Method of manufacturing a building panel and a building panel

Abstract

A method of manufacturing a building panel (10). The method includes applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a carrier for forming a first layer (11), applying a second binder and free lignocellulosic or cellulosic particles on the first layer (11) for forming a second layer (12), wherein the first binder is different from the second binder, and applying heat and pressure to the first and second layers (11, 12) to form a building panel. Also, such a building panel (10).

Claims

1. A method of manufacturing a building panel, comprising applying a first binder and free lignocellulosic or cellulosic particles on a first surface of a core for forming a first layer, the core being a wood based board, the core possessing a second surface opposite to the first surface, applying a second binder and free lignocellulosic or cellulosic particles on the first layer for forming a second layer, wherein the first binder is different from the second binder, applying heat and pressure to the first and second layers to form the building panel, and applying a balancing layer on the second surface of the core opposite to the first surface, wherein the first binder is urea formaldehyde resin and the second binder is melamine formaldehyde resin.

2. A method according to claim 1, wherein applying the first binder and said free lignocellulosic or cellulosic particles comprises applying a first mix comprising the first binder and said free lignocellulosic or cellulosic particles.

3. A method according to claim 2, wherein the first mix is a first powder mix.

4. The method according to claim 2, wherein applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles, the first binder is 45-60% of the first mix by weight, and the second binder is 45-60% of the second mix by weight.

5. The method according to claim 2, wherein applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles, and a binder concentration of the first binder in the first mix is equal to the binder concentration of the second binder in the second mix.

6. A method according to claim 1, wherein said first binder is applied in liquid form.

7. A method according to claim 6, wherein said free lignocellulosic or cellulosic particles are applied onto the liquid first binder.

8. A method according to claim 1, wherein applying the second binder and said free lignocellulosic or cellulosic particles comprises applying a second mix comprising the second binder and said free lignocellulosic or cellulosic particles.

9. A method according to claim 8, wherein the second mix is a second powder mix.

10. A method according to claim 1, wherein said second binder is applied in liquid form.

11. A method according to claim 10, wherein said free lignocellulosic or cellulosic particles are applied onto the liquid second binder.

12. A method according to claim 1, wherein the second layer further comprises wear resistant particles.

13. A method according to claim 1, wherein the binder concentration of the first layer substantially correspond to the binder concentration of the second layer.

14. A method according to claim 1, wherein the building panel is a floor panel.

15. The method according to claim 1, wherein the balancing layer is applied to the core before the applying of the first binder and the free lignocellulosic or cellulosic particles.

16. The method according to claim 1, wherein the applying of the first binder and the free lignocellulosic or cellulosic particles consists of applying a first dry powder of urea formaldehyde resin and free lignocellulosic or cellulosic particles, and the applying of the second binder and the free lignocellulosic or cellulosic particles on the first layer for forming the second layer consists of applying a second dry powder of melamine formaldehyde resin and free lignocellulosic or cellulosic particles on the first layer.

17. A method of manufacturing a building panel, comprising: applying a first layer comprising a first binder and free lignocellulosic or cellulosic particles on a first surface of a board, applying a second layer comprising a second binder and free lignocellulosic or cellulosic particles on the first layer, the first binder being uncured when the second layer is applied, and applying heat and pressure to the board, the first layer, and the second layer to cure the first and second layers thereby forming the building panel, wherein the first binder is different from the second binder, wherein the first binder is urea formaldehyde resin, a mixture comprising urea formaldehyde resin, or a co-polymer comprising urea formaldehyde resin, and wherein the second binder is melamine formaldehyde resin, a mixture comprising melamine formaldehyde resin, or a co-polymer comprising melamine formaldehyde resin.

18. The method according to claim 17, wherein the first binder and the free lignocellulosic or cellulosic particles of the first layer are applied as a first mix on the first surface of the board, the second binder and the free lignocellulosic or cellulosic particles of the second layer are applied as a second mix on the first mix, and the first and second mixes are substantially homogenous such that the first and second layers of the building panel each possess a substantially uniform composition after the first and second mixes are formed into the building panel.

19. The method according to claim 18, wherein the first and second mixes are each a dry powder.

20. The method according to claim 17, wherein the first mix cures faster than the second mix when the heat and pressure are applied.

21. A method of manufacturing a building panel, comprising: applying a first layer comprising a first binder and free lignocellulosic or cellulosic particles on a first surface of a core, the first layer being applied as a dry powder mix in an amount of 100-700 g/m.sup.2, applying a second layer comprising a second binder and free lignocellulosic or cellulosic particles on the first layer, the first binder being uncured when the second layer is applied, the second layer being applied as a dry powder mix in an amount of 100-700 g/m.sup.2, and applying heat and pressure to the board, the first layer, and the second layer to cure the first and second layers thereby forming the building panel, wherein the first binder is different from the second binder, the first binder comprising urea formaldehyde resin and the second binder comprising melamine formaldehyde resin.

22. The method according to claim 21, wherein a ratio of the amount of the dry powder mix of the first layer to the amount of the dry powder mix of the second layer is 1:1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The disclosure will by way of example be described in more detail with reference to the appended schematic drawings, which show embodiments of the disclosure.

(2) FIG. 1 schematically illustrates a method of manufacturing a building panel according to a first embodiment.

(3) FIG. 2 illustrates a building panel.

(4) FIG. 3 schematically illustrates a method of manufacturing a building panel according to a second embodiment.

(5) FIG. 4 schematically illustrates a method of manufacturing a building panel according to a third embodiment.

DETAILED DESCRIPTION

(6) FIG. 1 schematically illustrates a production line for a process for manufacturing a building panel 10. The production line comprises a first applying unit 1 and a second applying unit 2. The production line further comprises a conveying belt 6, a stabilisation unit 7 for applying moisture, a heating unit 8 for heating and/or drying powder mixes, and a pressing unit 9.

(7) A first mix 3 is applied by the first applying unit 1. The first mix 3 comprises lignocellulosic or cellulosic particles and a first binder. The first mix 3 may further comprise additives. The first mix 3 is applied as a powder. Preferably, the lignocellulosic or cellulosic particles are mixed with the first binder in powder form. The first mix 3 is preferably a substantially homogenous mix.

(8) In one embodiment, as an alternative or complement to the mix, the first binder and the lignocellulosic or cellulosic particles are applied separately. The first binder may be applied as one layer and the lignocellulosic or cellulosic particles may be applies as another layer. Subsequent steps, described below in relation to a mix, are applicable also for a first layer formed by such a first binder layer and a lignocellulosic or cellulosic particles layer.

(9) The first binder may be urea formaldehyde resin, a mixture comprising urea formaldehyde resin, or a co-polymer comprising urea formaldehyde resin such as melamine-urethane formaldehyde (MUF).

(10) In one embodiment, the first binder may be phenol formaldehyde resin, a mixture comprising phenol formaldehyde resin, or a co-polymer comprising phenol formaldehyde resin.

(11) In one embodiment, the first binder may be a thermoplastic binder. The thermoplastic binder may be polyvinyl acetate (PVAC), a mixture comprising polyvinyl acetate, or a co-polymer comprising polyvinyl acetate. The thermoplastic binder may be polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PE), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate or acrylic, a mixture comprising polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PE), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate or acrylic, or a co-polymer comprising polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PE), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate, methacrylate or acrylic.

(12) In one embodiment, the first binder may be a mixture comprising a thermoplastic binder and a thermosetting resin such as an amino resin. The thermoplastic binder may be polyvinyl acetate, polyvinyl chloride, polypropylene, polyethylene, or polyurethane. The thermosetting resin may be urea formaldehyde resin or melamine formaldehyde resin. A co-polymer may be formed of a thermoplastic binder such as polyvinyl acetate and amino resin such as urea formaldehyde, melamine formaldehyde and/or phenol formaldehyde, especially at low pH.

(13) The lignocellulosic particles comprise lignin. The lignocellulosic particles may be refined particles such as refined wood fibres. The cellulosic particles comprise no lignin or substantially no lignin (e.g., less than 5% lignin by weight). The cellulosic particles may be at least partly bleached particles such as at least partly bleached wood fibres.

(14) The first mix 3 is applied by the first applying unit 1 on a first surface of a carrier. The first applying unit 1 is preferably a scattering unit adapted to scatter the first mix 3 on the carrier. The carrier may be the conveyor belt 6. In the embodiment shown in FIG. 1, the carrier is a core 5. The core 5 is preferably a wood based board such as a HDF, MDF, particleboard, OSB, or WPC (Wood Plastic Composite). The core 5 is arranged on the conveyor belt 6 such that the conveyor belt 6 conveys the core 5. The first mix 3 is adapted form a first layer 11 arranged on a first surface of the core 5. The first mix 3 may be applied in an amount of 100-700 g/m2. The first mix 3 may comprise 45-60% by weight binder.

(15) The first mix 3 may further comprise additives or fillers having sound-absorbing properties such as cork particles and/or barium sulphate (BaSO4).

(16) In one embodiment, the first mix 3 may be stabilised before the second mix 4 is applied (not shown). The first mix 3 may be stabilised by moisture. The moisture may be finely dispersed or may include droplets of a liquid. The first mix 3 may also attract humidity from the air, thereby applying moisture to the first mix 3. The liquid forming the moisture may be water, an alcohol, ink, a binder, preferably a thermosetting binder, more preferably melamine formaldehyde, or a mixture thereof. The liquid may further include substances such as additives, agents, pigments and/or primers, for example controlling a subsequent printing process. The first mix 3 may be dried in a heating device, for example by means of infrared light. The first mix 3 may be pre-pressed before the second mix 4 is applied.

(17) In one embodiment, a print may be printing in the first mix 3 prior to applying a second mix 4, preferably by digital printing.

(18) A second mix 4 is applied by the second applying unit 2 on the first mix 3. The second mix 4 comprises lignocellulosic or cellulosic particles and a second binder. The second binder is a thermosetting binder, preferably an amino resin such as urea formaldehyde, melamine formaldehyde or phenol formaldehyde, or a combination thereof, or co-polymer thereof. The second binder may be melamine formaldehyde resin (MF). The second mix 4 may further comprise additives. Preferably, the second mix 4 further comprises wear resistant particles such as aluminium oxide (corundum). The second mix 4 is applied as a powder. Preferably, the lignocellulosic or cellulosic particles are mixed with melamine formaldehyde resin in powder form. The second mix 4 is preferably a substantially homogenous mix. The second mix 4 may further comprise pigments.

(19) In one embodiment, as an alternative or complement to the mix, the second binder and the lignocellulosic or cellulosic particles are applied separately. The second binder may be applied as one layer and the lignocellulosic or cellulosic particles may be applies as another layer. Subsequent steps described below in relation to a mix are applicable also for a second layer formed by such a second binder layer and a lignocellulosic or cellulosic particles layer.

(20) Preferably, the second binder may be in form of melamine formaldehyde resin, a mixture comprising melamine formaldehyde resin, or a co-polymer comprising melamine formaldehyde resin.

(21) The lignocellulosic particles comprise lignin. The lignocellulosic particles may be refined particles such as refined wood fibres. The cellulosic particles comprise no lignin or substantially no lignin (e.g., less than 5% lignin by weight). The cellulosic particles may be at least partly bleached particles such as at least partly bleached wood fibres.

(22) The second applying unit 2 is preferably a second scattering unit adapted to scatter the second mix 4 on the first mix 3. The second mix 4 is adapted to form a second layer 12 arranged on the first layer 11. The second mix 4 may be applied in an amount of 100-700 g/m2. The second mix 4 may comprise 45-60% by weight binder.

(23) The relation between the amount of the first mix 3 and of the second mix 4 applied may for example be 2:3, 1:1, or 1:4 or amounts there between.

(24) Both the first and the second mixes 3, 4 may comprise additives such as wetting agents, release agents, catalysts, anti-static agents, anti-slip agents and pigments etc. By adding a higher amount of catalysts to the first mix 3 compared to the second mix 4, the first layer may be cured faster, thereby preventing binders from transferring from the second mix 4 to the first mix 3.

(25) The first mix 3 and the second mix 4 are thereafter stabilized in the stabilization unit 7. Moisture is applied to the first and the second mixes 3, 4. The moisture may be finely dispersed or may include droplets of a liquid. The first and second mixes 3, 4 may also attract humidity from the air, thereby applying moisture to the first and second mixes 3, 4. The liquid forming the moisture may be water, an alcohol, ink, a binder, preferably a thermosetting binder, more preferably melamine formaldehyde, or a mixture thereof. The liquid may further include substances such as additives, agents, pigments and/or primers, for example adapted to control a subsequent printing process.

(26) The first and second mixes 3, 4 are thereafter dried in a heating device 8, preferably by means of infrared light (IR).

(27) A print may be printed in the second mix 4 prior to pressing, preferably by digital printing.

(28) In one embodiment, the first and second mixes may be pre-pressed.

(29) The core 5 having the first and the second mixes 3, 4 applied thereon is thereafter conveyed to a pressing unit 9. The pressing unit 9 may be a continuous or static press. Heat and pressure are applied to the first and second mix 3, 4 such that the binders are cured and a first and a second layer 11, 12 are formed on the core 5. An embossed press plate may be used to form an embossed structure of the second layer 12.

(30) FIG. 2 discloses a building panel 10 formed by the method described above. The building panel 10 comprises a core 5, a first layer 11 and a second layer 12. The core 5 may be a wood-based board such as HDF, MDF, particleboard, OSB, or WPC (Wood Plastic Composite). The first layer 11 forms a sub-layer arranged on a first surface of the core 5. The first layer 11 comprises as described above a first mix 3 comprising lignocellulosic or cellulosic material and the first binder of the above described type. The second layer 12 forms a top layer arranged on the first layer 11. The second layer 12 comprises as described above a second mix 4 comprising lignocellulosic or cellulosic material and the second binder of the above described type. The second layer 12 may be a decorative surface layer. The second mix 4 may further comprise pigments, a print etc. A print, preferably printed by digital printing, may be printed in the second mix 4, preferably before curing. Preferably, the second layer 12 comprises wear resistant particles such as aluminium oxide.

(31) The first layer 11 and the second layer 12 may be differently coloured, for example by adding different pigments to the first mix 3 and the second mix 4. A decorative groove may be formed in the second layer 12 such that the first layer 11 is visible.

(32) A balancing layer 14 may be applied to a second surface of the core 5, opposite the first surface, as shown in FIG. 2. The balancing layer 14 is adapted to balance forces formed by the first and second layers 11, 12 during pressing, cooling and climate changes. The balancing layer 14 may also be formed of a mix comprising lignocellulosic or cellulosic material and a binder, preferably a thermosetting binder. The thermosetting binder may an amino resin such as urea formaldehyde or melamine formaldehyde. The mix is cured during the above described pressing to form a balancing layer. The balancing layer 14 may be produced as described in WO 2012/141647.

(33) In the embodiments described above with reference to FIG. 1 and FIG. 2, the first mix 3 is applied on a core 5 arranged on the carrier. In one embodiment, the first mix 3 is applied directly on the carrier. The carrier may be a conveyor belt 6, a temporary carrier such as a plate etc. As described above, the first mix 3 comprises lignocellulosic or cellulosic particles and the first binder of the above described type, for example comprising urea formaldehyde resin, phenol formaldehyde resin, or a thermoplastic binder.

(34) The second mix 4 is applied on the first mix 3. The second mix comprises as described above lignocellulosic or cellulosic particles and the second binder of the above described type. The second binder may, for example, be a thermosetting resin, preferably an amino resin such as melamine formaldehyde, urea formaldehyde, phenol formaldehyde or a combination thereof. The second mix 4 may further comprise wear resistant particles, pigments, additives etc. The first and second mixes 3, 4 may be stabilised as described above with reference to FIG. 1. Heat and pressure is applied to the first and second mix 3, 4 in a pressing unit as described above. The first mix 3 is formed to a first layer 11. The second mix 4 is cured to a second layer 12. By pressing, the first and second layers 11, 12 are simultaneously adhered to each other. Thereby, a panel comprising a first and a second layer 11, 12 are formed. The panel may be adhered to a core in a later process, in a similar way as a compact laminate.

(35) FIG. 3 schematically illustrates a production line for a process for manufacturing a building panel 10 according to a second embodiment. The production line comprises a first applying unit 21, a second applying unit 22, a third applying unit 23, and fourth applying unit 24. The production line further comprises a conveying belt 6, optional heating units (not shown) for heating and/or drying the layers, and a pressing unit 9.

(36) The first applying unit 21 applies a first binder 31 in liquid form on a first surface of the carrier. In the embodiment shown in FIG. 3, the carrier is a core 5. The core 5 is preferably a wood based board such as a HDF, MDF, particleboard, OSB, or WPC (Wood Plastic Composite). The core 5 is arranged on the conveyor belt 6 such that the conveyor belt 6 conveys the core 5.

(37) The first binder 31 is thus applied as a liquid dispersion. The dispersion may be a solution or a suspension. The first binder may dissolved in a solvent, preferably water. The binder content of the dispersion may be 30-90% by weight.

(38) The first binder 31 may be urea formaldehyde resin, a mixture comprising urea formaldehyde resin, or a co-polymer comprising urea formaldehyde resin such as melamine-urethane formaldehyde (MUF).

(39) In one embodiment, the first binder 31 may be phenol formaldehyde resin, a mixture comprising phenol formaldehyde resin, or a co-polymer comprising phenol formaldehyde resin.

(40) In one embodiment, the first binder 31 may be a thermoplastic binder. The thermoplastic binder may be polyvinyl acetate (PVAC), a mixture comprising polyvinyl acetate, or a co-polymer comprising polyvinyl acetate. The thermoplastic binder may be polyvinyl chloride (PVC), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate or methacrylate, a mixture comprising polyvinyl chloride (PVC), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate or methacrylate, or a co-polymer comprising polyvinyl chloride (PVC), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate, methacrylate or acrylic.

(41) In one embodiment, the first binder 31 may be a mixture comprising a thermoplastic binder and a thermosetting resin such as an amino resin applied in liquid form. The thermoplastic binder may be polyvinyl acetate, or polyurethane. The thermosetting resin may be urea formaldehyde resin or melamine formaldehyde resin. A co-polymer may be formed of a thermoplastic binder such as polyvinyl acetate and amino resin such as urea formaldehyde, melamine formaldehyde and/or phenol formaldehyde, especially at low pH.

(42) The dispersion comprising the first binder 31 may further comprise additives, pigments and fillers. The dispersion may further comprise additives or fillers having sound-absorbing properties such as cork particles and/or barium sulphate (BaSO4).

(43) The second applying unit 22 applies, preferably scatters, lignocellulosic or cellulosic particles 32 into the liquid first binder 31 applied on the core. Preferably, the lignocellulosic or cellulosic particles 32 are applied into a wet binder layer arranged on the core.

(44) The lignocellulosic or cellulosic particles 32 are free particles when applied into the liquid first binder. For example, the lignocellulosic or cellulosic particles 32 may be applied as a powder.

(45) The lignocellulosic particles comprise lignin. The lignocellulosic particles may be refined particles such as refined wood fibres. The cellulosic particles comprise no lignin or substantially no lignin (e.g., less than 5% lignin by weight). The cellulosic particles may be at least partly bleached particles such as at least partly bleached wood fibres.

(46) The first binder 31 applied in liquid form and the lignocellulosic or cellulosic particles 32 forms a first layer 11. The first layer 11 may be dried, preferably by applying heat or IR, prior to further processing steps.

(47) In one embodiment, a print may be printing in the first layer 11 prior to applying a second layer 12, preferably by digital printing.

(48) A third applying unit 23 applies a second binder 33 in liquid form on the first layer 11.

(49) The second binder 33 is thus applied as a liquid dispersion. The dispersion may be a solution or a suspension. The second binder may dissolved in a solvent, preferably water. The binder content of the dispersion may be 30-90% by weight.

(50) The second binder 33 may be a thermosetting binder, preferably an amino resin such as urea formaldehyde, melamine formaldehyde or phenol formaldehyde, or a combination thereof, or co-polymer thereof. The second binder may be melamine formaldehyde resin (MF), a mixture comprising melamine formaldehyde resin, or a co-polymer comprising melamine formaldehyde resin.

(51) The dispersion comprising the second binder 33 may further comprise additives. Preferably, the dispersion further comprises wear resistant particles such as aluminium oxide (corundum).

(52) The fourth applying unit 24 applies, preferably scatters, lignocellulosic or cellulosic particles 32 into the liquid second binder 33 applied on the core. Preferably, the lignocellulosic or cellulosic particles 32 are applied into a wet binder layer arranged on the core.

(53) The lignocellulosic or cellulosic particles 32 are free particles when applied into the liquid second binder 33. For example, the lignocellulosic or cellulosic particles 32 may be applied as a powder.

(54) The lignocellulosic particles comprise lignin. The lignocellulosic particles may be refined particles such as refined wood fibres. The cellulosic particles comprise no lignin or substantially no lignin (e.g., less than 5% lignin by weight). The cellulosic particles may be at least partly bleached particles such as at least partly bleached wood fibres.

(55) The second binder 33 applied in liquid form and the lignocellulosic or cellulosic particles 32 forms a second layer 12. The first layer 11, and the second layer 12, may be dried prior, preferably by applying heat or IR, to further processing steps.

(56) In one embodiment, a print may be printing in the second layer 12 prior to pressing, preferably by digital printing.

(57) The relation between the amount of the first layer 11 and of the second layer 12 may for example be 2:3, 1:1, or 1:4 or amounts there between.

(58) Both the dispersion comprising the first binder 31 and the dispersion comprising the second binder 33 may comprise additives such as wetting agents, release agents, catalysts, anti-static agents, anti-slip agents and pigments etc. By adding a higher amount of catalysts to the dispersion comprising the first binder compared to the dispersion comprising the second binder, the first layer may be cured faster, thereby preventing binders from transferring from the second layer 12 to the first layer 11.

(59) The core 5 having the first and the second layers 11, 12 applied thereon is thereafter conveyed to a pressing unit 9. The pressing unit 9 may be a continuous or static press. Heat and pressure are applied to the first and second layers 11, 12 such that the thermosetting binders are cured and a surface layer comprising the first and second layer 11, 12 is formed on the core 5. An embossed press plate may be used to form an embossed structure of the second layer 12.

(60) Embodiments of the resulting building panel produced according to the method described with reference to FIG. 3 may be similar to the building panel shown in FIG. 2. The concentration of the lignocellulosic or cellulosic particles in the first and second layer may differ through the layers compared to when layers are applied as a mix comprising the lignocellulosic or cellulosic particles and the binder.

(61) FIG. 4 schematically illustrates a production line for a process for manufacturing a building panel 10 according to a third embodiment. The production line comprises a first applying unit 34, and a second applying unit 36. The production line further comprises a conveying belt 6, optional heating units (not shown) for heating and/or drying the layers, and a pressing unit 9.

(62) The first applying unit 34 applies a first liquid dispersion 35 comprising a first binder and lignocellulosic or cellulosic particles on a first surface of the carrier. In the embodiment shown in FIG. 4, the carrier is a core 5. The core 5 is preferably a wood based board such as a HDF, MDF, particleboard, OSB, or WPC (Wood Plastic Composite). The core 5 is arranged on the conveyor belt 6 such that the conveyor belt 6 conveys the core 5.

(63) The lignocellulosic particles comprise lignin. The lignocellulosic particles may be refined particles such as refined wood fibres. The cellulosic particles comprise no lignin or substantially no lignin (e.g., less than 5% lignin by weight). The cellulosic particles may be at least partly bleached particles such as at least partly bleached wood fibres.

(64) The first binder is thus applied as a first liquid dispersion 35. The first liquid dispersion 35 may be a solution or a suspension. The first binder may dissolved in a solvent, preferably water. The binder content of the dispersion may be 30-90% by weight. The lignocellulosic or cellulosic particles content of the first liquid dispersion may be 10-40% by weight.

(65) The first binder may be urea formaldehyde resin, a mixture comprising urea formaldehyde resin, or a co-polymer comprising urea formaldehyde resin such as melamine-urethane formaldehyde (MUF).

(66) In one embodiment, the first binder may be phenol formaldehyde resin, a mixture comprising phenol formaldehyde resin, or a co-polymer comprising phenol formaldehyde resin.

(67) In one embodiment, the first binder may be a thermoplastic binder. The thermoplastic binder may be polyvinyl acetate (PVAC), a mixture comprising polyvinyl acetate, or a co-polymer comprising polyvinyl acetate. The thermoplastic binder may be polyvinyl chloride (PVC), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate or methacrylate, a mixture comprising polyvinyl chloride (PVC), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate or methacrylate, or a co-polymer comprising polyvinyl chloride (PVC), polyurethane (PU), polystyrene (PS), styrene acrylonitrile (SAN), acrylate, methacrylate or acrylic.

(68) In one embodiment, the first binder may be a mixture comprising a thermoplastic binder and a thermosetting resin such as an amino resin applied in liquid form. The thermoplastic binder may be polyvinyl acetate, or polyurethane. The thermosetting resin may be urea formaldehyde resin or melamine formaldehyde resin. A co-polymer may be formed of a thermoplastic binder such as polyvinyl acetate and amino resin such as urea formaldehyde, melamine formaldehyde and/or phenol formaldehyde, especially at low pH.

(69) The first liquid dispersion 35 comprising the first binder may further comprises additives, pigments and fillers. The dispersion may further comprise additives or fillers having sound-absorbing properties such as cork particles and/or barium sulphate (BaSO4).

(70) The first liquid dispersion 35 comprising the first binder and the lignocellulosic or cellulosic particles forms a first layer 11. The first layer 11 may be dried, preferably by applying heat or IR, prior to further processing steps.

(71) In one embodiment, a print may be printing in the first layer 11 prior to applying a second layer 12, preferably by digital printing.

(72) A second applying unit 36 applies a second liquid dispersion 37 comprising a second binder and lignocellulosic or cellulosic particles on the first layer 11.

(73) The second binder is thus applied as a second liquid dispersion 37. The second liquid dispersion 37 may be a solution or a suspension. The second binder may dissolved in a solvent, preferably water. The binder content of the dispersion may be 30-90% by weight. The lignocellulosic or cellulosic particles content of the second liquid dispersion may be 10-40% by weight.

(74) The second binder is a thermosetting binder, preferably an amino resin such as urea formaldehyde, melamine formaldehyde or phenol formaldehyde, or a combination thereof, or co-polymer thereof. The second binder may be melamine formaldehyde resin (MF), a mixture comprising melamine formaldehyde resin, or a co-polymer comprising melamine formaldehyde resin.

(75) The second liquid dispersion 37 comprising the second binder may further comprise additives. Preferably, the liquid dispersion further comprises wear resistant particles such as aluminium oxide (corundum).

(76) The lignocellulosic or cellulosic particles are free particles when applied into the liquid first and second binder. The lignocellulosic or cellulosic particles are applied as a powder.

(77) The lignocellulosic particles comprise lignin. The lignocellulosic particles may be refined particles such as refined wood fibres. The cellulosic particles comprise no lignin or substantially no lignin (e.g., less than 5% lignin by weight). The cellulosic particles may be at least partly bleached particles such as at least partly bleached wood fibres.

(78) The second dispersion 37 comprising the second binder and the lignocellulosic or cellulosic particles forms a second layer 12. The first layer 11, and the second layer 12, may be dried prior, preferably by applying heat or IR, to further processing steps.

(79) In one embodiment, a print may be printing in the second layer 12 prior to pressing, preferably by digital printing.

(80) The relation between the amount of the first layer 11 and of the second layer 12 may for example be 2:3, 1:1, or 1:4 or amounts there between.

(81) Both the first liquid dispersion 35 comprising the first binder and the second liquid dispersion 37 comprising the second binder may comprise additives such as wetting agents, release agents, catalysts, anti-static agents, anti-slip agents and pigments etc. By adding a higher amount of catalysts to the dispersion 35 comprising the first binder compared to the dispersion 37 comprising the second binder, the first layer may be cured faster, thereby preventing binders from transferring from the second layer 12 to the first layer 11.

(82) The core 5 having the first and the second layers 11,12 applied thereon is thereafter conveyed to a pressing unit 9. The pressing unit 9 may be a continuous or static press. Heat and pressure are applied to the first and second layers 11,12 such that the thermosetting binders are cured and a surface layer comprising the first and second layer 11,12 is formed on the core 5. An embossed press plate may be used to form an embossed structure of the second layer 12.

(83) Embodiments of the resulting building panel produced according to the method described with reference to FIG. 4 may be similar to the building panel shown in FIG. 2. The concentration of the lignocellulosic or cellulosic particles in the first and second layer may differ through the layers compared to when layers are applied as a mix comprising the lignocellulosic or cellulosic particles and the binder.

(84) 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. It is for example contemplated that the first layer is adapted to cover the carrier such that the colour of the carrier does not shine through. The first layer may form a sub-layer for a print layer.

(85) It is also contemplated that one layer may be applied according to one of the embodiments including a liquid binder, and that the other layer is applied according to any one of the embodiments including applying the binder in powder form. For example, the first binder may be applied in liquid form, and the second binder may be applied in powder form, or vice versa.

(86) It is also contemplated that more than one first layer and/or more than one second layer is applied on the carrier to form a building panel comprising more than one first layer and/or more than one second layer. The building panel may also comprise additional layers.

(87) It is also contemplated that the first layer and/or the second layer may be applied as a pre-preg. The first mix and/or the second mix of the above described type may be stabilised into a pre-preg, for example by applying moisture, prior to be applied on the carrier.

EXAMPLES

Example 1

Comparative Example 1

(88) 650 g/m2 of formulation A was scattered on a HDF board provided with a balancing layer. The product was pressed in short cycle press resulting in a balanced board to be used in further processing such as sawing and profiling. Sawing and profiling resulted in floor panels. The dimensional changes of the floor panels upon different climate conditions were inspected and used for comparison with products made according to the disclosure.

Example 2

Thermosetting Sub Layer

(89) 400 g/m2 of formulation B was scattered on a HDF board provided with a balancing layer. On top of formulation B 400 g/m2 of formulation A was scattered. The product was pressed in a short cycle press resulting in a balanced board to be used in further processing such as sawing a profiling. Sawing and profiling resulted in floor panels. The dimensional changes of the floor panels upon different climate conditions were inspected and found to be less than for the products made according to the Comparative Example 1.

Example 3

Comparative Example 2 Sub Layer

(90) 500 g/m2 of formulation D was scattered on a HDF board provided with a balancing layer. On top of formulation D 300 g/m2 of formulation C was scattered. The product was pressed in short cycle press resulting in a balanced board to be used in further processing such as sawing and profiling. Sawing and profiling resulted in floor panels. The dimensional changes of the floor panels upon different climate conditions were inspected and used for comparison with products made according to the disclosure.

Example 4

Thermoplastic Sub Layer

(91) 500 g/m2 of formulation E was scattered on a HDF board provided with a balancing layer. On top of formulation D 300 g/m2 of formulation C was scattered. The product was pressed in short cycle press resulting in a balanced board to be used in further processing such as sawing and profiling. Sawing and profiling resulted in floor panels. The dimensional changes of the floor panels upon different climate conditions were inspected and found to be less than for the products made according to the Comparative Example 2.

(92) Formulations

(93) TABLE-US-00001 A B C D E (wt-%) (wt-%) (wt-%) (wt-%) (wt-%) Lignocellulosic material 14.75 14.75 Cellulosic material 15.66 15.66 12 50 50 Melamine formaldehyde 52.5 13.125 75 30 15 resin Urea formaldehyde resin 39.375 Thermoplastic resin 15 Aluminum oxide 8.8 8.8 10 10 10 Titanium dioxide 3.4 3.4 3 10 10 Pigment preparation 4.89 4.89 Total 100 100 100 100 100