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US-12623372-B2 - Method to produce a veneered element and a veneered element

US12623372B2US 12623372 B2US12623372 B2US 12623372B2US-12623372-B2

Abstract

A method to produce a veneered element, including providing a first layer of a first powder and applying a second layer of a second powder above the first layer. Further the method includes applying a veneer layer above the second layer. Thereafter heating and pressing the first layer, the second layer and the veneer layer together to form the veneered element and forming a bevel at least partly along at least one side portion of the veneered element, where the first layer, the second layer and the veneer layer are at least partly exposed in the bevel.

Inventors

  • Magnus Nilsson
  • Sofia NILSSON

Assignees

  • Välinge Innovation AB

Dates

Publication Date
20260512
Application Date
20240626
Priority Date
20201208

Claims (17)

  1. 1 . A veneer element, comprising: a first layer, a second layer above the first layer, a veneer layer above the second layer, and a bevel arranged at least partly along at least one side portion of said veneer element, wherein the first layer, the second layer and the veneer layer are at least partly exposed in the bevel, and wherein the first layer is different from the second layer, wherein the second layer is thicker than the first layer, wherein the second layer is darker than the first layer, wherein the second layer is visible through at least a portion of an open feature of the veneer layer.
  2. 2 . The veneer element according to claim 1 , wherein the bevel has a depth of between 0.1 and 0.7 mm.
  3. 3 . The veneer element according to claim 1 , wherein the bevel has an angle α in the range of about 15 to about 75 degrees.
  4. 4 . The veneer element according to claim 1 , wherein the first layer comprises a first powder that has been heated and pressed together and the second layer comprises a second powder that has been heated and pressed together.
  5. 5 . The veneer element according to claim 1 , wherein the open feature of the veneer layer is at least partly filled with material originated from at least the second layer.
  6. 6 . The veneer element according to claim 5 , wherein the open feature of the veneer layer is a crack, cavity, hole and/or knot.
  7. 7 . The veneer element according to claim 1 , further comprising a substrate on which the first layer is arranged, wherein the substrate comprises one or more of: wood-based board, a particleboard, a thermoplastic board, a plywood, a lamella core, a veneer layer, a sheet and/or a non-woven.
  8. 8 . The veneer element according to claim 1 , wherein the bevel has a depth of between 0.2 and 0.5 mm.
  9. 9 . The veneer element according to claim 1 , wherein the bevel has an angle α in the range of about 20 to about 50 degrees.
  10. 10 . The veneer element according to claim 1 , wherein the bevel has an angle α in the range of about 30 to 45 degrees.
  11. 11 . The veneer element according to claim 1 , wherein the open feature of the veneer layer is a crack, cavity, hole and/or knot.
  12. 12 . The veneer element according to claim 1 , wherein the first layer comprises colouring.
  13. 13 . The veneer element according to claim 1 , wherein the second layer comprises colouring.
  14. 14 . The veneer element according to claim 1 , wherein the second layer comprises dark wood fibres.
  15. 15 . The veneer element according to claim 1 , wherein the veneer element is produced by: providing a first powder layer, applying a second powder layer above the first powder layer, applying a veneer layer above the second powder layer, heating and pressing the first powder layer, the second powder layer and the veneer layer together to form the veneer element, forming the bevel at least partly along at least one side portion of the veneer element.
  16. 16 . The veneer element according to claim 15 , wherein the second powder layer is applied in an amount of 50-150 g/m 2 .
  17. 17 . The veneer element according to claim 15 , wherein the second powder layer is applied in an amount of 80-120 g/m 2 .

Description

CROSS REFERENCE TO RELATED APPLICATIONS The present application is a continuation of U.S. application Ser. No. 17/543,962, filed on Dec. 7, 2021, which claims the benefit of Swedish Application No. 2051432-9, filed on Dec. 8, 2020. The entire contents of each of U.S. application Ser. No. 17/543,962 and Swedish Application No. 2051432-9 are hereby incorporated herein by reference in their entirety. TECHNICAL FIELD The present application relates to a method to produce a veneered element, and a veneered element. TECHNICAL BACKGROUND Floor coverings having a wooden surface may be of several different types. For example, solid wood flooring is formed of a solid piece of wood in form of a panel. Engineered wood floorings are formed of a surface layer of wood attached to a core, where the core may be a lamella core or a wood-based panel, such as plywood, MDF or HDF. Yet another example is a wood veneer being glued to a core, previously described. Wood veneer is a thin wood layer, e.g., having a thickness of 0.2-1 mm. Compared to solid wood and engineered wood flooring, wood veneer floorings can be produced to a lower cost since only a thin wood layer is used without losing the feeling of a natural wooden floor covering. WO2015002599 is a document disclosing a floor covering of yet another example, having a first layer and a second layer, including wood fibres, which can have different properties by having different binders. By having different binders tension resulting from pressing, cooling and/or climate changes can be reduced. Further, in an example, it is disclosed that a first layer may have pigments to create a uniform colour to be able to cover a surface of a carrier having an uneven colour. The first layer may then be a good base layer for printing with its uniform colour. The document however does not address the possibilities of controlling the layers further in order to create a desirable overall design of a building panel, such as a veneered element. The document does also not disclose any example of a floor covering having a veneer layer and therefore also does not disclose, e.g., the effect of appearance of the veneer layer of the overall design of the floor covering. WO2019139522 discloses a method to produce a veneered element and such a veneered element including a first layer, a second layer and a veneer layer. Described therein the layers below the veneer layer may have different properties, where one layer may be pigmented or dyed and the other layer may be free from pigments and/or dye, or where the layers differs in colour. In this way the design of the veneer layer can be controlled after pressing the layers together where the layers below at least partly permeate into the veneer layer and, if there are defects such as cracks or knots or holes, penetrate into open defects of the veneer layer. However, the document does not disclose the impact of the different types of layers on the overall design of the veneered element. WO2020145870 disclose another example of a method to produce a veneered element and such a veneered element but with the same drawbacks as for WO2019139522. SUMMARY An object of the present disclosure is to provide improvements over known art. This object is achieved by techniques defined herein. In a first aspect of the present disclosure, there is provided a method to produce a veneered element, comprising: providing a first layer of a first powder,applying a second layer of a second powder above the first layer,applying a veneer layer above the second layer,heating and pressing the first layer, the second layer and the veneer layer together to form a veneered element,forming a bevel at least partly along at least one side portion of the veneered element, wherein the first layer, the second layer and the veneer layer are at least partly exposed in the bevel. Examples of advantages with the above defined method is that the overall design of the veneered element is taken into consideration and that the overall design of the veneered element can be controlled by carefully choosing and combining different features of the first layer, the second layer and the veneer layer. In an embodiment the first powder and/or the second powder is applied as a powder having a predetermined content of moisture, such as between 5 and 80 wt %, preferably between 5 and 50 wt %, based on the total weight of the first powder and/or second powder without added moisture. An advantage with controlling the moisture content of the first powder and/or the second power is to facilitate the many different application alternatives, e.g. scattering, rolling or spraying. The first layer and/or the second layer may include a thermosetting binder. The thermosetting binder will, e.g., create a desirable curing when heat and pressure is applied. Further, the total amount of applied first powder and second powder may be more than 300 g/m2. This amount is preferred as it will provide the desirable curing for a st