Patent BE-1017168-A5 (BE)
Title: Manufacturing of coated panels e.g. a floor panel or a furniture panel, comprises forming a carrier sheet provided with resin coating, and providing a suspension that includes a portion of hard micro-particles
Filed: 2006-06-13
Granted: 2008-03-04
Abstract: The method for manufacturing coated panels e.g. a floor panel or a furniture panel, comprises forming a carrier sheet (3) provided with a resin (2) coating, and providing a suspension, which comprises a portion of hard micro-particles (9) at a upper side (7) of the already resin-pre-treated carrier sheet. The coated panels comprise a top layer (1), the carrier sheet, and a printed decor (6) or coloration. The hard micro-particles are incorporated into the top layer, which is situated above the printed decor or coloration. The method for manufacturing coated panels e.g. a floor panel or a furniture panel, comprises forming a carrier sheet (3) provided with a resin (2) coating, and providing a suspension, which comprises a portion of hard micro-particles (9) at a upper side (7) of the already resin-pre-treated carrier sheet. The coated panels comprise a top layer (1), the carrier sheet, and a printed decor (6) or coloration. The hard micro-particles are incorporated into the top layer, which is situated above the printed decor or coloration. The partially resintreated or resin-pre-treated carrier sheet has an amount of resin at the side intended to form the upper side. The ceramic particles are used for the micro-particles. A mixture of solids dissolved in water is used for the suspension (8), where the mixture comprises 70 wt.% of micro-particles and 30 wt.% of mixture of solids. The step of forming the resin-pretreated carrier sheet consists of the metered application of resin. Hard particles (14) are provided in the top layer at a location where they are situated in the final panel above the printed decor or coloration and below the micro-particles applied by means of a suspension in a resin layer. The hard particles situated beneath the micro-particles have a larger average size of 60-160 micrometer, and are applied in a separate step. The carrier sheet relates to an overlay (4) and the hard particles situated in the final panel are applied on that side of the carrier sheet that is intended to form the underside. The overlay consists of alpha cellulose paper into which hard particles such as aluminum oxide and/or glass fibers are integrated, and has a weight of 20-25 gram/m 2>. The resin-pre-treated carrier sheet in dry condition has a weight of 130-170 gram/m 2>. The carrier sheet forming the printed decor or coloration is a paper sheet having a weight of 70-90 gram/m 2>. The resin-pre-treated carrier sheet is dried to a residual moisture content of maximum 15% and maximum 7% respectively, before and after the suspension is applied. The suspension contains a dispersing agent maintaining the micro-particles in suspension. For the application of the suspension, use is made of a metering device, a spreading device by means of a knife, an application device with a wire doctor roll and/or raster roll, an application device with an air knife, or an application device by means of rolls and knives. The step of applying the suspension is performed in an application device, which is in line with a device applied during the step of forming the resin-pre-treated carrier sheet. When performing the method two ovens are used, and the application device is situated between these ovens by which the entire suspension is applied. The micro-particles have an average grain size of 5-30 micrometers. The suspension is free of cellulose. Independent claims are included for: (1) a coated panel; (2) a method for applying a substance on a material sheet; and (3) a material sheet.