METHOD FOR PRODUCING A WEAR RESISTANT THERMOPLASTIC SHEET AND CONSTRUCTION PANEL

专利摘要:
The present invention relates to a method of producing a wear resistant sheet, comprising providing a first sheet comprising a first thermoplastic material, applying wear resistant particles and a second thermoplastic material to the first sheet, and adhering the first sheet to the second thermoplastic binder and the wear-resistant particles to form a wear-resistant sheet.
公开号:BR112017000202B1
申请号:R112017000202-7
申请日:2015-07-02
公开日:2021-08-10
发明作者:Goran Ziegler；Niclas Hâkansson；Christer Lundblad
申请人:Vãlinge Innovation Ab；
IPC主号:

专利说明:

Field of Invention
[001] The present invention relates to a method of producing a wear-resistant thermoplastic sheet, a method of producing a building panel including such a wear-resistant thermoplastic sheet and a building panel. Technical Background
[002] Recently, the so-called Luxurious Vinyl Boards and Tiles (LVT) have had increasing success. These types of floor panels typically comprise a thermoplastic core, a thermoplastic decorative layer disposed on the core, a clear wear layer in the decor layer, and a coating applied to the wear layer. The thermoplastic material is often PVC. The wear layer is conventionally a PVC sheet, for example, having a thickness of 0.2 to 0.7 mm. The coating applied to the wear layer is conventionally a UV-curing polyurethane coating. The wear layer together with the coating provides the wear resistance of the floor panel and protects the decorative layer.
[003] However, when subjecting the decking panels to wear, it has been shown that the coating and the wear layer are relatively easily worn, or at least worn so that the appearance of the wear layer is affected, such as showing scratches and /or not being so transparent anymore. Compared to a conventional laminate floor panel, the wear resistance of an LVT floor panel is lower. However, LVT floors offer several advantages over, for example, laminate floors, such as deep engraving, dimensional stability against moisture, moisture resistance and sound absorption properties.
[004] It is therefore desirable to provide an LVT product having an improved wear resistance. It is also desirable to simplify the construction of the LVT product.
[005] It is known from United States document 2008/0063844 to apply a surface coating including aluminum oxide on a resilient floor covering. The coating is a wet coating.
[006] WO 2013/079950 describes a non-slip floor covering comprising at least two transparent polymeric layers, where particles of an aggregate material having an average particle size of between about 0.05 mm and about 0.8 mm are located between and/or within two or more polymeric layers. The particles improve the slip resistance of the floor covering. summary
[007] It is an objective of at least the embodiments of the present invention to provide an improvement over the techniques described above and the known technique.
[008] A further objective of at least the embodiments of the present invention is to improve the wear resistance of LVT floors.
[009] An additional objective of at least the embodiments of the present invention is to simplify the construction of LVT floors.
[0010] At least some of these and other objectives and advantages which will become apparent from the description have been achieved by a method of producing a wear resistant sheet according to a first aspect. The method includes a first sheet comprising a first thermoplastic material, applying wear-resistant particles and a second thermoplastic material to the first sheet, and adhering the first sheet to the second thermoplastic material and the wear-resistant particles to form a wear-resistant sheet. .
[0011] The first and second thermoplastic material may be thermoplastic materials of different types, or they may be thermoplastic materials of the same type.
[0012] An advantage of at least the embodiments of the present invention is that a wear resistant sheet having improved wear resistance is provided. By including wear resistant particles in the wear resistant sheet, the wear resistant particles provide additional wear resistance to the thermoplastic materials of the first and second sheets. The wear resistance of the sheet is improved compared to a conventional wear layer of LVT products.
[0013] Additionally, conventional coatings, e.g. a UV curable PU coating conventionally applied to the wear layer, can be replaced by the use of wear resistant sheet according to the invention. A conventional coating step can be replaced by laying out a single sheet. In this way, the production process is simplified and the number of steps in the production process is reduced by arranging a wear resistant sheet having improved wear resistance properties instead of multiple layers or coatings.
[0014] By using the different thermoplastic material in the first sheet and the thermoplastic material applied to the first sheet, it is possible to benefit from the different thermoplastic material having different properties. The desired properties of the first sheet material may differ from the desired properties of the thermoplastic material applied to the first sheet. For the layer formed by the second thermoplastic material and the wear resistant particles arranged in the first sheet, properties such as tensile strength and scratch resistance are important, and the choice of thermoplastic material can be made to match these criteria. Typically, the thermoplastic material for forming the layer applied to the first sheet can be more expensive compared to the thermoplastic material used, for example, in the printed film or as a core material. By using only such thermoplastic material in the layer disposed on the first sheet, the cost of the wear resistant sheet can be controlled. Additionally, the layer formed by the second thermoplastic material may have a layer thickness less than a layer thickness of the first sheet. By choosing different thermoplastic materials for the first sheet and overlay layer, thermoplastic materials can be used efficiently and cheaply. By adjusting layer thicknesses, materials can be used even more efficiently.
[0015] The purpose of wear-resistant particles is to provide wear resistance of the sheet when worn, not to provide slip resistance.
[0016] The second thermoplastic material may be in powder form when applied to the first sheet.
[0017] The second thermoplastic material may be in powder form when adhered to the first sheet, such as, for example, when pressed into the first sheet.
[0018] The first sheet, the second thermoplastic material and the wear-resistant particles can be adhered together by pressing the first sheet, the wear-resistant particles and the second thermoplastic material together. The wear resistant sheet is preferably transparent, or at least substantially transparent, for example having a light transmission index that exceeds 80%, preferably exceeds 90%. In this way, any decorative layer or decorative print is visible through the wear-resistant sheet. Preferably, the wear resistant sheet does not influence the impression of any decorative layer or decorative print arranged under the wear resistant sheet. The wear resistant sheet is preferably unpigmented.
[0019] The wear-resistant particles can be included, preferably fully included, by the first sheet and the second thermoplastic material after being adhered to each other.
[0020] Preferably, the wear resistant particles do not project from a surface of a layer formed by the second thermoplastic material after being adhered to the first layer. If the wear-resistant particles protrude beyond the surface of the layer formed by the second thermoplastic material, the wear-resistant sheet will cause wear to items located in the wear-resistance sheet. For example, when wear resistance sheet is used as a top surface of a floor, projected wear resistance particles will cause wear in socks, shoes, etc. Additionally, the engineered wear resistant particles will cause a rough and/or hard surface of the wear resistant sheet, as provided by a slip resistant surface. The purpose of the wear resistant particles included by the thermoplastic material is to provide wear existence when the second sheet is worn, not to improve slip resistance.
[0021] The wear resistance particles and the second thermoplastic material can be applied as a mixture. As an alternative or complement, the wear resistant particles and the second thermoplastic material can be applied separately.
[0022] The second thermoplastic material can be applied in cast form. The second thermoplastic material can be applied in an extrusion process such as an extrusion lamination or extrusion coating on the first sheet.
[0023] The first thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate , methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0024] The second thermoplastic material may be or comprise polyvinyl chloride (PVC) or polyurethane (PU). The second thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate , polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0025] The first sheet may substantially consist of thermoplastic material, preferably polyvinyl chloride, and optionally additives. Additives can be plasticizers, stabilizers, lubricants, degreasing agents, coupling agents, compatibilizers, crosslinking agents, etc.
[0026] The first sheet can be a decorative sheet. The first sheet can be printed, for example, by digital printing, direct printing, rotogravure printing, etc.
[0027] The second thermoplastic material may be or comprise polyvinyl chloride (PVC) or polyurethane (PU).
[0028] By the arrangement of the second thermoplastic material being or comprising polyurethane, no additional polyurethane-containing coating needs to be provided on top of the wear resistant sheet. In this way, the layer structure of an LVT product can be simplified. Additionally, compared to, for example, a conventional wear layer consisting substantially of PVC, a wear resistant sheet comprising a polyurethane (PU) upper obtains improved chemical resistance. Its scratch resistance and micro scratch resistance are also improved. A polyurethane (PU) top layer also provides improved resistance against dark heel marks. A further advantage is that curable polyurethane, such as UV curable polyurethane, shrinks during cure. By pressing a thermoplastic polyurethane (PU) material, no or at least little shrinkage occurs.
[0029] In one embodiment, the first thermoplastic material may be or comprise polyvinyl chloride (PVC) and the second thermoplastic material comprises polyurethane (PU). In this way, a wear resistant sheet having the properties of both polyvinyl chloride (PVC) and polyurethane (PU) is provided.
[0030] Wear resistant particles may comprise aluminum oxide. The wear resistant particles can comprise aluminum oxide such as corundum, carborundum, quartz, silica, glass, glass beads, glass beads, silicon carbide, front particles, hard plastic, reinforced or organic polymers, or a combination of the same.
[0031] Wear resistant particles may have an average particle size of less than 45 µm.
[0032] Wear-resistant particles may have an index of refraction similar to the index of refraction of the second thermoplastic material. Wear resistant particles can have a refractive index from 1.4 to 1.7. In one embodiment, the wear resistant particle may have a refractive index from 1.4 to 1.9, preferably from 1.5 to 1.8, eg from 1.7 to 1.8. The refractive index of wear resistant particles may not differ from the refractive index of the second thermoplastic material by more than +/20%.
[0033] A layer formed by the second thermoplastic material and the wear resistance particles may have a thickness of less than 75 µm, for example, such as about 50 µm, after being adhered to the first sheet, for example, by pressing.
[0034] The wear-resistant particles may have an average particle size less than the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles. The wear resistant particles can have an average particle size greater than the thickness of the layer formed by the second thermoplastic material and the wear resistant particles. However, during pressing, the wear-resistant particles are pressed into the first sheet so that the wear-resistant particles do not protrude beyond an upper surface of the layer formed by the second thermoplastic material and the wear-resistant particles after the pressure, although the wear-resistant particles have an average particle size that exceeds the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles.
[0035] The ratio between the size of the wear-resistant particles and the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles may be less than 1.5:1.
[0036] The thickness of the layer formed by the second thermoplastic material and the wear-resistant particles may be less than the thickness of the first sheet.
[0037] The method may further comprise applying scratch resistant particles to the first sheet, or together with the second thermoplastic material. The scratch resistant particles can be or comprise silica nanoparticles, preferably fused silica particles. Scratch resistant particles can be or comprise aluminum oxide.
[0038] According to a second aspect, a method of deforming a building panel is provided. The method comprises applying a wear resistant sheet produced according to the first aspect to a core, and applying pressure to the wear resistant sheet and core to form a building panel.
[0039] The core can be provided with a decorative layer. Core can be provided with an imprint on a core surface. The wear-resistant sheet can be arranged on the decorative layer, or on the print. Alternatively, the first sheet of the wear-resistant sheet can be a decorative layer.
[0040] The core may comprise a third thermoplastic material.
[0041] The first, second and third thermoplastic materials may be thermoplastic materials of different types, or may be of the same type of thermoplastic material. The first, second and third thermoplastic materials can be or comprise any of the following group: polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), terephthalate of polyethylene (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The core can be a thermoplastic core, a WPC (Wooden and Plastic Composite) etc. The core can be provided with multiple layers. The core can be foamed.
[0042] The core can be a wood-based panel or a mineral panel. The core can, in the modalities, be HDF, MDF, particle board, OSB, Composite Wood and Plastic (WPC).
[0043] The decorative layer can be a thermoplastic sheet. Decorative layer can comprise any of the thermoplastic materials listed above.
[0044] According to a third aspect, a method of producing a building panel is provided. The method includes providing a core, applying a first sheet comprising a first thermoplastic material to the core, applying wear resistant particles and a second thermoplastic material to the first sheet, and adhering the core to the first sheet to the second thermoplastic material and wear resistant particles to each other to form a building panel.
[0045] The first and second thermoplastic materials may be thermoplastic materials of different type, or they may be thermoplastic materials of the same type.
[0046] In one embodiment, the wear-resistant sheet is produced with respect to the formation of the building panel. The wear resistant sheet can be laminated together with the lamination of any other layer, eg a decorative layer, a balancing layer, etc., to the core.
[0047] An advantage of at least the embodiments of the present invention is that a wear resistant sheet having improved wear resistance is provided. By including wear resistant particles in the wear resistant sheet, the wear resistant particles provide additional wear resistance to the thermoplastic materials of the first and second sheets. The wear resistance of the sheet is improved compared to a conventional wear layer of LVT products.
[0048] Additionally, conventional coatings, for example a UV curable PU coating conventionally applied to the wear layer, can be replaced by the use of wear resistant sheet according to the invention. A conventional coating step can be replaced by laying out a single sheet. In this way, the production process is simplified and the number of steps in the production process is reduced by arranging a wear resistant sheet having improved wear resistant properties instead of multiple layers or coatings.
[0049] By using different thermoplastic materials in the first sheet and in the second thermoplastic material applied to the first sheet, it is possible to benefit from different thermoplastic materials having different properties. The desired properties of the thermoplastic material of the first sheet may differ from the desired properties of the second thermoplastic material applied to the first sheet. For the layer formed by the second thermoplastic material and the wear resistant particles arranged in the first sheet, properties such as stain resistance and scratch resistance are important, and the choice of thermoplastic material can be made to match these criteria. Normally, thermoplastic material suitable for forming the layer applied to the first sheet can be more expensive compared to the thermoplastic material used as, for example, printed film or core material. By using only such thermoplastic material in the layer disposed on the first sheet, the cost of the wear resistant sheet can be controlled. Additionally, the layer formed by the second thermoplastic material may have a layer thickness less than a layer thickness of the first sheet. By choosing different thermoplastic materials for the first sheet and overlay layer, thermoplastic materials can be used efficiently and cheaply. By adjusting layer thicknesses, materials can be used even more efficiently.
[0050] The purpose of wear resistant particles is to provide wear resistance of the sheet when being used, not to provide slip resistance.
[0051] The second thermoplastic material may be in powder form when applied to the first sheet.
[0052] The second thermoplastic material may be in powder form when adhered to the first sheet, such as, for example, when pressed into the first sheet.
[0053] The first sheet, the second thermoplastic material and the wear-resistant particles can be adhered together by pressing the first sheet, the wear-resistant particles and the second thermoplastic material together.
[0054] The first sheet together with the wear-resistant particles and the second thermoplastic material form a wear-resistant sheet, preferably transparent, or at least substantially transparent, for example, having a light transmission index exceeding 80%, preferably exceeding 90 %. In this way, any decorative layer or decorative print is visible through the wear-resistant sheet. Preferably, the wear resistant sheet does not influence the printing of any decorative layer or decorative print arranged under the wear resistant sheet. The wear resistant sheet is preferably unpigmented.
[0055] The wear resistant particles can be included, preferably fully included, by the first sheet and the second thermoplastic material after being adhered to each other.
[0056] Preferably, the wear resistant particles do not protrude from a surface of a layer formed by the second thermoplastic material, opposite the first sheet, after pressing. If the wear-resistant particles project beyond the surface of the second sheet, the wear-resistance sheet will cause wear on items located on the wear-resistance sheet. For example, when wear resistant sheet is used as a top surface of a floor, the engineered wear resistant particles will cause wear in socks, shoes, etc. Additionally, engineered wear resistant particles will cause a rough and/or hard wear resistant sheet surface, as provided by a slip resistant surface. The purpose of the wear resistant particles included by the thermoplastic material is to provide wear resistance when the second sheet is used, not to provide slip resistance.
[0057] The wear resistant particles and the second thermoplastic material can be applied as a mixture. As an alternative or complement, the wear resistant particles and the second thermoplastic material can be applied separately.
[0058] The second thermoplastic material can be applied in cast form. The second thermoplastic material can be applied in an extrusion process such as extrusion lamination or extrusion coating on the first sheet.
[0059] The first thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate , methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0060] The second thermoplastic material may be or comprise polyvinyl chloride (PVC) or polyurethane (PU). The second thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate , polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0061] In one embodiment, the first thermoplastic material comprises polyvinyl chloride (PVC) and the second thermoplastic material comprises polyurethane (PU).
[0062] Wear resistant particles may preferably comprise aluminum oxide. Wear resistant particles may comprise aluminum oxide such as corundum, carborundum, quartz, silica, glass, glass beads, glass beads, silicon carbide, diamond particles, hard plastic, reinforced and organic polymers, or combinations thereof .
[0063] Wear resistant particles can have an average particle size of less than 45 µm.
[0064] Wear resistant particles can have a refractive index similar to the refractive index of the second thermoplastic material. Wear resistant particles can have a refractive index from 1.4 to 1.7. In one embodiment, the wear resistant particle may have a refractive index from 1.4 to 1.9, preferably from 1.5 to 1.8, eg from 1.7 to 1.8. The refractive index of the wear resistant particles cannot differ from the refractive index of the second thermoplastic material by more than +/20%.
[0065] A layer formed by the second thermoplastic material and the wear-resistant particles may have a thickness of less than 75 µm, for example, such as about 50 µm, after having been adhered to each other.
[0066] The wear-resistant particles may have an average particle size less than the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles. The wear resistant particles can have an average particle size greater than the thickness of the layer formed by the second thermoplastic material and the wear resistant particles. However, during pressing, the wear-resistant particles are pressed into the first sheet so that the wear-resistant particles do not protrude beyond an upper surface of the layer formed by the second thermoplastic material and the wear-resistant particles after pressing, although the wear resistant particles have an average particle size exceeding the thickness of the layer formed by the second thermoplastic material and the wear resistant particles.
[0067] The ratio between the size of the wear-resistant particles and the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles may be less than 1.5:1.
[0068] The thickness of the layer formed by the second thermoplastic material and the wear-resistant particles may be less than the thickness of the first sheet.
[0069] The method may further comprise applying scratch resistant particles to the first sheet. Alternatively, or as a complement, the scratch resistant particles can be applied together with the second thermoplastic material. The scratch resistant particles can be or comprise silica nanoparticles, preferably fused silica particles. Scratch resistant particles can be or comprise aluminum oxide.
[0070] The core may comprise a third thermoplastic material.
[0071] The first, second and third thermoplastic materials may be thermoplastic materials of different types, or may be of the same type of thermoplastic material.
[0072] The third thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The core can be a thermoplastic core, a WPC (Wooden and Plastic Composite) etc. The core can be provided with multiple layers. The core can be foamed.
[0073] The core can be a wood-based panel or mineral panel. The core can, in the modalities, be HDF, MDF, particle board, OSB, Composite Wood and Plastic (WPC).
[0074] A decorative layer can be arranged on the core. In one embodiment, the method may comprise applying a decorative layer prior to applying the first sheet. The decorative layer can be a thermoplastic layer. The decorative layer may be a wood dust layer comprising a heat-setting binder and lignocellulosic and cellulosic particles. The decorative layer may be a thermoplastic layer applied as a powder, preferably comprising an impression created on the thermoplastic material in powder form. The decorative layer can be a layer of wood varnish, a layer of cork or a decorative paper.
[0075] In one embodiment, the first sheet is disposed directly on the core. The core can be provided with a print, and the first sheet is arranged in the print. Alternatively, or as a complement, the first sheet can be a decorative sheet. The first sheet can be printed, for example, by digital printing, direct printing, rotogravure, etc. Preferably, the print is provided on a surface of the first sheet facing the core.
[0076] The method may further comprise applying a wear resistant coating to the sheet. The coating may comprise acrylate or methacrylate monomer or acrylate or methacrylate oligomer. The coating can be radiation cured, such as UV curing or electron beam curing.
[0077] According to a fourth aspect, a method for producing a wear resistant sheet is provided. The method comprises providing a carrier, applying wear resistant particles and a second thermoplastic material to the carrier, and adhering the wear resistant particles and second thermoplastic material together to form a wear resistant sheet.
[0078] The modalities of the fourth aspect show the advantages of the first aspect, which were previously discussed, where the previous discussion is also applicable to the building panel.
[0079] The second thermoplastic material may be in powder form when applied to the carrier.
[0080] The second thermoplastic wear material may be in powder form when adhered to the carrier, such as, for example, when pressed into the carrier.
[0081] The first sheet, the second thermoplastic material and the wear-resistant particles can be adhered together by pressing the first sheet, the wear-resistant particles and the second thermoplastic material together.
[0082] The wear resistant sheet is preferably transparent, or at least substantially transparent, for example having a light transmission index that exceeds 80%, preferably exceeds 90%. In this way, any decorative layer or decorative print is visible through the wear-resistant sheet. Preferably, the wear resistant sheet does not influence the printing of any decorative layer or decorative print arranged under the wear resistant sheet. The wear resistant sheet is preferably unpigmented.
[0083] The wear-resistant particles can be included, preferably fully included, by the first sheet and the second thermoplastic material after being adhered to each other.
[0084] Preferably, the wear resistant particles do not project from a surface of a layer formed by the second thermoplastic material after being adhered to the first sheet. If the wear-resistant particles project beyond the surface of the layer formed by the second thermoplastic material, the wear-resistance sheet will cause wear on items located on the wear-resistance sheet. For example, when wear resistant sheet is used as a top surface of a floor, the projection of wear resistant particles will cause wear on socks, shoes, etc. Additionally, engineered wear resistant particles will cause a rough and/or hard wear resistant sheet surface, as provided by a slip resistant surface. The purpose of the wear resistant particles included by the second thermoplastic material is to provide wear resistance when the second sheet is used, not to provide slip resistance.
[0085] The wear resistant particles and the second thermoplastic material can be applied as a mixture. As an alternative or complement, the wear resistant particles and the second thermoplastic material can be applied separately.
[0086] The second thermoplastic material can be applied in cast form. The second thermoplastic material can be applied in an extrusion process such as an extrusion lamination or extrusion coating on the carrier.
[0087] In one embodiment, the carrier may be a first sheet comprising a first thermoplastic material as discussed above with respect to the third aspect.
[0088] The carrier can be a substrate.
[0089] In one embodiment, the carrier may be a temporary carrier such as a removable sheet or carrier means.
[0090] In one embodiment, the bearer may be a core. The core can be a thermoplastic core, a Wood Plastic Composite (WPC), a wood-based panel or a mineral panel. The adhering step may comprise adhering the carrier to the second thermoplastic material and the wear resistance particles.
[0091] The second thermoplastic material can be or comprise polyvinyl chloride (PVC) or polyurethane (PU).
[0092] The method may further comprise releasing the wear resistant sheet from the carrier.
[0093] Wear resistant particles may comprise aluminum oxide. Wear resistant particles can comprise carborundum, quartz, silica, glass, glass beads, glass beads, silicon carbide, diamond particles, hard plastic, reinforced polymers and organics.
[0094] Wear resistant particles can have an average particle size of less than 45 µm.
[0095] Wear resistant particles can have a refractive index similar to the refractive index of the second thermoplastic material. Wear resistant particles can have a refractive index of 1.4 to 1.7. In one embodiment, the wear resistant particulate may have a refractive index from 1.4 to 1.9, preferably from 1.5 to 1.8, eg 1.7 to 1.8. The refractive index of wear resistant particles cannot differ from the refractive index of the second thermoplastic material by more than +/20%.
[0096] A layer formed by the second thermoplastic material and wear-resistant particles may have a thickness of less than 75 µm, for example, such as about 50 µm, after they have been adhered to each other.
[0097] The wear-resistant particles may have an average particle size less than the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles. The wear resistant particles can have an average particle size greater than the thickness of the layer formed by the second thermoplastic material and the wear resistant particles. However, during pressing, the wear-resistant particles are pressed into the carrier so that the wear-resistant particles do not protrude beyond an upper surface of the layer formed by the second thermoplastic material and the wear-resistant particles after pressing, despite that the wear resistant particles have an average particle size that exceeds the thickness of the layer formed by the second thermoplastic material and the wear resistant particles.
[0098] The ratio between the size of the wear-resistant particles and the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles may be less than 1.5:1.
[0099] According to a fifth aspect, a building panel is provided. The building panel comprises a core, a wear-resistant sheet disposed on a surface of the core, where the wear-resistant sheet comprises a second thermoplastic material and wear-resistant particles substantially evenly distributed in said second thermoplastic material.
[00100] The modalities of the fifth aspect incorporate the advantages of the first, which was discussed previously, where the previous discussion is also applicable to the building panel.
[00101] The wear resistant sheet is preferably transparent, or at least substantially transparent, for example having a light transmission index exceeding 80%, preferably exceeding 90%. In this way, any decorative layer or decorative print is visible through the wear-resistant sheet. Preferably, the wear resistant sheet does not influence the printing of any decorative layer or decorative print arranged under the wear resistant sheet. The wear resistant sheet is preferably unpigmented.
[00102] Wear resistant particles can be included, preferably fully enclosed, by the second thermoplastic material.
[00103] Preferably, the wear resistant particles do not protrude from a surface of a layer formed by the second thermoplastic material. If the wear-resistant particles protrude beyond the surface of the second sheet, the wear-resistance sheet will cause wear to items located on the wear-resistance sheet. For example, when wear resistant sheet is used as a top surface of a floor, the engineered wear resistant particles will cause wear in socks, shoes, etc. Additionally, the engineered wear resistant particles will cause a rough and/or hard wear resistant sheet surface, as provided by a slip resistant surface. The purpose of the wear resistant particles included by the thermoplastic material is to provide wear resistance when the second sheet is used, not to provide slip resistance.
[00104] The wear resistant sheet may further comprise a first sheet comprising a first thermoplastic material.
[00105] The first thermoplastic material can be or comprise polyvinyl chloride (PVC). The first thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate , polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[00106] The second thermoplastic material can be or comprise polyvinyl chloride (PVC) or polyurethane (PU). The second thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate , polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[00107] Wear resistant particles may preferably comprise aluminum oxide. Wear resistant particles may comprise aluminum oxide such as corundum, carborundum, quartz, silica, glass, glass beads, glass beads, silicon carbide, diamond particles, hard plastic, reinforced and organic polymers, or a combination of the same.
[00108] Wear resistant particles may have an average particle size of less than 45 µm.
[00109] Wear resistant particles may have a refractive index similar to the refractive index of the second thermoplastic material. Wear resistant particles can have a refractive index from 1.4 to 1.7. In one embodiment, the wear resistant particle may have a refractive index from 1.4 to 1.9, preferably from 1.5 to 1.8, eg 1.7 to 1.8. The refractive index of the wear resistant particles cannot differ from the refractive index of the second thermoplastic material by more than +/20%.
[00110] A layer formed by the second thermoplastic material and the wear-resistant particles may have a thickness of less than 75 µm, for example, such as about 50 µm, after being adhered.
[00111] The wear-resistant particles may have an average particle size less than the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles. The wear resistant particles can have an average particle size greater than the thickness of the layer formed by the second thermoplastic material and the wear resistant particles. However, during pressing, the wear resistant particles are pressed into the core or any intermediate layer such as a first sheet so that the wear resistant particles do not protrude beyond an upper surface of the layer formed by the second thermoplastic material. and to wear resistant particles after pressing, although the wear resistant particles have an average particle size exceeding the thickness of the layer formed by the second thermoplastic material and the wear resistant particles.
[00112] The ratio between the size of the wear-resistant particles and the thickness of the layer formed by the second thermoplastic material and the wear-resistant particles may be less than 1.5:1.
[00113] The thickness of the layer formed by the second thermoplastic material and the wear-resistant particles may be less than the thickness of the first sheet.
[00114] The building panel may additionally comprise a decorative layer arranged on the core, where the wear-resistant sheet is arranged on the decorative layer.
[00115] The core may comprise a third thermoplastic material. The third thermoplastic material can be or comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[00116] The core can be a thermoplastic core, a Wood Plastic Composite (WPC), a wood-based panel or a mineral panel. Brief Description of Drawings
[00117] The present invention will be described, by way of example, in greater detail with reference to the attached schematic drawings that illustrate the embodiments of the present invention.
[00118] Figure 1 illustrates a method of producing a wear-resistant sheet according to a first modality;
[00119] figure 2 illustrates a method of producing a wear-resistant sheet according to a second mode;
[00120] figure 3 illustrates a building panel;
[00121] figure 4 illustrates a method of producing a building panel;
[00122] figures 5A and 5B illustrate embodiments of a building panel;
[00123] Figure 6A illustrates a method of producing a wear-resistant sheet;
[00124] Figure 6B illustrates a method of producing a building panel. Detailed Description
[00125] A method of producing a wear resistant sheet 10 according to an embodiment will now be described with reference to figure 1. Figure 1 illustrates a production line for producing a wear resistant sheet 10.
[00126] The first sheet 1 comprises a first thermoplastic material. The first thermoplastic material can be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral , polybutylene terephthalate, or a combination thereof.
[00127] In figure 1, the first sheet 1 is provided as a continuous screen. In other embodiments, the first sheet 1 can also be cut into separate sheets. The first sheet 1 can also be formed by an extrusion process. The first sheet 1 can also be formed from a layer of powder comprising the first thermoplastic material in powder form.
[00128] Preferably, the first sheet 1 is formed of thermoplastic material. The first sheet 1 can consist substantially of thermoplastic material, and optionally additives. Additives can be plasticizers, stabilizers, lubricants, grease removal agents, coupling agents, compatibilizers, crosslinking agents, etc.
[00129] In one embodiment, the first sheet 1 is a PVC sheet.
[00130] The first sheet 1 can have a thickness of 0.1 to 1 mm.
[00131] In an embodiment, the first sheet 1 is a decorative sheet. The first sheet 1 can be printed, for example, by digital printing, direct printing, rotogravure, etc.
[00132] As illustrated in figure 1, an application device 3 applies, preferably spreads, a second thermoplastic material 5 in powder form and wear-resistant particles 4 on the first sheet 1. In figure 1, the thermoplastic material 5 and the particles 4 wear resistant are applied as a mixture. Thermoplastic material 5 and wear resistant particles 4 can also be applied separately. Preferably, if applied separately, the wear resistant particles 4 are applied first, and the second thermoplastic material 5 is applied to the wear resistant particles 4.
[00133] The second thermoplastic material 5 may be the same as in the first sheet 1, or it may be different from the thermoplastic material of the first sheet 1. The second thermoplastic material 5 may be polyvinyl chloride (PVC), polyester, polypropylene (PP) , polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[00134] In the embodiment illustrated in Figure 1, the second thermoplastic material 5 is applied as a powder. By powder is meant powder which has formed pellets of thermoplastic material, dry mixtures of thermoplastic material, or agglomerates of thermoplastic material. The grains can comprise thermoplastic material 5 and wear resistant particles 4. The agglomerates can comprise both thermoplastic material 5 and wear resistant particles 4.
[00135] The average particle size of the thermoplastic material 5 may be less than 500 µm, preferably from 50 to 250 µm. Thermoplastic material 5 in a dry mix may be less than 500 µm in size. The grains of thermoplastic material 5 can have an average particle size of 200 to 4000 µm, preferably less than 1000 µm.
[00136] In the embodiment illustrated in Figure 1, the wear-resistant particles 4 and the second thermoplastic material 5 are applied as a mixture.
[00137] In the embodiments, the second thermoplastic material 5 can be applied in cast form, which is described in greater detail with reference to figure 6A. The wear resistant particles 4 can be mixed with the second thermoplastic material 5 in molten form or applied separately. The second thermoplastic material 5 in molten form can be applied in an extrusion process such as extrusion lamination and extrusion coating on the first sheet 1.
[00138] Wear resistant particles 4 can be aluminum oxide particles such as corundum. Alternatively, as a complement, the wear resistant particles 4 can be carborundum, quartz, silica, glass, glass beads, glass beads, silicon carbide, diamond particles, hard plastic, reinforced polymers or organics.
The wear resistant particles 4 preferably have an average particle size within the range of 10 to 200 µm, preferably within the range of 50 to 120 µm, such as 50 to 100 µm. Wear resistant particles 4 may have an average particle size of less than 50 µm, preferably less than 45 µm. Wear resistant particles 4 can be spherical in shape or irregular in shape. Wear resistant particles 4 can be surface treated. Wear resistant particles 4 can be silane treated particles.
[00140] Wear resistant particles 4 can have a refractive index similar to the refractive index of the second thermoplastic material 5. Wear resistant particles can have a refractive index from 1.4 to 1.7. In one embodiment, the wear resistant particle may have a refractive index from 1.4 to 1.9, preferably from 1.5 to 1.8, eg from 1.7 to 1.8. The refractive index of wear resistant particles cannot differ from the refractive index of the second thermoplastic material by more than +/20%.
[00141] Wear resistant particles can be applied in an amount of 20 to 100 g/m2, preferably in an amount of 40 to 60 g/m2.
[00142] The wear-resistant particles can have an average particle size less than the thickness of the layer formed by the wear-resistant particles and the second thermoplastic material after pressing. However, the wear resistant particles can have an average particle size greater than the thickness of the layer formed by the wear resistant particles and the second thermoplastic material 5 after pressing. During pressing, the wear-resistant particles are pressed into the first sheet so that the wear-resistant particles do not protrude beyond an upper surface of the layer formed by the second thermoplastic material 5, although the wear-resistant particles have an average size of particle exceeding the thickness of the layer formed by the wear resistant particles and the second thermoplastic material after pressing.
[00143] The ratio between the size of the wear-resistant particles and the thickness of the layer formed by the wear-resistant particles and the second thermoplastic material after pressing can be less than 1.5:1.
[00144] Scratch resistant particles (not shown) can also be applied to the first sheet 1, as a mixture together with the thermoplastic material 5 and the wear resistant particles 4 or separately. By scratch resistant particles is meant particles which improve the scratch or scratch resistant properties of the sheet. Scratch resistant particles can be applied together with wear resistant particles 4, for example, as a mixture, or they can be applied separately. Preferably, the scratch particles are disposed on an upper part of the layer formed by the thermoplastic material 5 and the wear resistant particles 4. The scratch resistant particles can be or comprise silica nano particles, preferably fused silica particles. Scratch resistant particles can be or comprise aluminum oxide.
The scratch resistant particles may be disk-shaped particles, preferably having a width/thickness ratio equal to or greater than 3:1, more preferably equal to or greater than 5:1. Such disk-shaped particles orient along the surface of the sheet, thus improving the scratch resistance of the sheet. Scratch resistant particles can have an average particle size of 1 to 50 µm, preferably 10 to 20 µm.
[00146] Additives can also be applied to the first sheet 1, or together with the second thermoplastic material. Additives can be plasticizers, stabilizers, lubricants, gas removal agents, coupling agents, compatibilizers, crosslinking agents, etc.
[00147] In one embodiment, the first sheet 1 is a PVC sheet and the second thermoplastic material 5 is polyurethane (PU) in powder form. In one embodiment, the first sheet 1 is a PVC sheet and the second thermoplastic material 5 is PVC in powder form.
[00148] The first sheet 1 and the second thermoplastic material 5 in powder form are thereafter adhered to each other, for example by being pressed together, to form a wear-resistant sheet 10 comprising the first sheet 1, the second thermoplastic material 5 and wear-resistant particles 4.
[00149] The first sheet 1 and the second thermoplastic material 5 in powder form can be pressed together in a calendering process. As illustrated in Figure 1, the first sheet 1 and the second thermoplastic material 5 in powder form are pressed together in continuous pressing 6. The first and second sheets can be adhered together by pressure only, by heat and pressure, by pressure and adhesive , or by heat, pressure and adhesive. Preferably, both pressure and heat are applied in order to adhere the second sheet and second thermoplastic material together. As an alternative or complement to a calendering process, continuous or static pressure can also be used. The pressing operation can, for example, be done as a hot-hot process, a hot-cold process, etc. The pressing can be carried out with an engraved pressure die or pressure roller so that an engraved structure is formed on the wear resistant sheet.
[00150] Depending on the thermoplastic materials and process used, the applied pressure can be from 5 to 100 bar, applied, for example, for 5 to 500 seconds. The temperature can be from 80 to 300°C, such as 100 to 250°C, such as 150 to 200°C.
[00151] By the process described above with reference to figure 1, a wear resistant sheet 10 is formed. The wear resistant sheet 10 can be formed as a continuous sheet, or it can be cut into separate sheets. The second thermoplastic material 5 and the wear-resistant particles 4 form an upper part of the wear-resistant sheet 10. Preferably, the wear-resistant particles 4 can be substantially homogeneously distributed in the upper part of the wear-resistant sheet 10. The first sheet 1 forms an underside of wear resistant sheet 10. As seen in a cross section of wear resistant sheet, wear resistant particles 4 are heterogeneously distributed across wear resistant sheet 10. There is a higher concentration of wear resistant particles. wear 4 on the tops of the wear-resistant sheet 10 than on the bottoms of the wear-resistant sheet 10.
[00152] After the adhesion of the layers, the wear resistant particles are included by the first sheet and the second thermoplastic material. Preferably, the wear resistant particles 4 are completely enclosed by the second thermoplastic material. Although the wear resistant particles and the second thermoplastic material can be applied as a mixture, during pressing, the second thermoplastic material melts and encloses the wear resistant particles. Preferably, the wear resistant particles do not protrude beyond the surface of the layer formed in the second thermoplastic material facing away from the first sheet. In this way, a wear resistant sheet having a smooth surface can be formed.
[00153] The wear resistant sheet 10 is preferably transparent, or substantially transparent.
[00154] The second thermoplastic material 5 and the wear-resistant particles 4 can be formed into a layer, which can have a thickness of 0.01 to 1 mm, preferably as measured in the final product, for example after pressing or extrusion. Preferably, the layer formed by the second thermoplastic material 5 and the wear resistant particles 4 have a thickness of less than 0.5 mm, more preferably less than 75 µm such as about 50 µm, preferably as measured in the final product, e.g. after pressing or extruding.
[00155] Different additives can be included in the first sheet 1 compared to the second thermoplastic material 5 in powder form in order to obtain different properties in different layers of the wear resistant sheet 10.
[00156] A wear resistant sheet 10' can also be produced according to the embodiment described with reference to figure 2. In the embodiment illustrated in figure 2, a second thermoplastic material 5 in the form of powder and wear resistant particles 4 are applied , preferably spread, by an application device 3 on a carrier 7. The carrier 7 can be a substrate. Carrier 7 can, for example, be a tear-off sheet or press plate treated with Teflon®. It is also contemplated that the carrier 7 may be a core 21, for example, provided with a print. The core 21 can be a thermoplastic core, a WPC (Wooden and Plastic Composite), a wood-based panel such as HDF or MDF, a mineral panel, etc. It is contemplated that a first thermoplastic material in powder form can be applied to the carrier.
[00157] The second thermoplastic material 5 can be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[00158] By powder also means powder having grains formed from thermoplastic material 5, dried mixtures of thermoplastic material 5, or agglomerates of thermoplastic material 5. The grains may comprise both thermoplastic material 5 and wear-resistant particles 4. can comprise both thermoplastic material 5 and wear-resistant particles 4.
[00159] The average particle size of the thermoplastic material 5 may be less than 500 µm, preferably from 50 to 250 µm. Thermoplastic material 5 in a dry mix may be less than 500 µm in size. The grains of thermoplastic material 5 may have an average particle size of 200-4000 µm, preferably less than 1000 µm.
[00160] A layer of the second thermoplastic material 5 is applied to the carrier 7. Preferably, the second thermoplastic material 5 and the wear resistant particles 4 are applied as a mixture. The second thermoplastic material 5 and the wear resistant particles 4 can also be applied separately. Preferably, if applied separately, the wear resistant particles 4 are applied first, and the second thermoplastic material 5 is applied to the wear resistant particles 4.
[00161] In the embodiment illustrated in Figure 2, the second thermoplastic material 5 is applied in powder form. In embodiments, the second thermoplastic material 5 can be applied in cast form, which is described in more detail with reference to Figure 6A. The wear resistant particles 4 can be mixed with the second thermoplastic material 5 in molten form or applied separately. The second thermoplastic material 5 in molten form can be applied in an extrusion process such as extrusion lamination and extrusion coating on carrier 7.
[00162] More than one type of thermoplastic material 5 can be applied to carrier 7. Thermoplastic materials having different properties can be applied. As an example, a PVC powder can be applied, and a PU powder can be applied to the PVC powder to form a wear resistant sheet 10' having different properties. Wear resistant particles 4 can be applied between PVC powder and PU powder. Different types of additives can also be added to different thermoplastic materials in order to form a wear resistant sheet 10' having different properties in different layers.
The wear resistant particles 4 can be aluminum oxide particles such as corundum. Alternatively, or as a complement, wear resistant particles 4 can be carborundum, quartz, silica, glass, glass beads, glass beads, silicon carbide, diamond particles, hard plastic, reinforced and organic polymers, or a combination of the same.
The wear resistant particles 4 preferably have an average particle size within the range of 10 to 200 µm, preferably within the range of 50 to 120 µm, such as from 50 to 100 µm. Wear resistant particles 4 preferably have an average particle size of less than 50 µm, preferably less than 45 µm. Wear resistant particles 4 may have an irregular shape. Wear resistant particles 4 can be surface treated. Wear resistant particles 4 can be silane treated particles.
[00165] Wear resistant particles 4 can have a refractive index similar to the refractive index of the second thermoplastic material 5. Wear resistant particles can have a refractive index from 1.4 to 1.7. In one embodiment, the wear resistant particle may have a refractive index from 1.4 to 1.9, preferably from 1.5 to 1.8, eg from 1.7 to 1.8. The refractive index of wear resistant particles may not differ from the refractive index of the second thermoplastic material by more than +/20%.
[00166] Wear resistant particles can be applied in an amount of 20 to 100 g/m2, preferably in an amount of 40 to 60 g/m2.
[00167] The wear-resistant particles may have an average particle size less than the thickness of the layer formed by the wear-resistant particles and the second thermoplastic material after pressing. However, the wear resistant particles can have an average particle size greater than the thickness of the layer formed by the wear resistant particles and the second thermoplastic material after pressing. During pressing, the wear-resistant particles are pressed into the carrier so that the wear-resistant particles do not protrude beyond an upper surface of the layer, even though the wear-resistant particles have an average particle size that exceeds the thickness of the layer formed by the wear resistant particles and the second thermoplastic material after pressing.
[00168] The ratio between the size of the wear-resistant particles and the thickness of the layer formed by the wear-resistant particles and the second thermoplastic material after pressing may be less than 1.5:1.
[00169] Scratch resistant particles (not shown) can also be applied to carrier 7, either as a mixture together with thermoplastic material 5 and wear resistant particles 4 or separately. By scratch resistant particles are particles improving the scratch or scratch resistant properties of the sheet. Scratch resistant particles can be applied together with wear resistant particles 4, for example, as a mixture, or they can be applied separately. Preferably, the scratch particles are disposed on an upper part of the layer formed by the thermoplastic material 5 and the wear-resistant particles 4. The wear-resistant particles can be or comprise silica nanoparticles, preferably fused silica particles. Scratch resistant particles can be or comprise aluminum oxide.
[00170] Scratch resistant particles may be disc-shaped particles, preferably having a width/thickness ratio being equal to or exceeding 3:1, more preferably being equal to or greater than 5:1. Such disk-shaped particles orient along the surface of the sheet, thus improving the scratch resistance of the sheet. Scratch resistant particles can have an average particle size of 1 to 50 µm, preferably 10 to 20 µm.
[00171] Additives can also be applied to carrier 7. Additives can be plasticizers, stabilizers, etc. Additives can also be applied together with the second thermoplastic material 5.
[00172] The second thermoplastic material 5 in powder form and the wear resistant particles 4 are henceforth adhered together as fused together, preferably pressed together to form a wear resistant sheet 10'.
[00173] The second thermoplastic material 5 in the form of powder and wear resistant particles 4 can be pressed together in a calendering process. As illustrated in Figure 2, the second thermoplastic material 5 and the wear resistant particles 4 are pressed together in a continuous pressing 6. Preferably, both pressure and heat are applied in order to form a wear resistant sheet 10' of the second thermoplastic material 5 and wear resistant particles 4. As an alternative or complement to a calendering process, a continuous or static press can also be used. Pressing can, for example, be done as a hot-hot process, a hot-cold process, etc. The pressing can be done with an embossed press die or press roll so that an embossed structure is formed on the wear resistant sheet 10'. As described above, the second thermoplastic material 5 can also be extruded onto the carrier 7, such as extrusion coated or extrusion laminated onto the carrier.
[00174] Depending on the thermoplastic materials and process used, the applied pressure can be from 0.5 MPa to 10Mpa (5 to 100 bar), applied, for example, for 5 to 500 seconds. The temperature can be from 80 to 300°C, such as 100 to 250°C, such as 150 to 200°C.
[00175] By the process described above with reference to figure 2, a wear resistant sheet 10' is formed, comprising the second thermoplastic material and the wear resistant particles. Wear resistant sheet 10' is preferably transparent, or substantially transparent.
[00176] The wear resistant sheet may have a thickness of 0.01 to 1 mm, preferably as measured in the final product, for example after pressing or extrusion. Preferably, the wear resistant sheet has a thickness of less than 0.5mm, more preferably less than 0.1mm, preferably as measured in the final product, for example after pressing or extrusion.
[00177] After adhering the layers, the wear resistant particles are included by the first sheet and the second thermoplastic material. Preferably, the wear resistant particles 4 are completely enclosed by the second thermoplastic material. Although the wear resistant particles and the second thermoplastic material can be applied as a mixture, during pressing, the second thermoplastic material melts and encloses the wear resistant particles. Preferably, the wear resistant particles do not and project beyond the surface of the layer formed by the second thermoplastic material facing away from the first sheet. In this way, a wear resistant sheet having a smooth surface can be formed.
[00178] The wear-resistant sheet 10, 10' produced in accordance with the modalities described with reference to figure 1 and figure 2, can, in a subsequent step, be adhered to a core 21 to form a building panel 20, as illustrated in Figure 3. The building panel 20 may be a floor panel, a wall panel, a ceiling panel, a furniture component, etc.
[00179] The core 21 may comprise a third thermoplastic material. The third thermoplastic material can be the same as the first and/or second material, or it can be different from the first and/or second material.
[00180] The third thermoplastic material may comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate , polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The core can be formed from several layers. The core can be foamed.
[00181] In one embodiment, the core 21 comprises the third thermoplastic material and fillers. Fillers can comprise calcium carbonate, such as chalk and/or lime, or sand.
[00182] In one embodiment, core 21 is a Wood Plastic Composite (WPC), comprising the third thermoplastic material and wood particles as fillers.
[00183] The core 21 can be provided with a decorative 22 disposed on an upper surface of the core 21, as illustrated in Figure 3. The wear resistant sheet 10, 10' is then disposed on the decorative layer 22. The decorative layer 22 can be a decorative sheet comprising a thermoplastic material. The thermoplastic material of the decorative layer can be or comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. Decorative layer 22 is preferably printed, for example, by direct printing, rotogravure, or digital printing.
[00184] The core 21 can also be provided with a balancing layer (not shown) disposed on a lower surface of the core 21, opposite the decorative layer 22. Any intermediate layer can also be arranged between the core 21 and the decorative layer 22 .
[00185] The wear resistant sheet 10, 10' produced according to the method described above with reference to figure 1 or figure 2, is arranged in the decorative layer. The core 21, the decorative layer 22, and the wear resistant sheet 10, 10' are pressed together to form a building panel 20. Heat can also be applied when applying pressure. The core, decorative layer and wear resistant sheet can be pressed together in a continuous or static press, or in a calendering operation. Alternatively, wear resistant sheet 10, 10' optionally comprising decorative layer 22, may be adhered to core 21 by an adhesive, such as hot melt.
[00186] The wear resistant sheet 10, 10' is preferably transparent, or substantially transparent, for example, having a light transmission index that exceeds 80%, preferably exceeds 90%.
[00187] A coating (not shown) can be applied to the wear resistant sheet 10, 10'. The coating may comprise acrylate or methacrylate monomer or acrylate or methacrylate oligomer. The coating can be radiation curing such as UV curing or electron beam curing.
[00188] As an alternative to a separate decorative layer 22, an impression can be printed directly to the upper surface of the core 21. The wear resistant sheet 10, 10' is thus disposed directly on the core 21.
[00189] In one embodiment, when the wear resistant sheet 10 is produced in accordance with the embodiment described with reference to Figure 1, the first sheet 1 forms a decorative layer. A separate decorative layer 22 can then be excluded. The first sheet 1 can be printed, for example, by digital printing, direct printing, rotogravure, etc. Preferably, the print is provided on the side of the first sheet 1 adapted to face the core 21. The wear resistant sheet 10, in this embodiment, is arranged directly on the core 21 of the type described above.
[00190] One embodiment of the building panel 20 comprises a core 21 comprising PVC, a decorative sheet 22 comprising PVC, a wear resistant sheet 10 comprising PVC in the first sheet 1 and PU applied as the second thermoplastic material 5.
[00191] In other embodiments, the core 21 may be a wood-based panel or a mineral panel. The core can, for example, be an HDF, MDF, particle board, plywood, OSB, etc.
[00192] As an alternative to the decorative sheet, the decorative layer 22 can be formed of a thermoplastic material applied as a powder to the core. An impression can be made on the powdered thermoplastic material. The thermoplastic material in powder form can be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate , polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The wear resistant sheet 10, 10' is disposed on the powder layer and pressed. Core 21 can be of the type described above.
[00193] Another alternative to the decorative sheet is the application of a heat-setting binder, preferably an amino resin and in powder form, and lignocellulosic or cellulosic particles to form the decorative layer 22 on the core 21. An impression can be created on the core 21. Powder layer, or pigments can be included. The core can be of the type described above. The wear resistant sheet 10, 10' is disposed on the powder layer and pressed under heat so that the thermal setting binder of the decorative layer is cured.
[00194] Other alternatives for forming the decorative layer 22 are to provide a layer of varnish, such as a layer of varnish for wood, or a layer of varnish for cork or a paper layer to form the decorative layer.
[00195] The different layers, i.e. layer 21, decorative layer 22, wear resistant sheet 10, 10', can be provided as continuous layers or can be cut into separate sheets for the modality described with reference to figure 3 .
[00196] Figure 4 illustrates a method of producing a building panel 20 including forming a wear resistant sheet 10 integrated into the production of building panel 20. Building panel 20 may be a floor panel, a panel a wall panel, a ceiling panel, a furniture component, etc.
[00197] A 21 core is provided. The core 21 may comprise a third thermoplastic material. The third thermoplastic material can be the same as the first and/or second material, or it can be different from the first and/or second material.
[00198] The third thermoplastic material may comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate , polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The core 21 can be formed from several layers. The core can be foamed.
[00199] In one embodiment, the core 21 comprises the third thermoplastic material and fillers. Fillers can comprise calcium carbonate, such as chalk and/or lime, or sand.
[00200] In one embodiment, core 21 is a Wood Plastic Composite (WPC), comprising the third thermoplastic material and wood particles as fillers.
[00201] The core 21 can be provided with a decorative layer 22 disposed on an upper surface of the core 21. The wear resistant sheet 10 is then disposed on the decorative surface 22. The decorative layer 22 can be a decorative sheet comprising a thermoplastic material . The thermoplastic material of the decorative layer can be or comprise polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof. Decorative layer 22 is preferably printed, for example, by direct printing, rotogravure, or digital printing.
[00202] The core 21 can also be provided with a balancing layer (not shown) disposed on a lower surface of the core 21, opposite the decorative layer 22. Any intermediate layer or layers can be arranged between the core 21 and the decorative layer 22.
[00203] A first sheet 1 is arranged on the core 12. The first sheet 1 comprises a first thermoplastic material. The first thermoplastic material can be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral , polybutylene terephthalate, or a combination thereof.
[00204] A first sheet 1 is provided, preferably as a continuous web. The first sheet 1 can also be cut into smaller sheets. The first sheet 1 can also be formed in an extrusion process in connection with building panel production. The first sheet 1 can also be formed from a layer of powder comprising the first thermoplastic material in powder form.
[00205] Preferably, the first sheet 1 is formed of thermoplastic material. The first sheet can consist substantially of thermoplastic material, and optionally additives. Additives can be plasticizers, stabilizers, lubricants, gas removal agents, coupling agents, compatibilizers, crosslinking agents, etc.
[00206] In one embodiment, the first sheet 1 is a PVC sheet.
[00207] The first sheet 1 can have a thickness of 0.1 to 1 mm.
[00208] As illustrated in figure 4, an application device 3 applies, preferably spreads, a second thermoplastic material 5 in the form of powder and wear-resistant particles 4 from the first sheet 1. In figure 1, the second thermoplastic material 5 and the 4 wear-resistant particles are applied as a mixture. Thermoplastic material 5 and wear resistant particles 4 can also be applied separately. Preferably, and applied separately, the wear resistant particles 4 are applied first and the second thermoplastic material 5 is applied to the wear resistant particles 4.
[00209] The second thermoplastic material 5 may be the same as the first sheet 1, or it may be different from the thermoplastic material of the first sheet 1. The second thermoplastic material may be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[00210] In the embodiment illustrated in Figure 4, the second material 4 is applied as a powder. By powder also means powder which has formed grains of thermoplastic material 5, dry mixtures of thermoplastic material 5, or agglomerates of thermoplastic material 5. The grains may comprise thermoplastic material 5 and the wear-resistant particles 4. The agglomerates may comprise thermoplastic material 5 and wear-resistant particles 4.
[00211] The average particle size of the thermoplastic material 5 may be less than 500 µm, preferably from 50 to 250 µm. Thermoplastic material 5 in a dry mix may be less than 500 µm in size. The grains of thermoplastic material 5 can have an average particle size of 200 to 4000 µm, preferably less than 1000 µm.
[00212] In the embodiment illustrated in Figure 4, the wear-resistant particles 4 and the second thermoplastic material are applied as a mixture.
[00213] In the embodiment illustrated in Figure 4, the second thermoplastic material 5 is applied in powder form. In embodiments, the second thermoplastic material 5 can be applied in cast form, which is described in more detail with reference to Figure 6B. The wear resistant particles 4 can be mixed with the second thermoplastic material 5 in molten form or applied separately. The second thermoplastic material 5 in molten form can be applied in an extrusion process such as extrusion lamination and extrusion coating on the first sheet 1.
The wear resistant particles 4 can be aluminum oxide particles such as corundum. Alternatively, or as a complement, wear resistant particles 4 can be carborundum, quartz, silica, glass, glass beads, glass beads, silicon carbide, diamond particles, hard plastic, reinforced and organic polymers, or a combination of the same.
The wear resistant particles 4 preferably have an average particle size within the range of 10 to 200 µm, preferably within the range of 50 to 120 µm, such as 50 to 100 µm. Wear resistant particles 4 can have an average particle size of less than 50 µm, preferably less than 45 µm. Wear resistant particles 4 may have an irregular shape. Wear resistant particles 4 can be surface treated. Wear resistant particles 4 can be silane treated particles.
[00216] Wear resistant particles 4 can have a refractive index similar to the refractive index of the second thermoplastic material 5. Wear resistant particles can have a refractive index from 1.4 to 1.7. In one embodiment, the wear resistant particulate may have a refractive index from 1.4 to 1.9, preferably from 1.5 to 1.8, for example from 1.7 to 1.8. The refractive index of wear resistant particles cannot differ from the refractive index of the second thermoplastic material by more than +/20%.
[00217] Wear resistant particles can be applied in an amount of 20 to 100 g/m2, preferably in an amount of 40 to 60 g/m2.
[00218] The wear-resistant particles may have an average particle size less than the thickness of the layer formed by the wear-resistant particles and the second thermoplastic material after pressing. However, the wear resistant particles can have an average particle size greater than the thickness of the layer formed by the wear resistant particles and the second thermoplastic material after pressing. During pressing, the wear-resistant particles are pressed into the first sheet so that the wear-resistant particles do not protrude beyond an upper surface of the layer, even though the wear-resistant particles have an average particle size exceeding the thickness of the layer formed by wear resistant particles and second thermoplastic material after pressing.
[00219] The ratio between the size of the wear-resistant particles and the thickness of the layer formed by the wear-resistant particles and the second thermoplastic material after processing may be less than 1.5:1.
[00220] Scratch resistant particles (not shown) can also be applied to the first sheet 1. By scratch resistant particles means that the particles improve the scratch or scratch resistance properties of the first sheet 1. The scratch resistant particles can be applied together with the wear resistant particles, eg as a mixture, or can be applied separately. Preferably, the scratch particles are disposed on an upper part of the layer formed by the thermoplastic material 5 and the wear resistant particles 4. The scratch resistant particles can be or comprise silica nano particles, preferably fused silica particles. Scratch resistant particles can be or comprise aluminum oxide.
The scratch resistant particles may be disk-shaped particles, preferably having a width/thickness ratio equal to or greater than 3:1, more preferably equal to or greater than 5:1. Such disk-shaped particles orient along the surface of the sheet, thus improving the scratch resistance of the sheet. Scratch resistant particles can have an average particle size of 1 to 50 µm, preferably 10 to 20 µm.
[00222] Additives can also be applied to the first sheet 1, preferably together with the second thermoplastic material 5. Additives can be plasticizers, stabilizers, lubricants, gas removal agents, coupling agents, compatibilizers, crosslinking agents, etc.
[00223] In one embodiment, the first sheet 1 is a PVC sheet and the second thermoplastic material 5 is PU. In one embodiment, the first sheet 1 is a PVC sheet and the second thermoplastic material 5 is PVC.
[00224] The different layers, i.e. the core 21, the decorative layer 22, the first sheet 1, can be provided as continuous layers or can be cut into separate sheets.
[00225] The core 21, the first sheet 1 and the second thermoplastic material 5 in powder form with the wear resistant particles 4 are thereafter adhered together, for example pressed together, to form a building panel 20. The first sheet 1 and the second thermoplastic material 5 with the wear resistant particles 4 form a wear resistant sheet 10 of the building panel 20.
The wear resistant sheet 10 is preferably transparent, or substantially transparent, for example, having a light transmission index that exceeds 80%, preferably exceeds 90%.
[00227] The core 21, the first sheet 1 and the second thermoplastic material 5 are preferably pressed together in a pressing station 6. The pressing can be continuous or static. The first and second sheets can be adhered together by pressure alone, by heat and pressure, by pressure and adhesive, or by heat, pressure and adhesive. Preferably, pressure and heat are applied in order to adhere the first and second sheets together. The pressing operation can, for example, be carried out as a hot-hot process, a hot-cold process, etc. Depending on the thermoplastic materials and the process used, the applied pressure can be from 0.5 MPa to 10Mpa (5 to 100 bar), applied, for example, for 5 to 500 seconds. The temperature can be 80 to 300°C, such as 100 to 250°C, such as 150 to 200°C. The pressing can be carried out with an engraved pressing die or pressing roller so that an engraved structure is formed on the wear resistant sheet. As an alternative, the layers can be adhered together by an adhesive such as glue, eg hot melt.
[00228] The second thermoplastic material 5 and the wear resistant particles 4 form a layer, which may have a thickness of 0.01 to 1 mm, preferably as measured in the final product, for example after pressing or extrusion. Preferably, the layer formed by the second thermoplastic material 5 and the wear resistant particles 4 has a thickness of less than 0.5 mm, more preferably less than 75 µm such as around 50 µm, preferably as measured in the final product, for example , after pressing or extrusion.
[00229] After adhesion, the wear resistant particles are included by the first sheet and the second thermoplastic material. Preferably, the wear resistant particles are completely enclosed by the second thermoplastic material. Although the wear resistant particles and the second thermoplastic material can be applied as a mixture, during pressing, the second thermoplastic material melts and encloses the wear resistant particles. Preferably, the wear resistant particles do not protrude beyond the surface of the layer formed by the second thermoplastic material facing away from the first sheet. In this way, a wear resistant sheet having a smooth surface can be formed.
[00230] A coating (not shown) can be applied to wear resistant sheet 10. The coating may comprise acrylate or methacrylate monometer or acrylate or methacrylate oligomer. The coating can be radiation curing, such as UV curing or electron beam curing.
[00231] As an alternative to a separate decorative layer 22, an impression can be made directly on the upper surface of the core 21. The first sheet 1 is thus arranged directly on the core 21.
[00232] As an alternative to a separate decorative layer 22, the first sheet 1 can be a decor sheet. The first sheet 1 can be printed, for example, by digital printing, direct printing, rotogravure, etc. Preferably, the print is provided on one side of the first sheet 1 adapted to face the core 21. The first sheet 1 is thus arranged directly on the core 21.
[00233] As an alternative to the decorative sheet described above, the decorative layer 22 can be formed of a thermoplastic material applied as a powder to the core. An impression can be created on the powdered thermoplastic material. The thermoplastic material in powder form can be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate , polyvinyl butyral, polybutylene terephthalate, or a combination thereof. The first sheet 1 is arranged on the powder layer and pressed together with it, as described above. Core 21 can be of the type described above.
[00234] Another alternative to the decorative sheet described above is the application of a heat-setting binder, preferably an amino resin and in powder form, and lignocellulosic or cellulosic particles to form the decorative layer 22 on the core 21. An impression can be performed in the powder layer, or pigments can be included. The core can be of the type described above. The first sheet 1 is arranged on the powder layer and is pressed under heat as described above, so that the thermal setting binder of the decorative layer is cured.
[00235] Other alternatives for forming the decorative layer 22 are to provide a layer of varnish for wood, a cork layer or a paper layer for forming the decorative layer.
[00236] In one embodiment, the first sheet 1 can be a decorative sheet. The first sheet 1 can be provided with a print, for example, by digital printing, direct printing or rotogravure.
[00237] In one embodiment, both the decorative layer 22 and the first sheet 1 are excluded. The second thermoplastic material 5 in powder form and wear resistant particles 4 are applied directly to the core. The second thermoplastic material 5 is of the type described above. Core 21 is of the type described above. An upper surface of the core 21 may be provided with a print, preferably a fingerprint. Wear resistant particles 4 of the type described above can be applied together with the second thermoplastic material 5 as a mixture or separately. Scratch resistant particles of the type described above can also be applied.
[00238] The second thermoplastic material 5 is fused, preferably by the application of heat and pressure, to a wear resistant sheet 10' comprising the wear resistant particles 4 disposed in the core 12 in a pressing operation as described above.
[00239] It is contemplated that the core 21 may be excluded in the modalities described with reference to Figure 4. By adhering, for example, pressing, the decorative layer 22 and the second thermoplastic material 5 of the type described above with the wear-resistant particles 4, a decorative substrate having wear resistant properties is provided.
[00240] In addition to the building panel 20 described above with reference to Figure 3, building panels 20 having another structure can also be provided by the methods described above.
[00241] According to an embodiment, which is illustrated in Figure 5A, a building panel 20 comprising a core 21 of the type described above and a wear resistant sheet 10' manufactured in accordance with the embodiment described with reference to Figure 2 are provided. An upper surface of the core 21 may be provided with a print 23, for example created by digital printing, direct printing or gravure printing. Wear resistant sheet 10' is disposed directly on core 21.
[00242] The wear resistant sheet 10' is formed from the second thermoplastic material 5 of the type described above applied in powder form and the wear resistant particles 4 of the type described above. The wear resistant particles 4 are preferably substantially homogeneously distributed in the wear resistant sheet 10'.
[00243] According to an embodiment, which is illustrated in Figure 5B, a building panel 20 comprising a core 21 of the type described above and a wear resistant sheet 10 manufactured in accordance with the embodiment described with reference to Figure 1 are shown . Alternatively, the building panel 20 is manufactured in accordance with the embodiment described with reference to Figure 4, where the decorative layer 20 is excluded. The wear resistant sheet 10 is arranged directly on the core 12. The wear resistant sheet 10 comprises the first sheet 1 of the type described above and the second thermoplastic material 5 of the type described above applied with the wear resistant particles 4 of the type described above . The first sheet 1 can be a decorative sheet. The first sheet 1 can be provided with a print 23, for example created by digital printing, direct printing or rotogravure. Alternatively, or as a complement, an upper surface of the core 21 is provided with a print 23. The wear resistant sheet 10 is arranged directly on the core 21. The wear resistant sheet 10 can be produced integrated with the panel production method of construction, as described with reference to figure 4, or as a separate process as described with reference to figure 1.
[00244] According to an embodiment, the building panel 20 comprises a core 21 of the type described above and a wear resistant sheet 10' formed from the second thermoplastic material 5 of the type described above and the wear resistant particles 4 of the type described above applied directly to an upper surface of the core 21. The upper surface of the core 21 may be provided with a print 23, for example, printed by digital printing, direct printing or gravure printing.
[00245] Any of the building panels described above can be provided with a mechanical locking system. The mechanical locking system may be of the type described in WO 2007/015669, WO 2008/004960, WO 2009/116926 or WO 2010/087752, the entire contents of which are expressly incorporated by reference herein.
[00246] In all embodiments, the second thermoplastic material of the above type can be applied in an extrusion process, which is illustrated in figures 6A-B. In figure 6A, a first sheet 1 is provided. The first sheet 1 is of the type described above with reference to figures 1, 35A and 5B. In the embodiment illustrated in Figure 6A, the second thermoplastic material 5 of the type described above is mixed with the wear resistant particles 4 of the type described above. The second thermoplastic material 5 is preferably supplied as grains. The second thermoplastic material 5 in molten form is applied to the first sheet 1 comprising the first thermoplastic material by an extruder 8. The second thermoplastic material 5 is applied to the first sheet 1 by an extrusion process such as extrusion lamination or extrusion coating.
[00247] As an alternative to mixing the second thermoplastic material 5 with the wear resistant particles 4, the wear resistant particles 4 can be applied separately from the second thermoplastic material 5 (not shown). The wear resistant particles 4 can be applied to the first sheet 1 before applying the second thermoplastic material 5 by the extrusion process such as extrusion lamination or extrusion coating on the first sheet 1.
[00248] The method of producing a wear resistant sheet 10 by using an extrusion technique as described above with reference to figure 6A is also applicable when forming a building panel corresponding to the embodiment illustrated in figure 4, which is illustrated in Figure 6B.
[00249] In figure 6B, a first sheet 1 and a core 21 are provided. The first sheet 1 and the core 21 are of the type described above with reference to figures 3, 4 and 5A-5B. In the embodiment illustrated in Figure 6B, the second thermoplastic material 5 of the type described above is mixed with the wear resistant particles 4 of the type described above. The second thermoplastic material 5 is preferably supplied as grains. The second thermoplastic material 5 in molten form is applied to the first sheet 1 comprising the first thermoplastic material by an extruder 8. The second thermoplastic material 5 is applied to the first sheet 1 by an extrusion process such as extrusion lamination or extrusion coating.
[00250] As an alternative to mixing the second thermoplastic material 5 with the wear resistant particles 4, the wear resistant particles 4 can be applied separately from the second thermoplastic material 5 (not shown). The wear resistant particles 4 can be applied to the first sheet 1 before applying the second thermoplastic material 5 by the extrusion process such as extrusion lamination or extrusion coating on the first sheet 1.
[00251] The core 21, the first sheet 1 provided with wear resistant particles 4 and the second thermoplastic material 5 are adhered together to form a building panel 20, for example, by pressing such as calendering as illustrated in figure 6B. Alternatively, the layers can be adhered together by means of an adhesive, such as hot melt.
[00252] It is also contemplated that co-extrusion can be used to form the wear resistant sheet. The first sheet comprising the first thermoplastic material and a second sheet comprising the second thermoplastic material can be formed by co-extruding the first and second sheets. Wear resistant particles can be mixed with the second thermoplastic material, or applied separately to the first and/or second sheet.
[00253] It is contemplated that there are numerous modifications of the modalities described herein, which are still within the scope of the invention as defined by the appended claims. For example, it is contemplated that more than one wear resistant sheet may be disposed on a core to form a building panel.
[00254] For example, it is contemplated that after pressing, the boundaries between the first sheet 1 and the layer formed by the second thermoplastic material 5 powdered and the wear resistant particles 4 may be less distinct.ExampleExample 1: Comparative example
[00255] A PVC wear layer sheet with a thickness of 0.3 mm was positioned on a decorative sheet with a thickness of 0.1 mm. The two sheets were laminated onto a PVC core material using a temperature of 160°C, a pressure of 2.0 MPa (20 bar) and a pressing time of 40 seconds. The resulting product was an LVT product. The LVT product was found to have a wear resistance of 3200 revolutions as tested in a Taber abrader.Example 2: PVC powder composition on sheet
[00256] A PVC wear layer sheet with a thickness of 0.3 mm was positioned on a decorative sheet with a thickness of 0.1 mm. 150 g/m2 of powder composition comprising 90% by weight PVC and 10% by weight Al203 were spread on the wear layer sheet. The PVC powder composition and the two sheets were laminated to a PVC core material using a temperature of 160°C, a pressure of 2.0 MPa (20 bar) and a pressing time of 40 seconds. The resulting product was an LVT product. The LVT product was found to have a wear resistance greater than 8000 revolutions as tested in a Taber abrader.Example 3: PU powder composition on sheet
[00257] A PVC wear layer sheet with a thickness of 0.3 mm was positioned on a decorative sheet with a thickness of 0.1 mm. 150 g/m2 of a powder composition comprising 90% by weight PU powder and 10% by weight Al203 was spread on the wear layer sheet. The PU powder composition and the two sheets were laminated onto a PVC core material using a temperature of 160°C, a pressure of 2.0 MPa (20 bar) and a pressing time of 40 seconds. The resulting product was an LVT product. The LVT product was found to have a wear resistance greater than 8000 revolutions as tested on a Taber abrader.Example 4: PU sheet on PVC sheet
[00258] A printed decorative PVC sheet having a thickness of 0.08 mm was arranged on a core comprising three layers and having a thickness of 4 mm. A PVC wear layer having a thickness of 0.25 mm was disposed on the decorative PVC sheet. Wear resistant particles in the form of aluminum oxide were applied in an amount of 40 g/m2 to the PVC wear layer. A PU sheet having a thickness of 0.05 mm was disposed on the wear resistant particles and PVC wear layer. The different layers were pressed together in a cold-hot-wire process. The applied pressure was 1.0 MPa (10 bar). The temperatures applied in the cold-hot-cold process were 50°C, 140°C and 50°C. The product was pressed at 140°C for 4 minutes. Total pressing time was approximately 55 minutes. The resulting product was an LVT product. The LVT product was found to have a wear resistance greater than 8000 revolutions as tested in a Taber abrader.

权利要求:
Claims (29)
[0001]
1. Method of producing a wear-resistant sheet (10), comprising: providing a first sheet (1) comprising a first thermoplastic material; applying wear-resistant particles (4) and a second thermoplastic material (5 ) on the first sheet (1); and the adhesion of the first sheet (1) to the second thermoplastic material (5) and to the wear-resistant particles (4) to form a wear-resistant sheet (10), characterized in that the second thermoplastic material (5) is applied to the first. sheet (1) in powder form or in cast form.
[0002]
2. Method according to claim 1, characterized in that the wear-resistant particles (4) are waxed by the first sheet (1) and the second thermoplastic material (5) after being adhered to each other.
[0003]
3. Method according to claim 1 or 2, characterized in that the wear-resistant particles (4) and the second thermoplastic material (5) are applied as a mixture.
[0004]
4. Method according to any of the preceding claims, characterized in that the first thermoplastic material comprises polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylates, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0005]
5. Method according to any of the preceding claims, characterized in that the second thermoplastic material comprises polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylates, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0006]
6. Method according to any one of the preceding claims, characterized in that the second thermoplastic material (5) comprises polyvinyl chloride (PVC) or polyurethane (PU).
[0007]
7. Method according to any one of the preceding claims, characterized in that the first sheet (1), the second thermoplastic material (5) and the wear-resistant particles (4) are adhered together by pressing, preferably without a sticker.
[0008]
8. Method according to any one of the preceding claims, characterized in that the wear-resistant particles (4) comprise aluminum oxide.
[0009]
9. Method according to any one of the preceding claims, characterized in that the wear-resistant particles (4) have an average particle size of less than 45 µm.
[0010]
10. Method according to any one of the preceding claims, characterized in that the thickness of a layer formed by the second thermoplastic material (5) and the wear-resistant particles (4) is less than 75 μm after being adhered one to the other.
[0011]
11. Method according to any one of the preceding claims, characterized in that the wear-resistant sheet (10) is transparent.
[0012]
12. Method of producing a building panel (20), comprising: providing a core (21); applying a first sheet (1) comprising a first thermoplastic material to the core (21); applying resistant particles wear (4) and a second thermoplastic material (5) in the first sheet; and the adhesion of the core (21) to the first sheet (1) and to the second thermoplastic material (5) and to the wear-resistant particles (4) to form a building panel (20), characterized by the fact that the second thermoplastic material (5 ) be applied to the first sheet (1) in powder or cast form.
[0013]
13. Method according to claim 12, characterized in that the wear-resistant particles (4) are waxed by the first sheet (1) and the second thermoplastic material (5) after they have been adhered to each other.
[0014]
14. Method according to claim 12 or 13, characterized in that the wear-resistant particles (4) and the second thermoplastic material (5) are applied as a mixture.
[0015]
15. Method according to any one of claims 12 to 14, characterized in that the first thermoplastic material comprises polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS) , polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylates, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0016]
16. Method according to any one of claims 12 to 15, characterized in that the second thermoplastic material comprises polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS) , polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylates, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0017]
17. Method according to any one of claims 12 to 16, characterized in that the second thermoplastic material (5) comprises polyvinyl chloride (PVC) or polyurethane (PU).
[0018]
18. Method according to any one of claims 12 to 17, characterized in that the first sheet (1), the second thermoplastic material (5) and the wear-resistant particles (4) are adhered together by pressing, preferably without an adhesive.
[0019]
19. Method according to any one of claims 12 to 18, characterized in that the wear-resistant particles (4) comprise aluminum oxide.
[0020]
20. Method according to any one of claims 12 to 19, characterized in that the wear-resistant particles (4) have an average particle size of less than 45 µm.
[0021]
21. Method according to any one of claims 12 to 20, characterized in that a thickness of a layer formed by the second thermoplastic material (5) and the wear-resistant particles (4) is less than 75 μm after they have adhered each other.
[0022]
22. Building panel (20), characterized in that it comprises: a core (21); a wear resistant sheet (10, 10') arranged on a surface of the core (21) where the wear resistant sheet (10 10') comprises a second thermoplastic material (5) and wear-resistant particles (4) distributed substantially evenly within said second thermoplastic material (5).
[0023]
23. Building panel according to claim 22, characterized in that the wear-resistant particles (4) are included by the second thermoplastic material (5) and the core (21).
[0024]
24. Building panel according to claim 22 or 23, characterized in that the wear resistant sheet (10, 10') further comprises a first sheet (1) comprising a first thermoplastic material.
[0025]
25. Building panel according to claim 24, characterized in that the first thermoplastic material comprises polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylates, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0026]
26. Building panel according to any one of claims 22 to 25, characterized in that the second thermoplastic material comprises polyvinyl chloride (PVC), polyester (PE), polypropylene (PP), polyethylene (PE), polystyrene ( PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylates, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.
[0027]
27. Building panel according to any one of claims 22 to 26, characterized in that the wear-resistant particles (4) comprise aluminum oxide.
[0028]
28. Building panel according to any one of claims 22 to 27, characterized in that the wear-resistant particles (4) have an average particle size of less than 45 µm.
[0029]
29. Building panel according to any one of claims 22 to 28, characterized in that a thickness of a layer formed by the second thermoplastic material (5) and the wear-resistant particles (4) is less than 75 μm.

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同族专利:

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EP3169533A4|2017-12-20|

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JP6685273B2|2020-04-22|

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EP3169533A1|2017-05-24|

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UA120705C2|2020-01-27|

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WO2016010471A1|2016-01-21|

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EA035047B1|2020-04-22|

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WO2016010472A1|2016-01-21|

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MX2017000379A|2017-05-01|

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CN106536213A|2017-03-22|

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JP2017530028A|2017-10-12|

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BR112017000330A2|2017-11-07|

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AU2015290300A1|2017-01-12|

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US20200180282A1|2020-06-11|

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MX2017000380A|2017-05-01|

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JP2017527461A|2017-09-21|

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EP3169532A4|2017-12-20|

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US20160016391A1|2016-01-21|

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BR112017000330B1|2021-08-17|

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AU2015290301B2|2019-07-18|

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KR20170032349A|2017-03-22|

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US20210053322A1|2021-02-25|

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AU2015290301A1|2017-01-12|

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US10059084B2|2018-08-28|

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EA201692553A1|2017-04-28|

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EA201692551A1|2017-04-28|

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AU2015290300B2|2019-05-16|

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JP6622787B2|2019-12-18|

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US10493731B2|2019-12-03|

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KR20170031169A|2017-03-20|

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US20160016390A1|2016-01-21|

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CN106536214A|2017-03-22|

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EA032991B1|2019-08-30|

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EP3169532A1|2017-05-24|

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US20190091977A1|2019-03-28|

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US10780676B2|2020-09-22|

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BR112017000202A2|2017-10-31|

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法律状态:
2020-04-28| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-06-29| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-08-10| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 02/07/2015, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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SE1450894|2014-07-16|

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SE1450895|2014-07-16|

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SE1450894-9|2014-07-16|

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SE1450895-6|2014-07-16|

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SE1550455-8|2015-04-16|

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SE1550455|2015-04-16|

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PCT/SE2015/050783|WO2016010472A1|2014-07-16|2015-07-02|Method to produce a thermoplastic wear resistant foil|

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