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AU2011236087A1 - Wood veneer panel and method of making the same - Google Patents

Wood veneer panel and method of making the same Download PDF

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Publication number
AU2011236087A1
AU2011236087A1 AU2011236087A AU2011236087A AU2011236087A1 AU 2011236087 A1 AU2011236087 A1 AU 2011236087A1 AU 2011236087 A AU2011236087 A AU 2011236087A AU 2011236087 A AU2011236087 A AU 2011236087A AU 2011236087 A1 AU2011236087 A1 AU 2011236087A1
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AU
Australia
Prior art keywords
wood veneer
resin layer
substrate
panel
supporting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
AU2011236087A
Inventor
Peter Chan
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PAMB Pty Ltd
Original Assignee
PAMB Pty Ltd
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Filing date
Publication date
Application filed by PAMB Pty Ltd filed Critical PAMB Pty Ltd
Priority to AU2011236087A priority Critical patent/AU2011236087A1/en
Publication of AU2011236087A1 publication Critical patent/AU2011236087A1/en
Abandoned legal-status Critical Current

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Abstract

Abstract The present invention relates to a wood veneer panel comprising: a supporting panel; a first resin layer coated on top of the supporting; a decoration substrate overlaying the first resin layer; a second resin layer coated on top of the decoration substrate; a wood veneer substrate overlaying the second resin layer; a third resin layer coated on top of the wood veneer substrate; and a protective substrate overlaying the third resin layer. ____ ___ ___ ___ ____ ___ ___ ___ ___13 10 Figure 1

Description

- 1 WOOD VENEER PANEL AND METHOD OF MAKING THE SAME Technical Field The present invention relates to a wood veneer panel and method of making the same. In particular the present invention relates to a panel with a natural wood veneer surfaced for 5 used in flooring, and other heavy duty applications. Background Previously, many attempts have been made to improve the appearance of fibre panel to make it more resemble to realistic wood board. The furniture, wall or flooring panels or the like manufactured from such panels thus appear to be of a higher value because the .0 observer, due to the natural grain of the veneers, gets the impression of precious massive wood, which is more expensive compared to the supporting panel. In addition, such surfaces are more pleasant to look at. For the protection of the surface, which is only formed of natural wood on the surface, against dirt, damage and dust entering the pores of the veneer, the veneered panel is provided with a varnish layer, which, incidentally, can be visually and .5 tactually attractive. Typically, this kind of panel comprised of a core, formed from a plurality of decorative paper sheets printed with a wood grain pattern which are impregnated with a resin. Positioned above the core is a decorative sheet which is typically a pigmented cellulose paper containing a printed pattern design, or alternatively a solid color paper, which may 0 also be impregnated with a resin. The decorative sheet, in the case of a print, is generally covered with a transparent or semi-transparent protective overlay sheet comprising a cellulose paper impregnated with a resin such as a melamine-formaldehyde resin, or modified melamine-formaldehyde resin, generically referred to as a "melamine resin." The overlay sheet protects the decorative sheet from abrasion, scratches, chemicals, burns, and 25 the like. The decorative laminates are typically made by stacking the core sheets, decorative sheet, and overlay sheet together, inserting the collated stack between press plates, and then applying a temperature and pressure sufficient to cause the laminating resins to flow between the respective layers and subsequently cure. In one prior product, a thin natural wood veneer is bonded to a decorative paper core, 30 which core has been impregnated with a resin. The wood is then coated with a lacquer, such as, for example, a lacquer containing polyurethane and/or polyacrylate or polymethacrylate resins. To build up the protective lacquer coating, the wood veneer surface is repeatedly coated, dried, sanded, recoated, etc. While such laminates provide realistic wood grain surfaces, the lacquers used to coat the veneer do not provide the tough, abrasion and 35 impact resistant surface that conventional decorative laminates with a cured melamine resin surface possess. Such laminates are typically limited to use on vertical surfaces such as -2 cabinets and wall coverings. Further, the necessity of repeatedly applying, drying, and sanding the coating adds substantially to the cost of producing such laminates. Panels manufactured this way suffer the defects of showing white spots on the surface of the final product. When the wood veneer is damaged during the manufacture process, it is 5 impossible to repair the damages or refine the wood veneer surface any further. However, there has heretofore remained a need in the art for a wood veneer panel that provides the visual effects of a natural wood product. Summary of the Invention In accordance with a first aspect of the invention, there is provided a wood veneer panel .0 comprising: a supporting panel; a first resin layer coated on top of the supporting; a decoration substrate overlaying the first resin layer; a second resin layer coated on top of the decoration substrate; .5 a wood veneer substrate overlaying the second resin layer; a third resin layer coated on top of the wood veneer substrate; and a protective substrate overlaying the third resin layer. Preferably, the wood veneer panel further comprises a balance layer 17 is attached to the bottom of the supporting panel. 0 Preferably, the supporting panel comprises any one of a chipboard, particle board, High Density Fibre (HDF) board, (Medium Density Fibre) MDF board or a multiplex board. Preferably, the supporting panel has a thickness of typically 5 to 50 mm. Preferably, the first resin layer, second resin layer or third resin layer comprises any one or a combination of penol resins, melamine-formaldehyde resins, modified melamine 25 formaldehyde resins, polyurethane and/or polyacrylate or polymethacrylate resins. Preferably, the decorative substrate is saturated with melamine. Preferably, the wood veneer substrate comprises natural wood veneer. Preferably, the wood veneer substrate has a thickness of usually 0.1 to 2.0 mm. Preferably, the protective substrate comprises a UV coating. 30 Preferably, the protective substrate comprises an abrasion resistant paper. In a second aspect of the present invention, there is provided a method of manufacturing a wood veneer panel comprising the steps of: securing a decorative substrate to a supporting panel with a first resin layer coated between the decorative substrate and the supporting panel; 35 securing a wood veneer substrate to the decorative substrate with a second resin layer coated between the wood veneer substrate and the decorative substrate; -3 stablising the supporting panel, first resin layer, decorative layer, second resin layer and the wood veneer substrate by cold pressing; refining the wood veneer substrate; coating a third resin layer over the wood veneer substrate and allowing the 5 third resin layer to set; applying a protective substrate over the third resin layer; applying a balance layer at the bottom of the supporting panel; and subjecting the wood veneer panel to heat press. Preferably, the method further comprises the step of cutting joints to the wood veneer .0 panel. Preferably, the joints comprise tongue and groove joints. Preferably, the supporting panel comprises any one of a chipboard, particle board, High Density Fibre (HDF) board, (Medium Density Fibre) MDF board or a multiplex board. Preferably, the first resin layer, second resin layer or third resin layer comprises any one .5 or a combination of penol resins, melamine-formaldehyde resins, modified melamine formaldehyde resins, polyurethane and/or polyacrylate or polymethacrylate resins. Preferably, the decorative substrate is saturated with melamine. Preferably, the protective substrate comprises a UV coating or an abrasion resistant paper. 0 Brief Description of the Drawings Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings in which: Figure 1 is an exploded section view of a chipboard according to an embodiment of the present invention. 25 Detailed Description of the Preferred Embodiment Reference is now made to Figure 1, there is provided a wood veneer panel 10 comprising a supporting panel 11, a first resin layer 12 coated on top of the supporting, a decoration substrate 13 overlaying the first resin layer, a second resin layer 14 coated on top of the decoration substrate, wood veneer substrate 15 overlaying the second resin layer, a 30 third resin layer coated on top of the wood veneer substrate 16, and a protective substrate 16 overlaying the third resin layer. Preferably, a balance layer 17 is attached to the bottom of the supporting panel. The supporting panel 11 can be a chipboard, particle board, High Density Fibre (HDF) board, (Medium Density Fibre) MDF board or a multiplex board, having a thickness of 35 typically 5 to 50 mm. Resins such as any one or a combination of penol resins, melamine-formaldehyde resins, modified melamine-formaldehyde resins, polyurethane and/or polyacrylate or -4 polymethacrylate resins can be used for forming the first resin layer 12, second resin layer 14 and third resin layer 16. The amount of resins applied to each layers is around 10g 200g per meter square. Preferably, the decorative substrate 13 is saturated with melamine to provide better 5 bonding with the first resin layer 12 and second resin layer 14. In one embodiment, the wood veneer substrate 15 comprises natural wood veneer such as timber veneer of a thickness of usually 0.1 to 2.0 mm. Such natural wood veneer should not be impregnated with a resin before overlaying to the second resin layer 14. Such pre processing step will deform the shape of the natural wood veneer and make it difficult to .0 overlay to the resin layer. In addition, such pre-processing step will prevent any repairing and refining of the wood veneer. In one embodiment, the protective substrate 17 comprises a UV coating which can protect the wood veneer from any damages to the wear and tear. Lacquer can be applied to the protective layer to improve the protection and appearance of the panel. In another .5 embodiment, the protective substrate comprises an abrasion resistant paper. The method of manufacturing the wood veneer panel of an embodiment of the present invention is now described. The method comprising the steps of: securing a decorative substrate 13 to a supporting panel 11 with a first resin layer 12 coated between the decorative substrate and the supporting panel; 0 securing a wood veneer substrate 15 to the decorative substrate with a second resin layer 14 coated between the wood veneer substrate and the decorative substrate; stablising the supporting panel, first resin layer, decorative layer, second resin layer and the wood veneer substrate by cold pressing; repairing, and/ or refining the wood veneer substrate; 25 coating a third resin layer over the wood veneer substrate and allowing the third resin layer to set; applying a protective substrate over the third resin layer; applying a balance layer at the bottom of the supporting panel; subjecting the wood veneer panel to heat press. 30 Preferably, joints, such as tongue and grooves joints, are cut to the wood veneer panel 10 for easy fitting. It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present 35 embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
-5 Any reference to prior art contained herein is not to be taken as an admission that the information is common general knowledge, unless otherwise indicated.

Claims (19)

1. A wood veneer panel comprising: a supporting panel; 5 a first resin layer coated on top of the supporting; a decoration substrate overlaying the first resin layer; a second resin layer coated on top of the decoration substrate; a wood veneer substrate overlaying the second resin layer; a third resin layer coated on top of the wood veneer substrate; and .0 a protective substrate overlaying the third resin layer.
2. A wood veneer panel according to claim 1, further comprising a balance layer 17 is attached to the bottom of the supporting panel.
3. A wood veneer panel according to claim 1 or claim 2, wherein the supporting panel comprises any one of a chipboard, particle board, High Density Fibre (HDF) board, .5 (Medium Density Fibre) MDF board or a multiplex board.
4. A wood veneer panel according to any of the preceding claims, wherein the supporting panel has a thickness of typically 5 to 50 mm.
5. A wood veneer panel according to any one of the preceding claims, wherein the first resin layer, second resin layer or third resin layer comprises any one or a '0 combination of penol resins, melamine-formaldehyde resins, modified melamine formaldehyde resins, polyurethane and/or polyacrylate or polymethacrylate resins.
6. A wood veneer panel according to any one of the preceding claims, wherein the decorative substrate is saturated with melamine.
7. A wood veneer panel according to any one of the preceding claims, wherein the 25 wood veneer substrate comprises natural wood veneer.
8. A wood veneer panel according to any one of the preceding claims, wherein the wood veneer substrate has a thickness of usually 0.1 to 2.0 mm.
9. A wood veneer panel according to any one of the preceding claims, wherein the protective substrate comprises a UV coating. 30
10. A wood veneer panel according to any one of claims 1 to 8 wherein the protective substrate comprises an abrasion resistant paper.
11. The method of manufacturing a wood veneer panel comprising the steps of: securing a decorative substrate to a supporting panel with a first resin layer coated between the decorative substrate and the supporting panel; 35 securing a wood veneer substrate to the decorative substrate with a second resin layer coated between the wood veneer substrate and the decorative substrate; -7 stablising the supporting panel, first resin layer, decorative layer, second resin layer and the wood veneer substrate by cold pressing; refining the wood veneer substrate; coating a third resin layer over the wood veneer substrate and allowing the 5 third resin layer to set; applying a protective substrate over the third resin layer; applying a balance layer at the bottom of the supporting panel; and subjecting the wood veneer panel to heat press.
12. The method according to claim 11 further comprising the step of cutting joints to the .0 wood veneer panel.
13. The method according to claim 12 wherein the joints comprising tongue and groove joints.
14. The method according to any one of claims 11 to 13, wherein the supporting panel comprises any one of a chipboard, particle board, High Density Fibre (HDF) board, .5 (Medium Density Fibre) MDF board or a multiplex board.
15. The method according to any one of claims 11 to 14, wherein the first resin layer, second resin layer or third resin layer comprises any one or a combination of penol resins, melamine-formaldehyde resins, modified melamine-formaldehyde resins, polyurethane and/or polyacrylate or polymethacrylate resins. 0
16. The method according to any one of claims 11 to 15, wherein the decorative substrate is saturated with melamine.
17. The method according to any one of claims 11 to 16, wherein the protective substrate comprises a UV coating or an abrasion resistant paper.
18. A wood veneer panel substantially as hereinbefore described with reference 25 to the embodiment illustrated in accompanying Figure 1.
19. A method of manufacturing wood veneer panel substantially as hereinbefore described with reference to the embodiment illustrated in accompanying Figure 1.
AU2011236087A 2011-10-18 2011-10-18 Wood veneer panel and method of making the same Abandoned AU2011236087A1 (en)

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Application Number Priority Date Filing Date Title
AU2011236087A AU2011236087A1 (en) 2011-10-18 2011-10-18 Wood veneer panel and method of making the same

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Application Number Priority Date Filing Date Title
AU2011236087A AU2011236087A1 (en) 2011-10-18 2011-10-18 Wood veneer panel and method of making the same

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AU2011236087A1 true AU2011236087A1 (en) 2013-05-02

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015154124A1 (en) * 2014-04-11 2015-10-15 Guangzhou Australian Eucalyptus Timber Flooring Co Ltd Method of manufacturing a timber composite, the timber composite obtained and decorative panels comprising such timber composite
US20170036424A1 (en) * 2014-04-11 2017-02-09 Guangzhou Australian Eucalyptus Timber Flooring Co Ltd. Method for manufacturing high density composite wood board and high density composite wood board with emboss effect
CN108527990A (en) * 2018-03-21 2018-09-14 江苏博大木业有限公司 A kind of preparation method and high pressure fiber decoration board of continous way production high pressure fiber decoration board
US10100535B2 (en) 2014-01-10 2018-10-16 Valinge Innovation Ab Wood fibre based panel with a surface layer
AU2015201455B2 (en) * 2014-04-11 2018-12-06 Unilin Bv Method of manufacturing a timber composite
US10286633B2 (en) 2014-05-12 2019-05-14 Valinge Innovation Ab Method of producing a veneered element and such a veneered element
US10442152B2 (en) 2013-11-27 2019-10-15 Valinge Innovation Ab Floorboard
US10442164B2 (en) 2013-11-27 2019-10-15 Valinge Innovation Ab Floor, wall, or ceiling panel and method for producing same
US10576715B2 (en) 2015-07-10 2020-03-03 Aladdin Manufacturing Corporation Flooring board with a thin veneer wood aesthetic and durable surface
US10828881B2 (en) 2016-04-25 2020-11-10 Valinge Innovation Ab Veneered element and method of producing such a veneered element
US10981362B2 (en) 2018-01-11 2021-04-20 Valinge Innovation Ab Method to produce a veneered element
US11072156B2 (en) 2013-11-27 2021-07-27 Valinge Innovation Ab Method for producing a floorboard
US11167533B2 (en) 2018-01-11 2021-11-09 Valinge Innovation Ab Method to produce a veneered element and a veneered element
US11313123B2 (en) 2015-06-16 2022-04-26 Valinge Innovation Ab Method of forming a building panel or surface element and such a building panel and surface element
US11597187B2 (en) 2019-01-09 2023-03-07 Valinge Innovation Ab Method to produce a veneer element and a veneer element

Cited By (33)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11485126B2 (en) 2013-11-27 2022-11-01 Valinge Innovation Ab Method for producing a floorboard
US11072156B2 (en) 2013-11-27 2021-07-27 Valinge Innovation Ab Method for producing a floorboard
US12103273B2 (en) 2013-11-27 2024-10-01 Välinge Innovation AB Floor, wall, or ceiling panel and method for producing same
US10926509B2 (en) 2013-11-27 2021-02-23 Valinge Innovation Ab Floorboard
US10857765B2 (en) 2013-11-27 2020-12-08 Valinge Innovation Ab Floor, wall, or ceiling panel and method for producing same
US10442164B2 (en) 2013-11-27 2019-10-15 Valinge Innovation Ab Floor, wall, or ceiling panel and method for producing same
US10442152B2 (en) 2013-11-27 2019-10-15 Valinge Innovation Ab Floorboard
US11890847B2 (en) 2014-01-10 2024-02-06 Välinge Innovation AB Method of producing a veneered element
US10988941B2 (en) 2014-01-10 2021-04-27 Valinge Innovation Ab Method of producing a veneered element
US11318726B2 (en) 2014-01-10 2022-05-03 Valinge Innovation Ab Wood fibre based panel with a surface layer
US11370209B2 (en) 2014-01-10 2022-06-28 Valinge Innovation Ab Method of producing a veneered element
US10100535B2 (en) 2014-01-10 2018-10-16 Valinge Innovation Ab Wood fibre based panel with a surface layer
US11701867B2 (en) 2014-04-11 2023-07-18 Flooring Industries Limited, Sarl Method of manufacturing a timber composite, the timber composite obtained and decorative panels comprising such timber composite
AU2015201455B2 (en) * 2014-04-11 2018-12-06 Unilin Bv Method of manufacturing a timber composite
US10538064B2 (en) 2014-04-11 2020-01-21 Guangzhou Austrailian Eucalyptus Timber Flooring Co Ltd. Method of manufacturing a timber composite, the timber composite obtained and decorative panels comprising such timber composite
US20170036424A1 (en) * 2014-04-11 2017-02-09 Guangzhou Australian Eucalyptus Timber Flooring Co Ltd. Method for manufacturing high density composite wood board and high density composite wood board with emboss effect
US10213989B2 (en) 2014-04-11 2019-02-26 Guangzhou Australian Eucalyptus Timber Flooring Co Ltd. Method of manufacturing a timber composite, the timber composite obtained and decorative panels comprising such timber composite
WO2015154124A1 (en) * 2014-04-11 2015-10-15 Guangzhou Australian Eucalyptus Timber Flooring Co Ltd Method of manufacturing a timber composite, the timber composite obtained and decorative panels comprising such timber composite
US11338557B2 (en) 2014-04-11 2022-05-24 Flooring Industries Limited, Sarl Method of manufacturing a timber composite, the timber composite obtained and decorative panels comprising such timber composite
US20220194060A1 (en) * 2014-04-11 2022-06-23 Guangzhou Australian Eucalyptus Timber Flooring Co Ltd Method of manufacturing a timber composite, the timber composite obtained and decorative panels comprising such timber composite
US10286633B2 (en) 2014-05-12 2019-05-14 Valinge Innovation Ab Method of producing a veneered element and such a veneered element
US11313123B2 (en) 2015-06-16 2022-04-26 Valinge Innovation Ab Method of forming a building panel or surface element and such a building panel and surface element
US10576715B2 (en) 2015-07-10 2020-03-03 Aladdin Manufacturing Corporation Flooring board with a thin veneer wood aesthetic and durable surface
US11904588B2 (en) 2016-04-25 2024-02-20 Välinge Innovation AB Veneered element and method of producing such a veneered element
US10828881B2 (en) 2016-04-25 2020-11-10 Valinge Innovation Ab Veneered element and method of producing such a veneered element
US11167533B2 (en) 2018-01-11 2021-11-09 Valinge Innovation Ab Method to produce a veneered element and a veneered element
US10981362B2 (en) 2018-01-11 2021-04-20 Valinge Innovation Ab Method to produce a veneered element
US11738540B2 (en) 2018-01-11 2023-08-29 Välinge Innovation AB Method to produce a veneered element and a veneered element
US11850829B2 (en) 2018-01-11 2023-12-26 Välinge Innovation AB Method to produce a veneered element and a veneered element
CN108527990B (en) * 2018-03-21 2019-05-03 江苏博大木业有限公司 A kind of preparation method and high pressure fiber decoration board of continous way production high pressure fiber decoration board
CN108527990A (en) * 2018-03-21 2018-09-14 江苏博大木业有限公司 A kind of preparation method and high pressure fiber decoration board of continous way production high pressure fiber decoration board
US11597187B2 (en) 2019-01-09 2023-03-07 Valinge Innovation Ab Method to produce a veneer element and a veneer element
US11975508B2 (en) 2019-01-09 2024-05-07 Välinge Innovation AB Method to produce a veneer element and a veneer element

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