Fibre based panels with a wear resistance surface

Abstract

Building panels with a homogenous decorative surface having a wear layer comprising fibres, binders and wear resistant particles. A building panel including a surface layer and a core, the core including wood fibres, and the surface layer including a substantially homogenous mix of wood fibres, a binder and wear resistant particles, the substantially homogenous mix of wood fibres including natural resins.

1 . (canceled) 
     
     
         2 . A method of manufacturing a building panel comprising a core and a surface layer, the method comprising a step of:
 applying a mix comprising coated wood fibres, a second binder, color pigments, and wear resistant particles on a first surface of the core; and   curing the mix by applying pressure and temperature to form the surface layer on the core,   wherein the coated wood fibres comprise wood fibres pre-coated with a first binder, and   wherein the coated wood fibres are at least partially cured with the first binder.   
     
     
         3 . The method according to  claim 2 , wherein the first binder is a melamine resin. 
     
     
         4 . The method according to  claim 2 , wherein the first binder is urea formaldehyde resin. 
     
     
         5 . The method according to  claim 2 , wherein the coated wood fibres are obtained from recycled flooring. 
     
     
         6 . The method according to  claim 5 , wherein the flooring is a laminate flooring. 
     
     
         7 . The method according to  claim 5 , wherein the flooring is a HDF or HDF-based laminate flooring. 
     
     
         8 . The method according to  claim 5 , wherein the coated wood fibres are formed by mechanical cutting and separation of the flooring to small wood fibres. 
     
     
         9 . The method according to  claim 2 , wherein the coated wood fibers are obtained from cutting and machines of edges of a wood-based board. 
     
     
         10 . The method according to  claim 2 , wherein the core comprises coated wood fibres obtained from recycled HDF or HDF based laminate flooring. 
     
     
         11 . The method according to  claim 2 , wherein the method further comprises applying a balancing layer on a second surface of the core, the second surface being on an opposite side of the core from the first surface. 
     
     
         12 . The method according to  claim 2 , wherein the panel is a floor panel. 
     
     
         13 . The method according to  claim 2 , wherein the second binder is a thermosetting or thermoplastic resin. 
     
     
         14 . The method according to  claim 2 , wherein the coated wood fibres comprise aluminum oxide or small melamine/paper flakes. 
     
     
         15 . The method according to  claim 2 , wherein the building panel is formed to a floor panel with mechanical locking systems at opposite edges. 
     
     
         16 . A method of manufacturing a building panel comprising a core and a balancing layer, the method comprising a step of:
 applying a mix comprising coated wood fibres, a second binder, color pigments, and wear resistant particles on a second surface of the core; and   curing the mix by applying pressure and temperature to form the balancing layer on the core,   wherein the coated wood fibres comprise wood fibres pre-coated with a first binder, and   wherein the coated wood fibres are at least partially cured with the first binder.   
     
     
         17 . The method according to  claim 16 , wherein the first binder is a melamine resin. 
     
     
         18 . The method according to  claim 16 , wherein the first binder is urea formaldehyde resin. 
     
     
         19 . The method according to  claim 16 , wherein the coated wood fibres are obtained from recycled flooring. 
     
     
         20 . The method according to  claim 19 , wherein the flooring is a laminate flooring. 
     
     
         21 . The method according to  claim 19 , wherein the flooring is a HDF or HDF-based laminate flooring. 
     
     
         22 . The method according to  claim 19 , wherein the coated wood fibres are formed by mechanical cutting and separation of the flooring to small wood fibres. 
     
     
         23 . The method according to  claim 16 , wherein the coated wood fibers are obtained from cutting and machines of edges of a wood-based board. 
     
     
         24 . The method according to  claim 16 , wherein the core comprises coated wood fibres obtained from recycled HDF or HDF based laminate flooring. 
     
     
         25 . The method according to  claim 16 , wherein the core comprises a surface layer on a first surface of the core, the first surface being on an opposite side of the core from the second surface. 
     
     
         26 . The method according to  claim 16 , wherein the panel is a floor panel. 
     
     
         27 . The method according to  claim 16 , wherein the second binder is a thermosetting or thermoplastic resin. 
     
     
         28 . The method according to  claim 16 , wherein the coated wood fibres comprise aluminum oxide or small melamine/paper flakes. 
     
     
         29 . The method according to  claim 16 , wherein the building panel is formed to a floor panel with mechanical locking systems at opposite edges.