• 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:
    Decorative panel or profile, wherein this panel or profile comprises at least one substrate, a decor and a wear layer applied to the decor, characterized in that the aforementioned wear layer mainly consists of lacquer, a material sheet and any hard particles, the aforementioned lacquer being a radiation-curing lacquer or a lacquer that dries by evaporating a solvent.
    公开号:BE1024356B1
    申请号:E2017/5274
    申请日:2017-04-20
    公开日:2018-02-05
    发明作者:Bruno Paul Louis Vermeulen；Christophe Naeyaert
    申请人:Unilin Bvba；
    IPC主号:
    专利说明:

    (30) Priority data:
    07/07/2016 BE 2016/5570 (73) Holder (s):
    UNILIN BVBA 8710, WIELSBEKE Belgium (72) Inventor (s):
    VERMEULEN Bruno Paul Louis 3680 ALDENEIK-MAASEIK Belgium
    NAEYAERT Christophe 8490 JABBEKE Belgium (54) Decorative panel or profile (57) Decorative panel or profile, this panel or profile comprising at least one substrate, a decor and a wear layer applied to the decor, characterized in that the aforementioned wear layer consists mainly of lacquer a material sheet and any hard particles, the aforementioned lacquer being a radiation-curing lacquer or a lacquer that dries by evaporation of a solvent.
    BELGIAN INVENTION PATENT
    FPS Economy, K.M.O., Self-employed & Energy
    Publication number: 1024356 Filing number: BE2017 / 5274
    Intellectual Property Office
    International Classification: B44C 5/04 E04F 15/10 Date of Issue: 05/02/2018
    The Minister of Economy,
    Having regard to the Paris Convention of 20 March 1883 for the Protection of Industrial Property;
    Having regard to the Law of March 28, 1984 on inventive patents, Article 22, for patent applications filed before September 22, 2014;
    Having regard to Title 1 Invention Patents of Book XI of the Economic Law Code, Article XI.24, for patent applications filed from September 22, 2014;
    Having regard to the Royal Decree of 2 December 1986 on the filing, granting and maintenance of inventive patents, Article 28;
    Having regard to the application for an invention patent received by the Intellectual Property Office on 20/04/2017.
    Whereas for patent applications that fall within the scope of Title 1, Book XI, of the Code of Economic Law (hereinafter WER), in accordance with Article XI.19, § 4, second paragraph, of the WER, the granted patent will be limited. to the patent claims for which the novelty search report was prepared, when the patent application is the subject of a novelty search report indicating a lack of unity of invention as referred to in paragraph 1, and when the applicant does not limit his filing and does not file a divisional application in accordance with the search report.
    Decision:
    Article 1
    UNILIN BVBA, Ooigemstraat 3, 8710 WIELSBEKE Belgium;
    represented by
    SCHACHT Benny, Ooigemstraat 3, 8710, WIELSBEKE;
    VAN HOOYDONCK Guy, Ooigemstraat 3, 8710, WIELSBEKE;
    a Belgian invention patent with a term of 20 years, subject to payment of the annual fees as referred to in Article XI.48, § 1 of the Economic Law Code, for: Decorative panel or profile.
    INVENTOR (S):
    VERMEULEN Bruno Paul Louis, Grinaraweg 14, 3680, ALDENEIK-MAASEIK;
    NAEYAERT Christophe, Wetstraat 3A, 8490, JABBEKE;
    PRIORITY:
    07/07/2016 BE 2016/5570;
    BREAKDOWN:
    Split from basic application: Filing date of the basic application:
    Article 2. - This patent is granted without prior investigation into the patentability of the invention, without warranty of the Merit of the invention, nor of the accuracy of its description and at the risk of the applicant (s).
    Brussels, 05/02/2018,
    With special authorization:
    BE2017 / 5274
    Decorative panel or profile.
    This invention relates to decorative panels and profiles, and in particular to floor panels.
    More specifically, the invention relates to floor panels with a substrate and a top layer applied to it with a printed decor. Such floor panels are widely known, for example from WO 97/47834. The floor panels disclosed there concern, inter alia, floor panels with a substrate which mainly consists of an HDF plate with a laminate layer directly pressed thereon, which comprises one or more paper sheets soaked in melamine resin, including preferably a paper sheet with a printing in, for example, a wood or stone motif. , namely a so-called decor paper.
    It is known that the melamine surface of such laminate panel gives rise to ticking noises when using it. A variety of solutions to this problem are known from the prior art. It is known from WO 03/016655 to provide a sound-absorbing layer such as a cork layer under the melamine layer. It is known from WO 2010/088769, among others, to provide the melamine layers with a coating of a flexible monomer. WO 2009/101217 and WO 2010/070474 give examples of laminate panels in which the top layer, instead of melamine resin, is mainly built up of polyvinyl chloride (PVC). In the case of WO 2010/070474, these are panels with a printed decor that can be formed on the substrate and are finished with a transparent PVC layer.
    The panels whose top layer is made entirely of PVC have a loss of scratch resistance compared to the traditional melamine surface. In addition, the PVC layer must be made considerably thicker than a melamine layer in order to obtain a comparable wear resistance. The nature and thickness of the PVC layer gives rise to a plastic look of the floor panel, especially in that
    BE2017 / 5274 cases where an imitation of a product such as wood, stone or ceramic is sought. The relief that can be obtained in a PVC layer is blurred, which detracts from the truthfulness of the imitation obtained. The aforementioned WO 2010/070474 aims to remedy this by providing the surface with indentations obtained by a combination of chemical and mechanical techniques.
    The present invention aims primarily to provide an alternative floor panel which provides a solution to one or more of the problems with the prior art panels.
    To this end, the invention relates to a floor panel with a substrate and a top layer applied to it, wherein the aforementioned top layer comprises a printed decor applied between a foamed bottom layer, preferably of PVC or another thermoplastic material, and a transparent wear layer, characterized in that the said wear layer is free of PVC, is not foamed, and has a thickness less than the thickness of said foamed PVC underlayer. The invention offers a compromise between sound absorption and faithful imitation. As already mentioned, the latter is especially important in the imitation of wood, stone or ceramic.
    It goes without saying that the aforementioned wear layer is preferably made harder or more wear-resistant than the foamed bottom layer. For this purpose, the wear layer can be designed in various possible ways.
    According to a first possibility, the wear layer can use a thermoplastic material with a higher glass transition temperature than the material of the bottom layer, for example with a higher gloss transition temperature than that of PVC, or with a glass transition temperature of more than 80, or even 90 ° C or more. For example, it is possible to opt for a wear layer of polystyrene (PS), polypropylene (PP), preferably isotactic polypropylene, polymethyl methacrylate (PMMA), polycarbonate (PC) or a polyamide (PA).
    j
    BE2017 / 5274
    According to a second possibility, the wear layer can use a material with a curing mechanism other than PVC. PVC cures by cooling and the wear layer is currently chosen for a material that cures by a mechanism other than cooling. This may be a thermally cured material such as a melamine based resin, a UV curable lacquer layer, an electron beam curable lacquer layer, an excimer cured lacquer layer, a drying lacquer layer or the like. Preference is given to a radiation-curable lacquer layer, such as a UV-curable lacquer layer, preferably an acrylic-based lacquer layer, a urethane-based lacquer layer, a polyester-based lacquer layer or an epoxy-based lacquer layer. Due to the use of a radiation-curing lacquer layer, the underlayer is minimally or not addressed during the curing of the lacquer layer.
    According to a third possibility, for the wear layer, use can be made of a material that encloses hard particles. These are preferably hard particles such as aluminum oxide or silicon oxide, which preferably have an average particle size between 20 and 200 micrometers. Preferably, a content of such particles is used from 2 to 20 grams per square meter. It is noted that this third option is preferably combined with one of the preceding measures. For example, a radiation-curing lacquer layer can be used which encloses the aforementioned hard particles.
    It is clear that the wear layer in the context of the present invention is seen as the full layer between printed decor and the surface of the panel. Furthermore, it is clear that this wear layer is preferably essentially or even completely built up as in the above possibilities. However, it is not excluded that the wear layer on the surface of the panel still comprises a superficial coating.
    Preferably, the thickness of the wear layer is less than half the thickness of the bottom layer, or even less than 25% of the thickness of the bottom layer. A good value for the thickness of the wear layer is between 0.1 and 0.5 millimeters, and better still between 0.15 and 0.3 millimeters. Such a limited thickness, especially in the case of
    BE2017 / 5274 radiation-cured coatings containing aluminum oxide particles, another wear resistance sufficient for floor panel applications.
    Preferably, the aforementioned printed decor consists of a printing formed directly on the aforementioned underlayer, whether or not after the aforementioned underlayer has been pretreated, for instance with uniformly colored layers. The printing can here be carried out by the deposition of pigment-containing inks on the above-mentioned bottom layer, for instance by means of a digital inkjet printer. At least inks with the basic colors cyan, magenta, yellow and black (CMYK) are preferably used. However, it is not excluded that one or more so-called spot colors are used. These are colors that are matched to the decor to be printed. In the case of wood motifs, a reddish color is then eligible. Preferably, the printing is formed on the basis of UV-curable inks. Since little or no heat is required for the curing of the inks, the bottom layer is not affected by the curing of the inks.
    As aforementioned, the aforementioned wear layer preferably concerns a lacquer layer, such as an acrylic-based layer or a urethane-based layer. In general, a lacquer layer is preferably used which can be cured by radiation or which can be cured by drying out a solvent.
    The aforementioned wear layer is preferably cured on the basis of UV radiation, electron radiation and / or excimer radiation.
    The aforementioned wear layer preferably comprises hard particles, such as aluminum oxide particles.
    According to a special embodiment, the aforementioned wear layer comprises a material sheet, such as a paper sheet. Such a material sheet significantly contributes to the impact resistance of the floor panel and reduces the risk of the usually hard but brittle wear layer cracking. The material sheet makes the wear layer more ductile, which is also interesting when subsequently machining the edges of the floor panel. The
    BE2017 / 5274 ductility of the wear layer reduces the risk of splintering edges when milling any coupling means. Moreover, such a material sheet forms a barrier against the displacement of any wear-resistant or hard particles in the still wet wear layer during production, so that these particles can be more effective in the obtained floor panel. The inventors have surprisingly found that when using a pure, unfilled paper, such as an alpha cellulose paper, the transparency of the top layer should hardly be lost, even in the case of a top layer based on radiation-curable lacquers, such as acrylic-based or urethane-based coatings. On the contrary, the thickness of the wear layer can be further limited while maintaining impact and wear resistance, so that the transparency or in other words, the visibility of the printed decor through the wear layer, can be increased. The possible particles in the wear layer are largely immobilized by the presence of the material sheet until their position is finally frozen when the lacquer layer hardens. In the most preferred embodiment of this, the wear layer comprises a material sheet comprising hard particles embedded on it. This may be, for example, a so-called Mead overlay, for example as described in US 5,820,937, in which an alpha cellulose paper is filled during production with aluminum oxide particles or other wear-resistant particles. In such an embodiment, the hard particles are pre-eminently held in a fixed position in the thickness of the wear layer, moreover, no special measures have to be taken to keep the hard particles in suspension in the lacquer layer or other material of the wear layer. The latter leads to a reduced risk of loss of transparency due to the use of any suspending agents and to a smoother production process. Also when machining the edges, there is less risk of hard particles coming off, as these are held together somewhat in the material sheet. Obviously, where hard particles are used, either embedded in a material sheet or mixed in the actual material of the wear layer, for example, in a radiation hardening paint, or both, the preferred features of the above third possibility for the wear layer may be are applied.
    BE2017 / 5274
    As mentioned, the aforementioned bottom layer preferably comprises or consists of foamed PVC. It is preferably foamed PVC of the type used in so-called cushion vinyl and / or foamed PVC with a plasticizer share of 12phr or more, for example 20 phr or more. The degree of foaming of the bottom layer is preferably such that a density reduction compared to the non-foamed material is greater than 20 percent, and preferably even greater than 50%. Preferably it is mainly a closed cell type foam or the substantially closed type or cell type.
    Preferably, the aforementioned bottom layer is foamed at least chemically. This can be done, for example, by adding azodicarbonamide as a foaming agent to the PVC composition. According to a variant, the above-mentioned bottom layer can be foamed at least mechanically. In such a case it is, for example, about adding expanding granules to the PVC composition, such as, for example, polystyrene-based granules or those known under the brand name Expancel ©.
    There are various possibilities for applying the aforementioned underlayer to the substrate.
    According to a first possibility, the above-mentioned bottom layer is adhered to the above-mentioned substrate via an adhesive layer. Such an embodiment allows a smooth production of the foamed PVC bottom layer, for instance on a continuous production line specially provided for this purpose. To allow such production, the foamed PVC underlayer preferably includes a support, such as a glass fiber-based support, for example a glass fiber (non woven) or glass fabric (woven). Such a carrier gives the final floor panel a certain impact resistance.
    According to a second possibility, the aforementioned bottom layer is adhered directly to the substrate without the use of adhesive layers. According to this possibility, a PVC plastisol is preferably used, which is applied to the surface of the substrate in liquid or pasty form and foamed there. Bee
    BE2017 / 5274 the bottom layer is preferably cooled by means of a pressing element, for instance by means of one or more pressing rollers or pressing belts, such that its thickness can be slightly calibrated.
    Irrespective of the manner in which the bottom layer is adhered to the substrate, this bottom layer preferably comprises a glass fiber or glass fabric. As already mentioned, such glass fiber or glass fabric contributes to the impact resistance of the floor panel. According to a particularly preferred embodiment, said glass web or glass fabric is located on the top surface of said bottom layer, or at least in the top quarter of the thickness of said bottom layer. Such an embodiment is particularly important when the wear layer and / or the printed decor is to some extent brittle, or at least is considerably more brittle than the PVC underlay. In such a case there is a risk that the lacquer layer breaks. The presence of a fiberglass-based layer or other reinforcing layer near the wear layer can significantly reduce this risk. The inventor has determined that, for example, with acrylic-based and / or radiation-cured lacquer layers, this solution may be sufficient for floor applications.
    For the substrate, use is preferably made of a substrate which mainly consists of an MDF or HDF board material.
    Preferably, the floor panel of the invention is further characterized in that it is provided with mechanical coupling parts on at least two opposite edges and that these coupling parts, in a coupled condition of two such floor panels, provide a clamping effect of the aforementioned underlayers against each other at the location of the concerning edges. With such an embodiment a certain watertightness of the edges can be obtained. This is important, for example, in cases where the substrate uses a porous and / or wood-based substrate, for example in the case of MDF or HDF.
    According to a special embodiment, the above-mentioned substrate is provided on at least two opposite edges with a coating which prevents the penetration of moisture
    Prevents or limits BE2017 / 5274 in the substrate, the covering in question being formed overlapping with the edge of the aforementioned underlayer. In other words, according to this embodiment, a moisture-resistant coating is provided at the edge of the floor panel, said coating extending from the substrate to at least over the boundary with the above-mentioned underlayer. Preferably, the coating extends further, namely at least beyond the boundary with the printed decor and / or with the wear layer.
    Preferably, the wear layer is provided with a structure or relief formed by depressions on the surface thereof. Preferably, this structure contributes to the imitation of the pattern depicted in the printed decor and / or the structure forms a demarcation of the printed decor, for example on at least one edge thereof. For example, in the case of a wood imitation, it is possible to work with indentations in the form of wood tracks and / or veins. According to another example, it is possible to work with a demarcation of the decor in the form of chamfers or other chamfers. In the case of stone decor, a structure can be used that mimics the presence of cement joints.
    Preferably, the wear layer is provided with structural parts which continue into the aforementioned underlayer, or, in other words, the printed decor is also structured. Such an embodiment is particularly interesting in the realization of structural parts such as chamfers, because in this way, despite the limited thickness of the wear layer, they can nevertheless be made deep. The relief obtained in the printed decor itself also contributes to the panel's faithful imitation. According to a special example of this, even the optional reinforcement layer, for example the glass fiber or glass fabric, can follow the contour of the respective structural parts.
    It is noted that the above-mentioned special embodiment in which the wear layer comprises a material sheet is an example of a second independent aspect of the present invention. The second aspect aims at an improved impact resistance, ductility, transparency and / or wear resistance of products containing a
    BE2017 / 5274 coating. To this end, the present invention relates to a decorative panel or profile, wherein this panel or profile comprises at least a substrate, a decor and a wear layer applied to the decor, characterized in that the aforementioned wear layer mainly consists of lacquer, a material sheet and any hard particles, the aforementioned lacquer being a radiation-curing lacquer or a lacquer that dries by evaporation of a solvent. The wear layer preferably consists of 70 gr / m 2 to 160 gr / m 2
    Preferably, the aforementioned material sheet is a paper sheet, preferably an alpha cellulose paper. Preferably, the paper sheet has a weight of 25 g / m 2 to 65 g / m 2 .
    According to the most preferred embodiment, said material sheet is a paper sheet, preferably an alpha cellulose paper sheet, which comprises embedded hard, e.g. mineral, particles, such as aluminum oxide particles or corundum. Preferably, the respective paper sheet comprises 2 to 20 grams per square material of such particles and preferably with an average particle size between 20 and 200 micrometers. Preferably, the paper sheet has a weight, including embedded particles, from 25 g / m 2 to 65 g / m 2 . This may, for example, be a paper sheet in accordance with the aforementioned US 5,820,937.
    Preferably the aforementioned lacquer is an acrylic based radiation curing lacquer.
    It is understood that a decorative panel having the features of the present second aspect of the invention may also have the features of the first aspect or the preferred embodiments thereof.
    According to the variant of the second aspect, the invention relates to a decorative profile. This may be, for example, the type of profile that is used for finishing a floor covering, such as a transition profile, end profile, plinth or the like. This variant provides for a smooth production of profiles that match with decorative panels, for example in particular matching with decorative panels
    BE2017 / 5274 which comprise a print formed on the substrate and are finished with a transparent lacquer layer. With such panels, unlike DPL laminate panels, for example, printed paper with a motif matching the printing of the decorative panel is not commonly available. If this decorative sheet or paper sheet were already available, the thick lacquer layer makes it difficult to coat a profiled substrate. According to the present variant of the second aspect, the invention can lead to a decorative profile of floor quality that can be produced in a simpler manner, and thus creates more freedom for the design of such profiles.
    According to a third independent aspect, the invention also relates to a method for manufacturing a decorative panel or profile, for instance with the features of the second aspect. To this end, the invention relates to one comprising at least the following steps:
    - the step of providing a carrier;
    the step of liquidly applying a layer of transparent lacquer to said carrier;
    the step of applying a material sheet in the aforementioned lacquer; preferably the material sheet is a paper sheet, for example a paper sheet with embedded hard particles;
    the step of curing the aforementioned lacquer, preferably by means of steel, and / or by drying.
    Preferably, the aforementioned support is a plate-shaped or profiled substrate. This may, for example, be an MDF or IIDF based substrate. Other options, such as plywood, chipboard, mineral-based or plastic-based substrates are not excluded. It is clear that a plate-shaped substrate is preferably used for the realization of a decorative panel and that a profiled substrate is preferably used for the realization of a decorative profile. In case the method of the third aspect of the invention is used for manufacturing decorative panels with the features of at least the first aspect, the aforementioned carrier is designed as a plate-shaped
    BE2017 / 5274 substrate on which a foamed layer, preferably of PVC, has been applied. Other composite substrates, either layered or otherwise, are of course not excluded.
    According to a variant, the above-mentioned carrier is a paper or a foil and the method preferably further comprises the step of applying the above-mentioned carrier to a plate-shaped or profiled substrate. The application is preferably carried out by gluing the carrier in question to the substrate, for instance by means of a so-called sheathing process, for example of the type known from US 3,296,056 or US 4,198,455. The method of the third aspect allows the transparent lacquer layer to be made thinner, while at the same time achieving a wear resistance required for, for example, application in floors. The limited thickness of the lacquer layer ensures a smooth application of the carrier on the substrate. The obtained wear resistance of the decorative panel or profile preferably reaches at least the wear class AC2 or higher, even up to AC5 and higher, expressed in accordance with EN 13329-annex E.
    According to the most preferred embodiment, the material sheet is untreated when applied in the aforementioned lacquer. It is preferably a material sheet, namely a paper sheet, which exclusively consists of cellulose fibers in which hard particles may be embedded. The paper sheet is preferably free from brighteners, such as titanium dioxide, and other fillers, such as clay and / or calcium carbonate. In other words, the ash content of the material sheet preferably consists essentially or completely of aluminum oxide, as may be the case with so-called overlapping paper or alpha cellulose paper, for example of the type known from US 5,820,937.
    According to an alternative, the material sheet in question is also provided with lacquer prior to its application in the lacquer, for example impregnated with lacquer. This is preferably the same lacquer as is provided on the carrier. Optionally, in such a case, the step of applying lacquer to the carrier can be omitted.
    BE2017 / 5274
    Preferably, said carrier is printed prior to the aforementioned liquid application of the lacquer, preferably by means of a digital printing technique, preferably by means of UV-curable or water-based inks. Solvent-based inks, latex inks or oil-based inks are not excluded. Preferably, the printing is formed on the relevant carrier, if necessary with the intervention of base layers, such as preparatory layers. In case the support is a plate-shaped or profiled substrate, it is preferably prepared with substrate at least with one or more layers of a uniform color and / or with a paper sheet. In case the carrier comprises a paper or a foil, the carrier is preferably at least prepared with an inkjet receiver coating.
    As mentioned earlier, the aforementioned material sheet is preferably a paper sheet, more preferably a paper sheet comprising embedded hard particles.
    Preferably, the aforementioned material sheet is pressed against the respective carrier in the aforementioned step of applying the aforementioned material sheet in the lacquer. The pressing can for instance be effected by means of one or more rollers.
    It is clear that preferred embodiments of the decorative panel or the decorative profile of the first and / or the second aspect give rise to respective preferred embodiments of the present third aspect of the invention and that the invention of the third aspect is eminently suitable for manufacturing the panels and / or profiles of the first and / or the second aspect of the invention.
    With the insight to better demonstrate the features of the invention, some preferred embodiments are described below, by way of example without any limitation, with reference to the accompanying drawings, in which:
    Figure 1 shows in perspective a floor panel according to the invention;
    BE2017 / 5274
    Figure 2 shows a cross section on a larger scale according to the line II-II shown in figure 1;
    Figure 3 shows an even larger scale view of the area indicated by F3 in Figure 2;
    Figures 4 to 6 show variants in a view similar to that of Figure 3, Figure 6 being an example of the second aspect of the invention;
    Figure 7 in a view similar to that of Figure 3 illustrates another embodiment of the second aspect of the invention;
    Figure 8 shows in perspective a decorative profile with the features of the second aspect of the invention; and
    Figure 9 shows a cross-sectional view and on a larger scale in the area indicated by F9 in figure 8.
    Figures 1 and 2 show an elongated floor panel 1 with a pair of long opposing edges 2-3 and a pair of short opposing edges 4-5. Both the short pair of edges 4-5 and the long pair of edge 2-3 are provided with coupling means or coupling parts 6, with which two such floor panels 1 can be coupled to the relevant edges 2-3-4-5 in such a way that they are locked both in a horizontal direction Hl perpendicular to the respective edge 2-34-5 and in the plane of the floor panels 1, and in a vertical direction VI perpendicular to the plane of the coupled floor panels 1. The coupling parts 6 are preferably the pair of long edges 2-3 are designed similarly to the coupling parts 6 to the pair of short edges 4-5, and they preferably both allow at least one coupling by means of a rotary movement along the relevant edges 2-3-4-5. However, it is not excluded that the coupling parts 6 on the respective pairs of edges 2-3 and 4-5 are of different design. For example, coupling parts 6 may be provided on the long edges which allow at least one coupling by means of such a revolving movement, while the coupling parts 6 on the short edges 4-5 allow at least one coupling by means of a translation movement, for example by means of of a horizontal sliding movement of the respective edges 4-5 towards each other
    BE2017 / 5274 or by means of a downward movement of the respective edges 4-5 towards each other.
    Figure 2 clearly shows that these coupling parts 6 can mainly be designed as a tooth 7 and groove 8, this groove 8 being bounded by an upper lip 9 and a lower lip 10. The aforementioned tooth 7 and groove 8 result in known manner in the above-mentioned locking in vertical direction VI. In order to obtain the locking in the horizontal direction H1, said tongue 7 and groove 8 are provided with locking parts, which mainly consist here of a projection 11 near the end of the lower lip 10 and a recess 12 co-operating therewith in the underside of the said tooth 7. On the right-hand side of figure 2 it is also shown that the cooperation of two such floor panels 1 in the example results in a deflection B of the lower lip 10. This results in so-called "prestressing", whereby two such floor panels 1 are actively towards each other be pressed.
    Figure 2 further clearly shows that the floor panel 1 of the example is of the type which has a substrate 13 and a top layer 14 applied thereon. The top layer 14 herein comprises at least a printed decor 15 and a transparent wear layer 16 above it.
    The special feature of the present invention consists in that the floor panel 1 between the aforementioned printed decor 15 and the aforementioned substrate 13 comprises a foamed underlay 17, preferably of PVC or another thermoplastic material, and that the aforementioned wear layer 16 is free of PVC and is not foamed. The thickness T1 of the wear layer 16 is less than the thickness T2 of the bottom layer 17. In this case, it concerns a bottom layer 17 comprising foamed PVC. The substrate 13 in this case comprises an HDF plate (High Density Fiberboard), with an average density of more than 750 kilograms per cubic meter. The materials of the top layer 14, bottom layer 17 and substrate 13 are chosen such that the hardness and / or wear resistance of the wear layer 16 is higher than the corresponding properties of the bottom layer 17. In this case, the wear layer mainly consists of a UV-cured acrylic lacquer That
    BE2017 / 5274 includes aluminum oxide particles. Preferably the wear layer 16 is at least ten percent and more preferably at least twenty percent harder than the bottom layer 17, the hardness being expressed on the Rockwell scale.
    The substrate 13 here concerns an internal layer of the floor panel 1 screen, which in itself consists of a single layer and wherein the relevant layer has a thickness T3 which is greater than half the thickness T of the entire relevant panel 1. Preferably the thickness T3 of the substrate 13 is at least 70% of the thickness T of the entire floor panel 1.
    In the example, the contour of the coupling parts 6 is completely formed in the substrate
    13. By contour is meant the surface which comprises all contact surfaces 18 between two coupled floor panels 1, with the exception of the contact surface 18A at the top edge 19 of the panels 1. It is of course not excluded that, for example, the underside of the upper groove lip 9 and / whether the top side of the tooth 7 in contact with it consists of the material of the bottom layer 17. In such a case, the remaining part of the contour of the coupling parts 6 is preferably formed in the material of the substrate 13.
    In the example, the bottom layer 17 extends above the horizontal level N1 defined by a central line of the floor panel 1. In this case, it even extends above the horizontal level defined by a central line of the coupling parts 6, determined by the tooth -in-groove coupling 7-8, which central line in this case is approximately equal to the level NI. The bottom layer 17, in the examples, is adhered directly to the substrate 13 without the use of adhesive layers.
    The aforementioned bias or deflection B provides a clamping effect of the aforementioned underlayers 17 against each other at the location of the respective edges 19, namely in this case at the contact surfaces 18A.
    Figure 3 clearly shows that an air chamber 20 is provided above the tongue-in-groove coupling 7-8 but below the surface of the floor panels 1. This air chamber 20
    BE2017 / 5274 in this case consists of undercuts 21 which are arranged on both the tongue and groove sides of the panels 1. It is of course possible to obtain such an air chamber 20 by applying such an undercut 21 on only one of the two sides 2-3, preferably on the groove side; for example, the undercut 21 can also be useful when joining the tongue 7 and groove 8. Due to the presence of said air chamber 20, the aforementioned clamping effect can be concentrated on the contact surfaces 18 A situated above this air chamber 20, so that the seam at the top edge 19 can remain closed.
    The bottom layer 17 forms more than 45 percent of the total thickness of the top layer 14. For the transparent or translucent wear layer 16, a radiation-cured lacquer layer with a thickness T1 of at least 0.1 millimeter is preferably used. Preferably, the wear layer is no thicker than 0.6 millimeters. The inventors have determined that a thickness T1 of 0.2 to 0.4 millimeters provides good wear resistance.
    The joint thickness T4 of said top layer 14 is preferably between 1.5 and 3 millimeters, a thickness T of 1.7 to 2.5 millimeters being desirable.
    For the substrate 13, it is possible to work with a sheet material, for example HDF or MDF, with a thickness T3 of 3 millimeters or more. Preferably, thickness t3 of the substrate 13 is between 4.5 and 7 millimeters.
    In the case of the example of figure 2, an optional counter layer 22 is applied to the underside of the substrate 13. Such a counter layer preferably consists of a material similar or equal to that of the wear layer 16 and / or the bottom layer 17.
    For the printed decor 15, use was made of UV-curable pigment-containing inks which have been deposited directly on the bottom layer 17, for instance by means of a digital printing device, such as an inkjet printer. The printing in this case is carried out without intermediate primer layers and the inks are thus deposited directly on the foamed underlayer 17. The inventor has surprisingly established
    BE2017 / 5274 that good printing quality could be obtained despite the presence of a foamed surface.
    In figure 3 it is further indicated with a dashed line that the bottom layer 17 comprises a glass fiber or glass fabric 23. The glass fiber or glass fabric 23 is hereby located in the top quarter 24 of the aforementioned bottom layer 17.
    Figure 4 shows a variant in which the substrate 13 is provided with a coating 25 which limits or prevents the penetration of moisture into the substrate 13. The respective coating 25 is overlapped with the edge or boundary 26 of the bottom layer 17. In this way, the substrate part is prevented from being immediately affected by moisture under the bottom layer 17 and thus the risk is reduced that effects, such as swelling of the substrate material by moisture penetration, become visible on the surface of the floor panel.
    Figure 5 shows another variant in which the wear layer 16 on its surface 27 is provided with a structure or relief of indentations 28. The indentation 29 is an example of an indentation for the imitation of wood tracks. The indentations 30 form a demarcation of the decor 15 in the form of chamfers on the edges 19 of the floor panel 1.
    In this case, the indentations 30 are an example of structural parts that continue into the bottom layer 17, the printed decor 15 also being structured at the location of these indentations 30. In this example, even the reinforcement layer 23 follows the contour of the indentations 30.
    Figure 6 shows a variant of a floor panel 1 with the features of the first aspect, which has been obtained by a method with the features of the third aspect. Here, the decorative panel, or floor panel 1 in this case, has a wear layer 16 which mainly consists of lacquer, a material sheet 31 and hard particles 32. The lacquer in this case is a UV-cured acrylic-based lacquer. The aforementioned material sheet 31 is an alpha cellulose paper sheet in which the aforementioned hard particles 32,
    BE2017 / 5274 in this case, aluminum oxide particles, are embedded. The ash content of the aforementioned material sheet 31 consists practically exclusively of the aforementioned aluminum oxide particles. The aforementioned lacquer layer is otherwise preferably free from hard particles 32.
    Figure 7 shows a decorative panel, in this case a floor panel 1, in which the wear layer 16 has the same design as in the case of the embodiment of Figure 6. The top layer 14 is in this case free from foamed layer. The printed decor 15 is a print formed directly on the substrate 13. To this end, the substrate 13 has been treated with a preparative uniformly colored layer 33 which provides a neutral printing base and improved adhesion with the deposited inks, or in other words the printed decor 15.
    Figure 8 shows a decorative profile 34 with the features of the second aspect of the invention, obtained according to the method of the third aspect of the invention. In this case it concerns a multifunctional profile 34 which can be adapted to form, at the choice of the consumer, an expansion profile or T-profile, a transition profile or an end profile. Multifunctional profiles are known for example from WO 2006/074824. The decorative profile 34 comprises a profiled substrate 13A, in this case composed of a T-shaped part 35 and two nose parts 36 which are located under the flanges 37 of the T-shaped part 35. The profiled substrate 13A in this case has a top surface 38 and two outwardly facing side surfaces 39 which join the top surface 38. The top surface 38 and the two side surfaces 39 are provided with a coating 40 with a printed decor.
    Figure 9 clearly shows that the coating 40 comprises a support 41 in the form of a paper or foil. The carrier 41 is provided with a printed decor 15 and finished with a wear layer 16. The wear layer 16 has a similar construction as the wear layers of figures 6 and 7. The coating 49 is applied in its entirety to the substrate 13A by means of a adhesive layer 42, for example by means of a coating process.
    BE2017 / 5274
    It is further noted in Figures 6, 7 and 9 that the composition of the transparent wear layer 16 is only schematically shown and that the cellulose fibers of the material sheet 31 may in practice be spread over a greater part of the thickness TI of the lacquer layer. In practice, the material sheet 31 in question can adjoin the printed decor 15. Preferably, the wear layer 16 on the surface has a zone formed by a portion of lacquer free of cellulose fibers.
    The present invention is by no means limited to the above-described embodiments, but such floor panels, decorative panels, decorative profiles and methods of manufacturing them can be realized without departing from the scope of the present invention.
    BE2017 / 5274
    权利要求:
    Claims (10)
    [1]
    Conclusions.
    1 Decorative panel or profile, wherein this panel or profile comprises at least a substrate, a decor and a wear layer applied to the decor, characterized in that the aforementioned wear layer consists mainly of lacquer, a material sheet and any hard particles, the aforementioned lacquer being a radiation-curing lacquer or a paint that dries by evaporation of a solvent.
    [2]
    Decorative panel or profile according to claim 1, characterized in that said material sheet is a paper sheet, preferably an alpha cellulose paper.
    [3]
    Decorative panel or profile according to claim 1 or 2, characterized in that the respective paper sheet comprises embedded hard particles.
    [4]
    Decorative panel or profile according to one of the preceding claims, characterized in that the above-mentioned lacquer is an acrylic-based radiation-curing lacquer.
    [5]
    5. Method for manufacturing a decorative panel or profile, the method comprising at least the following steps;
    - the step of providing a carrier;
    the step of liquidly applying a layer of transparent lacquer to said carrier;
    the step of applying a material sheet in the aforementioned lacquer;
    - the step of curing the aforementioned lacquer.
    [6]
    6. Method according to claim 5, characterized in that said carrier is a plate-shaped or profiled substrate.
    [7]
    Method according to claim 5, characterized in that said carrier is a paper or a foil and that the method preferably further comprises the step
    BE2017 / 5274 of applying the aforementioned support on a plate-shaped or profiled substrate.
    [8]
    Method according to any one of claims 5 to 7, characterized in that the said carrier is printed prior to the said step of applying the lacquer in liquid form, preferably by means of a digital printing technique, preferably by means of UV curable or water based inks.
    [9]
    9. A method according to any one of claims 5 to 8, characterized in that said material sheet is a paper sheet, preferably a paper sheet comprising embedded hard particles.
    Method according to one of claims 5 to 10, characterized in that with the
    Said step of applying said material sheet in the lacquer, the material sheet is pressed against the carrier.
    [10]
    11. - Floor panel with a substrate (13) and a top layer (14) arranged thereon, the aforementioned top layer (14) comprising a printed decor (15) arranged between a
    Foamed PVC bottom layer (17) and a transparent wear layer (16), characterized in that the aforementioned wear layer (16) is free of PVC, is not foamed, and has a thickness TI less than the thickness T2 of the aforementioned foamed PVC bottom layer (17), and wherein said wear layer (16) comprises a paper sheet with embedded alumina particles.
    BE2017 / 5274
    类似技术:
    公开号 | 公开日 | 专利标题
    US20190292796A1|2019-09-26|Fibre based panels with a wear resistance surface
    EP2242625B1|2016-05-04|Fibre based panels with a wear resistance surface
    BE1024723B1|2018-06-11|Floor panel and method for manufacturing a floor panel.
    KR20160138157A|2016-12-02|Composite boards and panels
    BE1024617B1|2018-05-02|Floor panel and method for manufacturing a floor panel.
    WO2018007932A2|2018-01-11|Floor panel
    BE1024356B1|2018-02-05|Decorative panel or profile
    JP6433669B2|2018-12-05|Floor board manufacturing method
    BE1021539B1|2015-12-10|PANEL AND METHOD FOR MANUFACTURING SUCH A PANEL
    同族专利:
    公开号 | 公开日
    BE1024356A1|2018-01-30|
    BE1024447B1|2018-02-27|
    BE1024447A1|2018-02-21|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    WO2001048333A1|1999-12-23|2001-07-05|Perstorp Flooring Ab|A process for the manufacturing of surface elements|
    WO2009065768A1|2007-11-19|2009-05-28|Välinge Innovation Belgium BVBA|Recycling of laminate floorings|
    WO2010070474A2|2008-12-19|2010-06-24|Flooring Industries Limited, Sarl|Coated panel and method for manufacturing such panel|
    DE202005019427U1|2005-12-13|2006-04-20|Schrägle, Benjamin|Layer composite slab for e.g. balcony floor, has core including two upper layers with fiber reinforcement on both sides, where upper layers have decorative layer that is connected with upper layers in firmly bonded manner|
    DE102006029963A1|2006-06-29|2008-01-03|Armstrong Dlw Ag|Flooring with an electrically conductive and / or antistatic, transparent, radiant or thermally cured acrylic polymer-based coating|
    UA111997C2|2012-04-02|2016-07-11|Кроноплюс Текнікал Аг|PANEL WITH COVER DIRECTED BY DIRECT PRINTING METHOD|
    BE1020722A3|2012-06-01|2014-04-01|Unilin Bvba|PANEL FOR FORMING A FLOOR COVERING AND METHOD FOR MANUFACTURING SUCH PANELS.|
    法律状态:
    2018-02-28| FG| Patent granted|Effective date: 20180205 |
    2021-02-03| MM| Lapsed because of non-payment of the annual fee|Effective date: 20200430 |
    优先权:
    申请号 | 申请日 | 专利标题
    BE2016/5570A|BE1024447B1|2016-07-07|2016-07-07|Floor panel|
    BE2016/5570|2016-07-07|PCT/IB2017/054010| WO2018007932A2|2016-07-07|2017-07-03|Floor panel|
    [返回顶部]