发明人：
BERGELIN, MARCUS | JACOBSSON, JAN | ZIEGLER, GÖRAN | RYBERG, MELKER
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.
技术问题语段：
The patent text discusses two types of flooring products: direct pressed laminated flooring (DPL) and new "paper free" wood fibre floor (WFF). The technical problem addressed in this text is to provide flooring products with a thicker and more impact-resistant surface layer that can be made with low cost and recycled materials, and that also have improved sound and moisture properties. There is also a problem of handling separate wood fibre layers that become brittle after curing, which is not ideal for use in flooring products.
技术功效语段：
The present invention provides a layer that can be made into a separate product and has less risk of damage compared to a conventional cured material. The layer can be attached to a core to form a surface layer of a building panel without the need for additional binder. The layer can be used for various applications such as protective layers, printing layers, decorative layers, wear layers, antistatic layers, and antibacterial layers. The powder mix layer is flexible and can adapt to curved surfaces, making it useful in furniture and flooring applications.
权利要求：
1. A method of forming a surface layer of a building panel, comprising 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), - tearing the powder mix layer (1) into smaller portions forming decorative elements, mixing the decorative elements with a powder mix, preferably a wood fibre mix, applying the mix of the decorative elements and the powder mix, on a core (5) to form a surface layer of a building panel (100).
2. 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.
3. The method according to claim 2, 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.
4. The method according to any one of claims 1-3, 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.
5. The method according to any one of claims 1-4, 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.
6. The method according to any one of claims 1-5, 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.
7. The method according to any one of claims 1-6, 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.
8. The method according to any one of claims 1-7, wherein the thermosetting binder (3) is a melamine resin.
9. The method according to any one of claims 1-8, 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.
10. The method according to claim 9, further comprising printing a print (71) on both sides of the powder mix layer (1).
11. The method according to any one of claims 1-10, further comprising applying liquid (31) in a pattern (32), preferably by means of digital printing.
12. The method according to any one of claims 1-11, further comprising curing the surface layer.
13. The method according to any one of claims 1-12, wherein the power mix layer (1) is a decorative layer.
14. The method according to any one of claims 1-13, wherein the powder mix (2) further comprises pigments.