WO2023193897A1

WO2023193897A1 - Panel and method for the manufacturing of a panel

Info

Publication number: WO2023193897A1
Application number: PCT/EP2022/059102
Authority: WO
Inventors: Walter Bachleitner; Jaime BLANCO NOTARIO; Gian Luca MARCHESE
Original assignee: Impress Tech Ltd.
Priority date: 2022-04-06
Filing date: 2022-04-06
Publication date: 2023-10-12
Also published as: WO2023194196A1

Abstract

The present invention is directed to panel (1), in particular wall, ceiling or flooring panel. The panel (1) comprises a carrier plate (2), in particular a high-density fiberboard, having a front major surface (3) and a rear surface (4). Thereby the front major surface (3) comprises a layer system (10) having the following layers in the given order as seen from the carrier plate (2): A print-receiving layer (11) based on biaxially oriented polypropylene, a decorative printing layer (12) applied on the print-receiving layer (11), and a wear layer (13) based on cast polypropylene.

Description

Panel and method for the manufacturing of a panel

1. Technical field

The present disclosure relates to a panel, in particular a wall, ceiling, furniture or flooring panel, and a method for the manufacturing of a panel.

2. Prior art

In the field of developing and manufacturing panels, such as flooring panels, it is regularly tried to improve the properties of the panels but also the corresponding manufacturing methods. Thereby, a variety of different panel properties is considered. These properties exemplarily include environmental friendliness such as recyclability, feel, appearance, and/ or durability such as fire, moisture, and/ or scratch resistance.

Particularly in the field of developing and manufacturing panels for visible surfaces, which may be also contact surfaces, it is essential that the panels have a visually appealing surface which is pleasant in skin contact but also durable. Further in this regard, particularly visible surfaces, which thus become the focus of attention, are required by end customers to exhibit a particularly high degree of environmental friendliness. Hence, it is understood that especially visible surfaces, which maybe contact surfaces, require a high level of environmental friendliness, pleasant feel, high quality appearance, and/ or increased durability.

Panels with decorative surfaces which are widely used are laminate panels, e.g. for wall, ceiling, furniture or floor coverings. Laminate panels are relatively inexpensive and easy to handle. Typically, they comprise a carrier plate made from medium density fiberboard (MDF) or high-density fiberboard (HDF) material, which allows for thermal recyclability. Thereby on the top side thereof a decor paper impregnated with a melamine resin is regularly applied. In current practice, attempts are made to design laminate panels so that they include a carrier layer of renewable material, ensure good impact sound insulation, and have a visually appealing and textured surface that also feels soft and warm when in skin contact. Such laminate panels, as exemplarily depicted in Fig. 5, regularly comprise the following layer system in the given order: (i) polymeric top layer with decorative properties, (ii) polyurethane adhesive layer, (iii) carrier layer such as a fiberboard, (iv) polyurethane adhesive layer, and (v) cork layer as integrated impact sound insulation.

Thereby first drawbacks with such laminate panels lie in recyclability. This is as it has shown that when separating the above-mentioned layers (i) to (v) for recycling them, the (i) polymeric top layer is often contaminated with adhering polyurethane. This impairs the grade purity of the polymer material, making recycling more difficult. Furthermore, sometimes even fiber material from the carrier layer adhering to the polyurethane contaminates the polymer material. Thereby recycling maybe further limited.

Moreover, second drawbacks particularly lie in the current configurations of the (i) polymeric top layer with decorative properties. Such polymeric top layers regularly comprise a print-receiving layer with a decorative printing layer applied thereon. Thereby these print-receiving layers in practice are often based on cast polypropylene or polyethylene terephthalate (PET) or polyvinyl chloride (PVC).

A driving force is to develop PVC free products in this market, as PVC has a clear drawback in recyclability and environmental friendliness. Therefore, polymeric top- layers based on PP and polyethylene terephthalate (PET) have been developed over the last years and brought to this market.

Thereby said PET is increasingly ruled out, also due to the high material price. Cast polypropylene on the other hand is becoming increasingly popular since it provides a pleasant feel, e.g. when walking on it. However, cast polypropylene is limited in temperature stability and/or dimensional stability. This results in problems when applying the decorative printing layer by means of existing printing systems, such as rotogravure printing systems.

Thus, it is an object of the present disclosure to provide a panel and a method for the manufacturing of a panel that overcome the aforementioned drawbacks at least partially. . Summary of the invention

This object is achieved, at least partly, by a panel and a method for the manufacturing of a panel, as defined in the independent claims. Further aspects of the present disclosure are defined in the dependent claims. Since the panel and the method for the manufacturing of a panel both relate to panels, it will be understood that advantages and/or features of the panel may also apply to the method and vice versa.

In particular, the object is achieved by a panel, in particular wall, ceiling, furniture or flooring panel, comprising a carrier plate, such as a high-density fiberboard (HDF), having a front major surface and a rear surface. Thereby the front major surface comprises a layer system having the following layers in the given order as seen from the carrier plate: A print-receiving layer based on biaxially oriented polypropylene; a decorative printing layer applied on the print-receiving layer, and wear layer based on cast polypropylene.

The carrier plate may be, for example, a board made of a wood-based material, such as a medium-density fiberboard or a high-density fiberboard, a particle board, an oriented strand board or similar. However, it can also be made of a plastic material, like LVT, rigid polymer core or expanded polymer core as well as mixed constructions which are widely used in the flooring industry. Typical substrates used in the industry for flooring applications are listed for example at the Multilayer Modular Flooring Association (MMFA) and can be found at their webpage (www.mmfa.eu). Thereby particularly high-density fiberboards (HDF) have proven to allow for a good recyclability. This is as a removal of layers adhering to the carrier plate is facilitated without being significantly contaminated by the polyurethane adhesive used for lamination and the material of the carrier plate, such as loose fibers which stick to that adhesive.

Since the front major surface comprises the layer system with the decorative printing layer it is understood that the front major surface may be referred to as “major” compared to the rear surface due to the importance of the decorative aspect of the layer system.

The rear surface maybe configured for being attached to a base surface, e.g. a wall, ceiling or floor surface. Exemplarily, the rear surface may be provided with insulative materials such as cork to reduce impact sound. Further exemplarily, it is understood that the rear surface may be provided with adhesive means and/or mechanical attachment means.

The print-receiving layer based on biaxially oriented polypropylene allows that the decorative printing layer is applied on the print-receiving layer with high quality. This is as compared to other materials which are currently used as print-receiving layers, like for example cast polypropylene, biaxially oriented polypropylene is stiffer and thereby reduces deformation during printing. Moreover, the higher stiffness also avoids that in processing steps after printing the decorative printing layer is damaged due to deformation. Further, biaxially oriented polypropylene in comparison to other materials used in practice, such as cast polypropylene, has a relatively low surface roughness what contributes to the decorative printing layer being applied on the printreceiving layer with high quality. Moreover, biaxially oriented polypropylene has a homogeneous surface structure which may further contribute to a high-quality decorative printing layer.

Further, tests have shown that the print-receiving layer based on biaxially oriented polypropylene can allow for higher adhesive strengths of the print-receiving layer on underlying layers such as the carrier board, in comparison to existing print-receiving layers e.g. based on cast polypropylene or polyethylene terephthalate. This particularly applies if the print-receiving layer is attached to a carrier board being a high-density fiberboard, a medium-density fiberboard or a particle board by means of a hotmelt adhesive (e.g. polyurethane or polypropylene hotmelt adhesive). This is one of the most common processes to laminate such polymer layers on above mentioned substrates.

Even further, the print-receiving layer based on biaxially oriented polypropylene may improve recyclability. This is as it has shown in peel tests that print-receiving layers based on biaxially oriented polypropylene exhibit cohesive fracture within the layer. Hence, the separated print-receiving layer has less or even no adhering material from the underlaying layer. One reason for the cohesive fracture within the print-receiving layer may lie therein that as above-mentioned, higher adhesive strengths of the printreceiving layer on the carrier board may be achieved compared to known layer materials. Moreover, another reason maybe that a high orientation of polymer molecules within the print-receiving layer in-plane allows for facilitated cohesive fracture perpendicular to the print-receiving layer.

Exemplarily, the print-receiving layer may be directly applied onto the carrier board. If the print-receiving layer is removed from the carrier board, cohesive fracture within the print-receiving layer avoids, that materials of the carrier board, e.g. fibers of an HDF or an MDF together with the used hotmelt adhesive, adhere to the print-receiving layer. This apparently facilitates recycling of the print-receiving layer.

From the expression wherein a layer is “based on” a particular material, it is understood that the layer primarily consists of this material. Nevertheless, it is understood that the layer may still comprise the usual proportions of additives, fillers, and/or the like.

The printing ink used for printing the decorative printing layer maybe water-based, solvent-based, based on any radiation curable formulation and/ or based on any other polymerizable printing ink, particularly based on polymerizable acrylic resins and/or other polycondensation resins. Nevertheless, it is understood that other types of printing inks may be used depending on the properties the panel is desired to have.

The wear layer based on cast polypropylene allows for a pleasant feel, e.g. when walking on it, due to cast polypropylene being relatively soft compared to materials such as PET and/or biaxially oriented polypropylene. Said pleasant feel but also the optical appearance maybe optionally even further improved by means of an embossed structure. Furthermore, a design of the wear layer based on polypropylene allows for better recyclability with the print-receiving layer which is also based on polypropylene. Further, the wear layer protects the print-receiving layer based on biaxially oriented polypropylene. Particularly, it is known that biaxially oriented polypropylene tends to splice due to the high orientation of polymer molecules. In this regard the wear layer based on cast polypropylene, avoids such a splicing, and protects the print-receiving layer.

The decorative printing layer may be applied on the print-receiving layer by means of rotogravure printing, flexography and/or digital printing. By using these printing technologies on the print-receiving layer based on biaxially oriented polypropylene prints of higher quality can be achieved. This is as the printability of biaxially oriented polypropylene is better compared to materials which are presently used such as cast polypropylene.

The layer system may further comprise at least one of the following layers between the carrier plate and the print-receiving layer in the given order as seen from the carrier plate: A bonding layer which is based on biaxially oriented polypropylene; a foamed layer which is optionally based on foamed polypropylene, and a pigmented layer comprising color pigments. Thereby the pigmented layer is optionally based on cast polypropylene.

By means of said bonding layer based on biaxially oriented polypropylene, higher adhesive strengths of the layer system on underlying layers such as the carrier board maybe achieved in comparison to existing layers which are e.g. based on cast polypropylene or polyethylene terephthalate. This particularly applies if the bonding layer is attached to a carrier board being a high-density fiberboard. Further, a design of the bonding layer based on polypropylene allows for better recyclability with the printreceiving layer which is also based on polypropylene.

By means of the foamed layer which is optionally based on foamed polypropylene the layer system may allow for a pleasant feel e.g. when walking on it. Moreover, a better impact sound isolation maybe achieved. Further, a design of the foamed layer based on polypropylene can allow for better recyclability with the print-receiving layer which is also based on polypropylene.

With the pigmented layer a refraction of light may be achieved such that the opacity, i.e. the degree of blocking the transmission of light, of the layer system maybe increased. Hence, improved optical properties may be achieved while the material usage can be decreased or at least maintained. Furthermore, a design of the pigmented layer based on polypropylene may allow for better recyclability with the print-receiving layer which is also based on polypropylene. Even further, if the pigmented layer is based on cast polypropylene a pleasant feel, e.g. when walking on it, maybe achieved due to cast polypropylene being relatively soft compared to materials such as PET and/or biaxially oriented polypropylene.

The opacity of the layer system is essential for the optical properties. This is as a low opacity of the layer system may deteriorate the decorative effect. Thereby, as mentioned above, the opacity of the layer system may be increased by means of a pigmented layer. Further, it has shown that the opacity of the layer system may be also increased in that a coating with color pigments is applied directly on the print-receiving layer, namely on the printing side beneath the decorative printing layer and/or the side which faces the carrier plate. Moreover, the print-receiving layer may itself have an opacity which lies in the range from 90 - 93% according to ASTM D-589. This is particularly preferred as further measures, such as additional layers, to increase the opacity of the layer system may then not be required. Alternative biaxially oriented polypropylene on the market shows comparably low opacity-levels of approx. 75% for the same material-thickness.

The layer system may comprise the bonding layer, the foamed layer, and the pigmented layer. Thereby the bonding layer and the foamed layer may be in contact with each other. Further, the foamed layer and the pigmented layer may be in contact with each other. By this configuration it is avoided that the layer system comprises superfluous layers while providing the advantages of the respective layers as described above. The carrier plate and the bonding layer may be in contact with each other by means of a hotmelt adhesive or the like, and the print-receiving layer may be in contact with the pigmented layer. By the carrier plate and the bonding layer based on biaxially oriented polypropylene being in contact with each other recyclability may be improved. This is as mentioned above, layers based on biaxially oriented polypropylene exhibit cohesive fracture within the layer during peel tests. Hence, the separated layer system has less or even no adhering material from the underlying layer, e.g. containing hotmelt adhesive and fibers from the board. In detail, when the layer system which was directly applied onto the carrier board is removed, it is avoided that materials of the carrier board, e.g. fibers of an HDF, adhere to the bonding layer. This facilitates recycling of the layer system. Further, by the print-receiving layer being in contact with the pigmented layer improved optical properties could be observed. Even further, by the carrier plate and the bonding layer being in contact with each other, and/or the print-receiving layer may be in contact with the pigmented layer it is avoided that the layer system comprises superfluous layers while providing the advantages of the respective layers as described above.

As above-mentioned the wear layer may have an embossed structure. Thereby a pleasant feel of the panel and/ or an optical appearance may be even further improved. This is as exemplarily textures of natural materials such as wood grains may be visually and/or haptically better replicated.

The wear layer may be in contact with the decorative printing layer, wherein the wear layer is optionally applied by means of melt lamination or glue lamination. By the wear layer and the decorative printing layer being in contact with each other it is avoided that the layer system comprises superfluous layers while providing the advantages of the respective layers as described above. Further, by directly applying the wear layer on the decorative printing layer, natural surfaces such as wood or stone, may be replicated in a particular realistic manner as an optical depth effect is at least partially avoided. Moreover, the application by means of melt lamination allows that no additional adhesive is required which might lead to contamination of the layer system. Further glue lamination, i.e. where an adhesive serves to laminate layers, may protect the decorative printing layer. This is as exemplarily no heat maybe required to laminate the wear layer.

The panel according to the present invention maybe particularly configured as follows.

The carrier plate may be a high-density fiberboard, a medium-density fiberboard, or a particle board, wherein the layer system may comprise the following layers in the given order as seen from the carrier plate: A bonding layer which is based on biaxially oriented polypropylene, wherein the bonding layer adheres to the carrier plate preferably by means of hotmelt adhesive or the like; A foamed layer which is based on foamed polypropylene, wherein the foamed layer contacts the bonding layer; A pigmented layer comprising color pigments, wherein the pigmented layer is based on cast polypropylene, wherein the pigmented layer contacts the foamed layer; The printreceiving layer, wherein the print-receiving layer contacts the pigmented layer; The decorative printing layer, and a wear layer, wherein the wear layer is based on cast polypropylene, wherein the wear layer is in contact with the decorative printing layer, wherein the wear layer is optionally applied by means of melt lamination or glue lamination, wherein further optionally the wear layer has an embossed structure. Since this panel configuration comprises layers which are already mentioned above, it is understood that the above-described advantages and/or further specifications may also apply for this configuration. Nevertheless, it is pointed at the aspect that this panel configuration exhibits a particularly improved recyclability. This is as multiple layers of the layer system are based on polypropylene. Hence, a high grade purity can be achieved.

Further, the wear layer may have an embossed structure, wherein a lacquer layer is applied directly above the wear layer as seen from the carrier plate, wherein the lacquer layer is applied on the embossed structure. Presently, lacquer layers are regularly applied on wear layers before embossing structures, such as wood grains. Hence, the lacquer layers may be damaged and/or distorted during embossing. Further, the lacquer layers need to provide sufficient elasticity to compensate for the deformation. By applying the lacquer layer on the embossed structure, it is avoided that the lacquer layer is deformed during embossing the embossed structure. Hence, the lacquer layer maybe based on a harder, i.e. less elastic, material. Thus, a higher resistance, e.g. against impact, scratch and/or chemicals, maybe achieved. Further, a damaging of the lacquer layer due to embossing itself can be avoided. Lacquer layers which may be used include corundum particles, acrylate, polymers, oligomers, additives, and/or the like. Furthermore, the lacquer layer may be applied by means of flexography or any other kind of application technology.

It is understood that a wear layer having an embossed structure, wherein a lacquer layer is applied directly above the wear layer as seen from the carrier plate, wherein the lacquer layer is applied on the embossed structure, may be applied in an alternative embodiment as follows. A panel, in particular wall, ceiling, furniture or flooring panel, may comprise a carrier plate having a front major surface and a rear surface, wherein the front major surface comprises a layer system having the following layers in the given order as seen from the carrier plate: A print-receiving layer based on a polymer, such as polypropylene, a decorative printing layer applied on the print-receiving layer, and a wear layer having an embossed structure, wherein a lacquer layer is applied directly above the wear layer as seen from the carrier plate, wherein the lacquer layer is applied on the embossed structure. Thereby it is understood that the layer system of such a panel may further comprise any layer which is specified above, which may be also specified as follows.

The print-receiving layer may have a thickness in a range from 3 pm to 150 pm, preferably from 5 pm to too pm, more preferably from 10 pm to 70 pm, even more preferably from 20 pm to 60 pm, and most preferably from 30 pm to 50 pm. These thicknesses on one hand have proven to be sufficient for printing while on the other hand the material use is kept on a moderate level. Further, for these thicknesses a cohesive fracture within the print-receiving layer could be observed which allowed a good separation from the underlying layer. Good separation means that the separated film is not contaminated with adhesive and/or fibers, whereas this aspect is not contradictory to a very good adhesion of the print receiving layer to the carrier plate. Moreover, it has been found that the bonding strength of such print receiving layers is higher than of products available on the market.

The bonding layer may have a thickness in a range from 3 pm to 40 pm, optionally from 5 pm to 30 pm, and further optionally from 10 pm to 25 pm. For these thicknesses an improved adhesion and/ or a cohesive fracture within the bonding layer could be observed.

The foamed layer may have a thickness in a range from 50 pm to 600 pm, optionally from 70 pm to 450 pm, and further optionally from too pm to 350 pm. These thicknesses on one hand have proven to be sufficient to allow for a pleasant feel while on the other hand the material use is kept on a moderate level.

The pigmented layer may have a thickness in a range from 5 pm to 200 pm, optionally from 10 pm to 150 pm, and further optionally from 20 pm to too pm. These thicknesses on one hand have proven to be sufficient to increase the opacity such that improved optical properties could be achieved while the material usage was kept on a moderate level. IO

The wear layer may have a thickness in a range from 50 |nm to 350 |nm, optionally from 70 pm to 300 pm, and further optionally from too pm to 280 pm. These thicknesses on one hand have proven to avoid at least partially that an optical depth effect is obtained while on the other hand still enough material is available to compensate for wear.

The object is further achieved, at least partly by a method for the manufacturing of a panel, in particular wall, ceiling, furniture or flooring panel, comprising the following steps: Providing a carrier plate, in particular a high-density fiberboard, having a front major surface and a rear surface, and applying a set of layers on the front major surface of the carrier plate, wherein the set of layers comprises a print-receiving layer based on biaxially oriented polypropylene, a decorative printing layer applied on the printreceiving layer, and a wear layer based on cast polypropylene. The layers of the set of layers maybe applied by laminating, gluing, melting, and/or any other suitable technique.

While the description of the panel refers to a “layer system”, the description of the method for the manufacturing of a panel refers to a “set of layers”. This is as the panel comprises a fix layer structure with layers which are arranged systematically, whereas the method comprises the step of applying layers which are not necessarily connected during application. Even further, during applying the set of layers, the layers maybe at least partially liquid. However, it is nevertheless understood that a panel which was manufactured according to the method of the present invention also comprises a “layer system”.

The decorative printing layer may be applied on the print-receiving layer by means of rotogravure printing, flexography and/ or digital printing. Respective advantages are described above with respect to the panel.

The set of layers may further comprise at least one of the following layers: A bonding layer which is based on biaxially oriented polypropylene; A foamed layer which is optionally based on foamed polypropylene, and a pigmented layer comprising color pigments, wherein the pigmented layer is optionally based on cast polypropylene. Respective advantages of these specific layers are described above with respect to the panel.

The set of layers maybe applied on the front major surface of the carrier plate in the given order as seen from the carrier plate: Optionally the bonding layer; Optionally the foamed layer; Optionally the pigmented layer; The print-receiving layer; The decorative printing layer, and the wear layer. Respective advantages of this layer arrangement are described above with respect to the panel.

The bonding layer, the foamed layer and the pigmented layer may be melt-laminated, wherein optionally the bonding layer, the foamed layer, the pigmented layer, and the print-receiving layer are melt-laminated. Thereby a reduction of process steps, such as gluing, may be achieved. Further, by means of melt-lamination an improved connection between the layers could be observed.

The set of layers may comprise the bonding layer, the foamed layer, and the pigmented layer. Thereby the bonding layer and the foamed layer may be in contact with each other after applying the set of layers on the carrier plate. The foamed layer and the pigmented layer maybe in contact with each other after applying the set of layers on the carrier plate. By this configuration it is avoided that the set of layers comprises superfluous layers while providing the advantages of the respective layers as described above.

The carrier plate and the bonding layer may be in contact with each other after applying the set of layers on the carrier plate, and the print-receiving layer maybe in contact with the pigmented layer after applying the set of layers on the carrier plate. By the carrier plate and the bonding layer based on biaxially oriented polypropylene being in contact with each other recyclability may be improved. This is as mentioned above, layers based on biaxially oriented polypropylene exhibit cohesive fracture within the layer during peel tests. Hence, the separated set of layers has less or even no adhering material from the underlying layer. In detail, when the set of layers which was directly applied onto the carrier board is removed, it is avoided that materials of the carrier board, e.g. fibers of an HDF and/or hotmelt adhesive, adhere to the bonding layer. This facilitates recycling of the set of layers. Further, by the print-receiving layer being in contact with the pigmented layer improved optical properties could be observed. Even further, by the carrier plate and the bonding layer being in contact with each other, and/or the print-receiving layer maybe in contact with the pigmented layer it is avoided that the set of layers comprises superfluous layers while providing the advantages of the respective layers as described above.

The wear layer may be in contact with the decorative printing layer after applying the set of layers on the carrier plate. The wear layer is optionally applied by means of melt lamination or glue lamination. By the wear layer and the decorative printing layer being in contact with each other it is avoided that the set of layers comprises superfluous layers while providing the advantages of the respective layers as described above. Further, by directly applying the wear layer on the decorative printing layer natural surfaces, such as wood or stone, may be replicated in a particular realistic manner as an optical depth effect is at least partially avoided. Moreover, the application by means of melt lamination allows that no additional adhesive is required which might lead to contamination of the set of layers.

Further, the wear layer may have an embossed structure, wherein a lacquer layer is applied directly above the wear layer as seen from the carrier plate, wherein the lacquer layer is applied on the embossed structure. Respective advantages are described above with regards to the panel.

It is understood that for the following thicknesses the advantages which are already described with respect to the panel apply.

The print-receiving layer may have a thickness in a range from 3 pm to 150 pm, preferably from 5 pm to too pm, more preferably from 10 pm to 70 pm, even more preferably from 20 pm to 60 pm, and most preferably from 30 pm to 50 pm.

The bonding layer may have a thickness in a range from 3 pm to 40 pm, optionally from 5 pm to 30 pm, and further optionally from 10 pm to 25 pm.

The foamed layer may have a thickness in a range from 50 pm to 600 pm, optionally from 70 pm to 450 pm, and further optionally from too pm to 350 pm.

The pigmented layer may have a thickness in a range from 5 pm to 200 pm, optionally from 10 pm to 150 pm, and further optionally from 20 pm to too pm.

The wear layer may have a thickness in a range from 50 pm to 350 pm, optionally from 70 pm to 300 pm, and further optionally from too pm to 280 pm.

4. Brief description of the accompanying figures

In the following, the accompanying figures are briefly described:

Fig. 1 shows a schematic cross-section of a first exemplary panel according to the present invention;

Fig. 2 shows a schematic cross-section of a second exemplary panel according to the present invention; Fig. 3 schematically illustrates an exemplary method according to the present invention;

Fig. 4 shows a diagram of an exemplary method according to the present invention, and

Fig. 5 shows a schematic cross-section of an exemplary panel according to prior art.

5. Detailed description of the figures

Fig. i shows a schematic cross-section of a panel i which comprises a carrier plate 2. The carrier plate 2 has a front major surface 3 and a rear surface 4. Thereby the front major surface 3 comprises a layer system 10. The layer system 10 comprises a printreceiving layer 11 based on biaxially oriented polypropylene, and a decorative printing layer 12 applied on the print-receiving layer 11. The print-receiving layer 11 is attached to the front major surface 3. Further, the panel comprises a wear layer 13, wherein the wear layer 13 is based on cast polypropylene. The wear layer 13 is in contact with the decorative printing layer 12

Fig. 2 shows a schematic cross-section of another panel 1 which also comprises a carrier plate 2. The carrier plate 2 has a front major surface 3 and a rear surface 4. Thereby the front major surface 3 comprises a layer system 10. Said layer system 10 comprises the following layers in the given order as seen from the carrier plate 2:

• A bonding layer 14 which is based on biaxially oriented polypropylene, wherein the bonding layer 14 adheres to the carrier plate 2.

• A foamed layer 15 which is based on foamed polypropylene, wherein the foamed layer 15 contacts the bonding layer 14.

• A pigmented layer 16 comprising color pigments, wherein the pigmented layer 16 is based on cast polypropylene, wherein the pigmented layer 16 contacts the foamed layer 15.

• A print-receiving layer 11 based on biaxially oriented polypropylene, wherein the print-receiving layer 11 contacts the pigmented layer 16.

A decorative printing layer 12 applied on the print-receiving layer 11. • A wear layer 13, wherein the wear layer 13 is based on cast polypropylene, wherein the wear layer 13 is in contact with the decorative printing layer 12, and wherein the wear layer 13 has an embossed structure (not shown).

• A lacquer layer 17 being applied directly above the wear layer 13 as seen from the carrier plate 2, wherein the lacquer layer 17 is applied on the embossed structure.

As further illustrated in Fig. 2, a further layer such as a cork layer 5 is attached to the rear surface 4, e.g. for damping purposes.

Fig. 3 schematically illustrates an exemplary method, respectively panel, according to the present invention, wherein, first, a carrier plate 2 having a front major surface 3 and a rear surface 4 is provided. Then, a set of layers 20 is applied on the front major surface 3 of the carrier plate 2. Thereby the set of layers 20 comprises the following layers which are applied on the front major surface 3 of the carrier plate 2 in the given order as seen from the carrier plate 2:

• A bonding layer 14 optionally based on biaxially oriented polypropylene.

• A foamed layer 15 optionally based on foamed polypropylene.

• A pigmented layer 16 comprising color pigments, wherein the pigmented layer 16 is optionally based on cast polypropylene.

• A print-receiving layer 11 based on biaxially oriented polypropylene.

• A decorative printing layer 12 applied on the print-receiving layer 11.

• A wear layer 13 based on cast polypropylene, wherein the wear layer 13 optionally has an embossed structure. The wear layer 13 is in contact with the decorative printing layer 12 after applying is finished.

The bonding layer 14, the foamed layer 15 and the pigmented layer 16 are melt- laminated. Thereby, the bonding layer 14 and the foamed layer 15 are in contact with each other. Further, the foamed layer 15 and the pigmented layer 16 are in contact with each other.

It is understood from Fig. 3 that the carrier plate 2 and the bonding layer 14 are in contact with each other after applying the set of layers 20 on the carrier plate 2. Moreover, the print-receiving layer 11 is in contact with the pigmented layer 16 after applying 120 the set of layers 20 on the carrier plate 2.

As illustrated in Fig. 1, a hotmelt adhesive layer 18 is arranged in the panel 1 of Fig. 1, namely between the print-receiving layer 11 and the carrier plate 2. However, the printreceiving layer 11 may be also directly applied onto the carrier plate 2 without the hotmelt adhesive layer 18. Further, as illustrated in Figs. 2 and 3, a hotmelt adhesive layer 18 serves to adhere the bonding layer 14 to the carrier plate 2. However, the bonding layer 14 may be also directly applied onto the carrier plate 2 without the hotmelt adhesive layer 18.

Fig. 4 shows a diagram of an exemplary method too for the manufacturing of a panel 1. The method comprises the following steps:

• Providing 110 a carrier plate 2 having a front major surface 3 and a rear surface 4.

• Applying 120 a set of layers 20 on the front major surface 3 of the carrier plate 2. Thereby the set of layers 20 comprises a print-receiving layer 11 based on biaxially oriented polypropylene, a decorative printing layer 12 applied on the print-receiving layer 11, and a wear layer 13, wherein the wear layer 13 is based on cast polypropylene.

Fig. 5 shows a prior art panel 1000. The prior art panel comprises in the following order: a polymeric top layer 1010 with decorative properties, a polyurethane adhesive layer 1020, a carrier layer 1030 such as a fiberboard, a further polyurethane adhesive layer 1040, and a cork layer 1050 as integrated impact sound insulation. Thereby in the art, different configurations of the polymeric top layer 1010 are known, wherein said layer itself often comprises a plurality of layers. However, known polymeric top layers 1010 regularly comprise a print-receiving layer with a decorative printing layer applied thereon. Thereby these print-receiving layers in practice are primarily based on cast polypropylene or biaxially oriented polyethylene terephthalate which leads to several drawbacks as mentioned above in the section “prior art”. List of reference si

1 panel

2 carrier plate

3 front major surface

4 rear surface

5 cork layer io layer system n print-receiving layer

12 decorative printing layer

13 wear layer

14 bonding layer

15 foamed layer

16 pigmented layer

17 lacquer layer

18 hotmelt adhesive layer

20 set of layers

100 method for the manufacturing of a panel

110 providing a carrier plate

120 applying a set of layers

1000 prior art panel

1010 polymeric top layer with decorative properties

1020 polyurethane adhesive layer

1030 carrier layer

1040 polyurethane adhesive layer

1050 cork layer

Claims

1. Panel (1), in particular wall, ceiling, furniture or flooring panel, comprising a carrier plate (2) having a front major surface (3) and a rear surface (4), whereby the front major surface (3) comprises a layer system (10) having the following layers in the given order as seen from the carrier plate (2):

A print-receiving layer (11) based on biaxially oriented polypropylene;

A decorative printing layer (12) applied on the print-receiving layer (11), and

A wear layer (13) based on cast polypropylene.

2. The panel (1) according to the preceding claim, wherein the decorative printing layer (12) is applied on the print-receiving layer (11) by means of rotogravure printing, flexography and/or digital printing.

3. The panel (1) according to one of the preceding claims, wherein the layer system

(10) further comprises at least one of the following layers between the carrier plate (2) and the print-receiving layer (11) in the given order as seen from the carrier plate (2):

A bonding layer (14) which is optionally based on biaxially oriented polypropylene;

A foamed layer (15) which is optionally based on foamed polypropylene, and

A pigmented layer (16) comprising color pigments, wherein the pigmented layer (16) is optionally based on cast polypropylene.

4. The panel (1) according to the preceding claim, wherein the bonding layer (14) and the foamed layer (15) are in contact with each other, and wherein the foamed layer (15) and the pigmented layer (16) are in contact with each other.

5. The panel (1) according to one of claims 3 or 4, wherein the carrier plate (2) and the bonding layer (14) are in contact with each other, wherein the print-receiving layer

(11) is optionally in contact with the pigmented layer (16).

6. The panel (1) according to one of the preceding claims, wherein the wear layer (13) has an embossed structure.

7. The panel (1) according to one of the preceding claims, wherein the wear layer (13) is in contact with the decorative printing layer (12), wherein the wear layer (13) is optionally applied by means of melt lamination or glue lamination.

8. The panel (1) according to one of claims 1 or 2, wherein the carrier plate (2) is a high-density fiberboard, a medium-density fiberboard, or a particle board, wherein the layer system (10) comprises the following layers in the given order as seen from the carrier plate (2):

A bonding layer (14) which is based on biaxially oriented polypropylene, wherein the bonding layer (14) adheres to the carrier plate (2);

A foamed layer (15) which is based on foamed polypropylene, wherein the foamed layer (15) contacts the bonding layer (14);

A pigmented layer (16) comprising color pigments, wherein the pigmented layer (16) is based on cast polypropylene, wherein the pigmented layer (16) contacts the foamed layer (15);

The print-receiving layer (11), wherein the print-receiving layer (11) contacts the pigmented layer (16);

The decorative printing layer (12), and

The wear layer (13), wherein the wear layer (13) is based on cast polypropylene, wherein the wear layer (13) is in contact with the decorative printing layer (12), wherein the wear layer (13) is optionally applied by means of melt lamination or glue lamination, and wherein further optionally the wear layer (13) has an embossed structure.

9. The panel (1) according to one of the preceding claims, wherein the wear layer (13) has an embossed structure, wherein a lacquer layer (17) is applied directly above the wear layer (13) as seen from the carrier plate (2), wherein the lacquer layer (17) is applied on the embossed structure.

10. Method (too) for the manufacturing of a panel (1), in particular wall, ceiling, furniture or flooring panel, comprising the following steps:

Providing (110) a carrier plate (2) having a front major surface (3) and a rear surface (4), and Applying (120) a set of layers (20) on the front major surface (3) of the carrier plate (2), wherein the set of layers (20) comprises a print-receiving layer (11) based on biaxially oriented polypropylene, a decorative printing layer (12) applied on the print-receiving layer (11), and a wear layer (13) based on cast polypropylene.

11. The method (100) according to the preceding method claim, wherein the decorative printing layer (12) is applied on the print-receiving layer (11) by means of rotogravure printing, flexography and/or digital printing.

12. The method (100) according to one of the preceding method claims, wherein the set of layers (20) further comprises at least one of the following layers:

A foamed layer (15) which is optionally based on foamed polypropylene, and

13. The method (too) according to the preceding method claim, wherein the set of layers (20) is applied on the front major surface (3) of the carrier plate (2) in the given order as seen from the carrier plate (2):

Optionally the bonding layer (14);

Optionally the foamed layer (15);

Optionally the pigmented layer (16);

The print-receiving layer (11);

The decorative printing layer (12), and

The wear layer (13).

14. The method (too) according to one of claims 12 or 13, wherein the bonding layer (14), the foamed layer (15) and the pigmented layer (16) are melt-laminated, wherein optionally the bonding layer (14), the foamed layer (15), the pigmented layer (16), and the print-receiving layer (11) are melt-laminated.

15- The method (loo) according to one of claims 12 to 14, wherein the bonding layer (14) and the foamed layer (15) are in contact with each other after applying (120) the set of layers (20) on the carrier plate (2), wherein the foamed layer (15) and the pigmented layer (16) are in contact with each other after applying (120) the set of layers (20) on the carrier plate (2).

16. The method (100) according to one of claims 12 to 15, wherein the carrier plate (2) and the bonding layer (14) are in contact with each other after applying (120) the set of layers (20) on the carrier plate (2), wherein the print-receiving layer (11) is optionally in contact with the pigmented layer (16) after applying (120) the set of layers (20) on the carrier plate (2).

17. The method (100) according to one of the preceding method claims, wherein the wear layer (13) is in contact with the decorative printing layer (12) after applying (120) the set of layers (20) on the carrier plate (2), wherein the wear layer (13) is optionally applied by means of melt lamination or glue lamination.

18. The method (too) according to one of the preceding method claims, wherein the wear layer (13) has an embossed structure, wherein a lacquer layer (17) is applied directly above the wear layer (13) as seen from the carrier plate (2), wherein the lacquer layer (17) is applied on the embossed structure.

19. The panel (1) or the method (too) according to one of the preceding claims, wherein the print-receiving layer (11) has a thickness in a range from 3 pm to 150 pm, preferably from 5 pm to too pm, more preferably from 10 pm to 70 pm, even more preferably from 20 pm to 60 pm, and most preferably from 30 pm to 50 pm.

20. The panel (1) according to one of claims 3 to 9 or the method (too) according to one of claims 12 to 18, wherein the bonding layer (14) has a thickness in a range from 3 pm to 40 pm, optionally from 5 pm to 30 pm, and further optionally from 10 pm to 25 pm.

21. The panel (1) according to one of claims 3 to 9 or the method (too) according to one of claims 12 to 18, wherein the foamed layer (15) has a thickness in a range from 50 pm to 600 pm, optionally from 70 pm to 450 pm, and further optionally from too pm to 350 pm.

22. The panel (1) according to one of claims 3 to 9 or the method (too) according to one of claims 12 to 18, wherein the pigmented layer (16) has a thickness in a range from 5 |iim to 200 |um, optionally from io pm to 150 pm, and further optionally from 20 pm to too pm.

23. The panel (1) or the method (too) according to one of the preceding claims, wherein the wear layer (13) has a thickness in a range from 50 pm to 350 pm, optionally from 70 pm to 300 pm, and further optionally from too pm to 280 pm.