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CN-122013952-A - Decorative panel and method for manufacturing the same

CN122013952ACN 122013952 ACN122013952 ACN 122013952ACN-122013952-A

Abstract

The present invention relates to a decorative panel, in particular a floor panel, a wall panel or a ceiling panel, comprising at least one core layer and at least one top layer, the core layer comprising a core upper surface and a core bottom surface, wherein the core layer comprises a composite material comprising at least one mineral material and at least one polymer, the top layer comprising at least one resin impregnated paper layer, wherein the core layer has a predetermined vicat softening temperature, and wherein the core upper surface of the core layer has a predetermined shore D hardness, whereby a panel with good water resistance and scratch resistance is obtained.

Inventors

  • Thomas Luc Martinet Bart
  • Tom Van Boyer
  • BONE SVEN

Assignees

  • 财纳福诺木业(中国)有限公司

Dates

Publication Date
20260512
Application Date
20211213
Priority Date
20211007

Claims (19)

  1. 1. A decorative panel, the panel comprising: -at least one core layer comprising a core upper surface and a core bottom surface, wherein the core layer comprises a composite material comprising at least one mineral material and at least one polymer, the ratio of the mineral material to the polymer being at least 3:1, and -At least one top layer comprising at least one resin impregnated paperboard layer; Wherein at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin; wherein the core layer has a Vicat softening temperature of at least 80 degrees Celsius, an Wherein the shore D hardness of the core upper surface of the core layer is at least 85.
  2. 2. The panel according to claim 1, wherein at least one resin impregnated paperboard layer is in direct contact with the core upper surface of the core layer.
  3. 3. The panel according to claim 1, wherein the at least one resin impregnated paperboard layer comprises at least one polymeric binder in an amount of at least 1% by weight.
  4. 4. A panel according to claim 3, wherein the at least one polymeric binder of the resin composition comprises polyurethane, polyester and/or polyepoxide.
  5. 5. The panel according to claim 1, wherein the weight of the at least one resin impregnated paperboard layer is at least 40 grams.
  6. 6. The panel according to claim 1, wherein the resin loading of the at least one resin impregnated paperboard layer is at least 100%.
  7. 7. The panel according to claim 1, wherein the at least one polymer of the composite material is selected from the group consisting of polyvinyl chloride, polypropylene, polyethylene terephthalate, polystyrene, polyethylene, polyurethane, acrylonitrile butadiene styrene copolymer and/or copolyester.
  8. 8. The panel according to claim 1, wherein at least one mineral material of the composite material is a magnesium-based mineral material selected from magnesium oxide, magnesium chloride and/or magnesium oxysulfate.
  9. 9. The panel according to claim 1, wherein the composite further comprises at least one additive configured to increase vicat softening temperature, wherein the at least one additive comprises an acrylonitrile styrene acrylate copolymer, an acrylonitrile butadiene styrene copolymer, a thermoset system, and/or an epoxy system.
  10. 10. The panel according to claim 1, wherein the surface energy of the core upper surface of the core layer is at least 50 dyn/cm.
  11. 11. The panel according to claim 1, wherein the roughness of the core upper surface of the core layer is at least 0.5 μιη.
  12. 12. The panel according to claim 1, comprising at least one backing layer comprising at least one resin impregnated paperboard layer, wherein at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin.
  13. 13. Panel according to claim 1, wherein the top layer comprises a plurality of wear resistant particles, in particular selected from aluminium oxide, corundum, silicon carbide, titanium dioxide, titanium oxide and/or diamond particles.
  14. 14. The panel according to claim 1, wherein the panel comprises two pairs of opposite side edges, wherein at least one pair of opposite side edges is provided with complementary coupling parts.
  15. 15. A method for manufacturing the decorative panel according to claim 1, the method comprising the steps of: a) Providing at least one core layer comprising a core upper surface and a core bottom surface, wherein the core layer comprises a composite material comprising at least one mineral material and at least one polymer, wherein the core layer has a softening temperature of at least 80 degrees celsius, and wherein the core upper surface of the core layer has a shore D hardness of at least 85; b) Providing at least one top layer on the core upper surface of the core layer, the top layer comprising at least one resin impregnated paperboard layer, wherein at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin; c) Applying a pressure of at least 12 MPa and a heat of at least 130 degrees celsius to an upper surface of the top layer for a first predetermined amount of time; d) The temperature is reduced to a value below 40 degrees celsius while maintaining a pressure of at least 12 MPa for a second predetermined amount of time.
  16. 16. The method of claim 15, wherein the first predetermined amount of time is in the range of 30 minutes to 60 minutes, and/or wherein the second predetermined amount of time is in the range of 5 minutes to 30 minutes.
  17. 17. The method of claim 15, wherein the temperature applied during step c) is in the range of 130 degrees celsius to 150 degrees celsius.
  18. 18. The method according to claim 15, wherein prior to step c) the core upper surface of the core layer is heat treated, sandblasted and/or corona treated.
  19. 19. The method of claim 15, further comprising step e) heat treating at a temperature of at least 90 degrees celsius and a substantially constant pressure of at least 1 Mpa for at least 1 minute.

Description

Decorative panel and method for manufacturing the same The present application is a divisional application of patent application No. 2021115196698, application day 2021, 12/13, and entitled "decorative panel and method of manufacturing a panel". Technical Field The present invention relates to a decorative panel, in particular a floor panel, a wall panel or a ceiling panel. The invention also relates to a method for manufacturing a decorative panel. Background In an attempt to combine the advantages of thermoplastic core materials (water resistance) and thermosetting resin impregnated cellulosic top layers (scratch resistance), studies have been conducted on floors. Difficulties arise when trying to bond the different layers sufficiently that delamination is not easy or rather complex manufacturing processes must be used. The thermoplastic composite core is generally not able to withstand the pressure and heat required to cure the top layer impregnated uncured resin nor the heat required to activate the hardener present in the polymer adhesive bonding the core and top layer together. Thermoplastics such as Polyvinylchloride (PVC) cores are known to soften or even completely melt at high temperatures, for example PVC having a low vicat softening temperature of about 65 degrees celsius and a melting point of about 150 degrees celsius. Such deformation of the core results in uneven thickness, breakage of the rigid top layer, etc. when trying to manufacture according to prior art. Since thermosetting resins such as melamine resins that impregnate the top layer are known to cure only at temperatures above 150 degrees celsius, it is desirable to increase the viscosity and stiffness of the core at high temperatures. Furthermore, the bonding of the thermosetting top layer on the thermoplastic core requires the use of an adhesive layer comprising a thermosetting resin and a polymeric adhesive or an epoxy resin, which requires activation with heat of more than 150 degrees celsius. Disclosure of Invention It is an object of the present invention to at least partially limit or eliminate the above-mentioned drawbacks of the known processes for manufacturing panels or to at least provide alternatives to the prior art. The invention relates to a decorative panel, in particular a floor panel, a wall panel or a ceiling panel, comprising: At least one core layer comprising a core upper surface and a core bottom surface and preferably comprising two pairs of opposite side edges, wherein the core layer comprises a composite material comprising at least one mineral material and/or at least one polymer, and -At least one top layer comprising at least one resin impregnated paperboard layer; wherein at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin and/or at least one polymeric binder; wherein the vicat softening temperature of the core layer is at least 80 degrees celsius, preferably at least 85 degrees celsius, and/or wherein the shore D hardness of the core upper surface of the core layer is at least 85. Detailed Description The panel according to the invention has several advantages over panels according to the prior art. Combining a core layer comprising at least one mineral material and at least one polymer and a top layer comprising at least one resin impregnated paperboard layer, wherein at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin and/or optionally at least one polymeric binder, and wherein the vicat softening temperature of the core layer is at least 80 degrees celsius, preferably at least 85 degrees celsius, and/or wherein the shore D hardness of the core upper surface of the core layer is at least 85, such that the panel not only has the water-proof benefits of a PVC panel, but also has the beneficial scratch resistance of a panel faced with resin impregnated paper. Preferably, at ambient temperature and/or a temperature of 23 degrees celsius, a core layer having a vicat softening temperature of at least 80 degrees celsius and a core upper surface of the core layer having a shore D hardness of at least 85 are used such that the core layer has a relatively high hardness while the core composition has the ability to retain such hardness upon heating (e.g., during attachment of one or more top layers). Thus, the combination of these features prevents deformation of the core layer during manufacture, use and/or handling. This technical effect was unexpectedly found because the skilled person would not consider the synergy between the hardness of the core layer and the vicat softening point to positively assist the lamination of the paper layer at high temperatures. One skilled in the art may consider either of these as contributing features, and not the synergy of the features described above. The panel according to the invention also has the advantage of a relatively good shrinkage, thus pre