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EP-3690165-B1 - METHOD FOR MANUFACTURING A PANEL

EP3690165B1EP 3690165 B1EP3690165 B1EP 3690165B1EP-3690165-B1

Inventors

  • MAESEN, CHRISTOPHE
  • CLEMENT, BENJAMIN
  • SEGAERT, MARTIN
  • MEERSSEMAN, LAURENT
  • THIERS, BERNARD

Dates

Publication Date
20260513
Application Date
20110428

Claims (12)

  1. Method for manufacturing a panel, wherein this panel is of the type which comprises at least a substrate and a top layer provided on this substrate, wherein said top layer comprises at least two synthetic material films, wherein said two films comprise a decor film and a transparent film, wherein said decor film is a printed synthetic material film chosen from the list consisting of a vinyl-based film, a polyethylene based film, a polyurethane based film and a polypropylene film, with the print being situated on the upper side of said film, and wherein said transparent film is a thermoplastic synthetic material film the material of which is chosen from the list consisting of polyvinyl chloride, polyethylene, polyurethane and polypropylene, characterized in that the method comprises at least a first step of providing said films on the substrate by means of a press treatment at a first temperature to form a package of said substrate and said synthetic material films, wherein said thermoplastic synthetic material forms the surface of said consolidated package, wherein said first step uses a calendar device or a continuous press device, wherein said first temperature is an increased temperature higher than room temperature (23°C), and at least a subsequent second step wherein a structure is formed in said thermoplastic synthetic material by means of a press treatment using a press device with a structured press element at a second temperature, said first temperature being higher than said second temperature, wherein the thermoplastic synthetic material, at the beginning of the second step, has a temperature at least higher than room temperature.
  2. Method according to claim 1, characterized in that said method further also comprises at least the step of providing a primer, preferably a polyurethane dispersion glue, on the substrate.
  3. Method according to claim 1 or 2, characterized in that said substrate relates to a wood-containing or wood-based substrate.
  4. Method according to any of the claims 1 to 3, characterized in that said substrate comprises a foamed synthetic material.
  5. Method according to any of the preceding claims, characterized in that no heat is supplied to said press device with said structured press element.
  6. Method according to any of the preceding claims, characterized in that the method comprises a step which is performed prior to the first step, wherein in this preceding step said two synthetic material films are laminated to a composed film.
  7. Method according to any of the claims 1 to 6, characterized in that said press treatment of said first step is performed with said first temperature situated between 80 and 150°C.
  8. Method according to any of the claims 1 to 7, characterized in that said press treatment of said first step is performed with a pressing time shorter than one minute.
  9. Method according to any of the preceding claims, characterized in that said thermoplastic material forming the surface of said consolidated package is structured exclusively by means of said second step.
  10. Method according to any of the preceding claims, characterized in that said decor film is a polyvinyl chloride film.
  11. Method according to any of the preceding claims, characterized in that the surface of said substrate which is provided with the top layer is porous.
  12. Method according to any of the preceding claims, characterized in that the material of said transparent film is polyvinyl chloride.

Description

This invention relates to panels and methods for manufacturing panels. More particularly, the invention relates to panels of the type which is at least composed of a substrate and comprises a top layer provided on this substrate, wherein said top layer comprises a printed motif and a transparent or translucent synthetic material layer, which is provided above said printed motif. Herein, this may relate, for example, to furniture panels, ceiling panels, floor panels or the like, which substantially consist of an MDF or HDF (Medium or High Density Fiberboard) basic panel or substrate and a top layer provided thereon. According to a first possibility, it relates to panels obtained by means of a method wherein one or more material layers are provided on the substrate, wherein at least one of these material layers is provided by means of a print which is performed directly on the substrate, wherein this print then forms at least a portion of said printed motif. According to a second possibility, it relates to panels obtained by means of a method wherein one or more material layers are provided on the substrate, wherein at least one of these material layers comprises a printed material sheet, wherein the print of the material sheet then forms at least a portion of said printed motif. The panels, manufactured according to said first possibility therefor, are known as such, for example, from US 1,971,067 or DE 195 32 819 A1. From said documents, it is also known that said material layers can comprise one or more primer layers, wherein these primer layers extend substantially underneath said print, and/or can comprise one or more finishing layers, which extend substantially above said print. Such finishing layers can comprise, for example, transparent or translucent synthetic material layers, which form a protective layer above the printed decor and, for example, can comprise wear-resistant particles, such as aluminum oxide. It is not excluded that this protective layer comprises a material sheet, such as a paper sheet. The state of the art in connection with panels which are provided with a print performed directly on the substrate further becomes clear also from WO 01/48333, WO 02/00449, WO 2004/042168, EP 1 454 763, DE 197 25 829 C1 and DE 10 2004 009 160 A1. It is known, amongst others, from WO 01/48333, that for realizing said material layers either lacquers or synthetic resins can be applied. In the case of synthetic resins, those are applied via a carrier sheet, which beforehand is provided with such synthetic resin and, by means of a heated press, is provided on the substrate. In the case of lacquers, for example, UV-hardening lacquers can be applied. Respectively, also wear-resistant particles are applied for obtaining a sufficient wear resistance on the surface of the panel. Such wear-resistant particles, however, lead to a reduced transparency of the material layer concerned. It is known, amongst others, from DE 197 25 829 C1 or EP 1 454 763, that one or more synthetic resins, applied in liquid condition, can be used for realizing said material layers. After these resin layers have dried, they are hardened in a heated press. By means of such method, paper-free top layers can be realized. According to the state of the art, an adherence of synthetic resins is only possible on water-based inks. However, the water-based inks are less resistant against UV radiation, for example, as a consequence of sunlight, than UV-based inks. Panels manufactured according to said second possibility therefor are known, for example, from WO 97/47834 and WO 01/96689. Such panels typically comprise a top layer provided above the substrate and being on the basis of thermo-hardening resin, wherein this top layer is composed, by means of a press treatment, of paper sheets provided with resin. One of these paper sheets usually is provided with a printed motif, whereas another paper sheet is transparent and serves as a protective layer for this printed motif. During said press treatment, also a relief can be realized in the surface of said transparent or translucent layer. WO 2010/084466, which is a document falling under Art. 54(3) and is not relevant to the question of inventive step, discloses floor panels on the basis of MDF or HDF, where upon a DPL top layer is provided by means of a press treatment at increased temperature. WO 2010/088769, which is a document falling under Art. 54(3) is not relevant to the question of inventive step, discloses a flooring panel with an MDF or HDF substrate to which e.g. a vinyl foil is joined. GB 2 376 916 discloses a laminate substrate made by heat sealing a substrate and a synthetic thermoplastic film, using an adhesive. WO 2009/141743 discloses heat pressing of a removable film using a structured press element. US 5 466 320 discloses floor tiles made of PVC. They are made by laminating, in a nip a preheated PVC film onto an extruded substrate comprising PVC. The present disclosure, in first i