WO2012001091A1 - A panel comprising a polymeric composite layer and a reinforcement layer - Google Patents

A panel comprising a polymeric composite layer and a reinforcement layer Download PDF

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Publication number
WO2012001091A1
WO2012001091A1 PCT/EP2011/060991 EP2011060991W WO2012001091A1 WO 2012001091 A1 WO2012001091 A1 WO 2012001091A1 EP 2011060991 W EP2011060991 W EP 2011060991W WO 2012001091 A1 WO2012001091 A1 WO 2012001091A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
panel
reinforcement layer
reinforcement
polymeric composite
Prior art date
Application number
PCT/EP2011/060991
Other languages
French (fr)
Inventor
Bruno Paul Louis Vermeulen
Original Assignee
Spanolux N.V.- Div. Balterio
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=42829578&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2012001091(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority to ES11728282T priority Critical patent/ES2634916T5/en
Priority to US13/807,434 priority patent/US20130183506A1/en
Priority to BR112012033497-2A priority patent/BR112012033497B1/en
Priority to CA2804167A priority patent/CA2804167C/en
Priority to RU2013101800/05A priority patent/RU2592523C2/en
Priority to EP11728282.2A priority patent/EP2588311B2/en
Priority to EP19180846.8A priority patent/EP3575080A1/en
Priority to PL11728282T priority patent/PL2588311T5/en
Priority to PL19180851T priority patent/PL3575081T3/en
Priority to EP19180847.6A priority patent/EP3564032A1/en
Application filed by Spanolux N.V.- Div. Balterio filed Critical Spanolux N.V.- Div. Balterio
Priority to EP19180849.2A priority patent/EP3564033A1/en
Priority to CN2011800426738A priority patent/CN103153609A/en
Priority to EP19180853.4A priority patent/EP3575082A1/en
Priority to EP19180851.8A priority patent/EP3575081B1/en
Priority to EP19180845.0A priority patent/EP3564031A1/en
Publication of WO2012001091A1 publication Critical patent/WO2012001091A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/22—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics reinforced
    • 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
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • 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
    • B32B21/10—Next to a fibrous or filamentary layer
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
    • E04F13/0878—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer the basic insulating layer comprising mutual alignment or interlocking means
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
    • 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
    • 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
    • E04F15/102—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 fibrous or chipped materials, e.g. bonded with synthetic resins
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/181—Insulating layers integrally formed with the flooring or the flooring elements
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • 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
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31971—Of carbohydrate
    • Y10T428/31989—Of wood

Definitions

  • the present invention relates to a panel f in particular a floor panel which comprises a polymeric composite layer,
  • a panel having a layer of a polymeric composite is known from WO 2008/122668.
  • the polymeric composite is SfPC, which is a composite of polymeric material and a natural fibre for example from any wood source. Due to the presence of polymers the dimensions of the known panels depend on
  • An object of the present invention is to provide a panel including a polymeric composite layer which is applicable in changing ambient conditions.
  • the panel according to the invention comprises a reinforcement layer for reinforcing the polymeric composite layer at least in the plane of the panel , which reinforcement layer is made of a material which is different from that of the polymeric composite layer.
  • the reinforcement layer may also reinforce the polymeric composite layer in a direction extending transversely to the plane of the panel.
  • An advantage of the panel according to the invention is that deformation of the polymeric composite layer in the plane of the panel is minimized. In other words, the sensitivity of the dimensions of the panel to ambient conditions is minimized.
  • the panel can be applied at locations where ambient conditions change, for example in case of floor panels that are connected to each other to form a flooring on a floor having a floor heating system, furthermore, in case of floor panels that are mutually connected to form, a flooring the expansion clearance between the wall and an adjacent floor panel can be minimized.
  • the reinforcement layer is thinner than the polymeric composite layer, for example less than 0.4 mm but a greater thickness is possible. It is noted that the reinforcement layer may be a sheet or plate; the layer may be self-supporting and/or made of one piece.
  • the polymeric composite may be a mixture of one or more polymers and non-polymeric or partly polymeric material.
  • non-poiyraeric or partly polymeric materials are chalk and carpet waste; jute, styrene butadiene (latex) , but a lot of alternative materials are conceivable .
  • the polymeric composite may further contain a coupling agent to improve the material cohesion.
  • Alternative additives are elastomers or materials having a high absorption capacit of fillers. This may also improve characteristics like UV resistance, humidity resistance and bending strength.
  • the fillers may be fibres, powders or the like.
  • the polymeric composite layer may be a composite of a polymer and a non-polymer composite substance.
  • the composite substance may be natural or non-natural fibres, particles or the like.
  • the polymeric composite layer s a PC layer made of wood plastic composite (WPC) and the reinforcement layer is a non-WPC
  • the reinforcement layer is incorporated within the polymeric composite layer since this creates an efficient reinforcement of the polymeric composite layer.
  • the polymeric composite layer is incorporated within the polymeric composite layer since this creates an efficient reinforcement of the polymeric composite layer.
  • reinforcement layer can easily be integrated in a. known pressing process for manufacturing a polymeric composite panel such that the reinforcement layer is embedded within the polymeric
  • the reinforcement layer may have an open structure.
  • the resul ting polymeric composite layer is continuous through open areas of the open structure, i.e. in a direction perpendicular to the plane of the panel.
  • the reinforcement layer may comprise longitudinal filaments and transversal, filaments extending in transverse direction with respect to the longitudinal filaments.
  • the filaments may be oriented perpendicularly with, respect to each other but this is no necessary.
  • the mutual distance of at least one of the longitudinal filaments and transversal filaments may vary within the reinforcement layer , which provides the
  • the mutual distance may vary between 1-5 filaments per cm. It is advantageous when the mutual distance is adapted to the size of the granulate of which the polymeric composite layer is made; in particular if the
  • the filaments may be made of glass fibre, or fibres of polyester high tenacity, polyester textile, cellulose, ara id, PEN, Nomex or other materials that are dimensionaliy insensitive to changing- ambient conditions such as temperature changes.
  • the filaments may be fixed to each other by fixing means, for example glue. Both the filaments and the fixing means will be selected such that, they are compatible with polymeric composite and preferably form a strong bona therewith. Additionally, binders may be added to the polymeric composite and/or to the reinforcement layers, such as acryiate, ethylenvinyl acetate, polyurethane, polyvinyl alcohol, polyvinyl acetate, polyvinylchlor ide, styrene butadiene or the like.
  • the panel may comprise at least another reinforcement layer, which is preferably located at a distance from the reinforcement layer.
  • a plurality of reinforcement layers is possible, as well.
  • the reinforcement layers may be located within the polymeric composite layer.
  • the panel according to the invention may be a floor panel, ceiling panel, wall panel, or the like,
  • Fig, 1 is an enlarged sectional view of an embodiment of a panel according to the invention.
  • Fig, 2 is a series of very schematic top views of different types of reinforcement layers, being applicable in the panel according to Fig. 1.
  • Fig. 3 is a series of perspective views of dif erent types of reinforcement layers, being applicable in the panel according to Fig. 1.
  • Fig. 4 is a very schematic view of an apparatus for manoracturinq a panel of Fig. 1.
  • Fig. 1 shows a cross-sectional view of an embodiment o a floor panel 1 according to the invention.
  • the floor panel 1 ncludes a WPC layer 2 made of wood plastic composite (WPC5 granulate and a reinforcement layer 3.
  • the reinforcement layer 3 is thinner than the WPC layer 2 and is intended to minimize dimensional changes of the WPC layer 2 in the plane of the panel 1, in this embodiment the reinforcement layer 3 is incorporated within the WPC layer 2 such that portions of the WPC layer 2 extend at both sides of the reinforcement layer 3. For stability reasons it is preferred that the thicknesses of these portions of the WPC layer 2 are substantially equal.
  • WPC an alternative polymeric composite may be applied.
  • the floor panel 1 according to Fig, 1 includes a top laminate on the WPC layer 2.
  • the top laminate is a high pressure laminate construction comprising at least a printed decorative layer 4 and an impregnated protective overlay 5 pressed together with heat ana pressure to become one single layer due to the impregnation material which is preferably a resin such as melamine resin.
  • the impregnation material which is preferably a resin such as melamine resin.
  • the me ⁇ amine resi is mixed with urea formaldehyde to obtain advantageous properties such as minimized shrinkage and reduced cloudiness.
  • the overlay paper 5 is preferably a high abrasive overlay which preferably has aluminium oxide or other abrasive resistant hard particles embedded in the surface of the paper.
  • a different layer type can be provided on the WPC layer, for example a polymeric film having a decoration pattern, which is printed on the film. The polymeric film may be melted to the WPC layer.
  • top laminate or top layer as described above consists of one or more paper layers, but also one or more wood veneer layers, vulcanized cellulose layers or other layers suitable as top layer are conceivable,
  • the design and overall upper layers can be textured such as embossed in register with the design of the printed decorative layer in order to even better imitate natural
  • material such as stone, brick, ceramic, wood, marble or the like.
  • a backing layer 6 is provided below the ft?PC layer 2 and is fixed to the unders de of the WPC layer 2,
  • the backing layer 6 can be used as a balancing layer and it may also have moisture resisting properties.
  • a paper layer 7 irsay be provided between the FC layer and the top laminate.
  • coupling means 8 to couple adjacent panels 1 together.
  • the coupling means 8 also include a mechanical locking system to lock the adjacent floor panels 1 not only in a direction perpendicular to the surface of the panels, but also in a direction parallel to the surface and perpendicular to the respective side of the floor panel 1,
  • Fig. 1 shows a tongue and a groove as coupling means 8
  • all coupling systems, including the use of adhesives is
  • the reinforcement layer 3 has an open structure, since this allows the portions of the WPC layer 2 at both sides of trie reinforcement layer 3 to contact each other during manuf cturing, hence creating an integral structure of the WPG layer 2 and the reinforcement layer 3.
  • Fig. 2 shows several examples of reinforcement layers 3 including an open structure.
  • the reinfo cement layers 3 as shown comprise parallel longitudinal filaments 9 and parallel transversal filaments 10 which extend in transverse direction with respect to the longitudinal filaments 9.
  • the filaments 9, 10 are
  • Fig. 2 also shows that the longitudinal filaments 9 and. transversal filaments 10 in the embodiments are perpendicularly orientated with respect to each order this is not necessary.
  • Fig. 2 also shows that the longitudinal filaments 9 and. transversal filaments 10 in the embodiments are perpendicularly orientated with respect to each order this is not necessary.
  • Fig. 2 also shows that the longitudinal filaments 9 and. transversal filaments 10 in the embodiments are perpendicularly orientated with respect to each order this is not necessary.
  • Fig. 2 also shows that the longitudinal filaments 9 and. transversal filaments 10 in the embodiments are perpendicularly orientated with respect to each order this is not necessary.
  • Fig. 2 also shows that the longitudinal filaments 9 and. transversal filaments 10 in the embodiments are perpendicularly orientated with respect to each order this is not necessary.
  • Fig. 2 also shows that the longitudinal filaments 9 and. transversal filaments 10 in the embodiments are perpendicular
  • einforcement layers 3 may vary in respect of mutual distances of the filaments 9, 10 in different directions, even within specific portions of the reinforcement layer 3, arid in filament dimensions ,
  • Fig, 3 shows examples of different reinforcement layers 3 in perspective view.
  • transversal filaments 10 may lay on each other and. may be mutually attached at intersections of the filaments 9, 10.
  • the longitudinal filaments each comprise parallel filaments 9' , 9 f ' which are attached to each other along the filaments 9' , 9' ' and interrupted by the transversal filaments 10 which are sandwiched between the parallel filaments 9 f , 9' ' at intersections of the filaments 9' , 9 ? ? and the transversal filaments 10,
  • the filaments 9, 10 may be laminated to a fabric 11, for example a non woven, as illustrated in the lower drawing of Fig. 3.
  • Fig. 4 shows an apparatus 12 for manufacturing laminate sheets S which may include a plurality of panels 1 ⁇ see Fig, 1 ⁇ which are cut from the sheets S and are finished in a manner well known in the prior art.
  • the apparatus 12 includes a first granulate supply 13 including a mechanism 14 which is adapted to supply si first layer of granulate 15 on a supporting conveyor belt 16.
  • the apparatus 12 further includes a second granulate supply 1.3 including a mechanism 18 which is adapted to supply a second layer of granulate 19,
  • the reinforcement layer 3 is supplied by unwinding it from a supply roller.
  • the second layer of granulate 19 is supplied on top of the reinforcement layer 3,
  • the granulate is made from, wood/plastic composite which is a material known in the prior art, it may include from about 30 wt to about 95 t% of at least one polymeric material and from about 5 wt% to about 80 wt3 ⁇ 4 of at least one natural fibre or flour by weight of the SPG layer.
  • wood/plastic composite which is a material known in the prior art, it may include from about 30 wt to about 95 t% of at least one polymeric material and from about 5 wt% to about 80 wt3 ⁇ 4 of at least one natural fibre or flour by weight of the SPG layer.
  • polymeric composite includes fibres, particles, flour or the like, that comprises one or more polymers itself, to which possibly one or more polymeric materials are added.
  • polymeric material can be one or more polymers having a
  • polyethylene such as polyethylene.
  • Other exemplary polymers include polypropylene, polyvinyl chloride, copolymer of PVC, and also other suitable thermoplastics.
  • the polymer material to be processed can be in powder, liquid, cubed, palletized form and/or any other form.
  • the polymeric material can be virgin, recycled or a mixture of both. Additionally, the polymeric material may be provided with natural or non-natural additives, and/or a coupling aqent to improve the material cohesion.
  • the polymeric material can be incorporated with a blowing agent to m ke a cellular foam structure core.
  • the natural fibres or flour have a specific moisture content, depending on the WPC-board specifications and
  • the natural fibres can be from any wood source, cellulose source, other natural sources, or any combination thereof. Generally, any natural fibre can be used, which is from trees, plants, parts thereof and the like. The specific
  • the bending stiffness will be higher if the WPC layer is made with longer fibres.
  • Synthetic fibres may also be used to enhance mechanical properties such as fiexural and tensile modules of the product.
  • the natural fibre or flour can be " virgin,, recycled or a mixture of both.
  • the natural fibres or flour can be incorporated with a foaming agent to make a cellular foam structure core,
  • the mechanisms 14, 18 may include a system provided by Schilling-Knobei GmbH, as is described, in WO 99/26773, which is incorporated herein by reference thereto, including a hopper which is resting on a metering roller which picks up the
  • the lower conveyor belts 16 has a greater length than a second, upper conveyor belt 20 which is positioned at a distance from the first and second granulate supply 13, 17.
  • the upper and lower conveyor belt 16, 20 run over a certain length parallel to each other and include various zones.
  • the first zone in the direction of conveyance of the conveyor belts 16, 20 is a heating zone 21.
  • the WPC- granulate is heated to such temperature that the granulate melts to a suf icient extent in order to weaken to a mass which can be shaped into a solid, continuous sheet.
  • the heating temperature depends on the polymer used in the WPC granulate and ca for example be between 180 °C and 250 * Cd In this exemplary
  • the heating zone 21 is divided in a first heating zone 21A and a second heating zone 21B with nip rollers 22 in between. These nip rollers 22 are positioned below the transport part of the lower conveyer belt 16 and above the transport part of the upper conveyor 20 to effect a first pressing action on the layers 15, 19 of melted granulate.
  • a second set of nip rollers 23 consisting of two pairs of upper and lower nip rollers effects a final pressing action on the layers 15, 19 of melted granulate and determines the final thickness of the sheet to be formed.
  • the reinforcement layer 3 preferably has an open structure such that the first and second layers of the melted granulate 15, 19 are pressed to each other through the open areas 11 of the reinforcement layer 3. This avoids any weak bond, between the layers 15, 19 due to the addition of the reinforcement layer 3,
  • the last zone within the conveyor belts 16, 20 is an annealing zone 24 by which the sheet layers 15, 19 are cooled and. brought in the final form.
  • the conveyor belts 16, 20 are formed by two reinforced, thermally stable coated belts, for example from glass plus Teflon®, The back sides of the belts are in contact with heating platens in the heating zones 21A, 213 and with cooling platens in the annealing zone 24.
  • the platens in the upper conveyor belt 20 are movable in vertical direction, while the platens in the lower conveyor belt 16 are rigidly moun ed .
  • the movabili y of the platens with the upper conveyor 20 is to create a gap according to the required thickness of the sheet to be formed.
  • the heating and cooling platens do no exert pressure on the granulate layers 15, 19 and only the calibrating nip rollers 22, 23 are adapted to exert a pressure on the melted granulate layers 15, 19 to determine the thickness thereof.
  • a layer of paper or other absorbing material 6, 7 to the lower side of the first layer 15 and upper side of the second layer 19 of granulate 3 in. order to be melted thereto, i.e. to be attached thereto through the melted plastic from the granulate.
  • the paper layers 6, 7 are supplied by unwinding them from supply rollers.
  • the paper layers 6, 7 are interposed between the first granulate layer 15 and the lower conveyor belt 16 and between the second qranulate layer 19 and the upper conveyor belt 20, respectively, so that they also assist in preventing the granulate layers 15, 19 from sticking- to the conveyor belts 16, 20,
  • the conveying speed of the paper layers 6, 7 and the reinforcement layer 3 will be adapted to that of the conveyor belts 16, 20 so that they are matching, but it is also possible than they are not positively supplied, but are pulled away by the friction between the paper and reinforcement layers and the granulate layers 15, 19 and the conveyor belts 16, 20.
  • paper layer 7 it is possible to supply a polymeric sheet, for example polypropylene, PVC, polyester or the like, to the melted layer of granulate of the 3 ⁇ 4PC layer,
  • the polymeric film melts and as a result after pressing, the resulting panel obtains a smooth surface at the side where the polymeric sheet is provided and melted.
  • the WPC layer has a coarse surface due to inhomogerieous mixing of the polymer and a composite substance
  • the melted polymeric layer on the WPC layer may also improve the stability and. stiffness of the resulting panel and further improve the adherence of sti.ll another polymeric film thereon which is provided at a later stage such that it does not fully melt.
  • This further polymeric film may be provided with a decoration pattern. It is also possible to provide a melted polymeric layer or film at rhe back side of the WPC layer, which may function as a balancing layer.
  • a cutting mechanism 25 to cut the continuous sheet web into separate sheets S which are then collected for further processing so as to form the floor panel 1 as shown in Fig, 1.
  • An alternative method of manufacturing the panels according to the invention is one in which a top laminate and optionally also a backing layer is fixed directly to the WPC layer simultaneously with, the formation of the WPC layer including the reinforcement layer 3.
  • the top laminate should then be of such structure that it can be supplied in rollers and can be fixed directly to the second WPC layer.
  • the top laminate or top layer may consist of paper layers, bat also one or more wood veneer layers or vulcanized cellulose layers are
  • the top laminate can be left out and the decor can be printed directly on the WPC material.
  • the raw WPC material can be embossed, and /or chafed/sanded in a particulate pattern to imitate natural materials such, as wood or stone.
  • the invention provides a. panel of which the dimensions are stable despite of varying ambient conditions.
  • the reinforcement layer may be fixed to an outer side of the WPC layer instead of being incorporated therein.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)
  • Panels For Use In Building Construction (AREA)

Abstract

A panel (1) comprises a polymeric composite layer (2) and at least a reinforcement layer (3) for reinforcing the polymeric composite layer (2) at least in the plane of the panel (1). The reinforcement layer (3) is made of a material which is different from that of the polymeric composite layer (2).

Description

A PANEL COMPRISING A POLYMERIC COMPOSITE LAYER AND A REINFORCEMENT LAYER
The present invention relates to a panel f in particular a floor panel which comprises a polymeric composite layer,
A panel having a layer of a polymeric composite is known from WO 2008/122668. In this case the polymeric composite is SfPC, which is a composite of polymeric material and a natural fibre for example from any wood source. Due to the presence of polymers the dimensions of the known panels depend on
temperature more strongly than for example wooden floor boards or panels mainly made of wood-based material, which limits the applicability of panels including a PC layer.
An object of the present invention is to provide a panel including a polymeric composite layer which is applicable in changing ambient conditions.
For this purpose the panel according to the invention comprises a reinforcement layer for reinforcing the polymeric composite layer at least in the plane of the panel , which reinforcement layer is made of a material which is different from that of the polymeric composite layer. The reinforcement layer may also reinforce the polymeric composite layer in a direction extending transversely to the plane of the panel.
An advantage of the panel according to the invention is that deformation of the polymeric composite layer in the plane of the panel is minimized. In other words, the sensitivity of the dimensions of the panel to ambient conditions is minimized. This means that the panel can be applied at locations where ambient conditions change,, for example in case of floor panels that are connected to each other to form a flooring on a floor having a floor heating system, furthermore, in case of floor panels that are mutually connected to form, a flooring the expansion clearance between the wall and an adjacent floor panel can be minimized. In practice, the reinforcement layer is thinner than the polymeric composite layer, for example less than 0.4 mm but a greater thickness is possible. It is noted that the reinforcement layer may be a sheet or plate; the layer may be self-supporting and/or made of one piece. The polymeric composite may be a mixture of one or more polymers and non-polymeric or partly polymeric material.
Examples of non-poiyraeric or partly polymeric materials are chalk and carpet waste; jute, styrene butadiene (latex) , but a lot of alternative materials are conceivable . The polymeric composite may further contain a coupling agent to improve the material cohesion. Alternative additives are elastomers or materials having a high absorption capacit of fillers. This may also improve characteristics like UV resistance, humidity resistance and bending strength. The fillers may be fibres, powders or the like. In general, the polymeric composite layer may be a composite of a polymer and a non-polymer composite substance. The composite substance may be natural or non-natural fibres, particles or the like. In a practical embodiment the polymeric composite layer s a PC layer made of wood plastic composite (WPC) and the reinforcement layer is a non-WPC
reinforcement layer.
Tn a preferred embodiment the reinforcement layer is incorporated within the polymeric composite layer since this creates an efficient reinforcement of the polymeric composite layer. In terms of manufacturing such an embodiment, the
reinforcement layer can easily be integrated in a. known pressing process for manufacturing a polymeric composite panel such that the reinforcement layer is embedded within the polymeric
composite layer. Such a process is described in WO 2008/122668,
The reinforcement layer may have an open structure. The advantage is that upon pressing melted granulate layers together whereas the reinforcement layer is sandwiched between the layers a strong bond between the melted granulate layers at open areas of the open structure can be achieved. As a. result the
reinforcement layer is fully integrated in the polymeric
composite layer without significantly weakening the panel at the reinforcement layer in a direction perpendicular to the plane of the panel. Thus, the resul ting polymeric composite layer is continuous through open areas of the open structure, i.e. in a direction perpendicular to the plane of the panel.
The reinforcement layer may comprise longitudinal filaments and transversal, filaments extending in transverse direction with respect to the longitudinal filaments. The filaments may be oriented perpendicularly with, respect to each other but this is no necessary. The mutual distance of at least one of the longitudinal filaments and transversal filaments may vary within the reinforcement layer , which provides the
opportunity to create a stronger rein orcement at predefined areas of the panel. For example, the mutual distance may vary between 1-5 filaments per cm. It is advantageous when the mutual distance is adapted to the size of the granulate of which the polymeric composite layer is made; in particular if the
granulate is not entirely melted it can still pass through the reinforcement l yer upon pressing. The filaments may be made of glass fibre, or fibres of polyester high tenacity, polyester textile, cellulose, ara id, PEN, Nomex or other materials that are dimensionaliy insensitive to changing- ambient conditions such as temperature changes.
It is noted that the filaments may be fixed to each other by fixing means, for example glue. Both the filaments and the fixing means will be selected such that, they are compatible with polymeric composite and preferably form a strong bona therewith. Additionally, binders may be added to the polymeric composite and/or to the reinforcement layers, such as acryiate, ethylenvinyl acetate, polyurethane, polyvinyl alcohol, polyvinyl acetate, polyvinylchlor ide, styrene butadiene or the like.
The panel may comprise at least another reinforcement layer, which is preferably located at a distance from the reinforcement layer. A plurality of reinforcement layers is possible, as well. The reinforcement layers may be located within the polymeric composite layer.
The panel according to the invention may be a floor panel, ceiling panel, wall panel, or the like,
The invention will hereafter be elucidated with reference to very schematic drawings showing an. embodiment of the invention by way of example.
Fig, 1 is an enlarged sectional view of an embodiment of a panel according to the invention.
Fig, 2 is a series of very schematic top views of different types of reinforcement layers, being applicable in the panel according to Fig. 1. Fig. 3 is a series of perspective views of dif erent types of reinforcement layers, being applicable in the panel according to Fig. 1.
Fig. 4 is a very schematic view of an apparatus for manoracturinq a panel of Fig. 1.
Fig. 1 shows a cross-sectional view of an embodiment o a floor panel 1 according to the invention. The floor panel 1 ncludes a WPC layer 2 made of wood plastic composite (WPC5 granulate and a reinforcement layer 3. The reinforcement layer 3 is thinner than the WPC layer 2 and is intended to minimize dimensional changes of the WPC layer 2 in the plane of the panel 1, in this embodiment the reinforcement layer 3 is incorporated within the WPC layer 2 such that portions of the WPC layer 2 extend at both sides of the reinforcement layer 3. For stability reasons it is preferred that the thicknesses of these portions of the WPC layer 2 are substantially equal. It is noted that instead of WPC an alternative polymeric composite may be applied.
Furthermore, the floor panel 1 according to Fig, 1 includes a top laminate on the WPC layer 2. In this example, the top laminate is a high pressure laminate construction comprising at least a printed decorative layer 4 and an impregnated protective overlay 5 pressed together with heat ana pressure to become one single layer due to the impregnation material which is preferably a resin such as melamine resin. Preferably the meίamine resi is mixed with urea formaldehyde to obtain advantageous properties such as minimized shrinkage and reduced cloudiness. The overlay paper 5 is preferably a high abrasive overlay which preferably has aluminium oxide or other abrasive resistant hard particles embedded in the surface of the paper. Is is noted that a different layer type can be provided on the WPC layer, for example a polymeric film having a decoration pattern, which is printed on the film. The polymeric film may be melted to the WPC layer.
The top laminate or top layer as described above consists of one or more paper layers, but also one or more wood veneer layers, vulcanized cellulose layers or other layers suitable as top layer are conceivable, The design and overall upper layers can be textured such as embossed in register with the design of the printed decorative layer in order to even better imitate natural
material/ such as stone, brick, ceramic, wood, marble or the like.
Preferably but not necessarily a backing layer 6 is provided below the ft?PC layer 2 and is fixed to the unders de of the WPC layer 2, The backing layer 6 can be used as a balancing layer and it may also have moisture resisting properties.
Furthermore, a paper layer 7 irsay be provided between the FC layer and the top laminate.
At least on two opposite sides of the floor panel 1 and preferably on all sides are formed coupling means 8 to couple adjacent panels 1 together. Pre erably, the coupling means 8 also include a mechanical locking system to lock the adjacent floor panels 1 not only in a direction perpendicular to the surface of the panels, but also in a direction parallel to the surface and perpendicular to the respective side of the floor panel 1, However the invention is not limited thereto at all. Although Fig. 1 shows a tongue and a groove as coupling means 8, all coupling systems, including the use of adhesives is
encompassed by the invention.
In a preferred embodiment the reinforcement layer 3 has an open structure, since this allows the portions of the WPC layer 2 at both sides of trie reinforcement layer 3 to contact each other during manuf cturing, hence creating an integral structure of the WPG layer 2 and the reinforcement layer 3. Fig. 2 shows several examples of reinforcement layers 3 including an open structure. The reinfo cement layers 3 as shown comprise parallel longitudinal filaments 9 and parallel transversal filaments 10 which extend in transverse direction with respect to the longitudinal filaments 9. The filaments 9, 10 are
oriented such that they envelope open areas 11. Although the longitudinal filaments 9 and. transversal filaments 10 in the embodiments are perpendicularly orientated with respect to each order this is not necessary. Fig. 2 also shows that the
einforcement layers 3 may vary in respect of mutual distances of the filaments 9, 10 in different directions, even within specific portions of the reinforcement layer 3, arid in filament dimensions ,
Fig, 3 shows examples of different reinforcement layers 3 in perspective view. The longitudinal filaments 9 and
transversal filaments 10 may lay on each other and. may be mutually attached at intersections of the filaments 9, 10.
Alternatively, the longitudinal filaments each comprise parallel filaments 9' , 9f ' which are attached to each other along the filaments 9' , 9' ' and interrupted by the transversal filaments 10 which are sandwiched between the parallel filaments 9f , 9' ' at intersections of the filaments 9' , 9? ? and the transversal filaments 10, Furthermore, the filaments 9, 10 may be laminated to a fabric 11, for example a non woven, as illustrated in the lower drawing of Fig. 3.
Fig. 4 shows an apparatus 12 for manufacturing laminate sheets S which may include a plurality of panels 1 {see Fig, 1} which are cut from the sheets S and are finished in a manner well known in the prior art.
The apparatus 12 includes a first granulate supply 13 including a mechanism 14 which is adapted to supply si first layer of granulate 15 on a supporting conveyor belt 16. The apparatus 12 further includes a second granulate supply 1.3 including a mechanism 18 which is adapted to supply a second layer of granulate 19,
Between the first granulate supply 13 and the second granulate supply 1"! the reinforcement layer 3 is supplied by unwinding it from a supply roller. The second layer of granulate 19 is supplied on top of the reinforcement layer 3,
The granulate is made from, wood/plastic composite which is a material known in the prior art, it may include from about 30 wt to about 95 t% of at least one polymeric material and from about 5 wt% to about 80 wt¾ of at least one natural fibre or flour by weight of the SPG layer. Alternatively, the
polymeric composite includes fibres, particles, flour or the like, that comprises one or more polymers itself, to which possibly one or more polymeric materials are added. The
polymeric material can be one or more polymers having a
polyoiefin group, such as polyethylene. Other exemplary polymers include polypropylene, polyvinyl chloride, copolymer of PVC, and also other suitable thermoplastics. The polymer material to be processed can be in powder, liquid, cubed, palletized form and/or any other form. The polymeric material can be virgin, recycled or a mixture of both. Additionally, the polymeric material may be provided with natural or non-natural additives, and/or a coupling aqent to improve the material cohesion. The polymeric material can be incorporated with a blowing agent to m ke a cellular foam structure core.
The natural fibres or flour have a specific moisture content, depending on the WPC-board specifications and
requi ements. The natural fibres can be from any wood source, cellulose source, other natural sources, or any combination thereof. Generally, any natural fibre can be used, which is from trees, plants, parts thereof and the like. The specific
selection of a particular type of wood and/or wood fibres can have an influence on the properties of the final panel. The fibres of an exotic hard wood type could for example be
substantially thicker and/or longer than normal fir wood. The bending stiffness will be higher if the WPC layer is made with longer fibres. Synthetic fibres may also be used to enhance mechanical properties such as fiexural and tensile modules of the product. The natural fibre or flour can be "virgin,, recycled or a mixture of both. Furthermore the natural fibres or flour can be incorporated with a foaming agent to make a cellular foam structure core,
The mechanisms 14, 18 may include a system provided by Schilling-Knobei GmbH, as is described, in WO 99/26773, which is incorporated herein by reference thereto, including a hopper which is resting on a metering roller which picks up the
material to be scattered on the conveyor belt 16, Other means are of course conceivable.
The lower conveyor belts 16 has a greater length than a second, upper conveyor belt 20 which is positioned at a distance from the first and second granulate supply 13, 17.
The upper and lower conveyor belt 16, 20 run over a certain length parallel to each other and include various zones. The first zone in the direction of conveyance of the conveyor belts 16, 20 is a heating zone 21. In this zone, the WPC- granulate is heated to such temperature that the granulate melts to a suf icient extent in order to weaken to a mass which can be shaped into a solid, continuous sheet. The heating temperature depends on the polymer used in the WPC granulate and ca for example be between 180 °C and 250 *Cd In this exemplary
embodiment, the heating zone 21 is divided in a first heating zone 21A and a second heating zone 21B with nip rollers 22 in between. These nip rollers 22 are positioned below the transport part of the lower conveyer belt 16 and above the transport part of the upper conveyor 20 to effect a first pressing action on the layers 15, 19 of melted granulate. A second set of nip rollers 23 consisting of two pairs of upper and lower nip rollers effects a final pressing action on the layers 15, 19 of melted granulate and determines the final thickness of the sheet to be formed.
As described hereinbefore the reinforcement layer 3 preferably has an open structure such that the first and second layers of the melted granulate 15, 19 are pressed to each other through the open areas 11 of the reinforcement layer 3. This avoids any weak bond, between the layers 15, 19 due to the addition of the reinforcement layer 3,
The last zone within the conveyor belts 16, 20 is an annealing zone 24 by which the sheet layers 15, 19 are cooled and. brought in the final form. The conveyor belts 16, 20 are formed by two reinforced, thermally stable coated belts, for example from glass plus Teflon®, The back sides of the belts are in contact with heating platens in the heating zones 21A, 213 and with cooling platens in the annealing zone 24. The platens in the upper conveyor belt 20 are movable in vertical direction, while the platens in the lower conveyor belt 16 are rigidly moun ed . The movabili y of the platens with the upper conveyor 20 is to create a gap according to the required thickness of the sheet to be formed. In principle, the heating and cooling platens do no exert pressure on the granulate layers 15, 19 and only the calibrating nip rollers 22, 23 are adapted to exert a pressure on the melted granulate layers 15, 19 to determine the thickness thereof.
As illustrated in Fig. 4 there is supplied a layer of paper or other absorbing material 6, 7 to the lower side of the first layer 15 and upper side of the second layer 19 of granulate 3 in. order to be melted thereto, i.e. to be attached thereto through the melted plastic from the granulate. The paper layers 6, 7 are supplied by unwinding them from supply rollers. The paper layers 6, 7 are interposed between the first granulate layer 15 and the lower conveyor belt 16 and between the second qranulate layer 19 and the upper conveyor belt 20, respectively, so that they also assist in preventing the granulate layers 15, 19 from sticking- to the conveyor belts 16, 20, The conveying speed of the paper layers 6, 7 and the reinforcement layer 3 will be adapted to that of the conveyor belts 16, 20 so that they are matching, but it is also possible than they are not positively supplied, but are pulled away by the friction between the paper and reinforcement layers and the granulate layers 15, 19 and the conveyor belts 16, 20.
Instead of paper layer 7 it is possible to supply a polymeric sheet, for example polypropylene, PVC, polyester or the like, to the melted layer of granulate of the ¾PC layer, The polymeric film melts and as a result after pressing, the resulting panel obtains a smooth surface at the side where the polymeric sheet is provided and melted. This is advantageous if the WPC layer has a coarse surface due to inhomogerieous mixing of the polymer and a composite substance, Additionally, the melted polymeric layer on the WPC layer may also improve the stability and. stiffness of the resulting panel and further improve the adherence of sti.ll another polymeric film thereon which is provided at a later stage such that it does not fully melt. This further polymeric film may be provided with a decoration pattern. It is also possible to provide a melted polymeric layer or film at rhe back side of the WPC layer, which may function as a balancing layer.
At a position downstream of the upper conveyor belt 20 there is arranged a cutting mechanism 25 to cut the continuous sheet web into separate sheets S which are then collected for further processing so as to form the floor panel 1 as shown in Fig, 1.
An alternative method of manufacturing the panels according to the invention is one in which a top laminate and optionally also a backing layer is fixed directly to the WPC layer simultaneously with, the formation of the WPC layer including the reinforcement layer 3. This means that the (paper) layers 6 and 7 are then formed by the materials for forming the top laminate and the backing layer which are directly fixed to the WPC layers by adherence thereto. The top laminate should then be of such structure that it can be supplied in rollers and can be fixed directly to the second WPC layer. The top laminate or top layer may consist of paper layers, bat also one or more wood veneer layers or vulcanized cellulose layers are
conceivable according to the present invention as long as they withstand the heat during pressing. In a further alternative embodiment, the top laminate can be left out and the decor can be printed directly on the WPC material, As an alternative or additionally, the raw WPC material can be embossed, and /or chafed/sanded in a particulate pattern to imitate natural materials such, as wood or stone.
From the foregoing, it will be clear that the invention provides a. panel of which the dimensions are stable despite of varying ambient conditions.
The invention is not limited to the embodiment shown in the drawings and described hereinbefore, which may be varied in different manners within the scope of the claims and the
technical equivalents. For example, the reinforcement layer may be fixed to an outer side of the WPC layer instead of being incorporated therein.

Claims

1. A panel {!) , comprising a polymeric composite layer (2) and at least a reinforcement layer (3) for reinforcing the polymeric composite layer (2) at least in the plane of the panel (l)f the reinforcement layer (3) being made of a material which is different from that of the polymeric composite layer
(2) .
2. A panel (1) according to claim 1, wherein the polymeric composite layer (2) is a WPC layer (2) made of wood plastic composite (WPC) and. the reinforcement layer (3) is a non-WPC reinforcement layer (3) ·
3. A panel (1) according to claim 1 or 2r wherein the reinforcement layer (3) is incorporated within the polymeric composite layer (2) .
4. A panel (1) according to one of the preceding cla ms, wherein the reinforcement layer (3) has an open
structu re .
5. A panel (1) according to claim , wherein the polymeric composite layer (2) is continuous through open areas (11) of the open structure,
6. Ά panel (1) according to one of he preceding claims, wherein the reinforcement layer (3) comprises a fibre web .
7. A panel (1) according to one of the preceding claims , wherein the reinforcement layer (3) comprises
longitudinal filaments (9, 9', 9r ' ) and transversal filaments (10) extending in transverse direction with respect to the longitudinal filaments (9, 9' , 9" ) .
8. A panel (1) according to claim 7, wherein the mutual distance of at least one of the longitudinal filaments (9, 9' , 9''} and transversal filaments (10) vary within the reinforcement layer,
9. A panel (1) according to one of the preceding claims and claim 2, wherein the thickness of portions of the WPC layer (2) at both sides of the reinforcement layer (3) is substantially eguai.
10. A panel (1) according to one of the preceding claims, wherein the reinforcement layer is a sheet or plate.
11. A panel (1) according to one of the preceding claims,, wherein the reinforcement layer is a self-supporting layer ,
12. A panel (1.) according to one of the preceding
S claims, wherein the reinforcement layer is made of one piece.
13. A panel (1) according to one of the preceding claims, wherein the panel (1) comprises at least another reinforcement layer, preferably located at a distance from the reinforcement layer (3) ,
0 14. A panel (1) according to one of the preceding claims, wherein the reinforcement layer is thinner than the polymeric composite layer,
15. A panel (1) according to one of the preceding claims, wherein the polymeric composite layer contains at least 30% polymer and preferably more than 50% polymer.
PCT/EP2011/060991 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer WO2012001091A1 (en)

Priority Applications (15)

Application Number Priority Date Filing Date Title
EP19180845.0A EP3564031A1 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
EP19180847.6A EP3564032A1 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
PL19180851T PL3575081T3 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
CA2804167A CA2804167C (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
US13/807,434 US20130183506A1 (en) 2010-06-30 2011-06-30 Panel comprising a polymeric composite layer and a reinforcement layer
EP11728282.2A EP2588311B2 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
EP19180846.8A EP3575080A1 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
ES11728282T ES2634916T5 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcing layer
BR112012033497-2A BR112012033497B1 (en) 2010-06-30 2011-06-30 PANEL UNDERSTANDING A POLYMERIC COMPCsITE LAYER AND A REINFORCEMENT LAYER
RU2013101800/05A RU2592523C2 (en) 2010-06-30 2011-06-30 Panel comprising polymer composite layer and reinforcing layer
PL11728282T PL2588311T5 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
EP19180849.2A EP3564033A1 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
CN2011800426738A CN103153609A (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
EP19180853.4A EP3575082A1 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer
EP19180851.8A EP3575081B1 (en) 2010-06-30 2011-06-30 A panel comprising a polymeric composite layer and a reinforcement layer

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP10167985.0 2010-06-30
EP20100167985 EP2402155A1 (en) 2010-06-30 2010-06-30 A panel comprising a polymeric composite layer and a reinforcement layer

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US (1) US20130183506A1 (en)
EP (9) EP2402155A1 (en)
CN (1) CN103153609A (en)
BR (1) BR112012033497B1 (en)
CA (1) CA2804167C (en)
DE (2) DE202011110970U1 (en)
ES (2) ES2869246T3 (en)
PL (2) PL3575081T3 (en)
PT (1) PT3575081T (en)
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WO (1) WO2012001091A1 (en)

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EP2599622A1 (en) * 2011-11-30 2013-06-05 Extruwood GmbH Compound profile made of wood and wood fibre reinforced plastic and use of such a profile
DE102013101798A1 (en) * 2012-11-23 2014-05-28 Hamberger Industriewerke Gmbh paneling
US8925275B2 (en) 2010-05-10 2015-01-06 Flooring Industries Limited, Sarl Floor panel
US9163414B2 (en) 2010-05-10 2015-10-20 Flooring Industries Limited, Sarl Floor panel
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