WO2020095196A1 - Panneau revêtu et procédé de fabrication de panneaux revêtus - Google Patents

Panneau revêtu et procédé de fabrication de panneaux revêtus Download PDF

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Publication number
WO2020095196A1
WO2020095196A1 PCT/IB2019/059486 IB2019059486W WO2020095196A1 WO 2020095196 A1 WO2020095196 A1 WO 2020095196A1 IB 2019059486 W IB2019059486 W IB 2019059486W WO 2020095196 A1 WO2020095196 A1 WO 2020095196A1
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WO
WIPO (PCT)
Prior art keywords
accordance
mentioned
layer
acrylate
resin
Prior art date
Application number
PCT/IB2019/059486
Other languages
English (en)
Inventor
Benjamin Clement
Sam LEDEGEN
Original Assignee
Unilin, Bvba
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
Priority claimed from BE20185787A external-priority patent/BE1026771B1/nl
Priority claimed from BE20195461A external-priority patent/BE1027438B1/nl
Priority claimed from BE20195469A external-priority patent/BE1026995B1/nl
Priority to CN201980073813.4A priority Critical patent/CN112969560A/zh
Priority to CA3116534A priority patent/CA3116534A1/fr
Priority to KR1020217015493A priority patent/KR20210090198A/ko
Application filed by Unilin, Bvba filed Critical Unilin, Bvba
Priority to EP19813649.1A priority patent/EP3877125A1/fr
Priority to US17/291,093 priority patent/US20220001572A1/en
Priority to BR112021007843-6A priority patent/BR112021007843A2/pt
Priority to AU2019375541A priority patent/AU2019375541A1/en
Priority to RU2021116332A priority patent/RU2770194C1/ru
Publication of WO2020095196A1 publication Critical patent/WO2020095196A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/53—Base coat plus clear coat type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27D—WORKING VENEER OR PLYWOOD
    • B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
    • B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27D—WORKING VENEER OR PLYWOOD
    • B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
    • B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
    • B27D1/08—Manufacture of shaped articles; Presses specially designed therefor
    • B27D1/083—Presses specially designed for making the manufacture of shaped plywood articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27D—WORKING VENEER OR PLYWOOD
    • B27D3/00—Veneer presses; Press plates; Plywood presses
    • B27D3/04—Veneer presses; Press plates; Plywood presses with endless arrangement of moving press plates, belts, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/04—Manufacture or reconditioning of specific semi-finished or finished articles of flooring elements, e.g. parqueting blocks
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/40—Distributing applied liquids or other fluent materials by members moving relatively to surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2201/00—Polymeric substrate or laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2203/00—Other substrates
    • B05D2203/20—Wood or similar material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • B05D3/065—After-treatment
    • B05D3/067—Curing or cross-linking the coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects

Definitions

  • This invention relates to coated panels, in particular floor panels, and also to a method for the production of floor panels.
  • the invention relates to panels with a substrate and a top layer applied thereto having a decor layer, for example a decor layer that comprises printing.
  • a decor layer for example a decor layer that comprises printing.
  • Such floor panels are widely known per se, for example from WO 97/47834.
  • the floor panels disclosed in said document relate among others to floor panels with a substrate that is chiefly composed of an HDF sheet with a laminate layer pressed directly onto it that comprises one or more paper sheets impregnated with melamine resin, preferably also including a paper sheet with printing in for example a wood or stone motif, specifically a so-called decorative paper.
  • the above-mentioned melamine resin forms among others a translucent wear layer above the decorative paper, but the transparency or translucency leaves much to be desired.
  • a backing layer or balancing layer On the underside of the substrate is a backing layer or balancing layer, also based on a paper sheet impregnated with melamine resin.
  • This backing layer provides a compensating effect for residual tensile stresses present in the cured melamine resin of the top layer. It remains possible to form extremely deep structures in the curing melamine surface. So-called white mountains frequently occur. These are zones in which inclusions are concentrated in the melamine surface. These primarily occur at sites in which deep indentations or structures are implemented.
  • WO 03/016655 discloses the application of a sound-damping layer such as a cork layer under the melamine layer. It is known from WO 2010/088769, among other documents, to provide the melamine layers with a coating of a flexible monomer.
  • WO 2009/101217 and WO 2010/070474 give examples of laminate panels wherein the top layer is composed, instead of melamine resin, mainly of polyvinyl chloride (PVC).
  • WO 2010/070474 discloses panels with a printed decor layer that can be formed on the substrate and is finished with a transparent PVC layer. Furthermore, a method is known from WO 01/47726 of finishing panels with a printed decor layer with a UV (ultraviolet) curing or electron beam curing acrylate resin. This process is difficult to integrate into existing methods for the production of laminate panels and requires complex material logistics, complex machines, and leads to a high cost. For example, electron beam curing requires an inert atmosphere, which makes it possible to carry out treatment at the plate level, and this technique is primarily applied to smaller panels or sheets in a physically closed lead space, with the purpose of neutralizing the occurrence of unhealthy gamma radiation.
  • the top layer is composed entirely of polyvinyl chloride (PVC)
  • PVC polyvinyl chloride
  • the PVC layer must be configured to be considerably thicker than a melamine layer in order to obtain comparable wear resistance.
  • the nature and thickness of the PVC layer give rise to a plastic-like appearance of the floor panel, especially in cases where imitation of a product such as wood, stone or ceramic is intended.
  • the relief that can be obtained in a PVC layer is unsharp, which detracts from the realistic appearance of the imitation obtained.
  • top layer is obtained from UV cured or electron beam cured acrylate, such as in WO 01/47726, favorable surface properties are achieved.
  • the relief that can be obtained in such a top layer is limited in that structural films must be applied, for example such as in EP2019735.
  • the present invention is first intended to provide an alternative coated panel wherein a solution is provided to one or more of the problems with the panels of the prior art.
  • the invention relates in the first independent aspect to a coated panel, preferably a floor panel, a wall panel or a furniture panel, with at least a substrate and a top layer applied thereto, wherein the above-mentioned top layer comprises at least a decor layer and a translucent or transparent wear layer, characterized in that the above- mentioned wear layer comprises a thermally cured acrylate resin and/or a thermally cured unsaturated polyester resin.
  • the resin is partially or completely cured in the thermal curing.
  • a cured unsaturated polyester resin refers to a polyester resin that was unsaturated before the curing and can be cured by crosslinking of the double bonds in the unsaturated polyester resin.
  • the use of a thermally cured acrylate resin and/or a thermally cured unsaturated polyester resin gives rise to new possibilities for designing the wear layer, while the excellent qualities of a wear layer of acrylate resin or unsaturated polyester resin are retained.
  • the wear layer can thus be cured by means of hot pressing with a structured pressing element.
  • the inventors have found that the structure of the pressing element is quite favorably copied in the curing acrylate resin and/or the curing unsaturated polyester resin.
  • the so-called chemical moisture or moisture that occurs as a byproduct of the reaction is not present, such that the risk that of formation of inclusions in the translucent layer is limited, even when one is working with deep structures, for example with a local depth of more than 400 pm, or even 1 mm or more with respect to the overall surface.
  • a thermally cured acrylate resin and/or thermally cured unsaturated polyester resin can have better transparency than a thermally cured melamine resin such as that available in the laminate panels of the prior art.
  • the inventors attribute this to the strong crimp of a polycondensing melamine resin. For this reason, and due to the brittleness of the melamine resin, the melamine resin in the cured state shows a significant number of microcracks, which is not the case in the wear layer based on thermally cured acrylate resin of the invention.
  • the inventors were able to determine that residual tensile stresses that can be present after curing in the wear layer are much lower in the case of the invention than in laminate panels of the prior art, such that the risk that the obtained panels or parts thereof will show bending is substantially reduced, even if one is to work without a backing layer.
  • the formed wear layer is further softer than a melamine surface, and together with the lower residual tensile stresses in the surface, this property allows for more acceptable scratching noises, specifically for a noise comparable to that of actual wood.
  • the thermal curing also allows more uniform curing to be obtained than is the case in UV cured acrylate resins. In the use of UV radiation for curing, the penetration of the light is limited in depth.
  • the thermal curing of the invention can be initiated by means of one or more thermoinitiators that are mixed homogeneously, or essentially homogeneously, with the acrylate resin or with the unsaturated polyester resin. In this manner, the curing reaction can take place throughout the thickness of a layer formed by acrylate resin or unsaturated polyester resin almost simultaneously and/or to the same degree.
  • thicker cured layers can be formed, for example layers with a thickness of between 50 and 1000 pm, more specifically between 60 and 300 pm, and even more specifically between 100 and 300 pm.
  • the qualities of the acrylate resin or the unsaturated polyester resin are expressed mainly if the above-mentioned acrylate resin or the above-mentioned unsaturated polyester resin is cured at least by means of a thermally initiated radical crosslinking reaction.
  • the above-mentioned curing preferably comprises at least a crosslinking of double carbon bonds present in the acrylate resin or in the unsaturated polyester, such as can be the case in UV or electron beam cured acrylate resins or unsaturated polyester resins.
  • the above-mentioned acrylate resin is cured, both by means of a thermally initiated radical crosslinking reaction wherein the double carbon bonds present in the acrylate resin undergo crosslinking, and by means of a crosslinking reaction wherein an oligomer or monomer with a hydroxyl (-OH) and/or an amine (-NH 2 ) and/or a carboxyl (-COOH) functionality is crosslinked with an isocyanate, aziridine carbodiimide, or the like.
  • This crosslinking reaction is promoted by means of the temperature used during the first crosslinking reaction.
  • the acrylate resin comprises or consists of a polyurethane acrylate resin.
  • curing agents such as isocyanate or aziridine in a UV curable coating
  • curing agents cause a second internal crosslinking, specifically of the hydroxyl (-OH) and/or carboxyl (- COOH) and/or amine (-NH 2 ) functional acrylate resins, to take place only in an uncontrolled manner and possibly with a long delay after the previous UV curing.
  • the above-mentioned particular possibility offers the possibility of providing coated panels with a wear layer obtained by applying a dual cure system, wherein the first crosslinking relates to a thermal curing.
  • the second crosslinking is initiated in a controlled manner, and it can be completed in a short period of time. In other words, this is an“instant dual cure system”.
  • the curing of the acrylate resin or the unsaturated polyester resin is further promoted by a thermoset promotor, such as for example by 2,4 pentanedione or N,N-di ethyl acetoacetamide, and/or by a thermoset accelerator, such as for example by a cobalt-free accelerator, such as by copper or iron complex, or by cobalt octoate, amine diethyl aniline, dimethyl-p-toluidine, or ethoxylated p-toluidine.
  • a thermoset promotor such as for example by 2,4 pentanedione or N,N-di ethyl acetoacetamide
  • a thermoset accelerator such as for example by a cobalt-free accelerator, such as by copper or iron complex, or by cobalt octoate, amine diethyl aniline, dimethyl-p-toluidine, or ethoxylated p-toluidine.
  • thermoinitiator can more generally be defined as a thermally unstable molecule that breaks down or disintegrates on exposure to heat, at least in one or more radicals.
  • the radicals produced then play the same role as the radicals that are produced in known photoinitiators in the UV curing of acrylate resins.
  • the thermally obtained radicals initiate the polymerization reaction of the double carbon bonds of the acrylate functionalities present in the acrylate resin.
  • the present invention relates in accordance with an independent second aspect to a coated panel, with at least a substrate and a top layer applied thereto, wherein the above-mentioned top layer comprises at least a decor layer and a translucent or transparent wear layer, characterized in that the above- mentioned wear layer is obtained based on a mixture of at least on the one hand acrylate resin and/or an unsaturated polyester resin and on the other hand a thermoinitiator.
  • the coated panels of the second aspect can show the features of the first aspect or the preferred embodiments thereof.
  • the mixture can further comprise crosslinking agents such as isocyanate, aziridine, carbodiimide or the like, such that the above-mentioned wear layer is obtained by means of the instant dual cure system mentioned in the context of the first aspect.
  • the mixture can also comprise thermoset promoters and/or accelerators such as those mentioned in the context of the first aspect of the invention.
  • thermoinitiator is an organic peroxide, preferably benzoyl peroxide, a methylbenzoyl peroxide, TPBIN (tertiary butylperoxy-3,5,5 trimethyl hexanoate) or lauryl peroxide.
  • TPBIN tertiary butylperoxy-3,5,5 trimethyl hexanoate
  • lauryl peroxide has the lowest activation temperature, and the curing of this resin can thus be completed quickly.
  • thermoinitiator at least benzoyl peroxide or methylbenzoyl peroxide.
  • methyl benzoyl peroxide is the most interesting, since it yields as a reaction product the less toxic toluene, instead of benzene in the case of benzoyl peroxide.
  • the reaction with lauryl peroxide gives rise to the formation of non-toxic aliphatics.
  • thermoinitiators examples include 2-butanone peroxide, persulfate, peroxydiphosphate and persulfate.
  • thermoinitiators examples include ketone peroxide, diacyl peroxide, peroxyketal, hydroperoxide, peroxydicarbonate, peroxymonocarbonate, preferably tert-butyl peroxy 3,5,5 trimethyl hexanoate (TPBIN).
  • azo-polymerization initiators such as azonitrile, azoester, hyponitrites and/or azoamide.
  • azonitrile such as azonitrile, azoester, hyponitrites and/or azoamide.
  • AIBN azobisisobutyronitrile
  • AMBN 2-methylbutyronitrile
  • APN azovaleronitrile
  • cesium ions such as cesium ions.
  • thermoinitiators can be combined.
  • the above-mentioned mixture comprises 0.1-5 parts of thermoinitiator per 100 parts of acrylate resin or per 100 parts of unsaturated polyester resin, and more preferably 0.5-2 parts of thermoinitiator per 100 parts of acrylate resin or per 100 parts of unsaturated polyester resin, and more preferably 0.1-2 parts of thermoinitiator per 100 parts of acrylate resin or per 100 parts of unsaturated polyester resin (if extra crosslinking is carried out with UV light, one can work with such a lower amount of thermoinitiator in order to obtain a similar final curing).
  • concentration of the thermoinitiator By changing the concentration of the thermoinitiator, the obtained chain length of the polymerized acrylate resin or the polymerized unsaturated polyester resin can be adjusted.
  • thermoinitiator With larger amounts of the thermoinitiator, the reaction comes to an end sooner, and shorter chain lengths are obtained, and with smaller amounts, longer chain lengths are obtained. With 0.5-2 parts of thermoinitiator per 100 parts of acrylate resin or per 100 parts of unsaturated polyester resin, a balance is reached between the rate of the reaction and the degree of crosslinking or the chain length.
  • the time frame to half or complete curing is preferably such that a sufficient flow of the resin can be achieved. Flow of the resin is important, for example in a case where the structure of a pressing element is to be copied onto the surface of the wear layer. This specifically requires displacement of the acrylate resin or the unsaturated polyester resin into all relief parts of the pressing element.
  • the flow of the acrylate resin or of the unsaturated polyester can be adjusted.
  • the flow can also be extended, optionally to an even further degree, in the case of acrylate resin by increasing the content of reactive diluting monomers or difunctional monomers, such as for example dipropylene glycol diacrylate (DPGDA), in the acrylate resin.
  • DPGDA dipropylene glycol diacrylate
  • the acrylate resin comprises between 20 and 60 percent by weight of monomers, preferably monofunctional and/or difunctional and/or trifunctional and/or tetrafunctional monomers.
  • the wear layer of the coated panel of the first and/or the second aspect comprises traces of a peroxide, such as benzoyl peroxide, methylbenzoyl peroxide and/or lauryl peroxide.
  • a peroxide such as benzoyl peroxide, methylbenzoyl peroxide and/or lauryl peroxide.
  • the wear layer comprises at least traces of a reaction product resulting from the reaction of the thermoinitiator and the acrylate resin.
  • the wear layer can comprise traces of benzene, toluene or aliphatics.
  • the above-mentioned wear layer is uniformly or essentially uniformly cured over its entire thickness.
  • thermal curing comprises chemical crosslinking-preferably of the double carbon bonds present in the acrylate resin-and/or of the double carbon bonds present in the unsaturated polyester resin.
  • Such a crosslinking reaction gives rise to extremely favorable wear characteristics.
  • the above-mentioned wear layer is obtained based on a mixture containing at least on the one hand acrylate resin and/or unsaturated polyester resin and on the other hand a photoinitiator. More preferably, the mixture comprises 0.1-5 parts of a photoinitiator per 100 parts of acrylate resin or per 100 parts of unsaturated polyester resin. More preferably, this mixture comprises 0.1-5 parts of two different photoinitiators per 100 parts of acrylate resin or per 100 parts of unsaturated polyester resin.
  • the photoinitiators are selected such that one photoinitiator cures the uppermost 20 pm of the wear layer (curing at the surface) and the other photoinitiator cures the wear layer more in depth (curing in depth). This allows more favorable curing of the wear layer to be obtained.
  • the above-mentioned decor layer comprises a carrier sheet provided with synthetic material, such as a paper sheet.
  • synthetic material such as a paper sheet.
  • a paper sheet can for example be a printed paper of the type that is applied for the production of laminate panels of the DPL type and/or a paper with a Gurley value of less than 30 seconds, or even less than 25 or 20 seconds.
  • the paper has a surface weight of 40 to 250 grams per square meter, and more preferably between 55 and 150, or between 65 and 90 grams per square meter.
  • the higher surface weights, specifically of between 90 and 150, are preferably applied in furniture panels, while the lower surface weights, specifically of between 65 and 90 grams per square meter, are preferably applied in floor panels.
  • the printing can be obtained in an analogous manner, for example by means of an offset printing process with printing cylinders, and/or in a digital manner, for example by means of an inkjet printing process, preferably in a so-called single-pass printer.
  • a film out of synthetic material such as a film of PVC (polyvinyl chloride) or PET (polyethylene terephthalate), whether printed or not, or a veneer.
  • films out of synthetic material are an example of wet impermeable layers and that the present inventors have found that because no chemical moisture is produced in the curing of the acrylate resin, a thermally cured wear layer, more specifically based on acrylate resin, can be formed on a film out of synthetic material or other impenetrable layer.
  • the synthetic material that is provided on the carrier sheet is a synthetic material that comprises double carbon bonds.
  • the synthetic material that is provided on the carrier sheet forms a part of the above-mentioned wear layer, wherein this part is located between the decor layer itself, for example a printed pattern or a veneer, and the part of the wear layer formed by thermally cured acrylate.
  • the part of the wear layer formed by the synthetic material of the decor layer can comprise hard particles such as particles of aluminum oxide, silicon oxide or silicon carbide.
  • the synthetic material that is provided on the carrier sheet is selected from the list of amino resins, urea formaldehyde, melamine urea formaldehyde, melamine formaldehyde, a polyurethane dispersion, an urethane-acryl copolymer dispersion, acrylate, latex, melamine acrylate, reactive acrylate monomers, optionally in combination with a cross linking agent such as carbodiimide, polyisocyanate or aziridine.
  • the synthetic material is preferably applied to the carrier sheet in a water-based mixture or dispersion, for example via immersion, one or more roll applications, and/or one or more spray or pouring applications.
  • This dispersion can be anionically, cationically, or non-ionogenically stabilized.
  • this carrier sheet comprises a digitally printed decor layer
  • the dispersion is preferably cationically stabilized in order to prevent possible salts or acids in an optional inkjet receiver coating from destabilizing the polyurethane dispersion.
  • the above-mentioned synthetic material it is of course not excluded for the above-mentioned synthetic material to be melamine formaldehyde.
  • a coating is applied that promotes bonding with thermally curing acrylate resin or thermally curing polyester resin.
  • Such a coating can comprise an aliphatic polyurethane dispersion, latex dispersion, a water-based UV curable substance such as water-based UV curable acrylate resin, melamine acrylate, a chemically modified melamine resin or an etherified melamine resin. It is of course not excluded for the above-mentioned synthetic material to be thermally curable acrylate resin or unsaturated polyester resin.
  • a cationically stabilized polyurethane dispersion such as in this case, to form a coating on and/or to impregnate a printed paper sheet constitutes an important finding per se.
  • the invention then also relates in accordance with a particular independent aspect to a method for the production of coated panels with a substrate and a decorative top layer with a printed paper sheet, characterized in that the method comprises at least the step of the provision of a cationically stabilized polyurethane dispersion on the paper sheet that is printed or is to be printed.
  • the printing of this paper sheet is preferably carried out in a digital manner and/or that this paper sheet comprises a previously applied coating with a pH of less than 7, preferably 5 or lower, for example an inkjet receiver coating.
  • the present particular aspect can of course show other preferred features such as those described earlier in this paragraph or described in the context of the other aspects of the present invention.
  • the polyurethane dispersion used can further also show the following characteristics.
  • a polyurethane dispersion is applied to the carrier sheet.
  • a polyurethane coating is obtained on the carrier sheet with a Konig hardness of 20 to 160 seconds, 40 to 120 seconds, and preferably 40 to 100 seconds, more preferably 40 to 80 seconds.
  • the inventor has found that this hardness gives rise to better adhesion to the thermally curing acrylate resin or thermally curing unsaturated polyester resin of the wear layer.
  • Polyurethane coatings with a higher Konig hardness can more easily lead to adhesion problems.
  • the softer polyurethane specifically with a Konig hardness of 20 to 160 seconds, 40 to 120 seconds, and preferably 40 to 80 seconds, shows better scratch resistance.
  • the polyurethane of the present example can also be located in the core of the carrier sheet.
  • the core of the carrier sheet impregnated with a polycondensing resin such as a melamine-based resin, while the polyurethane coating is mainly present at the surface of the carrier sheet.
  • a polycondensing resin such as a melamine-based resin
  • the polyurethane coating shows an elongation of between 40 and 400%, 100 and 300%, and preferably 120 and 250%.
  • the high elongation provides a bridge between the decorative paper, which as mentioned above can optionally be provided in the core with a polycondensing, for example a melamine-based, resin, and the thermally curing acrylate resin.
  • a polycondensing for example a melamine-based, resin
  • the thermally curing acrylate resin is at least obtained based on a multifunctional acrylate or methacrylate monomer and/or oligomer, such as a hexafunctional acrylate or methacrylate oligomer.
  • a multifunctional acrylate or methacrylate oligomer provides a hard layer, but one that is as brittle and wear-resistant as possible.
  • the polyurethane dispersion applied in accordance with the above-mentioned important example is water-based and comprises an acrylate functionality, and/or the dispersion comprises a UV acrylate, for example an epoxy modified polyurethane acrylate, such as for example the commercially available NeoRad UV20 40W.
  • a UV acrylate for example an epoxy modified polyurethane acrylate, such as for example the commercially available NeoRad UV20 40W.
  • improved adhesion can be obtained with thermally curing acrylate resin.
  • solvent for example, one can use DPnB (dipropylene glycol n-butyl ether), DPM (dipropylene glycol methyl ether); PM (propylene glycol methyl ether), 2-butoxy ethanol or di ethylene glycol.
  • the PU dispersion shows an MFFT (minimum film forming temperature, ISO 2115) of between 0 and 40°C, between 6 and 20°C, and preferably between 5 and l5°C.
  • MFFT minimum film forming temperature
  • Reactive 100% acrylate primer can also be used. This primer penetrates the melamine layer and can be covalently bonded to the transparent top layer that is later applied.
  • This acrylate primer can for example be composed of HDDA (1, 6-hexane diol diacrylate), ACMO (acryloyl morpholine), melamine acrylate or acidic adhesion acrylate.
  • the above-mentioned acrylate resin is at least obtained based on a monofunctional or difunctional acrylate or methacrylate monomer and/or oligomer.
  • a difunctional acrylate or methacrylate oligomer yields a tough or less brittle wear-resistant layer.
  • Trifunctional and/or tetrafunctional acrylates can also be used.
  • the above-mentioned acrylate resin is of the aliphatic type.
  • aging and/or discoloration are limited to the maximum degree.
  • the acrylate resin comprises 5 to 80 percent by weight of monomers, or more preferably 5 to 60 percent by weight, which can be monofunctional, difunctional or multifunctional.
  • Monomers in the acrylate resin can have one or more of the following effects: increasing the viscosity to the desired value, increasing the adhesion through better absorption in adjacent layers, such as in the substrate, or positively or negatively influencing the reactivity in the decor layer, significantly influencing the flexibility and/or brittleness of the obtained wear layer, setting the operational range for example in terms of the temperature to be used, and positively influencing the chemical resistance. For example, with a multifunctional monomer, better crosslinking, curing and chemical resistance can be achieved.
  • a trifunctional monomer such as TMPTA can be used.
  • difunctional monomers in view of the short chain length, promotion of the crosslinking and curing can also be achieved.
  • DPGDA dipropylene glycol diacrylate
  • the above-mentioned acrylate resin is at least obtained based on a mixture of two or more acrylate oligomers of different functionality, preferably based on a mixture of a multifunctional acrylate oligomer, wherein "multi" is considered to mean more than two, and a difunctional acrylate oligomer.
  • multi is considered to mean more than two
  • difunctional acrylate oligomer With such a mixture, the desired hardness and toughness of the final wear layer can be set.
  • the use of acrylate resin as a wear layer also makes it possible to mix in acrylates with particular characteristics.
  • the above-mentioned acrylate resin can at least be obtained with a chemically modified acrylate such as a fluoroacrylate.
  • acrylate resin By adding chemically modified acrylates to the acrylate resin, characteristics can be achieved such as water repellency, ease of maintenance, anti-fingerprint properties, and antimicrobial characteristics.
  • Other possible additives to the acrylate resin are metallic pigments and materials that improve the haptic interaction. The additives mentioned here have no or essentially no influence on thermal curing of the acrylate resin.
  • At least hard particles such as aluminum oxide particles, silicon oxide or silicon carbide particles are added to the acrylate resin or to the unsaturated polyester resin.
  • the above-mentioned hard particles are located between the above-mentioned decor layer and the part of the wear layer formed by means of the acrylate resin and/or thermally cured unsaturated polyester resin.
  • the above- mentioned hard particles can be located in a layer formed by this synthetic material.
  • at least 5 grams or at least 10 grams per square meter of such hard particles are added. Such particles can further increase the wear resistance.
  • the particles have a so-called mesh size of F 100 or smaller, but preferably not less than a mesh size of F320.
  • the latter roughly corresponds to an average particle size of between 30 and 125 pm.
  • the wear resistance of the obtained wear layer can, whether or not in combination with the presence of hard particles, also be adjusted by means of the thickness thereof.
  • the wear layer obtained base on thermally cured acrylate resin has at least a thickness of 50 pm, and preferably at least 100 pm.
  • the above-mentioned wear layer is obtained by means of 10 to 300 grams per square meter of the above-mentioned acrylate resin or the above-mentioned unsaturated polyester resin.
  • the wear layer is preferably obtained using 10 to 80 grams (dry solids)-and preferably 10 to 30 grams (dry solids)-per square meter of the acrylate resin or thermally cured unsaturated polyester resin, while, in the case of a floor panel, the wear layer is preferably obtained using 30 to 160 grams per square meter of the acrylate resin or the unsaturated polyester resin.
  • the wear layer is composed of various layers.
  • the wear layer comprises multiple layers that have the features described as embodiments for the wear layer in the first and/or second and/or fourth aspect of the invention, and/or are obtained by any embodiment of the method of the third aspect of the invention.
  • the thermally cured acrylate resin or the unsaturated polyester resin can be applied in the wear layer in multiple layers, and these layers can be identical with respect to chemical formulation, but they can also be different from one another in order to optimize the relationship of performance to cost or to optimize flow behavior in the press.
  • the compositions of these multiple layers differ from one another.
  • the uppermost layer of the wear layer comprise one or more of a fluorine- containing acrylate, a micro aluminum oxide, a silicone acrylate or a nanosilica.
  • the coated panel in accordance with any of the independent aspects of the invention is a floor panel, preferably suitable for floating installation.
  • the wear layer can show a particularly high wear and/or scratch resistance, but is also sufficiently soft to obtain a significant improvement in noise compared to conventional melamine surfaces.
  • the coated panel has a relief on its surface.
  • the relief also shows gloss differences. These gloss differences can occur in zones with at least two respective gloss levels, wherein these gloss levels can be clearly distinguished by the user and thus with the naked eye. More specifically, it is preferable for at least two gloss levels each to be used for the above-mentioned zones that are to be selected such that specified zones clearly manifest themselves as matte zones, while other zones manifest themselves as non-matte or glossy zones.
  • the matte zones on the coated panel for example a floor panel, preferably show a gloss level of 10 or more preferably less than 10, while the less matte or glossy zones show a gloss level of more than 10, and more preferably more than 20, all of this being measured in accordance with DIN 67530.
  • the difference in gloss level between the matte and glossy zones of the coated panel is preferably at least 10.
  • the present invention further relates in accordance with an independent third aspect to a method for the production of coated panels, wherein the panels comprise at least a substrate and a top layer applied thereto and the above-mentioned top layer comprises at least a decor layer and a translucent or transparent wear layer, characterized in that the method comprises at least the following steps:
  • the step of applying to the above-mentioned decor layer one or a combination of an acrylate resin, an unsaturated polyester resin, a coating composition that comprises an acrylate resin; wherein the acrylate resin, the unsaturated polyester resin or the coating composition optionally comprises a thermoinitiator and optionally a photoinitiator; and - the step of at least partial curing of the above-mentioned acrylate resin or unsaturated polyester resin or coating composition by means of hot pressing to form at least a part of the above-mentioned wear layer.
  • the coating composition or the acrylate resin comprises at least a multifunctional acrylate oligomer and 0.5 to 2 parts of benzoyl peroxide, methylbenzoyl peroxide or lauryl peroxide as a thermoinitiator per 100 parts of acrylate resin; and more favorably 0.1 to 2 parts of benzoyl peroxide, methylbenzoyl peroxide or lauryl peroxide as a thermoinitiator per 100 parts, and more favorably 0.1 to 1 parts of benzoyl peroxide, methylbenzoyl peroxide or lauryl peroxide as a thermoinitiator per 100 parts.
  • thermocured acrylate resin By means of the curing under pressure, maximum advantage is taken of the possibilities of thermocured acrylate resin or thermocured unsaturated polyester resin. It is clear that in this case as well, the above- mentioned instant dual cure system can be applied, wherein the lower amounts of the thermoinitiator can be used.
  • an acrylate resin - whether or not it constitutes an above-mentioned coating composition - or an unsaturated polyester resin
  • an acrylate resin or an unsaturated polyester resin that comprise oligomers and monomers is preferably used.
  • At least hard particles such as aluminum oxide particles, silicon oxide particles or silicon carbide particles are added to the acrylate resin or the unsaturated polyester resin or the coating composition.
  • the above-mentioned pressing is carried out by means of a so-called short cycle press or single-daylight press.
  • a press of the continuous type preferably a press makes use of moving pressing belts between which the whole to be pressed moves or a hot press roller.
  • a press of the continuous type that makes use of one or more press cylinders that are preferably textured.
  • the invention is of particular importance in the texturing of wear layers by means of press cylinders (in texturing, the top layer of the coated panel is provided with a relief).
  • the residence time under pressure is particularly short, and rapid thermally curing acrylate resin or rapid thermally curing polyester resin can sufficiently take on the structure of the pressing element even during such a short residence time.
  • the top layer of the coated panel is provided with a relief, including an exact copy of the different gloss levels.
  • the above-mentioned pressing is carried out at a temperature of 70 to 220°C (and preferably a temperature of 120 to 220°C) and/or at a pressure of 5 to 80 bar.
  • the inventors have achieved favorable results in pressing in a short cycle press at l95°C and 40 bar (approximately 40 kg/cm 2 ) for 22 seconds.
  • Such process parameters correspond to those used in the pressing of melamine-based laminate panels.
  • high temperatures and high pressures are not necessary in the pressing of thermally curing acrylate resin or thermally curing unsaturated polyester resin, and the process parameters can be adapted over a broad range, more specifically reduced until the desired efficacy is achieved.
  • the thermally curing acrylate resin - including the acrylate resin in the coating composition - or thermally curing unsaturated polyester resin preferably shows sufficient flow in cases of working with a structured pressing element.
  • the inventors have found that it can be important to rapidly increase the pressure of pressing so that the deformations due to the pressing element in order to form the desired structure in the surface and/or in the substrate of the panel are carried out before the curing of the acrylate resin has essentially taken place.
  • This is also important in cases wherein the wear layer of thermally curing acrylate resin is to adhere to an underlying layer that for example comprises polyurethane, such as to a carrier sheet, or decorative paper that is treated at its surface with a polyurethane dispersion such as described above.
  • the above-mentioned pressing is carried out with the help of a structured pressing element, such as with a structured press plate, for example of the type that is known per se from WO 2009/043910.
  • a so-called framework or frame is used in pressing that extends along all of the edges of the material to be pressed.
  • the purpose of such a framework or frame is to optionally counteract splashing of the acrylate resin or the unsaturated polyester resin out of the press when the pressure increases.
  • selection of the thickness of the framework or the frame makes it possible to set the exact desired thickness of the wear layer.
  • the frame or framework ensures that sufficient pressure is exerted on the curing acrylate resin or the curing unsaturated polyester resin.
  • the method of the invention further comprises the step of post-curing of the pressed wear layer by means of ultraviolet and/or electron radiation, both preferably carried out under an inert atmosphere.
  • a surface can be achieved that has relief and/or gloss differences comparable to the structures that can be achieved in a melamine surface, but with the quality and noise characteristics of an electron beam cured surface.
  • the wear layer that is pressed and structured by means of a pressing element can be post-cured by means of electron radiation under an inert atmosphere.
  • the above-mentioned pressing is carried out on a stack that comprises at least the substrate, the decor layer and the acrylate resin, unsaturated polyester resin or the coating composition.
  • a process is achieved that in many aspects corresponds to the course of a production process for laminate panels, such that said process can be simply incorporated into an existing laminate production.
  • the step of application to the above-mentioned decor layer of the acrylate resin or unsaturated polyester resin or coating composition is carried out while the decor layer is already part of a stack that comprises at least the substrate and the decor layer.
  • the above-mentioned decor layer comprises a carrier sheet, such as a paper sheet, and the method also comprises, in such a case, preferably at least the step of providing this carrier sheet with synthetic material.
  • the method can further also comprise the step of providing the above-mentioned synthetic material with hard particles such as particles of aluminum oxide, silicon oxide or silicon carbide.
  • This step can be carried out in practice in a variety of ways, for example by mixing the hard particles into the synthetic material before they are provided on this carrier sheet, or by applying the hard particles in the synthetic material after it has already been provided on the carrier sheet, for example by spreading these particles, or by roller application, spraying, or jet application of flowable mixtures or dispersions that comprise these particles .
  • the step of providing this carrier sheet with synthetic material comprises at least the application of a water-based or a water-borne UV curable synthetic material to the above-mentioned carrier sheet.
  • the step of providing this carrier sheet with synthetic material comprises at least the application of a UV curable substance, for example an acrylate resin and/or an unsaturated polyester, wherein this substance further comprises a thermoinitiator.
  • a UV curable substance for example an acrylate resin and/or an unsaturated polyester, wherein this substance further comprises a thermoinitiator.
  • This can be a so-called hydro-UV or a full hydro system in which a thermoinitiator is contained.
  • Solvent-based acrylates can also be used; after drying, these form a film that is not adhesive.
  • Such systems can comprise relatively long oligomers.
  • the treated carrier sheet can be dried to a non-sticking state. The final curing of the oligomers can then take place in the pressing.
  • the synthetic material that is provided on the carrier sheet preferably further comprises hard particles such as corundum particles, e.g. aluminum oxide particles.
  • hard particles such as corundum particles, e.g. aluminum oxide particles.
  • acrylates with a specific functionality such as acrylates that provide increased cleanability
  • this coating composition this acrylate resin or this unsaturated polyester resin can be gelled prior to the pressing and/or post-cured after the pressing by means of a UV irradiation, with or without an inert atmosphere (in order to counteract oxygen inhibition).
  • any UV irradiation prior to the pressing does not necessarily have to be carried out on all partial layers.
  • coating compositions are used in the method used that at least comprise: an acrylate resin, one or more components that comprise free hydroxyl groups, one or more components that comprise free isocyanate groups, optionally one or more thermoinitiators, optionally photoinitiators, and optionally one or more crosslinkers.
  • the coating composition can comprise hard particles in the manner of and as mentioned in the other independent aspects of the invention.
  • the coating composition comprises a hydroxyl functional acrylate and/or a hydroxyl functional urethane acrylate.
  • the coating composition comprises an isocyanate polymer and/or an isocyanate functional acrylate.
  • a condensation reaction occurs between hydroxyl and isocyanate groups of the coating composition, thus giving rise to crosslinking in the coating composition.
  • the method comprises the step of removing water and/or solvent from the coating composition, from the acrylate resin or from the unsaturated polyester resin.
  • the method comprises the step of gelling of the coating composition, the acrylate resin or the unsaturated polyester resin to a non-viscous state.
  • Such embodiments have the advantage of allowing a non-tacky intermediate product to be obtained, for example in a rolled-up state before carrying out the hot pressing.
  • the method comprises, after the hot pressing, the step of UV post-curing of the pressed wear layer, wherein crosslinking of double bonds occurs.
  • the coating composition, the acrylate resin or the unsaturated polyester resin preferably comprise photoinitiators. This UV curing preferably takes place under an inert atmosphere.
  • the method comprises, after the hot pressing, the step of thermal post-curing of the pressed wear layer, wherein crosslinking of double bonds occurs.
  • the coating composition, the acrylate resin or the unsaturated polyester resin preferably comprise thermoinitiators.
  • thermal post-curing after the hot pressing is carried out at a higher temperature than the hot pressing.
  • the method before the step of application to the above- mentioned decor layer of the or a combination of the coating composition, the acrylate resin or the unsaturated polyester resin; the method comprises the step of the application of an adhesion promoter to the above-mentioned decor layer.
  • the adhesion promoter comprises or consists of one or more of a polyurethane, a polyurethane dispersion, a water-based polyurethane dispersion, a polyurethane dispersion with acrylate functionality, a melamine acrylate or an acrylate primer. More preferably, a reactive low-viscosity acrylate primer is used.
  • Adhesion promoters such as those described in the first and/or second aspect of the invention can be used in the method of the third aspect of the invention.
  • this coating composition preferably comprises a solvent, for example butyl acetate.
  • a coating composition that comprises a solvent has a number of advantages. If the coating composition is applied to a decor layer that is thermoplastic, this solvent acts on this thermoplastic decor layer. In this manner, after curing of the wear layer, a better adhesion to the decor layer is obtained.
  • a decor layer that comprises a thermoplastic film, for example polyvinyl chloride (PVC); and more preferably a printed thermoplastic film, more preferably a printed thermoplastic polyvinyl chloride (PVC) film.
  • thermoplastic substrates can comprise fillers such as wood fibers, or inorganic fillers such as calcium, clay or chalk.
  • thermoplastic substrates can comprise polyvinyl chloride (PVC) or polyethylene or polypropylene as a thermoplastic.
  • the method preferably comprises the step of application of the decor layer to the substrate by unrolling the decor layer from a roll, and this decor layer is preferably a film out of synthetic material or a printed film out of synthetic material or a printed paper sheet - and preferably impregnated with a thermally curing resin. More preferably, the coating composition is laid on the decor layer by a dry method via unrolling from a roll.
  • a relief is pressed into the wear layer after the hot pressing, and after pressing of the relief, a post-curing of the wear layer is carried out thermally or by means of ETV radiation.
  • the wear layer is partially thermally cured in the hot pressing. However, the wear layer then still shows sufficient plastic properties to allow a relief to be pressed into it in subsequent processing-whether or not in a hot state. Because of the plastic behavior of the wear layer, this can be carried out in the form of the pressed relief, and without the occurrence of any cracks in the wear layer.
  • the wear layer is further cured so that it can be given its final characteristics.
  • thermoplastic substrates such as substrates that comprise polypropylene, polyethylene, polyvinyl chloride, whether or not with fillers such as wood fibers or wood particles or inorganic fillers such as for example calcium, clay or chalk.
  • the substrate comprises a thermoplastic, preferably PVC, polypropylene or polyethylene.
  • this thermoplastic is filled with fillers.
  • the decor layer comprises a film out of synthetic material, for example a polyvinyl chloride film, and more preferably, this film out of synthetic material is printed.
  • the decor layer can comprise or consist of a printing on the substrate.
  • the substrate comprises a wood fiberboard (such as MDF or HDF) or consists thereof; and the decor layer comprises a printed carrier sheet, preferably a printed paper sheet.
  • the carrier sheet is preferably impregnated with a thermally curing resin.
  • the method can also be carried out in accordance with a number of possibilities that are discussed below.
  • acrylate resin is specified, these possibilities also apply to the use of the coating composition that comprises an acrylate resin.
  • the acrylate resin or the unsaturated polyester resin or the coating composition is applied via a two-component lacquer.
  • This two-component lacquer can be dried by means of physical curing, while the thermally curing acrylate component or the thermally curing unsaturated polyester component is cured in the hot pressing.
  • thermoinitiators are applied with a different SADT (self accelerating decomposition temperature).
  • SADT self accelerating decomposition temperature
  • the lowest SADT is preferably selected such that it is below the pressing temperature, and the thermoinitiator can thus become effective prior to the pressing or prior to the activation of the other thermoinitiator. In activation of a thermoinitiator with the lowest SADT, some drying can be obtained.
  • the acrylate resin is applied as a 100% solid substance with both a photoinitiator and a thermoinitiator.
  • the acrylate resin can then be gelled by means of UV radiation in order to obtain some drying.
  • the coated paper can then optionally be stored at a temperature of less than the SADT of the thermoinitiator. Further or complete curing is then achieved in the hot pressing. After pressing, there is the option of carrying out further curing by means of UV radiation.
  • a hydro- or water-based lacquer with both a photoinitiator and a thermoinitiator is worked with. It is possible to work in the same manner as in the third possibility, with a similar option of carrying out further curing after pressing.
  • a solvent-based acrylate resin or unsaturated polyester resin that comprises a thermoinitiator and/or a photoinitiator. After the application of the solvent-based resin, the solvent is evaporated at low temperature. A tack-free surface is then obtained. The curing follows in pressing of the panel, optimally with extra curing by means of UV radiation after pressing.
  • a dual cure lacquer used, wherein a combination of hydroxyl functional acrylates is combined with isocyanate functional acrylates.
  • This lacquer comprises photoinitiators and/or thermal initiators. After evaporation of the solvent, the lacquer is not tacky, and the curing is achieved by crosslinking of the hydroxyl and isocyanate groups with accompanying curing via the double carbon bonds.
  • thermoinitiator in order to initiate the radical reaction.
  • the acrylate resin can then be gelled by means of hot air or (N)IR radiation.
  • the coated paper can then optionally be stored at a temperature of less than the SADT of the thermoinitiator. Further or complete curing is then achieved in the hot pressing. After pressing, there is the option of carrying out further curing by means of UV radiation, if a photoinitiator is to be present.
  • thermally cured acrylate resin layer or thermally cured unsaturated polyester to cover the entire surface of the floor panel, optionally with the exception of lowered edge areas, for example in the form of bevels or so-called chamfered edges. In this manner, sufficient water resistance is imparted to the entire surface.
  • the present invention in accordance with an independent fourth aspect, also relates to a coated panel with at least a substrate and a top layer applied thereto, wherein the above-mentioned top layer comprises at least a decor layer and a translucent or transparent wear layer, characterized in that the above-mentioned wear layer comprises an acrylate, wherein this acrylate comprises covalent bonds formed by reaction of hydroxyl groups with isocyanate groups.
  • Coated panels in accordance with the fourth aspect of the invention can be made by means of the method of the third aspect of the invention, wherein an acrylate resin or a coating composition that comprises an acrylate resin is used.
  • an adhesion promoter is preferably located between the decor layer and the wear layer.
  • the adhesion promoter comprises or consists of one or more of a polyurethane, a polyurethane dispersion, a water-based polyurethane dispersion, a polyurethane dispersion with acrylate functionality, a melamine acrylate or an acrylate primer, for example a reactive low-viscosity acrylate primer.
  • Adhesion promoters mentioned in the other aspects of the invention can be applied in this case.
  • Coated panels in accordance with the fourth aspect of the invention preferably comprise a relief in the wear layer. More preferably, this relief shows gloss differences.
  • coated panels in accordance with the fourth aspect of the invention have a decor layer that shows a wood pattern by printing and the wear layer comprises a relief in register with the wood pattern, and the relief more preferably comprises gloss differences in register with the wood pattern.
  • coated panels in accordance with the fourth aspect of the invention comprise a substrate that a comprises a thermoplastic, for example polyvinyl chloride, polyethylene or polypropylene.
  • this thermoplastic comprises one or more of fillers, for example wood fibers or inorganic fillers such as calcium, clay or chalk.
  • the decor layer comprises a film out of synthetic material or a printed film out of synthetic material, or the decor layer comprises printing on the substrate.
  • coated panels in accordance with the fourth aspect of the invention comprise a substrate that comprises or consists of a wood fiberboard (such as MDF or HDF).
  • the decor layer comprises a printed carrier sheet, preferably a printed paper sheet, and preferably a printed paper sheet impregnated with a thermally curing resin.
  • the method of the third aspect is preferably used for producing the coated panels of the first and/or the second aspect and/or the fourth aspect and/or the preferred embodiments thereof. It is clear that the coated panels of the first, the second, or the fourth aspect and/or obtained in accordance with the third aspect can show different structures. Several important possibilities are listed below, without this list being intended to be exhaustive.
  • the coated panel comprises a wood fiberboard as a substrate, a printed paper sheet provided with synthetic material as a decor layer, and the wear layer of the invention.
  • the printed paper sheet comprises a coating of polyurethane, at least on the surface that is oriented towards the wear layer.
  • the paper sheet in the core is impregnated with a melamine- based resin such as a modified melamine resin.
  • the polyurethane coating preferably has a Konig hardness of 50 to 70 seconds.
  • the wear layer preferably shows traces of benzene or toluene, or benzoyl peroxide or methylbenzoyl peroxide.
  • the coated panel shows at its surface, more specifically in the wear layer, a structure or relief with sections 400 pm deep or deeper and/or relief sections that penetrate into the substrate.
  • the coated panel comprises a substrate that is composed of synthetic material or a synthetic composite, more specifically of a thermoplastic or a thermoplastic composite.
  • This can for example be a substrate based on filled PVC (polyvinyl chloride), PP (polypropylene), PET (polyethylene terephthalate), PU (polyurethane).
  • the filler can comprise calcium carbonate or talc or another powder or substance, such as wood chips, bamboo chips, and/or other plant components.
  • PVC polyvinyl urethane
  • the decor layer can for example comprise a print configured on a film out of synthetic material, for example on a PVC film.
  • the wear layer then comprises, in accordance with the invention, at least a part obtained based on a thermally cured acrylate or a thermally cured unsaturated polyester. It is clear that the wear layer can also comprise further parts, such as a transparent film out of synthetic material, for example a transparent PVC film, that is then preferably located under the part that is formed by thermally cured acrylate or thermally cured unsaturated polyester.
  • This embodiment allows the provision of sharp relief characteristics and excellent surface properties on the surface of a panel that is primarily composed of thermoplastic.
  • the coated panel comprises a substrate that is at least partially cured together with the part of the wear layer formed from a coating composition or an acrylate resin or an unsaturated polyester resin and preferably also a decor layer.
  • the substrate can for example be formed based on a textile layer, woven or nonwoven, for example a so-called spunbond nonwoven layer, such as a textile layer based on glass fibers, steel fibers and the like that is preferably provided with thermally curing synthetic material, such as thermally curing acrylate resin or thermally curing unsaturated polyester. It is possible to form a coated panel of this third possibility in one step by pressing a stack with the textile layer provided with synthetic material, the decor layer and the wear layer in a hot press.
  • the coated panel comprises a substrate and a wear layer in accordance with the invention, but the decor layer is formed by the surface of the substrate.
  • the substrate can for example be the case in decorative plate materials such as wooden plate materials, for example for application of the invention in solid parquet, or oriented strand boards (OSB).
  • the top layer is formed as mentioned above in one of the first to the seventh possibilities, but the substrate is formed by a fiber cement plate, magnesium oxide-based plate, polyolefin-based plate, wood chip plate, OSB, filled soft PVC plate, filled hard or rigid PVC plate, foamed plate out of synthetic material, preferably a so-called closed-cell foamed plate out of synthetic material, a multilayer plate such as a multiplex plate or a synthetic material-based plate with both layers of soft PVC and layers of hard PVC or rigid PVC.
  • the present invention in accordance with an independent fifth aspect, also relates to a coated panel with at least a substrate and a top layer applied thereto, wherein the above-mentioned top layer comprises at least a decor layer, characterized in that between the above-mentioned decor layer and the substrate there is a thermally cured acrylate resin or a thermally cured unsaturated polyester resin and/or in that the decor layer is at least partially formed by a thermally cured acrylate resin or a thermally cured unsaturated polyester resin.
  • the coated panel thus does not necessarily have a wear layer.
  • this wear layer is not necessarily obtained based on a thermally cured acrylate resin or based on a thermally cured unsaturated polyester resin.
  • the inventors have found that the presence of a thermally cured acrylate resin or a thermally cured unsaturated polyester resin in any position in the top layer can lead to improvement in clicking sounds and other characteristics of the surface.
  • the acrylate resin or polyester resin and/or thermoinitiators used in the context of the fourth aspect may be the same as those discussed in the context of the first to the fourth aspect, with the understanding that they need not necessarily lead to a transparent or translucent layer.
  • the above-mentioned decor layer comprises at least a carrier sheet, such as a paper sheet, wherein thermally cured acrylate resin or thermally cured unsaturated polyester resin forms the bond between the above-mentioned carrier sheet and the substrate.
  • a carrier sheet such as a paper sheet
  • thermally cured acrylate resin or thermally cured unsaturated polyester resin forms the bond between the above-mentioned carrier sheet and the substrate.
  • thermally cured acrylate resin or thermally cured unsaturated polyester resin in the fourth aspect is configured to be colored, for example in that it comprises pigments such as titanium oxide.
  • the invention can possibly relate to a white panel that can be used per se for example as a furniture panel, or that as a semi-finished product can be used in a method wherein the white layer is used as a printing substrate for printing still to be carried out.
  • thermally cured acrylate resin or thermally cured unsaturated polyester resin forms a base layer for printing carried out thereon that at least partially forms the above- mentioned decor layer.
  • the above-mentioned decor layer is a veneer, wherein thermally cured acrylate resin or the non-thermally-cured unsaturated polyester resin preferably extends from the underside of the veneer into and/or through pores, cracks and other openings present in the veneer.
  • the acrylate resin or the polyester resin is preferably colored. In this manner, the acrylate resin or the polyester resin can form a colored filling at the surface of the veneer at the location of openings such as knot holes and cracks.
  • a wood fiberboard such as an MDF or HDF plate.
  • a wood fiberboard with low density specifically with an average density of less than 750 kg per cubic meter, or even 650 kg per cubic meter or lower.
  • the use of a plate of such low density contributes to further improvement of noise, for example the clicking noise, in the use of the coated panel, primarily in cases where these panels are used as floor panels in a floating installation.
  • the use of such wood fiber plates of low density is partly made possible by the lower residual tensile stresses in the surface of the panels of the preceding aspects.
  • a substrate is used that is free of unbound formaldehyde or free of formaldehyde.
  • The can for example be a wood fiberboard that is bonded by means of pMDI glue (polymeric methylene diphenyl diisocyanate).
  • pMDI glue polymeric methylene diphenyl diisocyanate
  • the top layer is also free of formaldehyde, for example chiefly built up based on paper and thermally curing acrylate resin and/or polyurethane, a completely low- formaldehyde or formaldehyde-free coated panel is obtained.
  • the invention in accordance with all of its aspects, taken separately, allows the above-mentioned top layer to comprise a water-impenetrable layer.
  • thermally curing acrylate resin or thermally curing unsaturated polyester resin in contrast to melamine formaldehyde, does not produce any so-called“chemical” water as a byproduct in the polymerization.
  • this chemical water it is important that this chemical water can escape, whether into the substrate or to the surface, and in such a case, water-impenetrable layers are an obstacle to be avoided.
  • the above-mentioned water-impenetrable layer is formed by a layer present between the above-mentioned decor layer and the substrate.
  • any moisture that is present on the surface of the coated panel cannot penetrate into the substrate, and a highly dimensionally-stable panel can be obtained with varying humidity.
  • the above-mentioned substrate comprises a wood fiberboard or consists thereof.
  • the above-mentioned water-impenetrable layer is formed by an ink layer that at least partially forms the above-mentioned decor layer.
  • water- impenetrable layers are TPU (thermoplastic polyurethane) films, polyester-based layers, aluminum foils, in particular non-perforated aluminum foil, and the like.
  • TPU thermoplastic polyurethane
  • the dimensional stability of the coated panels can be increased.
  • the present invention in accordance with all of its aspects, separately, can be applied in a particularly useful manner in coated panels on which the decor layer comprises printing based on UV cured inks.
  • the decor layer comprises printing based on UV cured inks.
  • UV cured inks can form a strong barrier for the above-mentioned chemical water of a melamine polycondensation reaction, which leads to all kinds of undesirable effects at the surface of the panels.
  • the present invention prevents or limits the formation of chemical water by using a thermally curing acrylate resin in the top layer.
  • the wear layer in the context of the present invention is considered to be the entire layer between the printed decor layer and the surface of the panel. Furthermore, it is clear that this wear layer is preferably essentially or even entirely composed using the above-mentioned thermally cured acrylate resin or thermally cured unsaturated polyester resin or the cured coating composition that comprises an acrylate resin. It is also not excluded for the wear layer at the surface of the panel to comprise another superficial coating and/or for a part of the wear layer to be formed by synthetic material that is originally applied to a carrier sheet of the decor layer as mentioned above.
  • the above-mentioned wear layer comprises a material sheet, such as a paper sheet.
  • a material sheet makes a considerable contribution to the impact resistance of the floor panel and reduces the risk that the usually hard but brittle wear layer will crack.
  • the material sheet makes the wear layer more ductile, which is also important in subsequent processing of the edges of the floor panel.
  • the ductility of the wear layer reduces the risk of splintered edges in milling of the optional coupling means.
  • such a material sheet forms a barrier against the displacement during production of any wear-resistant or hard particles into the still wet wear layer, so that these particles can be more effective in the obtained floor panel.
  • the wear layer comprises a material sheet that comprises embedded hard particles per se.
  • this can be a so-called Mead overlay, for example as described in US 5,820,937, wherein an alpha- cellulose paper is filled in the production thereof with aluminum oxide particles or other wear-resistant particles.
  • the hard particles are in particular maintained at a fixed position in the thickness of the wear layer, and there are also no special measures necessary in order to maintain the hard particles in suspension in the lacquer layer or other material of the wear layer. The latter leads to a reduced risk of transparency loss due to the addition of any suspension agents and to a smoother production process.
  • the coated panel of the invention is preferably a floor panel, in particular intended for floating installation.
  • the floor panel is further characterized in that mechanical coupling components are provided at at least two opposite edges and that in a state in which two such floor panels are coupled, these coupling components provide a clamping effect of the upper edges, particularly the wear layers, against one another at the site of the edges.
  • mechanical coupling components are provided at at least two opposite edges and that in a state in which two such floor panels are coupled, these coupling components provide a clamping effect of the upper edges, particularly the wear layers, against one another at the site of the edges.
  • the above-mentioned substrate is provided at at least two opposite edges with a coating or impregnation that prevents or limits the penetration of moisture into the substrate.
  • the coating is preferably configured overlapping with the edge of the top layer.
  • a moisture-resistant coating is provided on the edge of the floor panel, wherein this coating extends from the substrate at least over the boundary with the above-mentioned top layer.
  • the coating extends further, specifically at least over the boundary with the decor layer and/or the wear layer.
  • a wood fiberboard of low density specifically with a density of less than 750 or less than 650 kg per cubic meter
  • measures are preferably taken to increase the quality of the material on the edges of the substrate.
  • reinforcement or impregnation with MDI or PU can be carried out at the edges.
  • Another possibility is the application of an acrylate resin to these edges that can then preferably be cured by means of electron radiation. This curing can optionally be achieved together with the above-mentioned UV or electron beam post-curing.
  • the acrylate resin that is applied to the edges is a layer of viscous acrylate resin.
  • urea formaldehyde UF
  • MF melamine formaldehyde
  • the substrate can be impregnated from the underside with PU or MDI.
  • PU urea formaldehyde
  • the wear layer is preferably provided with a structure or relief formed by indentations at the surface thereof.
  • this structure contributes to the imitation of the pattern depicted in the printed decor layer and/or the structure forms a demarcation of the printed decor layer, for example on at least one edge thereof.
  • indentations in the form of wood pores and/or veins.
  • a demarcation of the decor layer in the form of bevels or other edgings.
  • stone decor it is possible to work with a structure that mimics the presence of mortar joints.
  • the invention makes it possible to form such a structure or relief with deep indentations for example with indentations of 400 pm or deeper.
  • bevels or other edgings can be formed with a depth of 400 pm.
  • the wear layer is provided with structural components that penetrate into the substrate, or, in other words, wherein the decor layer and the underlying substrate are also structured.
  • structural components such as edgings, because in this manner, they can be given a deep configuration despite the limited thickness of the wear layer.
  • the obtained relief in the decor layer itself also contributes here to the realistic imitation of the panel.
  • thermally curing acrylate resin is preferably provided, for example by selecting as a thermoinitiator benzoyl peroxide or methylbenzoyl peroxide.
  • the invention in accordance with one or more of its preceding aspects, relates to a decorative profile instead of a coated panel.
  • This can for example be the profile type that is used for the finishing of a floor coating, such as a transition profile, end profile, baseboard or the like.
  • This variant provides smooth production of profiles that are suitable for decorative panels, for example in particular suitable for the above-mentioned coated panels.
  • the invention can in accordance with the present variant lead to a decorative profile of floor quality that can be produced in a simpler manner and thus create more freedom for the design of such profiles.
  • the acrylate resin that is applied in the different aspects of the present invention can for example have the following composition:
  • TBCHA (4-tert-butylcyclohexyl acrylate), IBOA (isobornyl acrylate), THFA (tetrahydrofurfuryl acrylate), etc.), alkoxylated monofunctional monomers (PE4A, etc.), alkane monofunctional monomers (EOEOEA (2-(2- ethoxyethoxy)ethyl acrylate)), alkoxylated difunctional monomers, alkyl difunctional monomers, multifunctional monomers (TMPTA (trimethylolpropane triacrylate), GPTA (propoxylated glyceryl triacrylate), PET(T)A (pentaerythritol tri-(tetra)acrylate), etc.), acid-based adhesion promotor monomers; mono-, di- or multifunctional acrylate or methacrylate monomers are preferably used, preferably trifunctional so that the risk of occurrence of unpleasant odors is limited; as a particular example, TMPTMA (trimethylo
  • additives such as defoaming agents, leveling agents; preferably, 0.1 to 2 percent by weight of a leveling agent and/or 0.1 to 2 percent by weight of a defoaming agent is used;
  • a leveling agent for example, a silicone poly ether acrylate, such as TEGO Rad 2300, can be used;
  • a defoaming agent BYK 1790 can be used;
  • nanosilica or corundum for example, a dispersion of colloidal (nano)silica in a monomer such as a difunctional acrylate monomer can be used, or a dispersion of (nano)silica in butyl acetate or methoxypropyl acetate, or aluminum oxide platelets, for example with a particle size distribution of between 3 and 18 pm;
  • oligomers of unsaturated polyester polyester acrylate, urethane acrylate, polyether acrylate, melamine acrylate, polycarbonate acrylate, epoxy acrylate, amine modified acrylate or urethane (meth)acrylate, preferably a urethane (meth)acrylate of 2 to 10 functional and/or a urethane acrylate with the formula A-I-P-I-A, wherein
  • P polyol-long or short-chain polyester, poly ether, polycarbonate, di- or multifunctional
  • thermoinitiator preferably organic peroxide or an azo polymerization initiator
  • photoinitiator optionally, 0.1-5 percent by weight of a photoinitiator
  • urethane acrylate has the additional advantage of making hydrogen bridges present, which leads to favorable ratio of flexibility to hardness of the obtained layer. It is also possible to work with or additionally use so-called “specialty high functionality urethane acrylates,” for example with silicone based, hydrophilic functional or fluorinated acrylates.
  • the above-mentioned composition, or the acrylate resin to be cured or the cured saturated polyester in general can also comprise a photoinitiator, for example 0.1 to 10 percent by weight, preferably 1 to 10 percent by weight.
  • a photoinitiator for example 0.1 to 10 percent by weight, preferably 1 to 10 percent by weight.
  • photoinitiators such as hydroxyacetaphenones, acetophenones, aminoacetophenones, phosphine oxides, benzophenones, thioxanthones, benzoyl formates or polymeric photoinitiators.
  • These can for example be benzophenone or a phosphine oxide such as diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide.
  • Such a composition can further also comprise an amine synergist, for example 1 to 10 percent by weight.
  • an amine synergist promotes the UV curing.
  • the presence of a photoinitiator allows extra UV curing after thermal curing, for example after hot pressing, by means of which a structure is applied to the layer comprising acrylate resin, for example a wear layer.
  • the photoinitiator can be used in order to gel the acrylate resin or the unsaturated polyester resin for carrying out thermal curing.
  • the acrylate resin or the unsaturated polyester resin can be gelled on a carrier sheet, for example a paper sheet with printing or a decorative paper, before such a carrier sheet is incorporated into a stack to be pressed.
  • the gelling can also be used for the application of a backing layer to the underside of the substrate.
  • the above-mentioned composition can optionally comprise a UV absorber, for example 0.1 to 5 percent by weight, preferably 1 to 2%, or 1.5%.
  • a UV absorber 2-hydroxyphenyl-s-triazine, possibly with a content of 15-25% of 2-methoxy-l -propyl- acetate (for example BASF Tinuvin 477) can be used, or bis(l,2,2,6,6-pentamethyl-4- piperidyl) sebacate with a content of methyl l,2,2,6,6-pentamethyl-4-piperidyl sebacate (for example BASF Tinuvin 292).
  • matting agents such as fumed silica, whether or not treated with wax, precipitated silica, micronized organic polymer, polycondensed.
  • 0.1 to 8 percent by weight of such a matting agent can be used.
  • suitable matting agents are Evonik Acematt 3600 and PQ corporation Gasil ETV55C.
  • additives that facilitate cleanability, antislip additives, and antimicrobial additives are optionally used.
  • DPGDA difunctional monomer dipropylene glycol diacrylate
  • TBPIN thermoinitiator i.e. tertiary butylperoxy-3,5,5-trimethylhexanoate
  • DPGDA difunctional monomer dipropylene glycol diacrylate
  • thermoinitiator • 0.1-5%, preferably 0.5-5%, more preferably 1% of TBPIN thermoinitiator
  • thermoinitiator • 0.1-5%, preferably 0.5-5%, more preferably 1% of TBPIN thermoinitiator
  • DPGDA difunctional monomer dipropylene glycol diacrylate
  • thermoinitiator • 0.1-5%, preferably 0.5-5%, more preferably 1% of TBPIN thermoinitiator
  • DPGDA difunctional monomer dipropylene glycol diacrylate
  • thermoinitiator • 0.1-5%, preferably 0.5-5%, more preferably 1% of TBPIN thermoinitiator
  • DPGDA difunctional monomer dipropylene glycol diacrylate
  • thermoinitiator • 0.1-5%, preferably 0.5-5%, more preferably 1% of TBPIN thermoinitiator
  • a photoinitiator such as benzophenone, 1- hydroxycyclohexylphenyl ketone, XBPO (phosphine oxide phenyl bis(246- trimethyl benzoyl)), TPO (C22H21 P O2), or ITX (isopropyl thioxanthone). It is not excluded and is even desirable to add a mixture of photoinitiators, wherein one photoinitiator is used to cure the surface and the other photoinitiator is used to deep-cure the lacquer.
  • a photoinitiator such as benzophenone, 1- hydroxycyclohexylphenyl ketone, XBPO (phosphine oxide phenyl bis(246- trimethyl benzoyl)), TPO (C22H21 P O2), or ITX (isopropyl thioxanthone).
  • thermally curing acrylate resin is composed of the following components:
  • defoaming agents optionally defoaming agents, leveling agents, nanosilica and/or corundum (AI 2 O 3 ).
  • component A which consists of:
  • a hydroxyfunctional acrylate in butyl acetate as a solvent (30- 60% solvent), o 0.01-1% of a crosslinker, for example an organometallic compound such as dibutyl tin dilaurate or zinc neodecanoate,
  • component A which consists of:
  • a crosslinker for example an organometallic compound such as dibutyltin dilaurate or zinc neodecanoate,
  • component A which consists of:
  • a crosslinker for example an organometallic compound such as dibutyltin dilaurate or zinc neodecanoate,
  • DPGDA difunctional monomer dipropylene glycol diacrylate
  • thermoinitiator • 0.1-5%, preferably 0.-5%, more preferably 1% of TBPIN thermoinitiator
  • DPGDA difunctional monomer dipropylene glycol diacrylate
  • thermoinitiator • 0.1-5%, preferably 0.-5%, more preferably 1% of TBPIN thermoinitiator
  • a photoinitiator such as benzophenone, l-hydroxy-cyclohexylphenylketone,
  • XBPO phosphine oxide phenyl bis(246-trimethyl benzoyl)
  • TPO C22H21 P O2
  • ITX isopropyl thioxanthone
  • Fig. 1 shows a perspective view of a coated panel, more specifically a floor panel, with the features of the invention
  • Fig. 2 shows a larger-scale section along line II-II of Fig. 1;
  • Fig. 3 is a schematic view of several steps in a method with the features of the invention.
  • Figs. 4 and 5 show results of sound measurements of a panel with the features of the invention.
  • Fig. 6 shows a method with the features of the invention.
  • Fig. 1 shows a coated panel 1.
  • this is a rectangular floor panel that comprises a substrate 2 and a top layer 3 applied thereto with at least a decor layer 4 and a translucent or transparent wear layer 5.
  • the wear layer 5 comprises a thermally cured acrylate resin, wherein the curing is obtained by means of a thermally initiated radical crosslinking reaction.
  • the starting point is a mixture of acrylate resin and a thermoinitiator.
  • the wear layer can also comprise a cured polyester resin or a cured coating composition that comprises an acrylate.
  • the floor panel 1 is suitable for floating installation, and for this purpose, it is in this case provided with mechanical coupling means 10 both on the long pair of edges 6-7 and on the short pair of edges 8-9 that allow two of such floor panels 1 to be connected to one another at their respective edges 6-7-8-9.
  • Fig. 2 again clearly shows that at least the long pair of edges 6-7 of the floor panel 1 of Fig. 1 is provided with mechanical coupling means 10, chiefly in the form of a tooth 11 and a grove 12, wherein in the coupled state of two such floor panels 1 at these edges 6- 7, there is locking between the tooth 11 and the groove 12, both in a first direction Rl perpendicular to the surface 13 of the coupled panels 1 and in a second direction R2 perpendicular to the coupled edges 6-7 and in the plane 13 of the panels 1.
  • mechanical coupling means 10 are also provided that provide locking in corresponding directions, whether or not chiefly in the form of a tooth 11 and a groove 12.
  • a substrate 2 that comprises a wood fiberboard with a density of 750 kg per cubic meter or less.
  • the substrate 2 is impregnated on its edges 6-7 with MDI (methylene diphenyl diisocyanate) 14.
  • MDI methylene diphenyl diisocyanate
  • the impregnation or other reinforcement of the substrate material 2 near the upper edges 16 is also desirable in order to limit possible swelling due to penetration and/or printing effects during milling of the coupling means 10.
  • a backing layer 18 is also provided on the underside 17 of the panel 1. This is preferably carried out on a thermally cured acrylate resin and serves the main purpose of forming a barrier against any rising moisture. As explained in the invention, the wear layer 5 has a lower level of residual stresses, so that the backing layer 18 exerts only a minimal function as a balancing layer.
  • the backing layer 18 can thus also be omitted, particularly in cases where the substrate 2 itself is composed of watertight material and or has a water-repellent underside 17 and/or is treated in order to be somewhat water-repellent at least on the underside 17 of the substrate 2, for example in that the substrate material is impregnated with MDI on the underside 17.
  • the decor layer 4 of the floor panel 1 of Figs. 1 and 2 comprises a carrier sheet provided with synthetic material 19, more specifically a paper sheet 20 with a surface weight of approximately 70 grams per square meter.
  • the paper sheet 20 shows a printing 21 in the form of a wood motif.
  • the synthetic material used 19 comprises double carbon bonds and is more specifically polyurethane.
  • Fig. 3 again gives a schematic view of several steps in a method for producing the floor panel of Figs. 1 and 2.
  • a decor layer 4 that comprises at least a paper sheet 20 is taken as a basis.
  • the paper sheet 20 is provided per se with a printing 21.
  • the paper sheet 20, more specifically a paper web from which the paper sheet 20 is later to be obtained by cutting is provided with synthetic material 19.
  • the paper web is unrolled and impregnated in the core by means of a first synthetic material 19.
  • the core impregnation can limit the risk of splitting of the paper sheet 20 in the final coated panel 1.
  • this core impregnation takes place in two partial steps, specifically a first partial step S1A wherein synthetic material 19 is applied by means of a roller 22, and a second partial step S1B wherein the paper sheet 20 is immersed in a bath 23 comprising the synthetic material 19.
  • the synthetic material 19 that is applied in the first partial step S1A and in the second partial step S1B is the same.
  • the synthetic materials used in the first and the second partial steps can be different from each other, independently of the specific application technique used.
  • the paper sheet 20 follows a trajectory 24 that allows sufficient penetration of the first synthetic material 19 applied during the first partial step S1A.
  • a first synthetic material 19 modified melamine formaldehyde resin, modified urea formaldehyde resin or modified melamine urea formaldehyde resin.
  • the first synthetic material 19 comprises double carbon bonds.
  • the first synthetic material 19 is selected from the list of polyurethane, urethane-acryl copolymer, acrylate, latex, and a dispersion in combination with acrylate functionality.
  • Fig. 3 further shows that after the above-mentioned core impregnation, aluminum oxide particles can be applied in a third partial step S1C, for example, as in this case, by means of scattering treatment. This is preferably followed in a fourth partial step S1D by drying treatment in a hot air oven 25.
  • an interlamellar coating 26 can be applied that increases the compatibility with the wear layer 5 to be formed from thermally curing acrylate resin or thermally curing unsaturated polyester resin or a coating composition comprising an acrylate resin.
  • Such an interlamellar coating can for example be composed of a water- based polyurethane coating, a water-based UV curing substance or a melamine acrylate or reactive acrylate monomer.
  • a coating 27 can also be applied to the side of the paper sheet 20 that is intended to face the substrate 2.
  • the purpose of such a coating 27 is to provide better adhesion to the substrate 2.
  • such a coating 27 can also serve the purpose of providing noise damping.
  • a seventh partial step S1F the treated paper sheet 20 passes in this example through a cooling roller 28, and the paper web in divided into sheets.
  • a stack 29 is formed that comprises at least the substrate 2 and the decor layer 4, wherein the decor layer 4 in this case comprises a printed paper sheet 20 provided with synthetic material 19, obtained in step Sl .
  • the method of the invention comprises at least the third step S3 shown, specifically the step of applying to the decor layer 4 an acrylate resin (or an unsaturated polyester resin or a coating composition that comprises an acrylate resin) that comprises a thermoinitiator, and the fourth step S4 shown, specifically the step of at least partial curing of the above-mentioned resin by means of hot pressing.
  • an acrylate resin with a thermoinitiator is applied to the underside 17 of the substrate 2 to form a backing layer 18. It is clear that in this case, the third step S3, specifically the step of applying the resin to the decor layer 4, is carried out while the decor layer 4 is already part of a stack 29 that comprises at least the substrate 2 and the decor layer 4.
  • the pressing is carried out by means of a so-called short cycle press 30, and more specifically by means of a structured pressing element 31 or pressing plate.
  • the pressing is carried out on a stack 29 that comprises the substrate 2, the decor layer 4, the acrylate resin of the wear layer 5 and the backing layer 18.
  • the structure 32 of the pressing element 31 is copied in the surface of the wear layer 5.
  • Fig. 4 shows the results, shown by curves 33-34, of noise measurements carried out on the one hand on a melamine surface of a floor panel of the prior art (curve 33), and on the other hand on a thermally cured acrylate surface of a floor panel in accordance with the invention (curve 34).
  • Fig. 5 shows the results, shown by curves 37-38, of loudness measurements carried out on the one hand on a melamine surface of a floor panel of the prior art (curve 37), and on the other hand on a thermally cured acrylate surface of a floor panel in accordance with the invention (curve 38).
  • the floor panel of the prior art comprises a substrate of HDF, specifically wood fiberboard with an average density of approximately 950 kg per cubic meter.
  • the floor panel in accordance with the invention comprises a substrate of MDF, more specifically a wood fiberboard with an average density of approximately 650 kg per m 3 .
  • the results are measurements of loudness in phons, shown on the ordinate 35, as a function of frequency (Hz), shown on the abscissa 36, of a clicking sound made by a metal pin on this surface.
  • the results show that a clicking nose on the floor panel of the invention is less loud and that peaks disappear in the interval of 1000 to 5000 Hz. This allows a warmer and more wood-like noise to be achieved.
  • Fig. 6 shows another method for the production of a coated panel 1 with the features of the invention.
  • a floor panel 1 with a substrate 2 of synthetic material or synthetic material composite for example a floor panel of the type LVT (luxury vinyl tile) that comprises a substrate 2 of high filled soft, semi-rigid or rigid PVC.
  • the substrate 2 can be formed by extrusion of the synthetic material or the composition, or, as is the case here, in a first step Tl, can be formed by one or more scattering operations in which granules 39 or powders with a suitable composition are deposited on a conveyor belt 40 and consolidated between the belts 41 of a dual belt press.
  • a printed film out of synthetic material 24 can be unrolled onto the substrate 2 formed in order to form the decor layer 4, and in a third step T3, a translucent film out of synthetic material 43 can optionally be unrolled to form at least a part 5A of the wear layer 5.
  • a mixture of at least acrylate resin and a thermoinitiator is applied to the obtained whole, preferably to the translucent film out of synthetic material 43, for example by means of one or more rollers 44.
  • the substrate 2, the one or more films out of synthetic material and the mixture of acrylate resin and the thermoinitiator are then consolidated in a fifth step T5 or cured by means of a hot roller 45.
  • a structured roller is used.
  • the structure 32 of the roller 45 is favorably copied in thermally curing acrylate resin.
  • Such a method leads to a wear layer 5 with excellent esthetic and mechanical characteristics, without the need for an additional superficial UV cured lacquer layer, as is the case is for the LVT floor panels of the prior art.
  • the mixture of acrylate resin and a thermoinitiator can also be applied to a semi-finished product, either consolidated or not, which comprises a substrate of synthetic material or a synthetic material composite and at least a decor layer, for example to a semi-finished product with a substrate, a printed film out of synthetic material and optionally a transparent film out of synthetic material located above the printing.
  • a semi-finished product either consolidated or not, which comprises a substrate of synthetic material or a synthetic material composite and at least a decor layer, for example to a semi-finished product with a substrate, a printed film out of synthetic material and optionally a transparent film out of synthetic material located above the printing.
  • the whole of the semi-finished product and mixture can then be pressed in a short cycle press similar to the press 30 shown in step S4 of Fig. 3.
  • the present invention is by no means limited to the embodiments described above; rather such coated panels and methods for the production thereof can be realized without departing from the scope of the present invention. Furthermore, it is also possible to apply the concept of the invention in the texturing of packaging materials or flat materials such as posters, stationery, or lamination material for laminating profiles, such as baseboards and finishing profiles for floor coating.
  • the invention therefore also relates to a method for the production of packaging materials or flat materials, characterized in that the method comprises the step of applying a thermal curable acrylate resin or thermal curable unsaturated polyester to the actual packaging material or flat material, for example to the paper, the cardboard, the film out of synthetic material, the synthetic material, for example with a thermoinitiator, and of at least partially curing the above-mentioned acrylate resin or unsaturated polyester by means of hot pressing, wherein preferably a structured pressing element or press film is used. It is clear that such method can further show the preferred features of the invention in accordance with the third aspect, without it being required to obtain coated panels.

Abstract

L'invention concerne un panneau revêtu ayant au moins un substrat (2) et une couche supérieure (3) appliquée sur celui-ci, ladite couche supérieure (3) comprenant au moins une couche de décor (4) et une couche d'usure translucide ou transparente (5), caractérisé en ce que ladite couche d'usure (5) comprend une résine acrylique thermiquement durcie ou une résine de polyester insaturée thermiquement durcie. De préférence, le durcissement thermique durcit partiellement ou entièrement la résine. En particulier, ladite résine acrylique ou ladite résine de polyester insaturée est au moins partiellement durcie au moyen d'une réaction de réticulation radicalaire initiée thermiquement. L'invention concerne en outre un procédé de fabrication desdits panneaux revêtus (1), en particulier des panneaux de plancher.
PCT/IB2019/059486 2018-11-09 2019-11-05 Panneau revêtu et procédé de fabrication de panneaux revêtus WO2020095196A1 (fr)

Priority Applications (8)

Application Number Priority Date Filing Date Title
RU2021116332A RU2770194C1 (ru) 2018-11-09 2019-11-05 Панель с покрытием и способ изготовления панелей с покрытием
AU2019375541A AU2019375541A1 (en) 2018-11-09 2019-11-05 Covered panel and method for manufacturing covered panels
BR112021007843-6A BR112021007843A2 (pt) 2018-11-09 2019-11-05 painel revestido e método para fabricar painéis revestidos
CA3116534A CA3116534A1 (fr) 2018-11-09 2019-11-05 Panneau revetu et procede de fabrication de panneaux revetus
KR1020217015493A KR20210090198A (ko) 2018-11-09 2019-11-05 커버드 패널 및 커버드 패널의 제조 방법
CN201980073813.4A CN112969560A (zh) 2018-11-09 2019-11-05 覆盖的面板以及制造覆盖的面板的方法
EP19813649.1A EP3877125A1 (fr) 2018-11-09 2019-11-05 Panneau revêtu et procédé de fabrication de panneaux revêtus
US17/291,093 US20220001572A1 (en) 2018-11-09 2019-11-05 Covered panel and method for manufacturing covered panels

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
BE2018/5787 2018-11-09
BE20185787A BE1026771B1 (nl) 2018-11-09 2018-11-09 Bekleed paneel en werkwijze voor het vervaardigen van beklede panelen.
US201962836268P 2019-04-19 2019-04-19
US62/836,268 2019-04-19
BE2019/5461 2019-07-16
BE20195461A BE1027438B1 (nl) 2019-07-16 2019-07-16 Plaatmateriaal en vloerpaneel op basis van dergelijk plaatmateriaal
BE2019/5469 2019-07-18
BE20195469A BE1026995B1 (nl) 2018-11-09 2019-07-18 Bekleed paneel en werkwijze voor het vervaardigen van beklede panelen

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WO2021165812A1 (fr) 2020-02-17 2021-08-26 Flooring Industries Limited, Sarl Matériau de panneau, procédé de fabrication d'un matériau de panneau et panneau comprenant un tel matériau de panneau
WO2021224843A1 (fr) * 2020-05-08 2021-11-11 Unilin, Bv Feuille revêtue partiellement durcie
US11203224B2 (en) 2018-08-30 2021-12-21 Interface, Inc. Digital printing for flooring and decorative structures
EP4079527A1 (fr) 2021-04-21 2022-10-26 Flooring Industries Limited, SARL Panneau décoratif et procédé de fabrication d'un panneau décoratif
WO2022224086A1 (fr) 2021-04-21 2022-10-27 Flooring Industries Limited, Sarl Panneau décoratif et procédé de fabrication d'un panneau décoratif
EP4094938A1 (fr) 2021-05-25 2022-11-30 Flooring Industries Limited, SARL Procédé de fabrication d'un panneau enduit et d'un matériau décoratif stratifié
DE102021123733A1 (de) 2021-09-14 2023-03-16 Vits Technology Gmbh Verfahren zum Beschichten einer bedruckten Warenbahn
EP4205866A1 (fr) * 2021-12-29 2023-07-05 Zhejiang Tianzhen Technology Co., Ltd. Procédé de traitement de la surface d'un sol
WO2024009238A1 (fr) 2022-07-07 2024-01-11 Flooring Industries Limited, Sarl Panneau décoratif et procédé de fabrication d'un panneau décoratif

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EP4094938A1 (fr) 2021-05-25 2022-11-30 Flooring Industries Limited, SARL Procédé de fabrication d'un panneau enduit et d'un matériau décoratif stratifié
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WO2024009238A1 (fr) 2022-07-07 2024-01-11 Flooring Industries Limited, Sarl Panneau décoratif et procédé de fabrication d'un panneau décoratif

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