发明人：
JACOBSSON, JAN | ZIEGLER, GÖRAN | RYBERG, MELKER | BERGELIN, MARCUS
摘要：
The present invention relates to a method of manufacturing a separate and continuous layer (1) being essentially uncured. The method comprises applying a powder mix (2) comprising fibres and a thermosetting binder on a carrier (10), forming a powder mix layer (1), wherein the powder mix (2) is connected together such that the powder mix layer (1) is obtained and wherein the powder mix layer (1) is essentially uncured, and releasing the powder mix layer (1) from the carrier (10). The invention also relates to such a layer and a method for manufacturing a building panel.
技术功效语段：
The present invention provides a method for obtaining a flexible layer that can be easily handled and stored. The layer is formed from a powder mix that can be cured to form a continuous layer. The layer is less brittle and can be bent without cracking, making it easier to handle and store with reduced risk for damaging the product. The layer can be attached to a core simultaneously as curing the layer, eliminating the need for additional binder between the layer and the core. The layer can be used for various applications such as protective layer, printing layer, decorative layer, wear layer, balancing layer, antistatic layer, antibacterial layer, and furniture and flooring applications.
权利要求：
1. A method of manufacturing a separate and continuous layer (1) being essentially uncured, comprising - applying a powder mix (2) comprising fibres (4) and a thermosetting binder (3) on a carrier (10), - forming a powder mix layer (1), wherein the powder mix (2) is connected together such that the powder mix layer (1) is obtained and wherein the powder mix layer (1) is essentially uncured, and - releasing the powder mix layer (1) from the carrier (10).
2. The method according to claim 1, wherein said layer (1) is flexible.
3. The method according to claim 1 or 2, wherein the step of forming the powder mix layer (1) includes applying moisture (31) on the powder mix (2) such that the powder mix (2) is connected together.
4. The method according to claim 3, wherein a liquid forming the moisture (31) is water, an alcohol, an ink, a binder, preferably a thermosetting binder, more preferably melamine formaldehyde, or a mixture thereof.
5. The method according to any one of claims 1-4, wherein the step of forming the powder mix layer (1) includes heating the powder mix (2) such that the powder mix (2) is connected together.
6. The method according to any one of claims 1-5, wherein the step of forming the powder mix layer (1) includes drying the powder mix (2) such that the powder mix (2) is connected together.
7. The method according to any one of claims 1-6, wherein the step of forming the powder mix layer (1) includes applying pressure on the powder mix (2) such that the powder mix (2) is connected together.
8. The method according to any one of claims 1-7, wherein the fibres (4) are wood fibres, plastic fibres, mineral fibres or vegetable fibres such as jute, linen, flax, cotton, hemp, bamboo, bagasse and sisal, or a mixture thereof.
9. The method according to any one of claims 1-8, wherein the step of applying the powder mix (2) on the carrier (10) comprises applying the powder mix (2) on a supporting layer (8) arranged on the carrier (10).
10. The method according to any one of claims 1-9, further comprising arranging a reinforcement structure (7) in the powder mix (2).
11. The method according to claim 9 or 10, wherein the supporting layer and/or the reinforcement structure (7, 8) comprises a non-woven sheet, a paper sheet, mineral fibres, carbon fibres, textile fibres or nylon fibres.
12. The method according to any one of claims 1-11, further comprising printing a print (71) in the powder mix (2) and/or in the powder mix layer (1), preferably by means of digital printing.
13. The method according to claim 12, further comprising printing a print (71) on both sides of the powder mix layer (1).
14. The method according to any one of claims 1-13, further comprising applying liquid (31) in a pattern (32), preferably by means of digital printing.
15. A separate and continuous layer (1) being essentially uncured, comprising a powder mix layer (1) comprising a powder mix (2) including fibres (4) and a thermosetting binder (3), wherein the powder mix (2) is connected together to form the powder mix layer (1), and wherein the powder mix (2) is essentially uncured.