing layer 15 may include a wood veneer layer. In other examples, the backing layer may comprise a resin impregnated paper.

[0190] The building panel in fig. 6 may have been produced according to the method shown in fig. 3. The building panel 1 comprises the substrate 10. The substrate 10 may be a wood-based board such as MDF or HDF board. The substrate 10 may be a plywood board. The substrate 10 may be a lamella core. The substrate 10 may be a particleboard. The substrate 10 may be a thermoplastic board.

[0191] The intermediate layer 12 comprises a wood veneer layer. The intermediate layer 12 is attached to the first surface 10a of the substrate 10 by an adhesive. The adhesive layer comprises a binder. The binder may be applied in liquid form as shown in fig. 3. The binder may be or comprise a thermosetting binder, such as amino resins, epoxy resins, polyesters, polyurethanes, acrylics, or a combination thereof.

[0192] The wood veneer layer may have a thickness exceeding 0.6 mm, such as having a thickness of 0.6 - 1.5 mm. The wood veneer layer may be or comprise a birch veneer layer, a poplar veneer layer, a beech veneer layer, or a pine wood veneer.

[0193] The wood veneer layer of the intermediate layer 12 is reinforced by the binder. The wood veneer layer reinforced by the binder of the adhesive forms the intermediate layer 12. The surface layer 14 is attached to the intermediate layer 12 by an adhesive, which may form an adhesive layer 13. In the final building panel 1 , the adhesive layer 11 may be more or less distinct, and may in example no longer be present as a distinct layer.

[0194] The surface layer 14 comprises the wood veneer layer, which may have a thickness of 0.1 - 1 mm, such as 0.2 mm - 0.6 mm. The thickness of the wood veneer layer of the surface layer 14 is less than the thickness of the wood veneer layer of the intermediate layer 12.

[0195] As discussed above, the intermediate layer is more rigid and / or harder than the surface layer.

[0196] For example, the intermediate layer 12 may have Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN1534. The intermediate layer 12 may have Brinell hardness exceeding 49 N / mm2as measured in accordance with EN1534.

[0197] Further, the intermediate layer 12 may have a bending moment exceeding a bending moment of the surface layer 14 as measured in accordance with ISO 2493-2. The intermediate layer 12 may have a bending moment exceeding 50 millinewton-meter as measured in accordance with ISO 2493-2.

[0198] A coating layer 16 is applied to the upper surface of the surface layer. The coating layer 16 may be applied on a surface of the wood veneer layer. The coating layer 16 may be a hard coating and / or a rigid coating. The coating may for example be an UV curable coating, or an EB curable coating

[0199] The backing layer 15 is arranged on the second surface 10b of the substrate 10. The second surface 10b may be a lower surface of the substrate 10. The backing layer 15 may be attached to the second surface 10b of the substrate by an adhesive.

[0200] The backing layer 15 may include a wood veneer layer. In other examples, the backing layer may comprise a resin impregnated paper.

[0201] Fig. 7 shows an example of the building panel 1 wherein the backing layer 15 has a structure that is different from the layers arranged on the first surface 10a of the substrate 10, i.e., the intermediate layer 12, the surface layer 14 and at least one adhesive layer 11, 13. The backing layer 15 comprises one layer, for example a HPL or wood veneer layer, adhered to the second surface 10b of the substrate 10 by an adhesive. The building panel 1 in fig. 7 may be similar to the building panels 1 in figs. 4, 5 and 6.

[0202] Fig. 8 shows an example of a building panel 1 wherein the backing layer 15 has a structure similar to the structure of the layers arranged on the first surface 10a of the substrate 10, i.e., the intermediate layer 12, the surface layer 14 and at least one adhesive layer 11 , 13. The backing layer 15 may have a similar structure to the layers arranged on the first surface 10a of the substrate 10 in terms of the number of layers.

[0203] In the example shown in fig.8, the backing layer comprises an adhesive layer 19, adhering an intermediate layer 18 to the second surface 10b of the substrate 10. The intermediate layer 18 may be of the same type as the intermediate layer 12 arranged on the first surface 10a of the substrate 10. An adhesive layer 17 is adhering the backing layer 15 to the intermediate layer 18. The backing layer 15 may be of the same type as the surface layer 14 arranged on the first surface 10a of the substrate 10. For example, the backing layer 15 may comprise a wood veneer layer.

[0204] Fig. 9 shows an exploded view of an example of a building panel 1 . The building panel 1 comprises a backing layer 15, a substrate 10, an intermediate layer 12 arranged on a first surface 10a of the substrate 10, a surface layer 14 arranged on a surface of the intermediate layer 12 opposite the substrate 10. The surface layer 14 is adhered to the intermediate layer 12 by an adhesive layer 13 arranged between the surface layer 14 and the intermediate layer 12. The intermediate layer 12 is continuous in a longitudinal (L) and / or transverse (T) direction extending along a first surface 10a of the substrate 10. The intermediate layer 12 is more rigid and / or harder than the surface layer 14, such that the intermediate layer 12 is configured to at least partially convert pressure forces applied on a surface of the surface layer 14 opposite the intermediate layer 12 to tensile forces in the intermediate layer 12.

[0205] By being continuous, the intermediate layer may extend continuously between opposite edges of a first surface of the substrate, in a longitudinal (L) and / or transverse (T) direction. The intermediate layer may be extending without any interruptions, such as joints of individual building elements, from edge to edge of a first surface of the substrate. The intermediate layer may be pre-formed. The intermediate layer may be formed in one piece.

[0206] In all examples herein, the building panel may be a floor panel, a wall panel, a furniture component, a building component, a worktop, etc.

[0207] It is contemplated that there are numerous modifications of the embodiments described herein, which are still within the scope of the disclosure as defined by the appended claims.

[0208] EXAMPLES

[0209] Brinell measurement

[0210] Brinell hardness (HB) was measured in accordance with EN1534. Force applied was 1000 N, ball diameter 10 mm.

[0211] Reference'. An oak veneer having a thickness of 0.6 mm was adhered to a HDF core by an adhesive (3M™ Hi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours.

[0212] Mean HB was measured to 48.8 N / mm2for the reference.

[0213] Sample 7: An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer of polycarbonate having a thickness of 5 mm by an adhesive (3M™ Hi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0214] Mean HB was measured to 67.3 N / mm2for Sample 1 .

[0215] Sample 2 An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer comprising 3 layers of fibreglass sheets. The fibreglass sheets were formed by coating each sheet of fiberglass with a polyester / hardener mix (from Biltema Sweden AB) and stacked one on the other in a criss-cross manner to the required thickness, a steel roller was used to smoothen the sample and let it cure for 24 hours in room temperature (no added pressure). The oak veneer was adhered to the intermediate layer of 3 fibreglass sheets by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours. Mean HB was measured to 60.0 N / mm2for Sample 2.

[0216] Sample 3 An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer comprising 6 layers of fibreglass sheets. The fibreglass sheets were formed by coating each sheet of fiberglass with a polyester / hardener mix (from Biltema Sweden AB) and stacked one on the other in a criss-cross manner to the required thickness, a steel roller was used to smoothen the sample and let it cure for 24hours in room temperature (no added pressure). The oak veneer was adhered to the intermediate layer of 6 fibreglass sheets by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0217] Mean HB was measured to 57.3 N / mm2for Sample 3.

[0218] Sample 4: An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer comprising 15 layers of a backing paper (240 g / m2) impregnated with melamine formaldehyde. The intermediate layer was formed by pressing 15 layered backing papers at 190 °C, 70 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The oak veneer was adhered to the intermediate layer of 15 layers of backing papers by an adhesive (3M™ Hi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0219] Mean HB was measured to 62.3 N / mm2for Sample 4.

[0220] Sample 5'. An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer comprising 10 layers of a backing paper (240 g / m2) impregnated with melamine formaldehyde. The intermediate layer was formed by pressing 15 layered backing paper at 190 °C, 70 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The oak veneer was adhered to the intermediate layer of 10 layers of backing papers by an adhesive (3M™ Hi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0221] Mean HB was measured to 72.5 N / mm2for Sample 5.

[0222] Sample 6: An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer comprising 5 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde. The intermediate layer was formed by pressing 5 layered backing paper at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The oak veneer was adhered to the intermediate layer of 5 layers of backing papers by an adhesive (3M™ Hi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0223] Mean HB was measured to 51 .5 N / mm2for Sample 6.

[0224] Sample 7: An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer comprising 3 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde. The intermediate layer was formed by pressing 3 layered backing paper at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The oak veneer was adhered to the intermediate layer of 3 layers of backing papers by an adhesive (3M™ Hi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0225] Mean HB was measured to 53.9 N / mm2for Sample 7.

[0226] Sample 8: An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer comprising 1 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde. The intermediate layer was formed by pressing the backing paper at 190 °C, 35 seconds and at 40 bar. After pressing, the backing paper thus forms an HPL. The oak veneer was adhered to the backing paper by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0227] Mean HB was measured to 48.1 N / mm2for Sample 8.

[0228] Sample 9: An oak veneer having a thickness of 0.6 mm was adhered to an intermediate layer of a stainless steel sheet having a thickness of 1 .5 mm. The oak veneer was adhered to the steel sheet by an adhesive (3MTMHi- Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 72 hours. The intermediate layer was adhered to a HDF by an adhesive (3MTMHi-Strength Spray Adhesive 90), light pressure in room temperature (about 0.085 kg / cm2) for 24 hours.

[0229] Mean HB was measured to 73.1 N / mm2for Sample 9.

[0230] As seen by the above measurement, by including the intermediate layer as in Samples 1-9, an increased HB is obtained, such as a HB exceeding 49 N / mm2as measured in accordance with EN1534. Sample 10: Brinell hardness of a polycarbonate sheet (Makroclear™ , Aria Plast AB) having a thickness of 5 mm was measured.

[0231] Mean HB was measured to 150 N / mm2.

[0232] Sample 11: Brinell hardness of a polycarbonate sheet (Makroclear™ , Aria Plast AB) having a thickness of 12 mm was measured.

[0233] Mean HB was measured to 152 N / mm2.

[0234] Sample 12: An intermediate layer comprising 1 layer of a backing paper (240 g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing paper at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The intermediate layer was adhered to a HDF by an adhesive (Casco, Cascol Polyurethane), pressure applied 10 bar for 4 hours.

[0235] The intermediate layer was attached to the HDF in order to enable Brinell measurement on the paper in samples 12-14. Similar test procedure is used for samples 12-14 such the sampled can be compared.

[0236] Mean HB was measured to 84.0 N / mm2for Sample 12.

[0237] Sample 13: An intermediate layer comprising 2 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing papers at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The intermediate layer was adhered to a HDF by an adhesive (Casco, Cascol Polyurethane), pressure applied 10 bar for 4 hours.

[0238] Mean HB was measured to 95.6 N / mm2for Sample 13. Sample 14: An intermediate layer comprising 5 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing papers at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The intermediate layer was adhered to a HDF by an adhesive (Casco, Cascol Polyurethane), pressure applied 10 bar for 4 hours.

[0239] Mean HB was measured to 135 N / mm2for Sample 14.

[0240] As shown by samples 12-14, mean HB is increasing by the number of backing papers included in the intermediate layer and thereby by the thickness of the intermediate layer. As mean HB value is increasing by the number of papers, it can be seen that the mean HB value is different from and exceeds the HB value of the HDF layer. Therefore, the mean HB value measured is relevant for the intermediate layer itself.

[0241] Impact testing

[0242] Impact was tested by dropping a ball from a height and cracks are studied and measured. Magnification 10x and contrast medium was permanent marker. Underlay material was extruded PE having a thickness of 3 mm and density of 30 kg / m3. Test method in accordance with EN 14354, Annex C with the following derivations:

[0243] - testing performed at a drop height of 1400 mm only,

[0244] - sample size was 120 * 200 mm.

[0245] Reference 1: An oak veneer having a thickness of 0.6 mm was adhered to a HDF core by an adhesive (3MTM Hi-Strength Spray Adhesive 90). The oak veneer was lacquered with UL61496 / 48 6G & PET Protect 938 in an amount of 25 g / m2. The impact test results for reference 1 can be seen in Table 1 below. Table 1: Impact test results for Reference 1

[0246] Sample 7: 10 backing papers (melamine impregnated papers, 240 g / m2) that has been pressed (press parameters 190 °C, 70 seconds and 40 bar, pressed on HDF) and thereby substantially cured forms an intermediate layer. After pressing, the backing papers thus forms an HPL. An oak veneer having a thickness of 0.6 mm was adhered to the intermediate layer by an adhesive (3M™ Hi-Strength Spray Adhesive 90). The oak veneer was lacquered with UL61496 / 48 6G & PET Protect 938 in an amount of 25 g / m2. The impact test results for Sample 1 can be seen in Table 2 below.

[0247] Table 1: Impact test results for Sample 1 Reference 2 An oak veneer having a thickness of 0.6 mm was adhered to a HDF core by an adhesive (3MTMHi-Strength Spray Adhesive 90). The oak veneer was lacquered with UL61496 / 48 6G & PET Protect 938 in an amount of 50 g / m2. The impact test results for Reference 2 can be seen in Table 3 below.

[0248] Table 3: Impact test results for Reference 2

[0249] Sample 2: 10 backing papers (melamine impregnated papers, 240g / m2) that has been pressed (press parameters 190 °C, 70 seconds and 40 bar, pressed on HDF) and thereby substantially cured forms an intermediate layer. After pressing, the backing papers thus forms an HPL. An oak veneer having a thickness of 0.6 mm was adhered to the intermediate layer by an adhesive (3MTMHi-Strength Spray Adhesive 90). The oak veneer was lacquered with UL61496 / 48 6G & PET Protect 938 in an amount of 50 g / m2. The impact test results for Sample 2 can be seen in Table 4 below.

[0250] Table 4: Impact test results for Sample 2

[0251] As can be seen by comparing each reference with corresponding sample, the extension of the cracks has been reduced by the intermediate layer. As a consequence of the rigid intermediate layer, it is possible to lacquer the wood veneer positioned above the intermediate layer with a lacquer having a higher degree of crosslinking. Compared to lacquering with the same lacquer on a wood veneer layer being arranged directly on the HDF, cracks are at least reduced. Thereby, a lacquer with a higher degree of crosslinking can be used, which is more resistant to chemicals compared to a lacquer with a lower degree of crosslinking.

[0252] Bending moment testing

[0253] Bending moment was tested according to ISO 2493-2. Sample size width 38±0.2 mm, length 70±1 mm.

[0254] Reference: An oak veneer having a thickness of 0.6 mm was used as a reference. The bending moment according to ISO 2493-2 was measured to 27.9 millinewton-meter. Sample 1 An intermediate layer comprising 1 layers of a backing paper (240 g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing paper at 190 °C, 35 seconds and at 40 bar. After pressing, the backing paper thus forms an HPL. The bending moment according to ISO 2493-2 was measured to 2.5 millinewton-meter.

[0255] Sample 2 An intermediate layer comprising 2 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing papers at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The bending moment according to ISO 2493-2 was measured to 18.6 millinewton-meter.

[0256] Sample 3: An intermediate layer comprising 3 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing papers at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The bending moment according to ISO 2493-2 was measured to 60.0 millinewton-meter.

[0257] Sample 4: An intermediate layer comprising 4 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing papers at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The bending moment according to ISO 2493-2 was measured to 146.1 millinewton-meter.

[0258] Sample 5'. An intermediate layer comprising 5 layers of a backing paper (240g / m2) impregnated with melamine formaldehyde was provided. The intermediate layer was formed by pressing the backing papers at 190 °C, 35 seconds and at 40 bar. After pressing, the backing papers thus forms an HPL. The bending moment according to ISO 2493-2 was measured to 333.2 millinewton-meter.

[0259] Sample 6 An intermediate layer comprising a 0.6 mm beech veneer impregnated with 350 g / m2polyester resin (polyester / hardener mix from Biltema Sweden AB) was provided. The intermediate layer was cured in ambient conditions for 24 hours. The bending moment according to ISO 2493-2 was measured to 55.0 millinewton-meter.

[0260] Sample 7: An intermediate layer comprising a 0.6 mm beech veneer was impregnated with 350 g / m2polyester resin (polyester / hardener mix from Biltema Sweden AB), left to cure in ambient conditions for 24 hours, thereafter, impregnated with 300 g / m2of the same polyester resin and cured in ambient conditions for 24 hours. The bending moment according to ISO 2493-2 was measured to 60.1 millinewton-meter.

[0261] A bending moment exceeding 50 millinewton-meter is considered sufficient rigid to at least partially convert pressure forces applied on a surface layer to tensile forces in the intermediate layer

[0262] ITEMS

[0263] 1 . A building panel (1 ), comprising: a substrate (10), an intermediate layer (12) arranged on a first surface (10a) of the substrate (10), a surface layer (14) arranged on a surface of the intermediate layer )12) opposite the substrate (10), wherein the surface layer (14) comprising a wood veneer layer, wherein the surface layer (14) is adhered to the intermediate layer (12) by an adhesive layer (13) arranged between the surface layer (14) and the intermediate layer (12), and wherein the intermediate layer (12) is more rigid and / or harder than the surface layer (14), such that the intermediate layer (12) is configured to at least partially convert pressure forces applied on a surface of the surface layer (14) opposite the intermediate layer (12) to tensile forces in the intermediate layer (12).

[0264] 2. The building panel according to claim 1 , wherein the substrate (10) and the intermediate layer (12) are adhered to each other by an adhesive layer (11) arranged between the substrate (10) and the intermediate layer (12).

[0265] 3. The building panel according to claim 1 or 2, wherein the building panel (1) has Brinell hardness exceeding 49 N / mm2, as measured in accordance with EN1534.

[0266] 4. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN1534. 5. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has Brinell hardness exceeding 49 N / mm2, as measured in accordance with EN1534.

[0267] 6. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has a bending moment exceeding a bending moment of the surface layer (14), as measured in accordance with ISO 2493-2.

[0268] 7. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has a bending moment exceeding 50 millinewton-meter as measured in accordance with ISO 2493-2.

[0269] 8. The building panel according to any one of the preceding claims, wherein the wood veneer layer has a thickness between 0.1 mm and 1 mm, such as between 0.2 mm and 0.6 mm.

[0270] 9. The building panel according to any one of the preceding claims, further comprising a coating layer (16) on the surface of the surface layer (14) opposite the intermediate layer (12).

[0271] 10. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises at least one cured resin impregnated paper.

[0272] 11. The building panel according to claim 10, wherein the intermediate layer (12) comprises at least one high pressure laminate (HPL) layer.

[0273] 12. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises a polymer-based material.

[0274] 13. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises a cured thermosetting binder. 14. The building panel according to any one of claims 1-9, wherein the intermediate layer (122) comprises a thermoplastic binder

[0275] 15. The building panel according to any one of claims 1-9, wherein the intermediate layer (12) comprises an epoxy resin.

[0276] 16. The building panel according to any one of claims 1-9, wherein the intermediate layer (12) comprises polycarbonate.

[0277] 17. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises a fibre reinforcement.

[0278] 18. The building panel according to claim 17, wherein the fibre reinforcement comprises glass fibres.

[0279] 19. The building panel according to any one of claims 1-9, wherein the intermediate layer (12) comprises a wood veneer layer reinforced by a polymer-based material.

[0280] 20. The building panel according to any one of the preceding claims, wherein adhesive from the adhesive layer (13) is present in the surface layer (14) in a portion extending from a surface facing the adhesive layer into a thickness of the surface layer (14), said portion being less than 10 % of a thickness of the wood veneer layer.

[0281] 21. The building panel according to any one of the preceding claims, further comprising a backing layer (15) adhered to a second surface (10b) of the substrate (10) by an adhesive layer.

[0282] 22. A method to produce a building panel (1), comprising arranging an intermediate layer (12) on a first surface (10a) of a substrate (10), applying an adhesive layer (13) on a surface of the intermediate layer (12) and / or on a surface of a surface layer (14), arranging the surface layer (14) on the intermediate layer (12), wherein the adhesive layer (13) is arranged between the intermediate layer (12) and the surface layer (14), adhering the substrate (10), the intermediate layer (12) and the surface layer (14) to each other, wherein the surface layer (14) is adhered to the intermediate layer (12) by the adhesive layer (13), wherein the intermediate layer (12) is more rigid and / or harder than the surface layer, such that the intermediate layer (12) is configured to convert pressure forces applied on a surface of the surface layer (14) opposite the intermediate layer (12) to tensile forces in the intermediate layer (12).

[0283] 23. The method according to claim 22, wherein pressure applied when adhering the substrate (10), the intermediate layer (12), and the surface layer (14) to each other is less than 30 bar.

[0284] 24. The method according to claim 22 or 23, wherein arranging the intermediate layer (12) on the substrate (10) comprises applying an adhesive layer (11 ) on the substrate (10) and / or the intermediate layer (12), such that the intermediate layer (12) is adhered to the substrate (10) by the adhesive layer (11).

[0285] 25. The method according to any one of claims 22-24, wherein the intermediate layer (12) comprises a thermosetting binder, wherein the thermosetting binder is in a cured state when the surface layer (14) is applied to the intermediate layer (12).

[0286] 26. The method according to any one of claims 22-25, further comprising applying a coating layer (16) on the surface of the surface layer (14) opposite the intermediate layer (12). 27. The method according to any one of claims 22-26, wherein the building panel (1) has a Brinell hardness exceeding 49 N / mm2, as measured in accordance with EN1534.

[0287] 28. The method according to any one of claims 22-27, wherein the intermediate layer (12) has a Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN 1534.

[0288] 29. The method according to any one of claims 22-28, wherein the intermediate layer (12) has a bending moment exceeding a bending moment of the surface layer (14), as measured in accordance with ISO 2493-2.

[0289] 30. The method according to any one of claims 22-29, wherein the intermediate layer (12) has a bending moment exceeding 50 millinewtonmeter, as measured in accordance with ISO 2493-2.

[0290] 31 . The method according to any one of claims 22-30, wherein the wood veneer layer has a thickness between 0.1 mm and 1 mm, such as between 0.2 mm and 0.6 mm.

[0291] 32. The method according to any one of claims 22-31 , wherein the intermediate layer (12) comprises at least one of the following:

[0292] - a polymer-based material;

[0293] - at least one cured resin impregnated paper;

[0294] - a cured thermosetting binder;

[0295] - at least one high pressure laminate (HPL) layer;

[0296] - a thermoplastic binder;

[0297] - an epoxy binder;

[0298] - polycarbonate;

[0299] - a wood veneer layer reinforced by a binder;

[0300] -a metal layer, such as a metal foil. 33. The method according to any one of claims 22-32, wherein the intermediate layer (12) comprises a fibre reinforcement.

Claims

CLAIMS1 . A building panel (1 ), comprising: a substrate (10), an intermediate layer (12) arranged on a first surface (10a) of the substrate (10), a surface layer (14) arranged on a surface of the intermediate layer (12) opposite the substrate (10), wherein the surface layer (14) comprises a wood veneer layer, wherein the surface layer (14) is adhered to the intermediate layer (12) by an adhesive layer (13) arranged between the surface layer (14) and the intermediate layer (12), wherein the intermediate layer (12) is continuous in a longitudinal (L) and / or a transverse (T) direction extending along a first surface (10a) of the substrate (10), and wherein the intermediate layer (12) is more rigid and / or harder than the surface layer (14), such that the intermediate layer (12) is configured to at least partially convert pressure forces applied on a surface of the surface layer (14) opposite the intermediate layer (12) to tensile forces in the intermediate layer (12).

2. The building panel according to claim 1 , wherein the substrate (10) and the intermediate layer (12) are adhered to each other by an adhesive layer (11) arranged between the substrate (10) and the intermediate layer (12).

3. The building panel according to claim 1 or 2, wherein the building panel (1) has a Brinell hardness exceeding 49 N / mm2, as measured in accordance with EN1534.

4. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has a Brinell hardness exceeding a Brinellhardness of the wood specie of the wood veneer layer, as measured in accordance with EN1534.

5. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has a Brinell hardness exceeding 49 N / mm2, as measured in accordance with EN1534.

6. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has a bending moment exceeding a bending moment of the surface layer (14), as measured in accordance with ISO 2493-2.

7. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) has a bending moment exceeding 50 millinewton-meter, as measured in accordance with ISO 2493-2.

8. The building panel according to any one of the preceding claims, wherein the wood veneer layer has a thickness between 0.1 mm and 1 mm, such as between 0.2 mm and 0.6 mm.

9. The building panel according to any one of the preceding claims, further comprising a coating layer (16) on the surface of the surface layer (14) opposite the intermediate layer (12).

10. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises at least one cured resin impregnated paper.

11. The building panel according to claim 10, wherein the intermediate layer (12) comprises at least one high pressure laminate (HPL) layer.

12. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises a polymer-based material.

13. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises a cured thermosetting binder.

14. The building panel according to any one of claims 1-9, wherein the intermediate layer (12) comprises a thermoplastic binder15. The building panel according to any one of claims 1-9, wherein the intermediate layer (12) comprises an epoxy resin.

16. The building panel according to any one of claims 1-9, wherein the intermediate layer (12) comprises polycarbonate.

17. The building panel according to any one of the preceding claims, wherein the intermediate layer (12) comprises a fibre reinforcement.

18. The building panel according to claim 17, wherein the fibre reinforcement comprises glass fibres.

19. The building panel according to any one of claims 1-9, wherein the intermediate layer (12) comprises a wood veneer layer reinforced by a polymer-based material.

20. The building panel according to any one of the preceding claims, wherein adhesive from the adhesive layer (13) is present in the surface layer (14) in a portion extending from a surface facing the adhesive layer into a thickness of the surface layer (14), said portion being less than 10 % of a thickness of the wood veneer layer.

21. The building panel according to any one of the preceding claims, further comprising a backing layer (15) adhered to a second surface (10b) of the substrate (10) by an adhesive layer.

22. A method to produce a building panel (1), comprisingarranging an intermediate layer (12) on a first surface (10a) of a substrate (10), applying an adhesive layer (13) on a surface of the intermediate layer (12) and / or on a surface of a surface layer (14), arranging the surface layer (14) on the intermediate layer (12), wherein the adhesive layer (13) is arranged between the intermediate layer (12) and the surface layer (14), adhering the substrate (10), the intermediate layer (12) and the surface layer (14) to each other, wherein the surface layer (14) comprises a wood veneer layer, wherein the surface layer (14) is adhered to the intermediate layer (12) by the adhesive layer (13), wherein the intermediate layer (12) is continuous in a longitudinal (L) and / or a transverse (T) direction extending along a first surface (10a) of the substrate (10), and wherein the intermediate layer (12) is more rigid and / or harder than the surface layer, such that the intermediate layer (12) is configured to convert pressure forces applied on a surface of the surface layer (14) opposite the intermediate layer (12) to tensile forces in the intermediate layer (12).

23. The method according to claim 22, wherein adhering the substrate (10), the intermediate layer (12) and the surface layer (14) to each other comprises thereby forming a board (2), and wherein the method further comprises dividing the board (2), thereby forming the building panel (1).

24. The method according to claim 23, wherein the board (2) is divided in a longitudinal (L) and / or transverse (T) direction, extending along a first surface (10a) of the substrate (10).

25. The method according to claim 23 or 24, wherein dividing the board (2) comprises forming at least two building panels (1).

26. The method according to any one of claims 22-25, wherein a pressure applied when adhering the substrate (10), the intermediate layer(12), and the surface layer (14) to each other is less than 30 bar.

27. The method according to any one of claims 22-26, wherein arranging the intermediate layer (12) on the substrate (10) comprises applying an adhesive layer (11) on the substrate (10) and / or the intermediate layer (12), such that the intermediate layer (12) is adhered to the substrate(10) by the adhesive layer (11).

28. The method according to any one of claims 22-27, wherein the intermediate layer (12) comprises a thermosetting binder, wherein the thermosetting binder is in a cured state when the surface layer (14) is applied to the intermediate layer (12).

29. The method according to any one of claims 22-28, further comprising applying a coating layer (16) on the surface of the surface layer (14) opposite the intermediate layer (12).

30. The method according to any one of claims 22-29, wherein the building panel (1) has a Brinell hardness exceeding 49 N / mm2, as measured in accordance with EN1534.31 . The method according to any one of claims 22-30, wherein the intermediate layer (12) has a Brinell hardness exceeding a Brinell hardness of the wood specie of the wood veneer layer, as measured in accordance with EN 1534.

32. The method according to any one of claims 22-31 , wherein the intermediate layer (12) has a bending moment exceeding a bending moment of the surface layer (14), as measured in accordance with to ISO 2493-2.

33. The method according to any one of claims 22-32, wherein the intermediate layer (12) has a bending moment exceeding 50 millinewtonmeter, as measured in accordance with ISO 2493-2.

34. The method according to any one of claims 22-33, wherein the wood veneer layer has a thickness between 0.1 mm and 1 mm, such as between 0.2 mm and 0.6 mm.

35. The method according to any one of claims 22-34, wherein the intermediate layer (12) comprises at least one of the following:- a polymer-based material;- at least one cured resin impregnated paper;- a cured thermosetting binder;- at least one high pressure laminate (HPL) layer;- a thermoplastic binder;- an epoxy binder;- polycarbonate;- a wood veneer layer reinforced by a binder;-a metal layer, such as a metal foil.

36. The method according to any one of claims 22-35, wherein the intermediate layer (12) comprises a fibre reinforcement.

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