EP2994307A1 - Panneau comprenant un revêtement de surface solide sur un support déformable par la température - Google Patents
Panneau comprenant un revêtement de surface solide sur un support déformable par la températureInfo
- Publication number
- EP2994307A1 EP2994307A1 EP13884020.2A EP13884020A EP2994307A1 EP 2994307 A1 EP2994307 A1 EP 2994307A1 EP 13884020 A EP13884020 A EP 13884020A EP 2994307 A1 EP2994307 A1 EP 2994307A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- panel
- surface layer
- layer
- adhesive
- support layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B96/00—Details of cabinets, racks or shelf units not covered by a single one of groups A47B43/00 - A47B95/00; General details of furniture
- A47B96/20—Furniture panels or like furniture elements
- A47B96/205—Composite panels, comprising several elements joined together
- A47B96/206—Composite panels, comprising several elements joined together with laminates comprising planar, continuous or separate layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/06—Interconnection of layers permitting easy separation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/0215—Flooring or floor layers composed of a number of similar elements specially adapted for being adhesively fixed to an underlayer; Fastening means therefor; Fixing by means of plastics materials hardening after application
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/0215—Flooring or floor layers composed of a number of similar elements specially adapted for being adhesively fixed to an underlayer; Fastening means therefor; Fixing by means of plastics materials hardening after application
- E04F15/02155—Adhesive means specially adapted therefor, e.g. adhesive foils or strips
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
- B32B2262/0269—Aromatic polyamide fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0292—Polyurethane fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/102—Oxide or hydroxide
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/54—Yield strength; Tensile strength
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/542—Shear strength
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/554—Wear resistance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2479/00—Furniture
Definitions
- a panel comprising a solid surface coating on a thermally deformable support
- the invention relates to a panel.
- the invention relates to a recyclable panel.
- the invention relates to a deformable panel.
- the invention relates to a panel that can be divided to parts, and optionally deformed when heated.
- the invention relates to stackable panels.
- the invention relates to panels having a surface of which mechanical, electrical, or optical properties are engineered for the purpose of use.
- the invention relates to panels having a wear resistant surface.
- Such panels can be used in or for furniture.
- Such panels can be used in buildings.
- Such panel can be used for flooring or for work surfaces.
- Panels are often used in buildings. Panels can form part of furniture, they can be used as or in flooring, wall, or ceiling elements. In addition, such panels can be used in various desks and in shops as shop fittings. Panels can also be used for working surfaces in buildings. Working surfaces and flooring require good wear resistance of the surface that is exposed to wear. Moreover, in these applications, the surface is preferably moisture resistant, since water is often needed e.g. for cleaning such surfaces. Therefore, panels having a high wear resistance and high moisture resistance are known. For example plaques are used for the purpose. They, however are relatively expensive and fragile. Thereby a lot of labor force is needed for installation. Summary of the Invention
- a panel according to an embodiment of the invention has a thickness in a first direction, a length in a second direction, and a width in a third direction, wherein the thickness is smaller than the length and the thickness is smaller than the width.
- An embodiment of the panel comprises
- the panel further comprising
- thermosensitive area - a thermosensitive area
- the panel has a strength at a first temperature
- the panel can be separated to a first part and a second part at a second temperature using a stress, wherein
- the second temperature exceeds the first temperature by at least 30 °C and by at most 200 °C
- the stress is at most half of the strength.
- Figure 1 a shows, in a side view, an embodiment of a panel
- Figure 1 b shows, in a perspective view, the panel of Fig. 1 a
- Figure 1 c shows, in another perspective view, the panel of Fig. 1 a
- Figure 1 d shows, in a perspective view, the panel of Fig. 1 a
- Figure 1 e1 shows, in a side view, an embodiment of a panel at a first temperature, having a tensile strength and a shear strength c ss , and comprising a thermosensitive area arranged in the support layer,
- Figure 1 e2 shows, in a side view, the division of the panel of Fig. 1 e1 at a second temperature using a shear stress ⁇ ⁇ , wherein the second temperature is higher than the first temperature, and wherein the shear stress ⁇ ⁇ is less than the shear strength c ss at the first temperature,
- Figure 1 e3 shows, in a side view, the division of the panel of Fig. 1 e1 at a second temperature using a tensile stress wherein the second temperature is higher than the first temperature, and wherein the tensile stress at is less than the tensile strength a ts at the first temperature,
- Figure 1 e4 shows, in a side view, the separated first part of the panel of Fig.
- Figure 1 f 1 shows, in a side view, an embodiment of a panel at a first temperature, having a tensile strength a ts and a shear strength a ss , and comprising a thermosensitive area arranged on the support layer,
- Figure 1f2 shows, in a side view, the division of the panel of Fig. 1 f 1 at a second temperature using a shear stress a s , wherein the second temperature is higher than the first temperature, and wherein the shear stress a s is less than the shear strength a ss at the first temperature,
- Figure 1 g 1 shows, in a side view, an embodiment of a panel at a first temperature, having a tensile strength a ts and a shear strength a ss , and comprising a thermosensitive area arranged in the adhesive,
- Figure 1 g2 shows, in a side view, the division of the panel of Fig. 1 g 1 at a second temperature using a shear stress a s , wherein the second temperature is higher than the first temperature, and wherein the shear stress a s is less than the shear strength a ss at the first temperature,
- Figure 1 g3 shows, in a side view, the division of the panel of Fig. 1 g 1 at a second temperature using a tensile stress a t , wherein the second temperature is higher than the first temperature, and wherein the tensile stress a t is less than the tensile strength a ts at the first temperature,
- Figure 2a shows, in a top view, an adhesive layer and a surface layer
- Figure 2b shows, in a top view, an adhesive layer and a surface layer
- Figure 2c shows, in a top view, an adhesive layer and a surface layer
- Figure 3a shows, in a side view, heating of a panel comprising viscous adhesive
- Figure 3b shows, in a side view, heating of a panel comprising solid adhesive
- Figure 4 shows, in a side view, an adhesive layer
- Figure 5 shows, in a side view support layer
- Figure 6a shows, in a side view, an essentially planar panel
- Figure 6b shows, in a side view, form pressing the panel of Fig. 6a
- Figure 7a shows, in a side view, a panel having the shape of an open tube
- Figure 7b shows, in a side view, a panel having the shape of half a tube
- Figure 7c1 shows, in a side view, a panel having a planar central area and curved boundary areas
- Figure 7c2 shows, in another side view, the panel of Fig. 7c1 ,
- Figure 7d shows, in a side view, a panel having a curved central area and curved boundary areas
- Figure 8 shows, in a perspective view, a panel 100 that is curvilinear in two different directions.
- Panels are often used in buildings. Panels can for part of furniture, they can be used as or in flooring, wall, or ceiling elements. Panels can also be used for working surfaces in buildings. In addition, such panels can be used in various desks and in shops as shop fittings. Working surfaces and flooring require good wear resistance of the surface that is exposed to wear. Moreover, in these applications, the surface is preferably moisture resistant, since water is often needed e.g. for cleaning such surfaces. It is known to use plaques for the purpose.
- Some polymer materials are also resistant to moisture and wear. Moreover, the wear resistance can be increased by adding some filler material to a polymer matrix. Filler materials can also be used to engineer other properties of the composite material, such as electrical conductance (related to antistatic properties and EMC protection), resistance to electric discharge, thermal resistance, fire resistance, color, opaqueness, resistance to radiation (e.g. UV radiation), acoustic impedance, and hardness; or to bring some functionality to the surface layer, such as self-cleaning, easy-cleaning, change of color with temperature (thermochromism). In general, the properties can be engineered in either direction, such as increasing or decreasing the thermal conductance, or increasing or decreasing the wavelength that the surface layer emits, reflects, or absorbs, depending on the application.
- the material becomes more brittle, when such filler material is added.
- the polymer comprising the filler may be reasonable expensive, since some filler materials are expensive, whereby their addition makes the material more expensive. Some other filler material or materials can be used to reduce cost.
- a relatively thin layer is preferably used.
- the material is brittle. Handling of sheets of thin, brittle material, is very hard, whereby such materials are not commonly available.
- the engineered polymer composite material forms only a surface layer of a panel.
- Figures 1 a to 1 d show an embodiment of such a panel 100 in a side view and in some perspective views.
- the panel 100 has a thickness Tp in a first direction Sx, a length Lp in a second direction Sy, and a width Wp in a third direction Sz, wherein the thickness Tp is smaller than the length Lp and the thickness Tp is smaller than the width Wp.
- the first, the second, and the third directions (Sx, Sy, Sz) are orthogonal, and oriented as in a common right handed coordinate system, as depicted in Figs. 1 b to 1 d.
- the panel 100 comprises
- the surface layer 400 does not comprise wood.
- the support layer 200 comprises wood.
- the support layer 200 comprises wood and polymer material.
- the polymer material of the support layer 200 comprises natural polymer material and/or synthetic polymer material.
- the support layer 200 comprises different material than the surface layer 400.
- the support layer 200 may be made of different material than the surface layer 400.
- the surface layer 400 comprises materials, whereby these materials form a set of surface materials; and the support layer comprises at least a support material such that the set of surface materials does not comprise the support material. Wood is an example of such support material.
- the adhesive 300 consists of a different composition of material or materials than the support layer 200.
- the different composition refers to composition of same materials (in the adhesive 300 and the support layer 200) in different proportional quantities or to a composition (of the adhesive) comprising at least some material that the other material (of the support layer) does not comprise or to a composition (of the adhesive) that does not comprise some material that the other material (of the support layer) comprises.
- boundary between the adhesive 300 and the support layer 200 is observable.
- the adhesive 300 consists of a different composition of material or materials than the surface layer 400; in the sense discussed above. Thus boundary between the adhesive 300 and the surface layer 400 is observable.
- the material that is comprised by the support layer 200, but is not comprise by the surface layer 400 may be cheaper, lighter, and stronger than the material(s) of the surface layer 400.
- the panel 100 is easier to handle, lighter (in weight), and cheaper than a corresponding panel made of only the material of the surface layer 400.
- the panel 100 is more wear resistant than a corresponding panel made of only the material of the surface layer 200, at least from the side of the surface layer.
- many other properties of the surface layer 400 may be engineered using additional material admixed in the surface layer 400, e.g. to a polymer matrix.
- the feature "at least part of the surface layer 400 is arranged in the first direction Sx from the support layer 200" expresses two issues.
- adhesive 300 is not necessarily a uniform layer, whereby a part of the surface layer 400 may be in contact with the support layer 200.
- the panel 100 may be significantly curvilinear. In this case, even if the panel "has a thickness in a first direction", the thickness and the corresponding direction are necessarily measured in a location, which then defines the direction and the thickness at this location.
- the whole surface layer 400 is not necessarily located a distance apart from the support layer 200 in this direction.
- the properties of the surface layer 400 are engineered for better mechanical, visual, or other properties, as discussed above.
- the resistance to surface wear of the panel 100 is from 58 to 75 lost weight mm 3 /100 rev according to the standard DIN ISO 4586 T6.
- the lost weight is from 58 to 63 mnn 3 /100 rev; and in some embodiments, the lost weight is from 63 to 75 mm 3 /100 rev.
- the resistance to boiling water can be characterized by the increase in weight and/or visual properties of the surface.
- the surface layer 400 is resistant to boiling water such that the increase in weight according to standard DIN ISO 4586 T7 is from 0.1 % to 0.7 %; preferably from 0.1 % to 0.3 %.
- the surface layer 400 is resistant to boiling water such that the no visible change occurs according to the standard DIN ISO 4586 T7.
- the surface layer 400 of the panel 100 belongs to the class B according to its fire behavior or its fire resistance, as classified according to the European classification EN 13501 -1 : Fire Test to Building Material - Classification.
- the surface layer 400 of the panel 100 belongs to the class B-s1 according to its fire behavior or its fire resistance (same classification).
- the surface layer 400 of the panel 100 belongs to the class B-dO according to its fire behavior or its fire resistance (same classification).
- the surface layer 400 of the panel 100 belongs to the class B-s1 -d0 according to its fire behavior or its fire resistance (same classification), As for the standards, the latest version to these standards is referred to on 7 th May 2013.
- the opposing surfaces of the panel 100 have approximately the same size.
- the panel 100 comprises a top surface 140, wherein the top surface 140 has a surface normal parallel to the first direction Sx, and the surface layer 400 comprises the top surface 140.
- the panel 100 further comprises a bottom surface 130, wherein the bottom surface 130 has a surface normal parallel to the first direction Sx, and the support layer 200 comprises the bottom surface 130.
- the area of the top surface 140 is denoted by Atop.
- the area of the bottom surface 130 is denoted by Abot.
- the ratio Abot/Atop is from 0.25 to 4.
- the ratio Abot Atop is from 0.5 to 2.
- the ratio Abot/Atop is close to 1 or equal to 1 .
- the ratio may be e.g. from 0.8 to 1 .25, from 0.9 to 1 .1 , or from 0.95 to 1 .05.
- the support layer 200 may be greater than the surface layer 400, or equal in size.
- the ratio Abot/Atop may be from 1 to 4, from 1 to 2, from 1 to 1 .25, from 1 to 1 .1 , or from 1 to 1 .05. This ensures that the support layer 200 protects also the boundaries and edges of the surface layer 400.
- the building, furniture, or other structure comprising the panel 100 is preferably recycled. This is particularly true, if the materials are expensive, such as the material of the surface layer 400. However, such a panel 100, while comprising a support layer 200 and a surface layer 400 of different material, is hard to recycle. Therefore, according to an embodiment of the invention, the panel can be separated to two parts using heat. With reference to Figs. 1 e1 to 1 g3, an embodiment of the panel 100 further comprises
- thermosensitive area 500 thermosensitive area 500
- the panel 100 has a strength (such as shear strength ⁇ 88 or tensile strength a t8 ; cf. Fig. 1 e1 ) at a first temperature Te1 ,
- the panel 100 can be separated to a first part 101 and to a second part 102 at a second temperature Te2 using a stress (such as a shear stress ⁇ 8 or a tensile stress ⁇ t ; cf. Fig. 1 e2 to 1 e4), wherein
- a stress such as a shear stress ⁇ 8 or a tensile stress ⁇ t ; cf. Fig. 1 e2 to 1 e4
- the second temperature Te2 is more than the first temperature Te1 (i.e. Te2>Te1 ), and
- the stress is at most half of the strength (e.g. a t ⁇ 1 ⁇ 2 ⁇ ⁇ 8 or ⁇ 8 ⁇ 1 ⁇ 2 ⁇ 88 ).
- Te1 and Te2 preferably the second temperature exceeds the first temperature by at least 30 °C and by at most 200 °C.
- the lower limit, 30 °C allows for reasonably large temperature variations for the operation temperature of the panel.
- the upper limit 200 °C indicates that the thermosensitive area 500 is sensitive to temperature, and not only arbitrary material that melts.
- the stress is at most half of the strength is to be interpreted such that the stress with which the panel can be separated at the second temperature Te2 is less than the corresponding strength at the first temperature Te1 .
- the tensile stress at, with which the panel 100 can be divided at the second temperature is at most half of the tensile strength o ts of the panel at the first temperature (o t ⁇ 1 ⁇ 2 ⁇ ⁇ ⁇ 8 ).
- shear stress ⁇ 8 with which the panel 100 can be divided at the second temperature, is at most half of the shear strength ⁇ 88 at the first temperature ( ⁇ 8 ⁇ 1 ⁇ 2 ⁇ ⁇ SS ).
- a combination of shear and tensile stresses is used to determine the strength at the first temperature Te1
- a similar combination of shear and tensile stresses is used to separate the parts 101 and 102 apart from the panel 100 at the second temperature Te2. If the strength values are given for a point force (shear, tensile, or combination), the corresponding stress is also for a point force (shear, tensile, or combination, respectively). If the strength values are given for a distributed force, i.e. stress (shear, tensile, or combination), the corresponding stress is also for a distributed force, i.e. stress (shear, tensile, or combination, respectively).
- the same strain rate is used to test the stress ( ⁇ t , ⁇ 8 , or combination) by which the panel 100 can be separated to (at least) two parts at the second temperature Te2.
- the stress is less than the strength by a reasonably significant amount.
- This reasonably significant amount may refer, in case of tensile stress and strength to the ratios ⁇ / ⁇ ⁇ 8 ⁇ 1/2 (as above), ⁇ / ⁇ ⁇ 8 ⁇ 1/4, ⁇ / ⁇ ⁇ 8 ⁇ 1/10, or ⁇ / ⁇ ⁇ 8 ⁇ 1/20.
- This reasonably significant amount may refer, in case of shear stress and strength to the ratios ⁇ 8 / ⁇ 88 ⁇ 1/2 (as above), ⁇ 8 / ⁇ 88 ⁇ 1/4, ⁇ 8 / ⁇ 88 ⁇ 1/10, or ⁇ 8 / ⁇ 88 ⁇ 1/20.
- These ratios may apply also for a combination of shear and tensile stresses.
- the surface layer 400 comprises most of the valuable materials of the panel 100. Therefore, preferably the surface layer 400 can be recycled as a single piece. Therefore, in an embodiment the surface layer 400 is heat resistant to temperatures from the first temperature Te1 to the second temperature Te2.
- the term heat resistant to a temperature means that the surface layer 400 does not melt or burn at that temperature. Thus, the surface layer 400 does not melt or burn at the second temperature Te2 and at temperatures below Te2.
- the surface layer 400 may be heat resistant to temperatures up to a temperature exceeding the second temperature Te2 by at least 10 °C, 20 °C, 30 °C, or more.
- the surface layer 400 may be heat resistant to temperatures down to a temperature that is below the first temperature Te1 by at least 25 °C, 50 °C, 75 °C, or more. In an embodiment, the surface layer 400 is heat resistant to temperatures from the first temperature to 150 °C, preferably to 180 °C or to 200 °C.
- the strength of the panel 100 e.g. the shear strength c ss or the tensile strength which forms a reference value for the separation stress, can be measured e.g. in a typical use condition. Thus, in an embodiment the strength of the panel is the strength of the panel at the first temperature of 25 °C. In short, in an embodiment the first temperature is 25 °C.
- the second temperature may be e.g. at least 50 °C, preferably at least 60 °C, at least 70 °C, at least 100 °C, at least 120 °C, or at least 150 °C.
- the second temperature Te2 may exceed the first temperature Te1 by at least some value ⁇ , i.e. Te2-Te1 > ⁇ .
- the at least some value ⁇ be e.g. 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, or 100 °C.
- the second temperature Te2 may exceed the first temperature Te1 by at least 60 °C, or by any of the greater values listed above.
- the first temperature Te1 correspond to the normal operation temperature, i.e. 20 °C.
- the second temperature may be e.g. 50 °C, 70 °C or 90 °C.
- a temperature of at most 100 °C may be preferred in some embodiments, since in that case hot water can be used to heat the panel.
- the second temperature may be from 50 °C to 200 °C, such as from 70 °C to 1 10 °C.
- thermosensitive area 500 forms a layer.
- the thermosensitive area 500 may be a continuous layer, i.e. a layer without holes, grooves, or channels.
- the thermosensitive area 500 may be a discontinuous layer.
- the layer may, for example, comprise holes.
- the thermosensitive area may be an arrangement of dots or stripes of thermosensitive material.
- the layer is not necessarily planar; separation of the panel 100 is possible also when the thermosensitive area 500 is not planar.
- separation of the panel to two parts may be possibly even if the thermosensitive area 500 does not form a layer that extends through the panel 100.
- the area of the termosensitive area 500 is reasonably large compared to the area of the surface layer 400 (e.g. to the area Atop of the top surface 140).
- thermosensitive area 500 is Ats, wherein
- the ratio Ats/Atop is at least 25 %, preferably at least 50 %, at least 70 %, or at least 90 %.
- the area of the thermosensitive area, Ats is measured in a cross section, wherein the cross section has a surface normal parallel to the surface normal of the top surface 140 at the same point.
- a planar panel 100 e.g. Fig. 1 e1
- this is more or less evident, however, this applies also for the curvilinear panel, such as the panel of Fig. 7a.
- the termosensitive area 500 serves as a seed for dividing the panel 100 to the two parts 101 and 102, if the rest of the weak part of the panel is solid.
- the term weak part referring to the part of the panel 100 that breaks upon the division, but is not thermosensitive.
- the termosensitive area 500 may be the only solid object that joins the first part 101 to the second part 102.
- thermosensitive area 500 extends through the panel 100. In this embodiment,
- thermosensitive area 500 extends through the panel 100.
- thermosensitive area 500 extends in a direction parallel to the top surface 140. In this embodiment,
- the surface layer 400 has a top surface 140 having a surface normal parallel to the first direction Sx, and
- thermosensitive area 500 extends parallel to the top surface 140.
- thermosensitive area 500 extends through the panel 100 and the thermosensitive area 500 extends parallel to the top surface 140.
- thermosensitive area 500 is arranged in the support layer 200, whereby
- the panel 100 can be separated to the first part 101 (Fig. 1 e4) and the second part 102 such that
- the first part 101 comprises at least a part 201 (in Figs. 1 e2 to 1 e4 only a part) of the support layer 200 and the second part 102 comprises the surface layer 400.
- the second part 102 further comprises the adhesive 300 and a part 202 of the support layer 200.
- Figure 1 e1 shows, in addition to the features discussed above, how the shear strength a ss can be determined at the first temperature Te1 .
- the arrows near the symbol for shear strength indicate the direction of shear forces (imposing the shear stresses) in determining the shear strength.
- Figure 1 e1 shows how the tensile strength a ts can be determined at the first temperature Te1 .
- the arrows near the symbol for tensile strength indicate the direction of tensile forces (imposing the tensile stresses) in determining the tensile strength.
- the forces can be point forces or distributed. Even if not discussed before, the forces can be a combination of point and distributed forces.
- Figure 1 e2 shows a shear stress a s used to separate the panel 100 of Fig. 1 e1 to two parts 101 and 102 at the second temperature Te2. Since the thermosensitive area 500 is arranged in the support layer 200 as a thermosensitive layer, the panel 100 separates at this layer 500. Moreover, as depicted in the figure, the support layer 200 separates to a first part 201 and a second part 202.
- Figure 1 e3 shows a tensile stress at used to separate the panel 100 of Fig. 1 e1 to the two parts 101 and 102 at the second temperature Te2. Since the thermosensitive area 500 is arranged in the support layer 200, the panel 100 separates at this layer 500. Moreover, as depicted in the figure, the support layer 200 separates to a first part 201 and a second part 202.
- Figure 1 e4 shows in more detail the first part 101 separated from the panel 100 and the second part 102 separated from the panel 100.
- the first part 101 comprises only a part 201 of the support layer 200.
- the second part 102 comprises the surface layer 400.
- the second part 102 further comprises the adhesive 300 and a part 202 of the support layer 200.
- the thermosensitive area 500 can be arranged in the support layer 200, e.g. when the support layer 200 itself is a layered structure comprising thermally sensitive material in between the layers of the structure.
- the thermally sensitive material may be e.g. thermoplastic polymer. Material selections for the support layer 200 will be discussed in detail later.
- thermosensitive area 500 is arranged on the support layer 200, whereby
- the panel 100 can be separated to the first part 101 and the second part 102 such that
- the first part 101 comprises at least a part of the support layer 200 (in Fig. 1f2 the whole support layer) and the second part 102 comprises the surface layer 400.
- the first part 101 separated from the panel 100 comprises the support layer 200 (or a part of the support layer 200, since part of the material of the thermosensitive area 500 may be stuck with the adhesive 300).
- the second part 102 separated from the panel 100 comprises the surface layer 400 and further comprises the adhesive 300. Referring to Figs. 1 g 1 to 1 g3, in an embodiment
- thermosensitive area 500 (or another thermosensitive area), whereby
- the panel 100 can be separated to the first part 101 and the second part 102 such that
- the first part 101 comprises the support layer 200 and the second part 102 comprises the surface layer 400.
- the adhesive 300 itself is thermosensitive.
- both the parts (101 , 102) comprise some of the adhesive 300, as shown in the figures 1 g 1 to 1 g3.
- the adhesive 300 may form the thermosensitive area 500 also in combination with the support layer 200 or the surface layer 400.
- the adhesion between the adhesive 300 and the support layer 200 may be dependent on temperature.
- the adhesion between the adhesive 300 and the support layer 200 may decrease as the temperature increases.
- the panel 100 could be separated to two parts such that the adhesive 300 separates from the support layer 200. In this case, the first part
- the panel 100 could be separated to two parts such that the adhesive 300 separates from the surface layer 200.
- the first part 101 of the separated panel comprises the support layer 200 and the adhesive
- the second part 102 of the separated panel comprises the surface layer 400.
- the panel 100 may comprise multiple thermosensitive areas.
- the adhesive 300 may serve as a first thermosensitive area 500
- the support layer 200 may comprise one or more thermosensitive areas 500, e.g. when the support layer 200 is a layered structure comprising thermoplastic material in between the layers.
- the panel 100 can be separated to the first part 101 and the second part
- the first part 101 comprises at least a part of the support layer 200 and the second part 102 comprises the surface layer 400.
- the second part 102 of the panel 100 does not comprise much more material than the surface layer 400. This helps the recyclability of the panel 100.
- the size of the parts 101 , 102 after the separation can be affected by selecting a proper location for the thermosensitive area 500.
- the thermosensitive area 500 may be arranged at the intersection of the adhesive 300 and the surface layer 400. This can be done by selecting the adhesive such that the adhesion properties on the material of the surface layer 400 are dependent on temperature.
- the adhesive 300 itself may be thermosensitive (e.g. thermoplastic).
- the thermosensitive area 500 may be arranged in the support layer 200, close to the intersection of the adhesive 300 and the support layer 200.
- the surface layer 400 has a mass
- thermosensitive area 500 is arranged in the panel 100 such that
- the panel 100 can be divided to the first part 101 and the second part 102 in such a way that
- the second part 102 comprises the surface layer 400 and
- the mass of the second part 102 is at most 1 .1 times the mass of the surface layer 400, preferably at most 1 .05 times the mass of the surface layer 400.
- the thermosensitive area 500 comprises thermoplastic polymer.
- the temperature exceeds the melting temperature i.e. the deflection temperature of the thermoplastic polymer the parts 101 and 102 of the panel 100 become moveable with respect to each other. In this case reasonably low stresses (in comparison to the strength of the panel at the first temperature as discussed above) are needed to separate the parts 101 , 102 of the panel 100.
- the ratio ctAj ts may be e.g. at most 1/50 or 1/100, or higher, as discussed above.
- the ratio ⁇ 8 / ⁇ may be e.g. at most 1/50 or 1/100, or higher, as discussed above.
- the terms “melting temperature” and “deflection temperature” are used interchangeable in this description.
- the thermosensitive area 500 may comprise thermoset polymer having a reasonably low deflection temperature i.e. glass transition temperature. When the temperature exceeds the deflection temperature or the glass transition temperature, the parts 101 and 102 of the panel 100 become moveable with respect to each other. In this case higher stresses (in comparison to case of thermoplastic material and to the strength of the panel at the first temperature as discussed above) may be needed to separate the parts 101 , 102 of the panel 100.
- the ratio at/ats may be e.g. at most 1 /2 or 1 /5; or the ratio C S AJ ss may be e.g. at most 1 /2 or 1 /5.
- the terms "glass transition temperature” and “deflection temperature” are used interchangeable in this description.
- thermosensitive area 500 comprises thermoplastic polymer having a melting temperature.
- the surface layer 400 may comprise polymer.
- the surface layer 400 comprises polymer having a deflection temperature
- thermoplastic polymer of the thermosensitive area 500 is less than the deflection temperature of the surface layer 400.
- the deflection temperature of the surface layer 400 exceeds the melting temperature of the thermoplastic polymer of the thermosensitive area 500 by at least 10 °C, 20 °C, 30 °C, 40 °C, 50 °C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C or more.
- the melting temperature of the thermoplastic polymer of the thermosensitive area is at most 200 °C. More preferably at most 180 °C, 170 °C, 160 °C, 150 °C, 140 °C, 130 °C, or 120 °C.
- panels are preferably stored in piles. Therefore, panels - at least in a storage - are preferably planar or substantially planar.
- the properties of the surface layer 400 and the support layer 200 are different. The difference in the desired properties typically also inevitably leads to difference in thermomechanical properties, particularly in the thermal expansion. Therefore alternating temperature may bend the panel 100.
- the surface layer 400 is attached to the support layer 200 at a temperature, that is reasonably close to the temperature at which the panel 100 is later stored. This issue will be discussed in more detail below.
- Planar panels even if easy to store in piles, are relatively flexible. This is because the stiffness in general is dependent on the third power of the thickness. However, reasonable rigidity is often needed for panels 100 in use.
- the panel 100 is bent (by from pressing) before use. In effect, bending increases the dimension of the panel that is parallel to the thickness of the panel 100 (cf. e.g. Fig. 7c1 , wherein the boundary area is curved, thereby increasing the dimension in the direction Sx, and the thickness of the central area of the panel is parallel to Sx). In this way, the stiffness of the panel 100 is also increased.
- Some shapes of a bent panel 100 will be discussed later. In order to enable bending and stiffening of the panel, in an embodiment
- the support layer 200 comprises thermoplastic polymer.
- thermoplastic polymer may also serve as the thermosensitive area 500.
- the panel 100 comprises only one surface layer 400.
- the panel 100 is not plane symmetric.
- no plane that has the surface normal parallel to the first direction Sx is a plane of symmetry for the panel 100.
- the panel may be symmetric.
- the thermal expansion properties are also typically different. Referring to Figs. 1 c and 1 d, in an embodiment,
- the support layer 200 has a first coefficient of thermal expansion k1 in a direction d1 that is perpendicular to the first direction Sx, and a second coefficient of thermal expansion k2 in another direction that d2 is perpendicular to the first direction Sx, wherein the directions are selected such that the second coefficient of thermal expansion k2 is smaller than or equal to the first coefficient of thermal expansion k1 (i.e. k2 ⁇ k1 ),
- the surface layer 400 has a third coefficient of thermal expansion k3 in a direction d3 that is perpendicular to the first direction Sx, and a fourth coefficient of thermal expansion k4 in another direction d4 that is perpendicular to the first direction Sx, wherein the directions are selected such that the fourth coefficient of thermal expansion k4 is smaller than or equal to the third coefficient of thermal expansion k3 (i.e. k4 ⁇ k3), and
- the third coefficient of thermal expansion k3 is different from the first coefficient of thermal expansion k1 (i.e. k3 ⁇ k1 ).
- the third coefficient of thermal expansion k3 is greater than the first coefficient of thermal expansion k1 (i.e. k3 > k1 ).
- CTE coefficients of thermal expansion
- the coefficients of thermal expansion depend on the selection of materials, as will be discussed later.
- the support layer 200 may be anisotropic, whereby the first k1 and the second k2 coefficients of thermal expansion may be different.
- the surface layer 400 may be anisotropic, whereby the third k3 and the fourth k4 coefficients of thermal expansion may be different.
- coefficient of thermal expansion in a direction means the coefficient of thermal expansion (CTE) as measured in that particular direction.
- the first, second, third, and fourth CTEs are measured in a tangent plane of a curvilinear panel.
- the tangent plane that has the surface normal parallel to the first direction.
- the difference between the third coefficient of thermal expansion k3 and the first coefficient of thermal expansion k1 is due to the fact that the surface layer 400 should have different properties than the support layer 200.
- the surface layer 400 is preferably wear and moisture resistant and also typically fragile, while the support layer 200 is preferably light, cheap, and shock resistant.
- the thickness T2 of the surface layer 400 may reasonable close to the thickness T1 of the support layer 200.
- the thickness T2 of the surface layer 400 is less than the thickness T1 of the support layer 200.
- the ratio of the thickness T1 of the support layer 200 to the thickness T2 of the surface layer, i.e. T1/T2 is from 1 to 10; preferably from 1 .2 to 5
- the thickness of the support layer 200 is not necessarily constant. E.g. the boundary areas of the support layer 200 may be thinned. Alternatively or in addition, the boundary areas of the support layer 200 may be rounded. Moreover, the thickness of the surface layer 400 is not necessarily constant. E.g. the boundary areas of the surface layer 400 may be thinned. Alternatively or in addition, the boundary areas of the surface layer 400 may be rounded.
- the difference in the CTEs could result is some difficulties for manufacturing planar panels 100 that are bendable.
- the properties of the adhesive 300 should be selected such that excessive temperature changes before form pressing are avoided.
- the support layer 200 may comprise thermoplastic polymer and/or thermoset polymer having low deflection temperature.
- the panel 100 may be heated to a temperature, in which the thermoplastic polymer of the support layer melts or the thermoset polymer softens. In this temperature, the panel can be deformed. When cooled down, the panel 100 approximately keeps it shape.
- the term "approximately" here is written, since the different coefficients of thermal expansion bend the panel 100 upon heating or cooling. Even if the surface layer 400 may be brittle and may comprise thermoset polymer, the surface layer 400 may be deformable when reasonably thin, and reasonably supported by the adhesive 300 and the support layer 200. Properties of the adhesive
- Such panels before thermally deformed, are preferably in planar form.
- both the surface layer 400 and the support layer 200 are manufactured in planar form.
- changes in the temperature would impose thermal stress in the panel, which would bend the panel.
- the surface layer 400 would be attached to the support 200 in a high temperature using an adhesive 300 solidifying, hardening, or drying at that temperature, cooling down to storage temperature would result in curving.
- the adhesive is selected from a group of adhesives that can be bonded at a temperature from 0 °C to 50 °C.
- the adhesive is selected from a group of adhesives that can be bonded at a temperature from 10 °C to 30 °C.
- Such adhesives include self adhesives, self stick adhesives, and pressure sensitive adhesives in any form. Such adhesives further include adhesives that dry or harden in the described temperature range.
- self adhesive pressure sensitive adhesive
- self stick adhesive all refer to an adhesive which forms bond when pressure is applied to join the adhesive with the adherend.
- can be bonded refers to bonding in such a way that the adhesion strength between the surface layer 400 and the support layer 200 is reasonably high.
- the adhesion strength between the surface layer 400 and the support layer 200 is in this sense reasonably high at least when the adhesion strength is such that the adhesive can bear the gravitational load of the surface layer 400.
- the adhesive 300 can be bonded (to surface layer 400 and support layer 200) at the temperature from 0 °C to 50 °C (preferably from 10 °C to 30 °C) when the adhesion strength is such that when holding the panel 100 from the support layer 200 (in any orientation), the surface layer 400 does not fall from the panel 100 due to the gravitational force only.
- adhesive 300 can be bonded (to surface layer 400 and support layer 200) when the adhesion strength is such that when holding the panel 100 from the surface layer 400 (in any orientation), the support layer 200 does not fall from the panel 100 due to the gravitational force only.
- This test can be performed e.g. at the temperature 25 °C. The falling may not occur immediately; in the above, the part that falls off from the panel is considered to fall off from the panel, if and only if it falls off during the first day (24 hours) once the panel has been oriented for the test.
- the adhesive 300 is selected from a group of such adhesives that, when bonded at a temperature from 0 °C to 50 °C (preferably from 10 °C to 30 °C) to the surface layer 400 and the support layer 200, the adhesion strength between the surface layer and the support layer is at least 100 Pa. This corresponds to the aerial mass of the surface layer 400 or the support layer 200 of about 10 kg/m 2 .
- the adhesion strength between the surface layer and the support layer is at least 500 Pa or at least 1 kPa. Naturally the adhesion strength may be also much higher.
- the adhesion strength may refer to specifically to shear strength (e.g. vertically aligned panel and gravitational stress).
- the adhesion strength could refer to specifically to tensile strength (e.g. horizontally aligned roof panels and gravitational stress).
- the absolute values for the adhesion strength may be measured at the temperature 25 °C.
- the absolute values for the adhesion strength may be measured using a (shear) strain rate of at least 1/s.
- the adhesive is selected from a group of such adhesives that, when bonded at a temperature from 0 °C to 50 °C (preferably from 10 °C to 30 °C), the adhesion strength remains stable in a stable environment for at least one year.
- the expression "remains stable” can be interpreted in such a way, that
- the adhesion strength has a first value
- the adhesion strength has a second value, wherein - the second time is at least one year later than the first time, and
- the second value is at least half (and optionally at most twice) the first value.
- alternating environment may deteriorate the properties of the adhesive, whereby in the test, the panel 100 is kept in the first environment between the first time and the second time.
- stable environment refers to the stable first environments of the test, from the first time to the second time.
- environment refers to properties of the environment, such as at least temperature, humidity, and acceleration, and optionally lightning and pressure.
- the panel 100 may be deformed, such as bent, in later stages of use.
- the surface layer - possibly being fragile - is joined to the support essentially in all locations.
- the adhesive 300 forms an adhesive layer 300 that completely covers the support layer 200. In this way each location of the surface layer 400 becomes bonded to the support layer 200 with the adhesive 300. In practice, the adhesive 300 needs not to completely cover the support layer 200. Referring to Figs. 2a-2c, in an embodiment
- the panel comprises a top surface, wherein the top surface has a surface normal parallel to the first direction and the surface layer comprises the top surface,
- the surface layer comprises a bottom surface of the surface layer that is opposite to the top surface
- the ratio Aa/As is at least 50 %.
- the ratio is at least 75 %, least 90 %, or least 95 %.
- the area As may equal the area Atop of the top surface 140.
- the adhesive comprises pressure sensitive adhesive.
- the pressure sensitive adhesive can be supplied in the form of a tape (e.g. on a carrier film, as will be discussed). In this case the tape may be applied only to some locations between the support layer 200 and the surface layer 400. In these cases, the ratio Aa/As may be much less than the values given above. The ratio Aa/As may be e.g. at least 10 %, or at least 25 %. However, the non-bonded areas increase the risk of fracturing the surface layer 400. Therefore, preferably the ratio is high, as discussed above.
- Pressure sensitive adhesive can be applied onto a surface of the surface layer 400 or onto a surface of the support layer 200 alternatively or in addition without a film. In this case, the adhesive may be e.g. sprayed onto a surface.
- the adhesive 300 comprises viscous adhesive. This has the technical effect that the viscous adhesive allows for the surface layer 400 to slide with respect to the support layer 200 when the temperature of the panel changes. This reduces the thermal stresses in the system.
- the viscosity of an adhesive depends on temperature and on shear rate. In this sense, a viscous adhesive has a viscosity of at most 1000 Pas for the shear rate 1/s at the temperature 20 °C.
- the adhesive 300 allows for deformations, i.e. is not very viscous.
- the viscosity of the adhesive 300 is at most 100 Pas and more preferably at most 30 Pas; both values for the shear rate 1/s at the temperature 20 °C.
- the viscosity of the adhesive 300 can also be tested.
- the test is relatively simple. Referring to Fig. 3a when heating the panel 100, the surface layer 400 and the support layer 200 tends to expand differently. If the adhesive layer is viscous, it allows for sliding of these layer with respect to each other. Therefore, a stair can be observed in the edge of a heated panel, when the panel 100 comprises viscous adhesive.
- Some common viscous adhesive comprise acrylate and/or polyacrylate. They may comprise acrylates and/or polyacrylates. Thus, in an embodiment, the adhesive comprises at least one of acrylate and polyacrylate. Other common viscous adhesives may comprise acrylic (or acrylics) and/or polyurethane (or polyurethanes).
- the adhesive 300 may be arranged on a carrier film 310.
- the carrier film 310 may also be referred to as a liner. In a corresponding embodiment
- the panel 100 further comprises a carrier film 310 having a first side and a second side,
- the adhesive 300 is arranged on a first side of the carrier film 310, and
- the melting point (temperature) of the carrier film 310 is higher than the melting point of the adhesive 300.
- the melting point of the carrier film 310 is higher than the melting point of one of the adhesives (300, 320).
- the ordering of the adhesive 300, 320 is arbitrary, whereby the adhesive 300 can be considered the one having the lower melting point.
- the carrier film comprises at least one of polypropylene, polyethylene, and polyethylene terephthalate. The adhesive 300 can be selected such that it bonds well to the surface layer 400.
- the carrier film 310 may be a multilayered structure. In an embodiment
- the carrier film 310 comprises a first carrier layer and a second carrier layer
- the adhesive 300 is arranged on a first side of the carrier film, on the first carrier layer of the carrier film, and
- the carrier film 310 may be solid or foam. Solid carrier films are typically thin, e.g. less than 1 mm. Foam-like carrier films may be thicker, e.g. less than 2 mm. In either case, preferably the thickness of the carrier film 310 is at most 1 mm. The thickness of the carrier film 310 may be e.g. from 40 ⁇ to 3 mm. Preferably the thickness of the carrier film is from 60 ⁇ to 100 ⁇ . In practice a solid film may be deeded for such a thin carrier film 310.
- the thickness of the adhesive 310, or the other adhesive 320 on the carrier film 310 is preferably from 25 ⁇ to 50 ⁇ . If a carrier film 310 is not used, and a pressure sensitive adhesive is used (e.g. sprayed), the thickness of the layer of the adhesive 300 may be e.g. from 10 ⁇ to 1 mm, preferably from 25 ⁇ to 0.5 mm; and more preferably from 30 ⁇ to 100 ⁇ .
- Viscous adhesives 300 are particularly suitable for use with support layers 200 that swell also because of other reasons than temperature. For example, if plywood is used as support layer 200, the support layer may swell because of moistening. Viscous adhesive 300 enables the independent swelling on the support layer 200 and the surface layer 400, as discussed for thermal expansion. The swelling is determined by a moisture swelling coefficient, and also by a moisture absorbance. The moisture absorbance of the materials can be characterized e.g. by saturated water content. This means the maximum water content absorbed by the material in a given environment. In an embodiment, the saturated water content of the support layer 200 is more than the saturated water content of the surface layer 400.
- the saturated water content of the support layer 200 exceeds the saturated water content of the surface layer 400 by at least 50 % (provided that the saturated water content of the surface layer 400 is not zero).
- the saturated water content may be measured in given relative humidity (RH), pressure and temperature.
- the saturated water content may be measured e.g. in 50 % RH, and NTP conditions (in NTP, i.e. normal temperature and pressure, temperature equals 20 °C and pressure equals 101 .325 kPa). More often the saturated water content is measured in 100 % RH, and NTP conditions.
- RH relative humidity
- NTP i.e. normal temperature and pressure
- the saturated water content is measured in 100 % RH, and NTP conditions.
- the saturated water content for the surface layer 400 and for the support layer 200 are measured in the same conditions.
- the saturated water content of the support layer is more than the saturated water content of the surface layer at 50% relative humidity and normal pressure and temperature. In an embodiment, the saturated water content of the support layer exceeds the saturated water content of the surface layer by at least 50%.
- the adhesive 300 may comprise material that hardens or dries, to attach the support layer 200 to the surface layer 400. In a preferred embodiment, the adhesive comprises material that hardens or dries at a temperature from 0 °C to 50 °C. More preferably, the adhesive comprises material that hardens or dries at a temperature from 10 °C to 30 °C. Thus, with such adhesive the surface 400 and support 200 layer can be bonded together at the described temperature range.
- Such an adhesive may comprise at least one of polyvinyl acetate, ethylene- vinyl acetate (hotmelt), polyurethanes, polyurethane hot-melts, polypyrroline hot melts, moisture curing polyurethanes, epoxies, polyesters, acrylates, phenolics, phenol-formaldehyde, urea-melamine, melamine formaldehyde, resorcinol glue, silicones.
- polyurethanes and silicones may harden due to the presence of moisture in wood.
- such an adhesive comprises polyurethane and/or acrylate.
- Such an adhesive may comprise polyurethanes and/or acrylates.
- the thickness of the adhesive layer is preferably relatively small. This, on one hand increases the mechanical performance and impact properties of the panel 100, and on the other hand reduces the overall weight of the panel 100 and increases the machinability of the panel. In an embodiment,
- the adhesive 300 has a thickness Ta in the first direction Sx (Fig. 1 a), and
- the thickness Ta of the adhesive is from 30 ⁇ to 5 mm.
- the thickness Ta of the adhesive is from 30 ⁇ to 1 mm. More preferably, the thickness Ta of the adhesive is from 30 ⁇ to 0.5 mm.
- Thick adhesive 300 may be applicable, is the adhesive 300 forms a mass (substance). Such a mass can be used to engineer the properties of the panel. Moreover, such mass can be peeled away from the first part 101 of the panel and/or the second part 102 of the panel to improve recyclability of the materials.
- the adhesive 300 and the carrier film in combination have a thickness Ta in the first direction Sx (Fig. 1 a), and
- the thickness Ta of the adhesive is in the aforementioned range.
- the adhesive 300 may be thin in comparison to the support layer 200, whereby in an embodiment,
- the adhesive 300 has a thickness Ta in the first direction Sx
- the support layer 200 has a thickness T1 in the first direction Sx, and
- the thickness Ta of the adhesive 300 is less than the thickness T1 of the support layer 200 (i.e. Ta ⁇ T1 ).
- the adhesive 300 may be thin in comparison to the surface layer 400, whereby in an embodiment,
- the adhesive 300 has a thickness Ta in the first direction Sx
- the surface layer 400 has a thickness T2 in the first direction Sx, and
- the thickness Ta of the adhesive 300 is less than the thickness T2 of the surface layer 400 (i.e. Ta ⁇ T2).
- the support layer 200 may comprise polymer to enable deforming of the panel 100.
- the adhesive 300 may comprise thermoplastic adhesive. In an embodiment
- thermoplastic material has a melting point of at most 200 °C.
- the adhesive may serve as the termosensitive area 500, as discussed in connection with Figs. 1 g 1 to 1 g3.
- the adhesive may serve as the termosensitive area 500, as discussed in connection with Figs. 1 g 1 to 1 g3.
- the polymer material of the support layer 200 has a first deflection temperature
- the adhesive 300 comprises thermoplastic material having a melting point (i.e. melting temperature), wherein
- the melting point of the adhesive 300 is lower than the deflection point of the support layer 200.
- the thermal expansion properties of the adhesive 300 may also be selected according the thermal expansion properties of the support layer 200.
- the thermal expansion properties of the adhesive 300 may also be selected according the thermal expansion properties of the support layer 200.
- the adhesive 300 has a coefficient of thermal expansion, and - the coefficient of thermal expansion of the adhesive 300 is greater than the second coefficient of thermal expansion.
- the coefficient of thermal expansion of the adhesive 300 is greater than the first coefficient of thermal expansion. These selections reduce the thermal stress in between the adhesive 300 and the support layer 200.
- the adhesive has a CTE of ka.
- the ratio ka/k1 is from 0.5 to 2, preferably from 0.75 to 1 .3, and more preferably from 0.9 to 1 .1 .
- the ratio ka/k2 is from 0.5 to 2, preferably from 0.75 to 1 .3, and more preferably from 0.9 to 1 .1 .
- the thermal expansion properties of the adhesive 300 may also be selected according the thermal expansion properties of the support layer 400.
- the thermal expansion properties of the support layer 400 may also be selected according the thermal expansion properties of the support layer 400.
- the adhesive 300 has a coefficient of thermal expansion
- the coefficient of thermal expansion of the adhesive 300 is less than the third coefficient of thermal expansion.
- the coefficient of thermal expansion of the adhesive 300 is less than the fourth coefficient of thermal expansion. These selections reduce the thermal stress in between the adhesive 300 and the surface layer 400.
- the adhesive has a CTE of ka.
- the ratio ka/k3 is from 0.5 to 2, preferably from 0.75 to 1 .3, and more preferably from 0.9 to 1 .1 .
- the ratio ka/k4 is from 0.5 to 2, preferably from 0.75 to 1 .3, and more preferably from 0.9 to 1 .1 .
- the coefficients of thermal expansion can be measured along the second direction Sy and the third direction Sz.
- the support layer 200 has the first coefficient of thermal expansion k1 in a direction d1 that is parallel to the length Lp or the width Wp of the panel.
- the first CTE k1 is greater than or equal to the second CTE k2, whereby either CTE can be parallel to length or width.
- Support materials that are specially suitable for a support material of the panel comprise thermoplastic or thermoset material that has a reasonably low deflection temperature, as discussed above. Moreover, the support material is preferably at least one of
- the first coefficient of thermal expansion is at most 60 ppm/K; such as at most 30 ppm/K; or at most 10 ppm/K.
- the support 200 may e.g. comprise plywood.
- the first coefficient of thermal expansion may be e.g. from 4 ppm/K to 8 ppm/K; such as from
- the support 200 may e.g. comprise a particle board.
- the first coefficient of thermal expansion may be e.g. from 50 ppm/K to
- the support 200 may e.g. comprise glass fibre reinforced polymer.
- the first coefficient of thermal expansion may be e.g. about 30 ppm/K.
- a polymer support may have a CTE of as low as 15 ppm/K.
- the unit of the CTE is an abbreviation of "parts per million per Kelvin".
- the unit equals e.g. ( ⁇ / ⁇ )/ ⁇ .
- the CTE e.g. k
- ⁇ _ a dimension L in a reference temperature TO
- T a temperature T
- ⁇ _ k* L ⁇ (T-T0)
- d the direction of measurement
- four CTEs and four directions characterize some properties of the panel 100.
- the coefficients of thermal expansion (CTE) depend on the temperature. Unless otherwise stated, all the values of the CTEs in this description are given at the temperature 25 °C.
- the support layer 200 may be isotropic or essentially isotropic. In such a panel 100
- the ratio of the first coefficient of thermal expansion k1 to the second coefficient of thermal expansion k2 is at most 1 .5; preferably at most 1 .2.
- the support layer 200 comprises
- the support layer 200 comprises
- thermoplastic polymer that has a melting temperature of at most 180 °C, at most 170 °C, or at most 160 °C, or at most 150 °C.
- the melting temperature of a thermoplastic polymer can also be referred to as a deflection temperature, as the thermoplastic polymer can easily be deflected at the melting temperature and above.
- the support layer 200 comprises thermoplastic polymer that has a melting temperature of at least 20 °C, preferably at least 60 °C.
- the melting point of the thermoplastic polymer of the support layer 200 should not be too low.
- the support layer 200 comprises
- the support layer 200 comprises
- the support layer 200 comprises - thermoset polymer that has a deflection temperature of at most 200 °C.
- the support layer 20 comprises
- thermoset polymer that has a deflection temperature of at most 180 °C, at most 170 °C, or at most 160 °C, or at most 150 °C.
- thermoset polymer can also be referred to as a glass transition temperature, as the thermoset polymer can reasonably easily be deflected at the glass transition temperature and above.
- the support layer 200 comprises
- thermoset polymer that has a deflection temperature of at least 80 °C.
- the support layer 200 comprises
- thermoset polymer that has a deflection temperature of at least 120 °C.
- the thickness of the support layer 200 is from 3 mm to 25 mm. In some of these embodiments the thickness of the support layer 200 is from 6 mm to 20 mm. In some embodiments, the thickness of the support layer is from 3 mm to 20 mm; preferably from 4 mm to 15 mm, and most preferably from 6 mm to 12 mm.
- thermoplastic polymer of the support layer may be selected from the group comprising at least one of polyurethane, acrylic, polyvinyl alcohol, polyolefin, lignin, polyethylene, polypropylene, ethylene-vinyl acetate, vinyl, polyester, a co-polymer comprising ethylenes and propylenes, and mixtures of any two or more of them.
- the support layer 200 preferably comprises
- thermoplastic polymer in addition to thermoplastic polymer, additional material.
- the additional material is thermally stable in the melting temperature of the thermoplastic polymer.
- the melting point of the additional material is preferably more than the melting point of the thermoplastic material .
- the additional material does not have a well- defined melting point, i.e. the additional material does not melt. This could happen e.g. for ceramic particles, which are heat resistant to very high temperatures and e.g. for some polymers not having a melting point (decomposes before melting).
- the additional material may take the shape of curvilinear areas, planes, or fibres, whereby the additional material is "long" in at least one direction.
- curvilinear area refers to a material that could have been planar, but has been from pressed to a curvilinear shape. This has the effect the additional material mechanically supports the surface layer 400 during bending.
- the support layer 200 has a thickness T2 in the first direction
- - support layer 200 comprises pieces of additional material wherein
- the pieces of the additional material has the shape of at least one of curvilinear areas, planes, and fibres, wherein
- a piece of the additional material has a dimension in a direction that is in the tangent plane of the panel, such that
- the dimension of the piece of the additional material is greater than the thickness T2 of the support layer 200.
- a piece of the additional material has a dimension in a direction that is perpendicular to the first direction Sx, such that
- the dimension of the piece of the additional material is greater than half of the smaller of the length of the panel Lp and the width of the panel Wp.
- Fibres may be e.g. natural fibres.
- the fibres may be bonded together.
- the additional material comprises material that comprises natural fibres.
- the additional material comprises wood.
- a preferred embodiment of the support layer 200 comprises plywood that comprises thermoplastic adhesive.
- thermoplastic adhesive may serve as the thermosensitive area 500.
- a plywood panel can be bent, when the thermoplastic material in between the wooden layer is melt.
- the thermoplastic material is solidified, the plywood panel is stiff.
- the price of plywood is much less than that of a typical surface layer 400.
- the density of plywood is much less than that of a typical surface layer 400.
- the strength of plywood is much more than that of a typical surface layer 400.
- a support layer 200 may comprise plywood made of hardwood.
- Hardwood is wood from angiosperm trees or from monocotyledons. Hardwood contrasts with softwood (which comes from gymnosperm trees, also called conifers).
- the list of angiosperm trees (some hardwood) is wide, and includes e.g. alder, apple, aspen, birch, cherry, ebony, elm, eucalyptus, hickory, mahogany, maple, oak, rosewood, teak, walnut, and willow.
- the wood of the support layer 200 may comprise birch.
- Monocotyledons are of less importance in plywood industry.
- the density of a support layer 200 that comprises plywood comprising hardwood is from 500 kg/m 3 to 800 kg/m 3 .
- a support layer 200 may comprise plywood comprising softwood.
- the list of softwood include cedar, the genus tilia (e.g. linden, lime or basswood), pine (or generally the genus pinus), and spruce (or generally the genus picea).
- the wood of the support layer 200 may comprise spruce.
- the density of a support layer 200 that comprises plywood comprising softwood is from 300 kg/m 3 to 600 kg/m 3 .
- a plywood support comprising hardwood may be beneficial, since such a support is light, as compared to plywood comprising hardwood, and having the same thickness.
- a plywood support comprising hardwood may be beneficial, since such a support is stronger, as compared to plywood comprising softwood, and having the same thickness.
- the adhesive in between wooden veneer layers of plywood may be thermoset or thermoplastic.
- the support layer 200 comprises - at least a first wooden veneer layer and a second wooden veneer layer, and
- the term "at least part" here refers e.g. to a curvilinear panel such as the curvilinear panel of Fig. 7a.
- the adhesive in between wooden veneer layers of plywood comprise thermoplastic polymer.
- the support layer 200 comprises
- thermoplastic polymer in between the first wooden veneer layer and the second wooden veneer layer, wherein
- the support layer 200 comprises at least three wooden veneer layers. This helps the bendability of the panel 100.
- the support layer 200 has a symmetric structure. In a symmetric structure, a plane parallel to the bottom surface 130 (cf. Fig. 1 a) forms a symmetry plane for the support layer. In such a case, the symmetric structure gives rise to isotropy of the support layer 200. Isotropy may be beneficial for thermal expansion and dimensional stability.
- the support layer 200 could be substantially symmetric, wherein the term "substantially symmetric" refers to a support layer 200 that is formed from a symmetric structure by removing material and/or bending.
- the support layer 200 comprises symmetrical veneer structure in cross direction of the support layer.
- the support layer 200 may comprise an odd number of wooden veneer layers. This improves the isotropy of the support layer 200.
- the thickness of a wooden veneer layer is from 0.5 mm to 5 mm.
- the support layer 200 comprises natural fibre composite that comprises lignocellulosic fibers, plant fibers or wood fibers and thermoplastic adhesive comprising chemical groups capable to form covalent bonds between the adhesive and fibers.
- these chemical groups are anhydrides.
- Particle board is a composite material. It is an engineered wood product manufactured from wood chips, sawmill shavings, or even saw dust, and a synthetic resin or other suitable binder. The board may be pressed and/or extruded. In particle boards the wood chips do not form supporting layers. Therefore, the binder is preferably thermoset. However, the binder may comprise thermoplastic, or even consist of thermoplastic. In the latter case, the amount of material pressed out during form pressing depends on the applied pressure.
- a particle board may have the CTE as high as 60 ppm/K. The CTE of the particle board may be e.g.
- the properties of the particle board depend on the amount and type of the binder and the material comprising wood.
- the density of a particle board may vary from 250 kg/m 3 to 1300 kg/m 3 .
- Particle boards are typically classified as low density particle boards (density from 250 kg/m 3 to 450 kg/m 3 ), medium density particle boards (density from 550 kg/m 3 to 700 kg/m 3 ), and high density particle boards (density from 750 kg/m 3 to 1300 kg/m 3 ).
- the density is from 650 kg/m 3 to 750 kg/m 3 .
- a particle board is used as the support layer 200, preferably a low density particle board or a medium density particle board is used.
- the density may be e.g. from 400 kg/m 3 to 800 kg/m 3 .
- the additional material of the support layer 200 may comprise fibres.
- the additional material of the support layer may comprise synthetic organic or inorganic fibres.
- the additional material comprises woven or non-woven fibrous material such as at least one of carbon fibres, glass fibres, aramid fibres, polypropylene fibres, polyamide fibres (Nylon), and polyurethane fibres.
- the fibres may be arranged unidirectionally or in multiple directions.
- the fibrous material may form a woven structure, such as cloth, textile, or mat (e.g. glass fibre mat).
- the length of the fibre is at least ten times a width of the fibre.
- the support layer is reasonably light. Therefore, in an embodiment, - the density of the support layer 200 is at most 1600 kg/m 3 .
- the density of the support layer may be e.g. from 300 kg/m 3 to 1400 kg/m 3 .
- Typical values for plywood comprising hardwood or softwood were given above.
- the higher values i.e. from 800 kg/m 3 to 1400 kg/m 3
- the coefficients of thermal expansion can be measured along the second direction Sy and the third direction Sz.
- the surface layer 400 has the third CTE k3 in a direction d3 that is parallel to the length Lp or the width Wp of the panel 100.
- the third CTE k1 is greater than or equal to the fourth CTE k4, whereby either CTE can be parallel to length or width.
- the surface layer 400 has the third coefficient of thermal expansion k3 in a direction d3 that is parallel to the length Lp or the width Wp of the panel 100.
- the surface layer typically has a high CTE. Therefore, in an embodiment the third coefficient of thermal expansion k3 is at least 20 ppm/K; or at least 25 ppm/K; and it may also be at least 30 ppm/K. In addition to the third CTE, also the fourth CTE may be reasonably large. In an embodiment, the fourth coefficient of thermal expansion is at least 10 ppm/K, or at least 12 ppm/K. It may also be at least 15 ppm/K, or at least 20 ppm/K.
- the surface layer 400 may also be isotropic or substantially isotropic.
- the ratio of the third coefficient of thermal expansion k3 to the fourth coefficient of thermal expansion k4 (k3/k4) is at most 1 .5; preferably at most 1 .2.
- the ratio of the third coefficient of thermal expansion k3 (of the surface layer 400) to the first coefficient of thermal expansion k1 , i.e. k3/k1 is at least 1 .5, preferably at least 2, more preferably at least 3.
- the first CTE may be greater than the third CTE.
- the difference between the third coefficient of thermal expansion k3 (of the surface layer 400) and the first coefficient of thermal expansion k1 , i.e. k3 - k1 , is at least 10 ppm/K, at least 15 ppm/K, or at least 20 ppm/K.
- the difference between the first coefficient of thermal expansion k1 (of the support layer 200) and the third coefficient of thermal expansion k3, i.e. k1 - k3, is at least 10 ppm/K, at least 15 ppm/K, or at least 20 ppm/K
- the brittleness, i.e. fragility, of the panel can be characterized e.g. by impact resistance or by tensile strain at break, often referred to as elongation at break.
- elongation commonly refers to absolute measures such as mm
- strain commonly refers to relative measures such as %.
- unit of "elongation at break” is commonly proportional, i.e. %.
- elongation refers to tensile deformation.
- tensile strain at break is preferred in this application.
- the surface layer 400 can be brittle as such, i.e. when separated from the adhesive 300 and the support layer 200.
- the second part 102 of the panel 100 after the division of the panel 100, can be brittle.
- the surface of the panel 100 that comprises the surface layer 400 can be brittle.
- the panel 100 is brittle in such a way that the impact resistance of the surface layer 400, when the surface layer 400 has been separated from the adhesive 300 and the support layer 200, is at most 200 cm, wherein
- the impact resistance is defined as in the standard DIN ISO 4586.
- the impact resistance is at most 150 cm, at most 120 cm, or at most 100 cm.
- the panel 100 can be divided to the first part 101 and the second part 102 such that the second part 102 comprises the surface layer 400,
- the panel 100 is brittle in such a way that the impact resistance of the second part 102, when separated from the panel 100 such that the second part 102 comprises the surface layer 400,
- the impact resistance is defined as in the standard DIN ISO 4586.
- the impact resistance is at most 150 cm, at most 120 cm, or at most 100 cm.
- the panel 100 is brittle in such a way that the impact resistance of the surface of the panel that comprises the surface layer 400, is at most 200 cm, wherein
- the impact resistance is defined as in the standard DIN ISO 4586.
- the impact resistance is at most 150 cm, at most 120 cm, or at most 100 cm.
- the panel 100 is brittle in such a way that the impact resistance of the surface layer 400, when the surface layer 400 has been separated from the adhesive 300 and the support layer 200, is less than the impact resistance of the support layer 200, when the support layer 200 has been separated from the adhesive 300 and the surface layer 400.
- the panel 100 is brittle in such a way that the impact resistance (according to the drop test DIN ISO 4586) of the surface of the panel that comprises the surface layer 400, is less than the impact resistance of the surface of the panel that comprises the support layer 200.
- the surface layer 400 is more brittle than the support layer 400.
- a panel 100 can be separated to a first part 101 and a second part 102, wherein the second part 102 comprises the surface layer 400.
- the second part 102 comprises the surface layer 400, and the second part 102 (when separated from the panel) is more brittle than the first part 101 (when separated from the panel).
- the feature "more brittle” the impact resistance or the tensile strain at break can be used.
- the panel 100 can be divided to the first part 101 and the second part 102 such that the second part 102 comprises the surface layer 400,
- the second part 102 of the panel after being separated from the panel 100 comprises the surface layer 400 and has a second impact resistance (according to the drop test DIN ISO 4586), and
- a panel 100 can be separated to a first part 101 and a second part 102, wherein the second part 102 comprises the surface layer 400.
- the second part 102 comprises the surface layer 400.
- the panel 100 can be divided to the first part 101 and the second part 102 such that the second part 102 comprises the surface layer 400,
- the second part 102 of the panel after being separated from the panel 100 comprises the surface layer 400 and has a second tensile strain at break
- the second tensile strain at break is less than the first tensile strain at break.
- the tensile strain at break of the surface layer 400 is less than the tensile strain at break of the support layer 200.
- a panel 100 may fracture first on the side of the surface layer 400.
- the panel 100 is brittle is such a way that the tensile strain at break of the surface layer 400, when surface layer 400 has been separated from the adhesive 300 and the support layer 200, is e.g. at most 1 %, or less than 5 %, at the temperature 25 °C.
- the tensile strain at break may depend on the temperature.
- the panel 100 is brittle is such a way that the tensile strain at break of the surface layer 400, is at most 8 % at the temperature 25 °C, or less than 5 % at the temperature 25 °C.
- the surface layer 400 comprises polymer.
- the surface layer 400 further comprises filler material.
- Filler materials be used to engineer e.g. wear resistance, electrical conductance (related to antistatic properties and EMC protection), resistance to electric discharge, thermal resistance, fire resistance, color, opaqueness, resistance to radiation (e.g. UV radiation), acoustic impedance, and hardness; or to bring some functionality to the surface layer, such as self-cleaning, easy-cleaning, change of color with temperature (thermochromism).
- the properties can be engineered in either direction, such as increasing or decreasing the thermal conductance, or increasing or decreasing the wavelength that the surface layer emits, reflects, or absorbs, depending on the application.
- Some filler materials can be used to reduce cost; e.g. when the filler material is cheap.
- the polymer thus forms a polymer matrix for the filler material.
- the filler material comprises particles or the filler material comprises fibres.
- the polymer of the surface layer 400 comprises thermoset polymer.
- the polymer comprises at least one of acrylate, polyester, and epoxy.
- the polymer comprises thermoset polymer having the deflection temperature (e.g. the glass transition) temperature less than 170 °C or less than 160 °C.
- the deflection temperature of the surface layer may also be related to the deflection temperature (e.g. the melting point) of the thermoplastic polymer of the support layer.
- the support layer 200 comprises polymer
- the polymer of the support layer 200 has a deflection temperature Tm
- thermoset polymer having a glass transition temperature Tg, wherein
- the glass transition temperature Tg is at most the deflection temperature Tm, i.e. Tg ⁇ Tm.
- the surface layer 400 becomes deformable at a temperature, wherein the support layer 200 is also deformable.
- the heating energy needed is optimized.
- the temperature of the panel 100 during form pressing (Figs. 6a and 6b) is not excessively above the deflection temperature of the support layer 200.
- the temperature of the panel 100 during form pressing may exceed the deflection temperature of the support layer 200 by e.g. at least 10 °C, at least 20 °C, at least 30 °C, at least 40 °C, or at least 50 °C.
- the temperature of the panel 100 during form pressing may exceed the deflection temperature of the support layer 200 by e.g. at most 20 °C, at most 30 °C, at most 40 °C, at most 50 °C, or at most 60 °C.
- the polymer of the surface layer 400 comprises thermoplastic polymer.
- the polymer of the surface layer 400 comprises at least one of polyurethane, acrylonitrile butadiene styrene (ABS), acrylic (e.g. poly(methyl methacrylate), PMMA), fluoroplastic or fluoropolymer (e.g. polytetrafluoroethylene, PTFE), polyoxymethylene, polycarbonate, polyetheretherketone, cellulose acetate, polystyrene, polyamide-imide, polyphenylene, polyvinyl alcohol, polyolefin, lignin, polyethylene, polypropylene, and a co-polymer comprising ethylenes and propylenes.
- the surface layer may comprise multiple components of same type of material, such as polyurethanes and/or fluoroplymers.
- the polymer of the surface layer 400 affects the CTE of the surface layer 400.
- CTEs for some of the aforementioned materials include 200 ppm/K for polyethylene, from 100 ppm/K to 200 ppm/K to polypropylene, and 75 ppm/K for ABS.
- filler material may decrease the CTE.
- the polymer of the surface layer 400 has a deflection temperature of at most 200 °C, preferably at most 170 °C. In an embodiment, the polymer of the surface layer 400 has a deflection temperature of at least 80 °C, preferably at least 90 °C.
- the polymer of the surface layer 400 comprises thermoplastic polymer having the melting temperature of at most 200 °C, preferably at most 170 °C. In an embodiment, the polymer of the surface layer 400 comprises thermoplastic polymer having the melting temperature of at least 80 °C, preferably at least 90 °C.
- the polymer of the surface layer 400 comprises thermoset polymer having the glass transition temperature of at most 200 °C, preferably at most 170 °C. In an embodiment, the polymer of the surface layer 400 comprises thermoset polymer having the glass transition temperature of at least 80 °C, preferably at least 90 °C.
- the polymers are selected such that the polymer of the surface layer 400 remains reasonably rigid, even at a temperature, wherein the support layer 200 is deformable. In this way it is assured that the filler particles remain in their polymer matrix also during the deformation.
- the polymers are selected such that the polymer of the surface layer 400 remains reasonably rigid, even at a temperature, wherein the support layer 200 is deformable. In this way it is assured that the filler particles remain in their polymer matrix also during the deformation.
- thermo polymer of the support layer 200 has a first deflection temperature Tm1 .
- the surface layer 400 comprises thermoplastic polymer having a melting temperature Tm2, wherein
- the melting temperature Tm2 is higher than the deflection temperature Tm1 , i.e. Tm2>Tm1 .
- the surface layer 400 may be e.g. a polymer layer, a composite layer (i.e. polymer with filler material), or a laminate structure (i.e. layered structure).
- a layer of the laminate may be a reinforcing layer.
- the reinforcing layer may comprise fibrous material.
- the reinforcing layer may comprise synthetic fibrous material. These fibrous materials were discussed also in connection with the support layer 200.
- the filler material has the form of filler particles.
- the surface layer 400 comprises filler particles.
- thermoset and thermoplastic polymer in the surface layer were discussed. To summarize, in some embodiments,
- the support layer 200 comprises thermo polymer having a deflection temperature Tm1 .
- the polymer of the surface layer 400 comprises at least one of
- thermoset polymer having a glass transition temperature Tg that is less than the deflection temperature Tm1 , (i.e. Tg ⁇ Tm1 ) and
- thermoplastic polymer having a second melting temperature Tm2 that is greater than the deflection temperature Tm1 (i.e. Tm2>Tm1 ).
- the support layer 200 comprises polymer having a first deflection temperature
- the surface layer 400 comprises polymer having a second deflection temperature, wherein
- the second deflection temperature is less than the first deflection temperature.
- thermoplastic polymer of the surface layer does preferably not melt in the form press process.
- the support layer 200 comprises polymer having a deflection temperature
- the surface layer 400 comprises thermoplastic polymer having a melting temperature, wherein
- the melting temperature is higher than the deflection temperature.
- the surface layer 400 comprises surface polymer material and filler material, - the surface polymer material consist of a thermoplastic polymer or thermoplastic polymers,
- thermoplastic polymer has a melting temperature, which simultaneously is the highest melting temperature; or the multiple thermoplastic polymers have melting temperatures of which one is the highest melting temperature, - the support layer 200 comprises polymer having a deflection temperature, wherein
- the highest melting temperature is higher than the deflection temperature.
- the surface layer when the highest melting temperature is higher than the deflection temperature, the surface layer comprises thermoplastic polymer having higher melting temperature than the deflection temperature of the support layer 200.
- the surface layer 400 may comprise both thermoplastic and thermoset polymer, in which case the melting temperature of the thermoplastic polymer(s) of the surface layer may be less than the deflection point of the support layer 200.
- the surface layer 400 comprises hard filler particles, such as particles comprising rock, clay, brick, ceramic, titanium oxide ( ⁇ 2), alumina (AI2O3), and/or aluminium hydroxide (AI(OH) 3 ).
- the hardness of the material of such filler particles can be can be characterized by the Mohs scale of hardness.
- the material of the hard filler particles have the hardness of a least 2.5 on the Mohs scale of hardness.
- Such particles can be especially used in a matrix material comprising thermoset polymer. Particles can be treated with coupling agent(s), so that they are made compatible with the matrix or they can be bonded to the matrix by chemical bonds.
- Such a surface layer may be referred to as a "solid surface", the CTE of such a solid surface may be e.g. from 25 ppm/K to 35 ppm/K, e.g. 30 ppm/K.
- Such filler particles are typically heavy, and may have a small coefficient of thermal expansion.
- the coefficient of thermal expansion of the filler particles of the surface layer 400 is less than the coefficient of thermal expansion of the polymer of the surface layer 400.
- the density of the filler particles of the surface layer is at least 1800 kg/m 3 .
- Such particles have been observed to be resistant to wear.
- the surface layer comprises at least 50 m-%, preferably at least 65 m-%, and more preferably at least 80 m-% filler particles.
- m-% refers to mass percentage, sometimes called weight percent.
- Such a large filler material content may increase the density of the surface layer.
- the density of the surface layer is may be e.g. from 1400 kg/m 3 to 1900 kg/m 3 .
- the density of the surface layer is from 1600 kg/m 3 to 1800 kg/m 3 .
- the filler particles may - in addition or alternatively - have a fibrous inner structure.
- the surface layer 400 comprises filler particles (as the filler material), the filler particles comprising multiple smaller fibres, such as natural fibres.
- the surface layer 400 comprises particles in the form of natural cellulose fibres. Such particles can be especially used in a thermoplastic polymer matrix material.
- the natural cellulose fibres refer to organic natural fiber material that contain cellulose.
- the organic natural fiber material may originate from any plant material that contains cellulose.
- the natural cellulose fibres may comprise wood-based cellulose pulp fibers.
- the organic natural fiber material may comprise mechanically treated and/or chemically treated fibers and/or fiber-like particles.
- the treated particles used may comprise at least 30 m-% or at least 40 m-%, more preferably at least 50 m-% or at least 60 m-%, and most preferably at least 80 m-% or at least 90 m-% of mechanically treated organic natural fiber material.
- Mechanically treated may refer to organic natural fiber material, which is isolated from any organic natural raw material comprising cellulose by a mechanical pulping process. However, mechanical processing does not significantly reduce the amount of lignin in the raw material.
- Organic natural fibre material comprising lignin is prone to decompose (burn) more easily in high temperatures than fiber material free of lignin.
- chemically treated organic natural fiber material typically comprise less lignin.
- the chemically treated organic natural fibre material preferably comprises chemical pulp.
- the chemical pulp may be, for example, from kraft process or sulfite process, but also other chemical processes may be used, such as a soda pulping process.
- the chemical pulp is from the kraft process.
- lignin content of the chemically treated pulp is under 15 m-%, preferably under 10 m-% or under 5 m-%, more preferably under 3 m-%, under 2 m-% or under 1 m-% and most preferably under 0.5 m-%.
- the alfa cellulose content of the chemically treated pulp is above 50 m-%, preferably above 60 m-%, more preferably above 70 m-% and most preferably above 72 m-% or above 75 m-%.
- the alfa cellulose content of the chemically treated pulp is below 99 m-%, preferable below 90 m-%, more preferably below 85 m-% and most preferably below 80 m-%.
- the surface layer 400 comprises at least 20 m-% filler particles. Preferably the surface layer 400 comprises at least 25 m-%, and more preferably at least 30 m-% filler particles. The surface layer 400 may comprise at least 40 m-% or at least 50 m-% filler particles. Such a large filler material content may increase the density of the surface layer. Depending on the amount of natural cellulose fibres, the density of the surface layer may be e.g. from 900 kg/m 3 to 1200 kg/m 3 . In an embodiment, wherein the surface layer 400 comprises natural cellulose fibres, the density of the surface layer is from 970 kg/m 3 to 1 120 kg/m 3 .
- the lignin content of the surface layer 400 is low.
- the lignin content of the surface layer 400 may be e.g. at most 7.5 m-% (50 m-% filler particles, wherein the lignin content is at most 15 m- %).
- Some other limits calculated from the values above include a ligning content for the surface layer 400 of at most 6 m-%, at most 5 m-%, at most 4 m-%, at most 2 m-%, and at most 1 m-%. Also other value can be calculated, e.g. at most 0.2 m-%.
- the density of the surface layer 400 is greater than the density of the support layer 200. Regardless of the type of the filler particles are generally small . Small e.g. in comparison to the thickness of the surface layer. This ensures the possibility of a smooth surface. Such a smooth surface is easy to clean and also visually attractive. In an embodiment,
- the surface layer 400 comprises filler particles, wherein the each filler particle has three dimensions, and
- the filler particles have a particle size Dp that is the smallest value of the three dimensions
- the surface layer 400 has a thickness T2 in the first direction Sx, wherein
- the surface layer 400 comprises a multitude of filler particles, whereby the particle size Dp is a statistical measure of the filler particle size.
- the "filler particle size Dp" may refer e.g. to a statistical measure of the smallest dimension of the particles. The statistical measure may be e.g. the average or the median.
- particles can also be characterized by a size different from the smallest of its three dimensions. For example, the (linear) size of the particle can be taken as a diameter of a sphere having the same volume as the particle. Moreover, the median of the three dimension could be used a particle size, in particular, if a sieve is used to determine the particle size.
- an absolute values for the size in an embodiment,
- the surface layer 400 comprises filler particles
- the filler particles have three orthogonal dimensions (i.e. sized measured in different directions),
- the smallest of the three orthogonal sizes is at most 1 mm, preferably at most 100 ⁇ . In some embodiments, for at least 75 % of the filler particles, the smallest of the three orthogonal sizes is at most 50 ⁇ . Instead of the 75 % percentile, the median or the average value can be determined by measurements. In the corresponding embodiments,
- the smallest of the three orthogonal sizes is at most 1 mm, preferably at most 100 ⁇ or at most 50 ⁇ ;
- the average of the smallest of the three orthogonal sizes of the particles sizes is at most 1 mm, preferably at most 100 ⁇ or at most 50 ⁇ .
- the material cost of the surface layer 400 may be reasonably high. Moreover, the density of the surface layer can be high. To ensure a cost-effective and light panel, the surface layer 400 is preferably thin. In an embodiment, the thickness of the surface layer 400 is at most 15 mm, preferably at most 9 mm, and more preferably at most 6 mm. In some embodiments, the thickness of the surface layer 400 is at least 3 mm, or at least 4 mm. In addition or alternatively, in an embodiment, the thickness of the surface layer 400 is less than the thickness of the support layer 200. Preferable shapes of the panel
- panels are preferably stored in piles. Piles are easy to form when the panels 100 of the pile are planar or essentially planar at an operation temperature.
- the operation temperature may be e.g. from 0 °C to 50 °C, such as from 10 °C to 30 °C, such as 25 °C. Therefore, in an embodiment,
- the panel 100 has multiple non-meandering lines in a top surface 140 (cf. Figs. 1 a and 1 b) facing away from the support layer 200, and
- a radius of curvature is - by definition - well defined only for a line.
- a "radius of curvature of a non-meandering line of a surface” here refers to the radius of curvature of the line that belongs to the surface, and that is as straight as possible, i.e. non-meandering.
- a non-meandering line between a first point and a second point of the top surface 140 is the shortest line along the top surface 140 from the first point to the second point.
- the non- meandering line does not meander in the surface, but may curvilinear with the surface.
- the a "non-meandering line of a surface” and the “radius of curvature” are, in combination, defined such that the center of the osculating circle for the definition of the radius of curvature is located a distance apart from the top surface normal; possibly in a the direction of a surface normal of the tangent plane of the surface.
- a panel 100 can be form pressed to a curvilinear shape.
- Fig. 6a shows, in a side view, a panel 100.
- the support layer 200 comprises thermoplastic material.
- the thermoplastic material melts. This melting enables the formation of the panel.
- the panel can be heated before it is bent in a device, or a bending device can heat the panel 100 before bending.
- the panel 100 can be form pressed to a desired shape.
- the from pressing can be done in an apparatus for form pressing 500.
- the apparatus comprises a first surface 512 and a second surface 522.
- the first surface 512 may be the surface of a first body 510.
- the second surface 522 may be the surface of a second body 520.
- the surfaces 512, 522 are arranged to be movable towards each other. Thus, by inserting a panel in between these surfaces, and by moving the surfaces towards each other, the panel 100 becomes form pressed (i.e. bent).
- the apparatus for form pressing 500 may comprise a cooler arranged to cool the panel 100.
- the panel 100 may cool in between the surfaces 512, 522 by thermal conduction to these surfaces and/or the bodies 510, 520.
- the thermoplastic material solidifies. In this way, the panel 100 re-gains its rigidity.
- the panel is straight or substantially straight in at least one direction. In such a case, the top surface 140 of the panel 100 is easy to clean and guides liquids. Therefore, in an embodiment,
- the panel 100 has multiple non-meandering lines in a top surface 140 facing away from the support layer 200, and
- the radius of curvature of a non-meandering line is at least 5 m.
- the radius of curvature of at least one non-meandering line is large.
- the radius of curvature of all parallel non-meandering lines may be large.
- the panel 100 shows therein is straight in one direction, i.e. the third direction Sz, as shown in particular in Fig. 7c2. Therefore, the top surface 140 comprises a non-meandering line that has an essentially infinite radius of curvature. This non meandering line of the top surface 140 is parallel to the third direction Sz.
- An osculating surface if imagined on the surface 140 of the panel of Fig. 7c2, would have a large, possibly infinite, radius of curvature.
- the whole panel may be curved.
- the panel 100 may have the shape of an U -profile.
- Such an U -profile is bent only in a central area.
- a panel may be bent at a boundary area.
- - comprises a top surface 140 facing away from the support layer 200, - the top surface 140 has a first non-meandering line, and
- the radius of curvature of the first non-meandering line at most 2.2 m; preferably at most 1 .5 m or at most 1 m.
- the panel 100 may take the shape of a tube.
- the panel may have the shape of a half of a tube. In these shapes, the whole panel has been bent. Thus, also a boundary of the panel has been bent.
- Figures 7c1 , 7c2, and 7d show other embodiment, wherein the panel 100 has been form pressed such that the panel 100 is bent at least in a boundary area.
- the panel 100 comprises a top surface 140 facing away from the support layer 200,
- the top surface 140 comprises a boundary area 142
- the boundary area 142 has a first non-meandering line
- the radius of curvature of the first non-meandering line at most 2.2 m; preferably at most 1 .5 m or at most 1 m.
- the boundary area may also be more curved, whereby the radius of curvature of the first non-meandering line may be at most 50 cm, at most 25 cm, or at most 10 cm.
- the first non-meandering line may be selected such that the projection of the first non-meandering line to a plane having the surface normal parallel to the first direction Sx is perpendicular to the direction of the length Lp or the direction of the width Wp of the panel 100.
- the direction of the projection may also be parallel to a direction that has been the direction of the width Wp or the length Lp of the essentially planar panel 100 before bending. For example, and referring to Fig.
- the first non-meandering line may have been straight in the second direction Sy, but after bending the panel 100, this non-meandering line no longer is straight. However, its projection to the plane having the surface normal Sx still is directed in the second direction Sy.
- the panel 100 shows therein is curvilinear at the boundary area 142 and substantially straight at the center area 144.
- the boundary area 142 comprises a first non-meandering line selected such that the projection of the first non-meandering line to a plane having the surface normal parallel to the first direction Sx is perpendicular to the third direction Sz (i.e. to length Lp; cf. Fig. 1 b).
- This non-meandering line has the radius of curvature R1 , as depicted in figure 7c1 .
- boundary area refers to a set of points of the surface, wherein the distance of the point from the boundary of the surface is reasonably small . For example, a point r is in the boundary area, if
- This definition divides the panel, in the direction of length Lp, to three equally long areas, wherein two of the area are boundary areas.
- This definition divides the panel, in the direction of width Wp, to three equally wide areas, wherein two of the area are boundary areas.
- the ratio, D2/D1 ⁇ 3, defines a relatively wide boundary area.
- Other definitions, such as D2/D1 ⁇ 5, or D2/D1 ⁇ 10 are also possible. Different ratios can be applied in the direction of length Lp and the direction of width Wp.
- a central area is then just the part what is left over.
- central area is defined such that the top surface consist of a central area and boundary areas as defined above.
- the central area 144 is planar or substantially planar.
- the central area 144 is planar or substantially planar.
- the panel 100 comprises a top surface 140 facing away from the support layer, and
- the top surface 140 comprises a central area 144 (as defined above; cf. Fig. 7c1 ),
- the central area 144 has multiple non-meandering lines
- the radius of curvature of all non-meandering lines of the central area 144 is at least 5 m.
- the central area 144 is also curvilinear. However, preferably the central area 144 is concave, while the boundary area 142 is convex. This particularly beneficial, since in this embodiment, liquid is collected in the central area 144 by the fact it being concave. The liquid can be guided to a direction, provided that the panel 100 is slightly turned from horizontal. Moreover, it has been noticed that such a panel is relatively simple to manufacture using a (planar) panel as described. Such a panel may be manufactured by form pressing as discussed above. Moreover, since the CTE of the surface layer 400 is larger than the CTE of the support layer 200, cooling the panel 100 after from pressing may curve the panel 100.
- the central area may be curved due to manufacturing process.
- a planar panel having the material properties as discussed above may be relatively easily be bent to such a complex shape.
- the panel 100 comprises a first side and an opposite second side
- the panel 100 comprises a top surface 140 facing away from the support layer 200,
- the top surface 140 comprises a boundary area 142, - the boundary area 142 has a first non-meandering line,
- the radius of curvature R1 of the first non-meandering line at most 2.2 m; preferably at most 1 .5 m or at most 1 m, wherein
- the center of the osculating circle 151 for the radius of curvature R1 of the first non-meandering line is arranged on a first side of the panel
- the top surface 140 comprises a central area 144
- the central area 144 has second non-meandering line
- the second non-meandering line has a (non-infinite) radius of curvature R2,
- the center of the osculating circle 152 for the radius of curvature R2 of the second non-meandering line is arranged on a second side of the panel.
- the first non-meandering line may be selected such that the projection of the first non-meandering line to a plane having the surface normal parallel to the first direction Sx is perpendicular to direction of the length Lp or direction of the width Wp of the panel 100.
- the projection of the first non-meandering line to a plane having the surface normal parallel to the first direction Sx is perpendicular to the third direction Sz (i.e. the direction of length Lp).
- the first non-meandering line has been straight in the second direction Sy, but after bending the panel 100, this non-meandering line no longer is straight. However, its projection to the plane having the surface normal Sx still is directed in the second direction.
- the projection of the second non-meandering line to a plane having the surface normal parallel to the first direction Sx may be selected parallel to the projection of the first non-meandering line to a plane having the surface normal parallel to the first direction Sx.
- the projection of the second non-meandering line to a plane having the surface normal parallel to the first direction Sx selected parallel to the projection of the first non-meandering line to a plane having the surface normal parallel to the first direction Sx (i.e. parallel to the second direction Sy).
- the radius of curvature of the second non-meandering line is more than the radius of curvature of the first non-meandering line.
- the radius of curvature of the second non-meandering is less than 5 m, preferably less than 2.2 m, 1 .5 m, or 1 m.
- line is more than the radius of curvature of the first non-meandering line is less than 2.2 m, preferably less than 1 .5 m, less than 1 m, or less than 50 cm.
- the central area 144 of the top surface 140 of the panel, wherein the top surface 140 is comprised by the surface layer 400 is preferably concave. This ensures that the central area can collect liquids.
- the support layer 200 is arranged on the first side of the panel 100 (i.e. on the first side, wherein also the center of the first osculating circle 151 is arranged) and
- the surface layer 400 is arranged on the second side of the panel 100 (i.e. on the second side, wherein also the center of the second osculating circle
- a panel 100 can be bent such that is curvilinear to two different directions.
- Figure 8 shows a panel having the shape of a hemisphere or half of an egg, depending on the coordinate axes.
- the thickness Tp (Fig. 1 a) of the panel is from 6 mm to 50 mm. Typical examples of thicknesses comprise 7 mm, 9 mm, 10 mm, 15 mm, and 20 mm.
- a panel 100 can be used to manufacture furniture.
- a piece of furniture comprises a panel 100 as disclosed above.
- the piece of furniture may be a table.
- a table comprises a panel 100 as disclosed above.
- the table may be a kitchen table, i.e. a table for kitchen.
- Such a table for use in a kitchen comprises a panel 100 as disclosed above.
- the panel 100 may be used for a working surface.
- a working surface comprises a panel 100 as disclosed above.
- a panel 100 may be used, in particular, in rooms, wherein water is typically used for everyday operations, such as washing, and making food. Therefore a building may comprise
- a room such as a kitchen, a toilet, a showering room, or a sauna
- the room comprising a water tap
- the room further comprises
- the piece of furniture is arranged in the room.
- a building may, alternatively or in addition, comprise,
- a room such as a kitchen, a toilet, a showering room, or a sauna
- the room comprising a water tap
- the room further comprises
- a building may, alternatively or in addition, comprise,
- the floor comprises the panel 100 as discussed above.
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Laminated Bodies (AREA)
Abstract
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/FI2013/050514 WO2014181031A1 (fr) | 2013-05-10 | 2013-05-10 | Panneau comprenant un revêtement de surface solide sur un support déformable par la température |
Publications (2)
Publication Number | Publication Date |
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EP2994307A1 true EP2994307A1 (fr) | 2016-03-16 |
EP2994307A4 EP2994307A4 (fr) | 2017-03-15 |
Family
ID=51866848
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP13884020.2A Withdrawn EP2994307A4 (fr) | 2013-05-10 | 2013-05-10 | Panneau comprenant un revêtement de surface solide sur un support déformable par la température |
Country Status (2)
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EP (1) | EP2994307A4 (fr) |
WO (1) | WO2014181031A1 (fr) |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
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CN105220872B (zh) * | 2015-09-23 | 2018-05-11 | 合迪科技江苏有限公司 | 一种具有高效膜层的建筑铝合金模板及其制备方法 |
FR3073539B1 (fr) | 2017-11-13 | 2020-05-15 | Gerflor | Panneau rigide pour la realisation d'un revetement de sol |
WO2019113781A1 (fr) * | 2017-12-12 | 2019-06-20 | Avery Dennison Corporation | Adhésifs sensibles à la pression détachables ayant une résistance au pelage élevée et une aptitude à l'enlèvement |
US20220338526A1 (en) * | 2019-06-21 | 2022-10-27 | Carnegie Mellon University | Flour-based shape-changing foods, methods, systems and devices |
NL1043891B1 (nl) * | 2020-12-31 | 2022-07-21 | Csr Bv | Gas- en vloeistofdichte vloervoorziening van onderling vloeistofdicht te verbinden vloeistofdichte vloerpanelen voorzien van een eenzijdig of geïntegreerd meerzijdig afschot en een samengesteld of gescheiden vloeistof- en vaste stof opvangsysteem, reiniging systeem en afvoersysteem evenals een dergelijk vloerpaneel. |
NL2026988B1 (en) * | 2020-11-26 | 2022-07-04 | I4F Licensing Nv | Panel, in particular a floor, ceiling, or wall panel; a covering constructed by a multitude of such panels; and a method for the recycling of such a panel |
NL2029176B1 (en) * | 2021-09-13 | 2023-03-23 | Champion Link Int Corp | Panel and method for producing a panel |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US5624737A (en) | 1993-02-18 | 1997-04-29 | General Electric Company | Method for adhering materials having differing expansion properties and articles produced therefrom |
EP1151853A4 (fr) | 1999-11-22 | 2003-11-05 | Sumitomo Chemical Co | Stratifie se destratifiant facilement et composition de resine a cet effet |
TW490373B (en) | 2000-10-23 | 2002-06-11 | Matsushita Electric Works Ltd | Laminate with a peelable top layer and method of peeling off the top layer from the laminate |
FI20061151L (fi) | 2006-12-22 | 2008-06-23 | Upm Kymmene Oyj | Puulevy ja sen valmistusmenetelmä |
EP2517856A1 (fr) | 2011-04-19 | 2012-10-31 | Willem Aloysius Nijhuis | Structure de stratifié multicouches avec liaison réversible |
PL2749408T3 (pl) | 2012-12-28 | 2017-05-31 | Upm-Kymmene Wood Oy | Powlekany arkusz sklejki oraz sposób jej wytwarzania |
-
2013
- 2013-05-10 WO PCT/FI2013/050514 patent/WO2014181031A1/fr active Application Filing
- 2013-05-10 EP EP13884020.2A patent/EP2994307A4/fr not_active Withdrawn
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WO2014181031A1 (fr) | 2014-11-13 |
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