WO2023194196A1 - Panneau et procédé de fabrication d'un panneau - Google Patents

Panneau et procédé de fabrication d'un panneau Download PDF

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Publication number
WO2023194196A1
WO2023194196A1 PCT/EP2023/058272 EP2023058272W WO2023194196A1 WO 2023194196 A1 WO2023194196 A1 WO 2023194196A1 EP 2023058272 W EP2023058272 W EP 2023058272W WO 2023194196 A1 WO2023194196 A1 WO 2023194196A1
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WO
WIPO (PCT)
Prior art keywords
layer
carrier plate
panel
optionally
print
Prior art date
Application number
PCT/EP2023/058272
Other languages
English (en)
Inventor
Walter Bachleitner
Jaime BLANCO NOTARIO
Regina SEIDL
Original Assignee
Impress Tech Ltd.
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
Application filed by Impress Tech Ltd. filed Critical Impress Tech Ltd.
Publication of WO2023194196A1 publication Critical patent/WO2023194196A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin

Definitions

  • 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.
  • 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 recycl ability. Thereby on the top side thereof a decor paper impregnated with a melamine resin is regularly applied.
  • MDF medium density fiberboard
  • HDF high-density fiberboard
  • 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.
  • polymeric top layer with decorative properties (i) polyurethane adhesive layer, (iii) carrier layer such as a fiberboard, (iv) polyurethane adhesive layer, and (v) cork layer as integrated impact sound insulation.
  • 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.
  • 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.
  • PET polyethylene terephthalate
  • Cast polypropylene on the other hand is becoming increasingly popular since it provides a pleasant feel, e.g. when walking on it.
  • 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.
  • 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.
  • a carrier plate such as a high-density fiberboard (HDF)
  • 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.
  • a print-receiving layer based on biaxially oriented polypropylene
  • a decorative printing layer applied on the print-receiving layer
  • 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.
  • MMFA Multilayer Modular Flooring Association
  • 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.
  • a base surface e.g. a wall, ceiling or floor surface.
  • 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 thetreuceiving layer with high quality. Moreover, biaxially oriented polypropylene has a homogeneous surface structure which may further contribute to a high-quality decorative printing layer.
  • 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.
  • 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).
  • a hotmelt adhesive e.g. polyurethane or polypropylene hotmelt adhesive
  • 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 thetreuceiving layer on the carrier board may be achieved compared to known layer materials.
  • 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.
  • 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.
  • 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 maybe 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 maybe applied on the print-receiving layer by means of rotogravure printing, flexography and/or digital printing.
  • rotogravure printing flexography
  • 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.
  • said bonding layer based on biaxially oriented 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 theexcellentceiving layer which is also based on 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.
  • the pigmented layer 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 may be 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, may be 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.
  • 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 maybe improved.
  • layers based on biaxially oriented polypropylene exhibit cohesive fracture within the layer during peel tests.
  • 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.
  • materials of the carrier board e.g. fibers of an HDF, adhere to the bonding layer. This facilitates recycling of the layer system.
  • the print-receiving layer being in contact with the pigmented layer improved optical properties could be observed.
  • 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.
  • the wear layer may have an embossed structure.
  • a pleasant feel of the panel and/or an optical appearance maybe 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 have been embossed after being applied to the carrier plate. It has shown that thereby an improved synchronization of the decorative printing and the embossing, i.e., the embossed structure, can be achieved compared to the case where an already embossed layer is applied to the decorative printing layer. Accordingly, an improved, e.g., more precise, optical appearance may be achieved. Further, compared to the case when an already embossed wear layer is applied by means of glue lamination to the decorative printing layer, the amount of glue being required can be reduced. This is as a separate embossed wear layer has the surface structure mirrored at the bottom side which is to be attached to the decorative printing layer. The cavities of this surface structure must by filled with glue to avoid air bubbles.
  • This surplus of glue can be omitted when embossing the wear layer after being applied to the carrier plate. Furthermore, by embossing the structure into the wear layer after applying the set of layers on the front major surface, it is generally possible to attach theparticularlyceiving layer without an additional adhesive layer, e.g., a melt-adhesive. Particularly, this may be facilitated by primers on the side of the print-receiving layer which is attached on the carrier plate. It is understood that before embossing the wear layer may have a substantially flat top surface, whereby after embossing the wear layer may have a structured top surface. Said structure may imitate a wood and/ or stone structure.
  • 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.
  • the layer system comprises superfluous layers while providing the advantages of the respective layers as described above.
  • 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.
  • 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.
  • 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 may be 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; Theoccasionceiving 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
  • 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.
  • 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.
  • lacquer layers are regularly applied on wear layers before embossing structures, such as wood grains. Hence, the lacquer layers maybe damaged and/or distorted during embossing.
  • the lacquer layers need to provide sufficient elasticity to compensate for the deformation.
  • the lacquer layer maybe based on a harder, i.e. less elastic, material.
  • a higher resistance e.g. against impact, scratch and/or chemicals, maybe achieved.
  • 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.
  • the lacquer layer may be applied by means of flexography or any other kind of application technology.
  • 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
  • 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:
  • 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 100 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 IO 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 100 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 100 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.
  • 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. 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 thetreuceiving layer, and a wear layer based on cast polypropylene.
  • the layers of the set of layers may be applied by laminating, gluing, melting, and/or any other suitable technique.
  • 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.
  • 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 method may further comprise the method step of embossing a structure into the wear layer after applying the set of layers on the front major surface of the carrier plate. It has shown that thereby an improved synchronization of the decorative printing and the embossing, i.e., the embossed structure, can be achieved compared to the case where an already embossed layer is applied to the decorative printing layer. Accordingly, an improved optical appearance may be achieved. Further, compared to the case when an already embossed wear layer is applied by means of glue lamination to the decorative printing layer, the amount of glue being required can be reduced. This is as a separate embossed wear layer has the surface structure mirrored at the bottom side which is to be attached to the decorative printing layer.
  • embossing the structure into the wear layer after applying the set of layers on the front major surface it is generally possible to attach the print-receiving layer without an additional adhesive layer, e.g., a melt-adhesive. Particularly, this may be facilitated by primers on the side of the print-receiving layer which is attached on the carrier plate. It is understood that before embossing the wear layer may have a substantially flat top surface, whereby after embossing the wear layer may have a structured top surface. Said structure may imitate a wood and/or stone structure.
  • the step of embossing maybe conducted by means of a structured plate which is pressed into the wear layer, preferably at temperatures above 50°C.
  • 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.
  • 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.
  • 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.
  • the carrier plate and the bonding layer based on biaxially oriented polypropylene being in contact with each other recyclability maybe 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.
  • the 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.
  • 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.
  • 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 100 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 100 pm to 280 pm. 4. Brief description of the accompanying figures
  • 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
  • Fig. 5 shows a schematic cross-section of an exemplary panel according to prior art
  • Fig. 6 shows a schematic cross-section of a third exemplary panel according to the present invention.
  • Fig. 7 shows a diagram of a further exemplary method according to the present invention.
  • Fig. 8 graphically illustrates the exemplary method according to Fig. 7.
  • Fig. 1 shows a schematic cross-section of a panel 1 which comprises a carrier plate 2.
  • the carrier plate 2 has a front major surface 3 and a rear surface 4.
  • the front major surface 3 comprises a layer system 10.
  • the layer system 10 comprises apaticeiving 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.
  • 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.
  • 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 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.
  • 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 n based on biaxially oriented polypropylene.
  • a decorative printing layer 12 applied on the print-receiving layer 11.
  • 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.
  • 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.
  • 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.
  • 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.
  • the workflowceiving layer 11 may be also directly applied onto the carrier plate 2 without the hotmelt adhesive layer 18.
  • a hotmelt adhesive layer 18 serves to adhere the bonding layer 14 to the carrier plate 2.
  • 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 100 for the manufacturing of a panel 1. The method comprises the following steps:
  • 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.
  • a polymeric top layer 1010 with decorative properties
  • a polyurethane adhesive layer 1020 with decorative properties
  • a carrier layer 1030 such as a fiberboard
  • a further polyurethane adhesive layer 1040 such as a fiberboard
  • a further polyurethane adhesive layer 1040 such as a fiberboard
  • a cork layer 1050 as integrated impact sound insulation.
  • known polymeric top layers 1010 regularly comprise a print-receiving layer with a decorative printing layer applied thereon.
  • these print-receiving layers in practice are primarily based on cast polypropylene or biaxially oriented polyethylene terephthalate which leads to several drawbacks
  • the panel 1 according to Fig. 6 substantially corresponds to the panel of Fig. 1. However, unlike in Fig. 1, in the panel of Fig. 6 the print-receiving layer 11 is directly applied onto the carrier plate 2. Even though not depicted, the wear layer 13 preferably has an embossed structure which has been embossed after being applied the carrier plate 2.
  • the method 100 according to Fig. 7, compared to the method according to Fig. 4, further comprises the method step of embossing 130 a structure into the wear layer 13 after applying 120 the set of layers 20 on the front major surface 3 of the carrier plate 2.
  • a carrier plate 2 having a front major surface 3 and a rear surface 4 is provided 110.
  • a set of layers 20 is applied 120 on the front major surface 3 of the carrier plate 2.
  • the set of layers 20 comprises a print-receiving layer 11 based on biaxially oriented polypropylene, a decorative printing layer 12 applied on thepurposeceiving layer 11, and a wear layer 13, wherein the wear layer 13 is based on cast polypropylene.
  • the wear layer 13 has no embossed structure yet.
  • a structure is embossed 130 into the wear layer 13 by means of an embossing plate 135, preferably under the application of temperatures above 50°C.
  • the wear layer 13 of the panel 1 has an embossed structure.
  • the set of layers is applied by means of glue lamination with a hotmelt adhesive layer 18.
  • the set of layers may be laid onto the front major surface 3 and subsequently attached by means of the embossing step 130.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un panneau (1), en particulier un panneau de mur, de plafond ou de revêtement de sol. Le panneau (1) comprend une plaque de support (2), en particulier un panneau de fibres haute densité, ayant une surface principale avant (3) et une surface arrière (4). La surface principale avant (3) comprend ainsi un système de couches (10) ayant les couches suivantes dans l'ordre donné tel que vu depuis la plaque de support (2) : Une couche de réception d'impression (11) à base de polypropylène à orientation biaxiale, une couche d'impression décorative (12) appliquée sur la couche de réception d'impression (11) et une couche d'usure (13) à base de polypropylène coulé.
PCT/EP2023/058272 2022-04-06 2023-03-30 Panneau et procédé de fabrication d'un panneau WO2023194196A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EPPCT/EP2022/059102 2022-04-06
PCT/EP2022/059102 WO2023193897A1 (fr) 2022-04-06 2022-04-06 Panneau et procédé de fabrication d'un panneau

Publications (1)

Publication Number Publication Date
WO2023194196A1 true WO2023194196A1 (fr) 2023-10-12

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PCT/EP2022/059102 WO2023193897A1 (fr) 2022-04-06 2022-04-06 Panneau et procédé de fabrication d'un panneau
PCT/EP2023/058272 WO2023194196A1 (fr) 2022-04-06 2023-03-30 Panneau et procédé de fabrication d'un panneau

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PCT/EP2022/059102 WO2023193897A1 (fr) 2022-04-06 2022-04-06 Panneau et procédé de fabrication d'un panneau

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060073318A1 (en) * 2004-10-06 2006-04-06 Applied Extrusion Technologies, Inc. Opaque decorative film and construction laminates employing same
KR20190043425A (ko) * 2017-10-18 2019-04-26 대림산업 주식회사 이축연신 폴리프로필렌 데코시트 필름 및 이를 이용한 무늬목 제조방법
WO2019225386A1 (fr) * 2018-05-22 2019-11-28 共和レザー株式会社 Film décoratif, procédé de production de film décoratif, corps moulé décoratif et procédé de production de corps moulé décoratif
WO2020020547A1 (fr) * 2018-07-26 2020-01-30 Interprint Gmbh Utilisation d'une structure stratifiée multicouche
EP3865300A1 (fr) * 2018-10-12 2021-08-18 Dai Nippon Printing Co., Ltd. Film de résine transparent, feuille décorative et procédé de fabrication de feuille décorative

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060073318A1 (en) * 2004-10-06 2006-04-06 Applied Extrusion Technologies, Inc. Opaque decorative film and construction laminates employing same
KR20190043425A (ko) * 2017-10-18 2019-04-26 대림산업 주식회사 이축연신 폴리프로필렌 데코시트 필름 및 이를 이용한 무늬목 제조방법
WO2019225386A1 (fr) * 2018-05-22 2019-11-28 共和レザー株式会社 Film décoratif, procédé de production de film décoratif, corps moulé décoratif et procédé de production de corps moulé décoratif
WO2020020547A1 (fr) * 2018-07-26 2020-01-30 Interprint Gmbh Utilisation d'une structure stratifiée multicouche
EP3865300A1 (fr) * 2018-10-12 2021-08-18 Dai Nippon Printing Co., Ltd. Film de résine transparent, feuille décorative et procédé de fabrication de feuille décorative

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