• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of manufacturing a decorative panel, the method comprising the following steps: - the step of providing a substrate material (8); - the step of manufacturing a decorative top layer (7); - the step of applying the decorative top layer and the substrate material to each other; characterized in that for the production of the decorative top layer (7) at least two wooden veneer layers (23A-23B) are pressed with an intermediate layer (24) of thermosetting resin. The invention relates to a decorative panel (1) that can be obtained by means of this method.
    公开号:BE1022850B1
    申请号:E2015/5173
    申请日:2015-03-23
    公开日:2016-09-21
    发明作者:Frank Loncke；Laurent Meersseman
    申请人:Unilin, B.V.B.A.；
    IPC主号:
    专利说明:

    Method for manufacturing a decorative panel and decorative panel.
    This invention relates to a method for manufacturing a decorative panel and a decorative panel that can be obtained with such a method.
    More specifically, the invention relates to decorative panels, such as floor panels, which comprise a top or decorative layer based on wood. Such panels are well known per se, for example from WO 2010/122514. In the case of floor panels, this is referred to as ready-made, prefabricated or assembled parquet, also referred to in English as “Engineered Wood Parquet”, or veneer parquet.
    Composite parquet panels normally contain at least one substrate, a wood layer attached to it and a wood-based counter layer on the underside of the substrate. The wood layer located on the top side acts as a top and decorative layer and is usually made from hardwood. It may, however, be further treated at its upper side, for example to influence its appearance and / or to improve its surface quality, for example via coloring, the application of a wear-resistant and watertight transparent lacquer, and so on. The wood-based counter layer generally consists of a one-part thin layer of a cheap and generally soft wood. Such parquet panels are sensitive to impact impressions and can be scratch-sensitive. Due to their even poorer mechanical properties, soft woods are unusable as a top layer for such panels.
    The substrate of a composite parquet panel is traditionally composed of several transverse slats made of wood. Such substrate is also called lamella core. The slats usually consist of soft wood, such as spruce wood or hevea; With long-legged panels, it is also known to replace the slats on the short sides with strips from another material, such as HDF (High Density Fiber Board) or plywood, to increase the strength on these edges. Examples of this are described in DE 101 63 435, WO 2010/122514 and WO 2007/141605. Versions of composite parquet panels are also known in which the entire substrate is replaced by one continuous wood-fiber board, more particularly an MDF or HDF board, for example as described in DE 201 21 836.
    For panels for a different type of hard floor covering, namely for panels for laminate flooring, it is known from EP 0 355 829 A2 to apply several printed decorative layers provided with thermosetting resin with superimposed decorative layers in order to increase the wear resistance of the surface. in the top layer. The decorative layers contain identical prints, such that when a top decorative layer is severed locally, a corresponding decor part of an underlying decorative layer becomes visible. This technology is limited to printed decorative layers and furthermore has the disadvantage that when the print is worn the paper mass of the relevant decorative layer first becomes visible before the underlying print appears.
    The present invention aims in the first place at a method that leads to an alternative decorative panel, in particular a floor panel, with a top or decorative layer of wood. According to various preferred embodiments, solutions are offered for the problems with the floor panels from the prior art.
    To this end, the present invention relates to a method for manufacturing a decorative panel, preferably a floor panel, the method comprising the steps of: the step of providing a substrate material; - the step of manufacturing a decorative top layer; - the step of applying the decorative top layer and the substrate material to each other; characterized in that for the manufacture of the decorative top layer at least two wooden veneer layers are pressed with an intermediate layer of thermosetting resin. The use of thermosetting resin ensures that a harder layer of cured resin will form between the two wood layers. If, during use of the panel, wear were to be formed through the first layer, the underlying layer becomes visible, but is still protected by the resin.
    Moreover, during pressing, a portion of the resin may penetrate one or both of the coating layers, such that these layers are hardened internally. Preferably the resin penetrates, possibly locally but better substantially completely, at least the aforementioned first layer, namely the layer closest to the surface of the decorative panel, and optionally also the second layer. It is clear that an even further improvement of the wear resistance is obtained in this way.
    The method offers the possibility of using decorative top layers based on softer types of wood, such as spruce wood, in applications of high wear, such as in floor panels or furniture panels, such as worktops. Furthermore, the method can also lead to an improvement of the mechanical properties, such as impact resistance and wear resistance, with the usual types of wood, such as oak.
    The pressing preferably leads to a density increase of one or more of the relevant veneer layers. A density increase can lead to an increased impact resistance.
    Various components can be used for the thermosetting resin. Preferably a polycondensation resin is used, for example a resin based on melamine, melamine formaldehyde, urea, urea formaldehyde or phenol formaldehyde. It is also possible to work with pMDI (polymeric Methylene Diphenyl di-Isocyanate), or with other types of formaldehyde-free resins, for example based on starch, proteins or earbohydrates, such as sugars. According to the most preferred embodiment, use is made of melamine-containing resin and more preferably of melamine-based resin, such as a resin based on melamine-formaldehyde. It is clear that the thermosetting resin can still contain various additives, such as fluxes, hardeners and / or plasticizers.
    The aforementioned intermediate layer preferably relates to a separate layer, namely a layer that is separate from a veneer layer. Such a separate layer can be realized on various options, of which a number of important options are listed below.
    According to a first possibility, the resin is provided with a carrier sheet at least on the basis of which the carrier sheet is then preferably co-pressed between the respective two veneer layers and thus remains present in the final decorative top layer. Such a carrier sheet can for instance be a paper sheet, namely preferably a paper sheet with a dry weight of 50 grams per square meter or less, preferably 10 to 30 grams per square meter. In this way it is achieved that the paper mass between the two veneer layers remains relatively dim and does not become too noticeable when the first or upper veneer layer is being worn. However, preferably a paper sheet is used with a dry weight of more than 10 grams per square meter, such that sufficient resin can be applied on the basis of the carrier sheet in question. In the case of a filled, opaque, paper sheet, a coloring of the paper mass is preferably used to match the veneer layers. According to the most preferred embodiment, a paper sheet consisting of alpha-cellulose and preferably unfilled is used. Such a paper sheet is known from laminate technology as overlay paper. This paper has the advantage that it can become transparent when pressed. This is the case, for example, if a melamine-based resin were used for the thermosetting resin.
    According to the first possibility, the resin is preferably applied to and / or in the carrier sheet by means of techniques known per se from the laminate technology, for example by watering the carrier sheet in a resin bath, spraying resin onto the paper surface, the application of resin by means of screen rollers and the like. The resin is preferably impregnated in the carrier sheet, preferably paper sheet. The presence of resin in the core of the support sheet leads to a better split resistance in the compressed whole of the decorative top layer. To promote resin uptake in the paper, paper with a relatively open or porous structure is preferably chosen, for example paper with an average air resistance, as measured by the Gurley method (Tappi T460), of less than 30 or even better less then 25 seconds.
    According to a second possibility, the resin of the intermediate layer is provided with a scattering treatment at least on the basis of and / or the resin of the intermediate layer is applied as a powder. Preferably, resin particles are used that exhibit an average size of less than 1 millimeter, and more preferably less than 500 micrometres. In order to maintain good manageability and processability of the powder, use is preferably made of an average particle size of more than 10 micrometres, and even better of 30 micrometres or more. The inventor has determined that the use of powder resin allows to add resin to the intermediate layer with better accuracy, or higher resolution, than in the case of the aforementioned first possibility. Moreover, a more transparent intermediate resin layer is obtained. Such a layer will also be less conspicuous as a line when the decorative layer is observed from the side.
    According to a third possibility, a combination of several techniques is applied to apply the resin of the intermediate layer. For example, the aforementioned first and second possibility can be combined, or other techniques can be applied, such as applying a portion of the resin to a surface of one or more of the aforementioned veneer layers.
    Preferably, the resin of the intermediate layer is in a B stage just prior to pressing, or, when applied, is in this B stage. The so-called B-stage is an intermediate stage of the curing process in which certain thermosetting resins can be located. A certain cross-linking has already occurred in such a B stage, but the curing reaction is not yet complete, so that the resin can still be warmed to flow for the final curing that is irreversible. Such a B-stage can occur, for example, with the melamine, urea and phenolic resins mentioned above, and in particular with melamine formaldehyde resins. Because the resin is applied in the intermediate layer in B-stage, a smooth production of the top layer can take place. The final flow and curing allows the veneer layers to be joined together and the resin optionally to penetrate one or more of the veneer layers during pressing.
    It is clear that both in the aforementioned first possibility and second possibility the resin can be in the aforementioned B stage. In the case of the first possibility, the resin applied to the carrier sheet is then, for example, treated in an oven before it is applied between the veneer layers and / or before it is pressed.
    The resin of the intermediate layer preferably has a residual moisture content of less than 10 percent, for example of about 7 percent. A low residual moisture content is advantageous during pressing and reduces the risk of defects in the decorative top layer. This is because an excess of water can lead to the veneer layers being attacked and / or to the decorative layer exploding due to a too high vapor pressure in the intermediate resin layer.
    According to a special embodiment, the aforementioned intermediate layer comprises wear-resistant particles, for example particles of aluminum oxide, silicon oxide or silicon carbide. The particles preferably exhibit an average particle size between 20 and 200 micrometers. Aluminum oxide is preferably used. This is very advantageous in combination with a thermosetting resin based on melamine or melamine formaldehyde, since alumina has a refractive index that is approximately equal to that of the resin. As a result, even if they have an average particle size of more than 80 micrometers, the particles can hardly be noticed.
    In the case of the aforementioned first possibility of applying the resin, the aforementioned wear-resistant particles are preferably applied on the basis of the same carrier sheet, for example at least because they have been mixed in the resin and / or at least because they have been put into the paper during the production of paper. paper mass are mixed. Preferably, a carrier sheet is used whose paper mass is substantially free of wear-resistant particles, but wherein a resin layer is provided on the underside of the carrier sheet comprising wear-resistant particles. The underside of the carrier sheet is understood to mean that side which is provided to be directed towards the underside of the panel in the final decorative panel. In this way it is achieved that when the first upper veneer layer is worn through, it can also be worn relatively quickly through the carrier sheet and the particle-containing resin layer is exposed. This resin layer then forms a transparent wear-resistant layer above the underlying veneer layer. The absence of the worn-away carrier sheet has the advantage that the intermediate resin layer is better transparent.
    Preferably, between 5 and 50 grams per square meter of the abovementioned wear-resistant particles are used.
    Preferably, said intermediate layer comprises colorants, such as paints or staining agents, which can preferably draw into one or more of the aforementioned veneer layers upon pressing thereof. In this way, it is achieved that the intermediate resin layer is less conspicuously present, and it can optionally be obtained that the decorative top layer has a coloring spread over its thickness. Namely, it is easier to color in two veneer layers of half thickness or to penetrate with stain or paint than one veneer layer of full thickness. Moreover, a deeper coloring of the decorative top layer leads to less noticeable wear marks. According to a variant, the relevant veneer layers can be colored in prior to the pressing operation.
    In general, it is clear that the present invention is not limited to assembling a decorative top layer from only two veneer layers with an intermediate resin layer, but that more than two veneer layers, for example 4 to 9 veneer layers, preferably each time with such an intermediate resin layer, can be used. A decorative top layer is preferably obtained with a thickness of 2.5 millimeters or more, for example up to 4.5 millimeters.
    According to a special embodiment, the aforementioned two veneer layers have a different thickness, wherein, preferably, the first veneer layer, which is intended to be closer to the surface of the decorative panel or forms this surface, is the thinnest. Preferably, a first of the aforementioned veneer layers has a thickness of one millimeter or less, for example 0.4 to 0.8 millimeter, and a second of the aforementioned veneer layers has a thickness of one and a half millimeters or more, for example 2 to 3 millimeters. In this way the decorative top layer of the panel can be formed on the basis of only two veneer layers with an intermediate resin layer. Moreover, due to the limited thickness of the surface veneer, or the first veneer layer, a good penetration of the thermosetting resin and possible coloring of this layer can be obtained. The intermediate resin layer, certainly in the cases where it comprises a paper sheet and / or wear-resistant particles, then forms a high-performance wear layer for the underlying thicker veneer. The underlying veneer can also be penetrated at least superficially on the basis of the resin of the intermediate resin layer.
    Preferably, the aforementioned two veneer layers come from the same piece of solid wood, and are pressed in the same order and with the same orientation as in the piece of solid wood from which they were obtained. They are herein preferably mutually horizontally aligned. This means that they occupy the same or very similar position horizontally relative to each other as in the piece of solid wood from which they originate. In this way it is achieved that when a first veneer layer is being cut, the underlying veneer layer has a strongly similar wood pattern.
    Preferably, veneer layers are used that are obtained by sawing solid wood. When sawing, the wood structure is better preserved than in the case of cutting or peeling.
    It is clear that the present invention also relates to a decorative panel obtained by a method of the invention. Furthermore, the invention also relates in an independent manner to a decorative panel, said decorative panel comprising at least one substrate material and a decorative top layer applied thereto, characterized in that said top layer comprises at least two wood veneer layers pressed together by means of thermosetting resin. Preferably, the aforementioned thermosetting resin forms a separate layer between the aforementioned laminating layers. It is clear that such a decorative panel, and in particular its decorative layer, may further exhibit characteristics similar to those of the decorative panels obtained by the method of the invention, without necessarily having been obtained in such a way for this purpose.
    Preferably, said two layer layers are at least separated by a paper sheet, for example, a similar, preferably cured resin-soaked paper sheet, as is the case in the above-mentioned first possibility for the method of the invention.
    Preferably, said decorative layer comprises at least wear-resistant particles in a position between said two veneer layers. It is clear that the wear-resistant particles which have been mentioned in the context of the method of the invention can be used for this purpose.
    Both veneer layers preferably have a similar coloration.
    Preferably, the aforementioned two veneer layers are of different thickness, with a first veneer layer having a thickness of 1 millimeter or less, while a second veneer layer below it has a thickness of 1.5 millimeter or more.
    Preferably, the aforementioned two layers are from the same piece of solid wood and are located in the decorative top layer in the same order and orientation as in this piece of solid wood. Better still, they are also horizontally aligned or almost horizontally aligned as in the original piece of solid wood.
    The veneer layers preferably concern sawn veneer layers.
    With the insight to better demonstrate the features of the invention, an example is described below without any limiting character.
    EXAMPLE
    Six sawn oak veneer layers, each 0.5 millimeter thick, are stacked on top of each other with an intermediate resin layer in each case. The resin layer in each case consists of an overlay paper impregnated with melamine resin with a residual moisture content of 7%. The dry paper weight is 22 grams per square meter, and the applied resin in dry weight is 60 grams per square meter. In addition, the resin contains 10 grams per square meter of alumina particles with an average particle size of 90 micrometers. The resin is in the so-called B stage. The oak plating layers are compressed with the intermediate overlay papers at a pressure of 20 bar and a temperature of 200 ° C for 20 seconds. The wear-resistant particles, namely the aluminum oxide particles, are in each case located on the side of the overlay paper that is turned away from the final surface of the decorative top layer. The impact of the resulting decorative top layer is tested in accordance with EN 438-2: 2004. The diameter of the impact of a steel ball is decisive for the impact resistance. The wear resistance is evaluated by the depth of the wear track obtained in the tabertest after 2000 rpm. The results are presented in tabular form below.
    The results show that the impact resistance and wear resistance significantly increase by applying the method of the invention. The results further show that the resin of the interlayer penetrates to some extent into the upper spherical layer, since a significant difference in the depth of the wear track is already obtained before the first veneer layer is completely worn away, namely within the first 0.5 millimeter below the surface. In addition, the inventors have found that when the first 0.5 mm has worn through, the increase in the depth of the wear trace at the top layer of the example greatly weakens, while the wear of the standard oak top layer continues unabated. This is, in this case, due to the presence of the intermediate resin layer, paper layer and wear-resistant particles that shield the underlying veneer layer. For example, in the case of the top layer of the example, a depth of only 0.57 mm is observed after 12,000 turns.
    With the insight to better demonstrate the characteristics of the invention, a few preferred embodiments are described below as an example without any limiting character, with reference to the accompanying drawings, in which:
    Figure 1 represents a decorative panel according to the invention in perspective; Figures 2 and 3 show on a larger scale a cross-section according to the lines II-II and III-III indicated in figure 1;
    Figure 4 represents a variant in a view similar to that of Figure 3; Figure 5 shows how the floor panels of Figure 8 can be coupled to form a floating floor covering; and
    Figure 6 gives a view on a larger scale of the area indicated by F6 in Figure 2.
    Figure 1 shows a decorative panel, more particularly a floor panel 1, in accordance with the invention. The panel 1 is rectangular and elongated and comprises a pair of opposite short edges 2-3 and a pair of opposite long edges 4-5. The decorative top layer 6 is formed by composite veneer 7.
    Figure 2 clearly shows that the decorative panel 1 comprises a substrate material 8 on which the composite veneer 7 is provided, for example glued or otherwise fixed. The substrate material 8 in this case consists of a so-called slat core, wherein this core comprises several adjacent slats 9 which are oriented transversely to the length of the floor panel 1. Such slats 9 are preferably made from softwood, for example spruce or hevea. The outer slats 9A-9B that form the short edges 2-3 can be made of a different material, such as MDF / HDF or plywood. Such material allows better processing, for example for forming mechanical coupling means 10 therein by means of milling. A counter layer 11 is provided on the underside of the substrate material 8, for example glued or, on the other hand, fixed against the slat core. Such a counter layer 11 is preferably made of a wooden veneer layer with a thickness of at least 50 percent of the decorative top layer. According to a variant, a similarly constructed veneer 7 can be used for the counter layer 11 as for the top layer.
    Figures 2 and 3 show that both pairs of opposite edges 2-3-4-5 are provided with mechanical coupling means 10 which are essentially realized as a tooth 12 and a groove 13 bounded by an upper lip 14 and a lower lip 15, wherein the tooth 12 and the groove 12 are mainly responsible for locking in a vertical direction V, and wherein the tooth 12 and the groove 13 are provided with additional locking parts 16-17, which are mainly responsible for the locking in a horizontal direction H. The locking parts preferably comprise a protrusion 16 on the underside of the tooth 12 and a recess 17 in the lower groove lip 15. The coupling means 10 shown in figures 2 and 3 allow at least one coupling by means of a rotational movement W around the respective edges 2-3-4-5 and / or a coupling by means of a sliding movement S in a substantially horizontal manner from the edges 2-3-4-5 to be coupled to each other. e.
    Figures 4 and 5 show a variant with a pair of short edges 2-3 that allow a coupling to be obtained at least by means of a downward movement D. One edge 2 is provided with a male coupling part 18, while the other edge 3 is provided with a female coupling part 19. By means of the downward movement D, the male coupling part 18 is pressed into the female coupling part 19 to be locked therein in the vertical direction V, following a pair of cooperating protrusions 20 and recesses 21. In this case the recess 21 partly formed by a resilient element 22 present in the female coupling part 19.
    Figure 6 gives a detail of the composite structure of the composite veneer 7 that forms the decorative surface 6. The composite veneer 7 in this case is formed by two veneer layers 23A-23B arranged one above the other with an intermediate layer 24 of cured thermosetting resin. Furthermore, the composite veneer 7 has a structure on the decorative surface 6, wherein the summer wood 25 emerges as a protruding part 26.
    In the example of Figure 6, the two veneer layers 23A-23B have a different thickness, wherein the first veneer layer 23A that is closer to the decorative surface 6 is thinner than the underlying veneer layer 23B.
    The present invention is by no means limited to the embodiments described above, but such method and decorative panel can be realized in various variants without departing from the scope of the present invention.
    权利要求:
    Claims (16)
    [1]
    Conclusions.
    Method for manufacturing a decorative panel, the method comprising the steps of: - the step of providing a substrate material (8); - the step of manufacturing a decorative top layer (7); - the step of applying the decorative top layer and the substrate material to each other; characterized in that for the manufacture of the decorative top layer at least two wooden veneer layers (23A-23B) are pressed with an intermediate layer (24) of thermosetting resin.
    [2]
    Method according to claim 1, characterized in that the intermediate layer (24) is a separate layer.
    [3]
    Method according to claim 2, characterized in that the resin of the intermediate layer is provided with a carrier sheet at least on the basis of.
    [4]
    Method according to claim 3, characterized in that the aforementioned carrier sheet is a paper sheet, preferably from alpha-cellulose.
    [5]
    Method according to one of claims 2 to 4, characterized in that the resin of the intermediate layer is provided with a scattering treatment at least on the basis of.
    [6]
    Method according to one of the preceding claims, characterized in that the resin of the intermediate layer is in a B stage.
    [7]
    Method according to one of the preceding claims, characterized in that the resin of the intermediate layer has a residual moisture content of less than 10 percent.
    [8]
    Method according to one of the preceding claims, characterized in that the aforementioned intermediate layer comprises wear-resistant particles.
    [9]
    Method according to one of the preceding claims, characterized in that the aforementioned intermediate layer comprises colorants.
    [10]
    Method according to one of the preceding claims, characterized in that the aforementioned veneer layers (23A-23B) have a different thickness, the veneer layer (23A) intended to be closer to the surface of the decorative panel (1) the thinnest.
    [11]
    Method according to one of the preceding claims, characterized in that a first of the aforementioned veneer layers (23A) has a thickness of one millimeter or less and a second of the aforementioned veneer layers (23 B) has a thickness of one and a half millimeters or more .
    [12]
    Decorative panel, wherein this decorative panel (1) comprises a substrate material (8) and a decorative top layer (7) applied thereto, characterized in that the above-mentioned top layer (7) consists of at least two wooden blocks pressed together by means of thermosetting resin. layer layers (23A-23B).
    [13]
    The decorative panel according to claim 12, characterized in that said two layer layers (23A-23B) are at least separated by a paper sheet.
    [14]
    Decorative panel according to claim 12 or 13, characterized in that the said decorative top layer comprises at least wear-resistant particles in a position between the aforementioned two layer layers (23A-23B).
    [15]
    Decorative panel according to one of the claims 12 to 13, characterized in that both layers have a similar coloration.
    [16]
    Decorative panel according to one of the preceding claims, characterized in that the above-mentioned two veneer layers are of different thickness, wherein a first veneer layer (23A) has a thickness of 1 millimeter or less, while a second veneer layer (23B) is located below it a layer having a thickness of 1.5 millimeters or more.
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    同族专利:
    公开号 | 公开日
    BE1022850A1|2016-09-21|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US20060234009A1|2005-04-13|2006-10-19|Byung-Hyun Roh|Anti-caster surface laminate|
    US20120315452A1|2009-11-27|2012-12-13|Lg Hausys, Ltd.|Reinforced wood flooring and method for manufacturing same|
    法律状态:
    2021-09-30| PD| Change of ownership|Owner name: FLOORING INDUSTRIES LIMITED, SARL; LU Free format text: DETAILS ASSIGNMENT: CHANGE OF OWNER(S), CHANGE OF LEGAL ENTITY; FORMER OWNER NAME: UNILIN, BV Effective date: 20210723 Owner name: FLOORING INDUSTRIES LIMITED, SARL; LU Free format text: DETAILS ASSIGNMENT: CHANGE OF OWNER(S), CHANGE OF LEGAL ENTITY; FORMER OWNER NAME: UNILIN, B.V.B.A. Effective date: 20210723 |
    优先权:
    申请号 | 申请日 | 专利标题
    US201562135780P| true| 2015-03-20|2015-03-20|
    US62/135,780|2015-03-20|PCT/IB2016/051476| WO2016151435A1|2015-03-20|2016-03-16|Method for manufacturing a decorative panel and decorative panel|
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