KR-102963502-B1 - Covered panel and method for manufacturing a covered panel

KR102963502B1KR 102963502 B1KR102963502 B1KR 102963502B1KR-102963502-B1

Abstract

The present invention relates to a coated panel having at least a substrate (2) and an upper layer (3) applied to said substrate, wherein the upper layer (3) comprises at least a decorative layer (4) and a translucent or transparent wear layer (5), and said wear layer (5) comprises a thermosetting acrylate resin or a thermosetting unsaturated polyester resin. Preferably, the thermosetting partially or wholly cures said resin. In particular, said acrylate resin or unsaturated polyester resin is cured by a thermally initiated radical crosslinking reaction. The present invention also relates to a method for manufacturing such a coated panel (1), in particular a floor panel.

Inventors

클레망 벤자맹
레더헌 삼

Assignees

유니린 비브이

Dates

Publication Date: 20260511
Application Date: 20191105
Priority Date: 20181109

Claims (20)

As a coated panel (1) having at least a substrate (2) and an upper layer (3) applied to the substrate, The upper layer (3) comprises at least a decorative layer (4) and a translucent or transparent wear layer (5), and The above wear layer (5) comprises a thermosetting acrylate resin or a thermosetting unsaturated polyester resin, and the thermosetting partially or entirely hardens the resin, and The above wear layer (5) is obtained based on a mixture comprising, on one hand, an acrylate resin and/or an unsaturated polyester resin and on the other hand, at least two types of thermal initiators, and The above decorative layer (4) comprises a carrier sheet, and the carrier sheet comprises a printed paper sheet provided with a synthetic material (19), and The above-mentioned coated panel (1) has relief on its surface, A coated panel characterized in that the above relief is provided by a hot pressing process, heat curing is performed in the hot pressing process, and the two or more types of heat initiators are activated in the hot pressing process.
In Article 1, A coated panel characterized in that the above acrylate resin or unsaturated polyester resin is cured by a thermally initiated radical crosslinking reaction.
In Article 1, A coated panel characterized by the above curing comprising at least cross-linking of double carbon bonds present in the acrylate resin or unsaturated polyester resin.
In Article 1, A coated panel characterized in that the above two or more types of thermal initiators are organic peroxide, or benzoyl peroxide, or lauryl peroxide, or tertiary butylperoxy-3,5,5-trimethylhexanoate (TBPIN).
In Article 1, A coated panel characterized by the above mixture comprising 0.1-5 parts of a thermal initiator per 100 parts of acrylate resin or 100 parts of unsaturated polyester resin.
In Article 1, The above-mentioned wear layer (5) is a coated panel characterized by containing a small amount of peroxide.
In Article 1, The above-mentioned wear layer (5) is characterized by being uniformly or essentially uniformly hardened over its entire thickness, forming a coated panel.
In Article 1, A coated panel characterized by the thermal curing comprising chemical crosslinking of double carbon bonds present in the acrylate resin or the unsaturated polyester resin.
In Article 1, A coated panel characterized by the above mixture further comprising a photoinitiator.
In Article 9, A coated panel characterized by the above mixture comprising 0.1-5 parts of two different photoinitiators in 100 parts of acrylate resin or 100 parts of unsaturated polyester resin.
In Article 1, The above synthetic material (19) is a coated panel characterized by including double carbon bonds.
In Article 1, The above-mentioned wear layer comprises a thermosetting acrylate resin or a thermosetting unsaturated polyester resin, and the above-mentioned synthetic material (19) is selected from a list of combinations of amino resin, urea formaldehyde, melamine urea formaldehyde, melamine formaldehyde, polyurethane, urethane-acrylic copolymer, melamine acrylate, melamine formaldehyde, acrylate, latex, dispersion, and optionally a crosslinking agent, characterized by a coated panel.
In Article 1, A coated panel characterized in that the wear layer comprises a thermosetting acrylate resin, wherein the acrylate resin is obtained based on at least a multifunctional acrylate monomer and/or oligomer, such as a hexafunctional acrylate oligomer.
In Article 1, A coated panel characterized in that the wear layer comprises a thermosetting acrylate resin, wherein the acrylate resin is obtained based on at least a monofunctional, difunctional, or trifunctional acrylate monomer and/or oligomer.
In Article 1, A coated panel characterized in that the wear layer comprises a thermosetting acrylate resin, and the acrylate resin is obtained from at least chemically modified acrylate.
In Article 1, A coated panel characterized in that the above-mentioned wear layer comprises a thermosetting acrylate resin, and the acrylate resin is of an aliphatic type.
In Article 1, A coated panel characterized in that the wear layer is composed of multiple layers, and the wear layer comprises multiple layers having the features described for the wear layer of claim 1.
In Article 17, A coated panel characterized in that the top layer of the above-mentioned wear layer comprises one or more of fluorine-containing acrylate, micro aluminum oxide, silicon acrylate, or nanosilica.
In Article 1, The coated panel (1) is characterized as being a floor panel suitable for floating equipment.
In Article 1, The above coated panel (1) is a coated panel characterized by having a relief on its surface having a difference in gloss.

Description

Covered panel and method for manufacturing a covered panel The present invention relates to a coated panel, in particular a floor panel, and a method for manufacturing a floor panel. More specifically, the present invention relates to a panel having a substrate and an upper layer applied to the substrate, the upper layer comprising a decorative layer, for example, a decorative layer including a print. Such floor panels are widely known in themselves, for example, from WO 97/47834. The floor panel disclosed in the said document relates to a floor panel having a substrate mainly composed of an HDF sheet having a laminate layer pressed directly on top, comprising, most preferably, one or more paper sheets impregnated with melamine resin, for example, a paper sheet having a print on a wood or stone motif, particularly also including so-called decorative paper. The aforementioned melamine resin forms a translucent wear layer particularly on the decorative paper, but transparency or translucency is highly required. On the lower side of the substrate, there is a backing layer or balancing layer based on a paper sheet impregnated with melamine resin. This backing layer provides a compensating effect for residual tensile stress present in the cured melamine resin of the upper layer. It is still possible to form a very deep structure on the surface of the cured melamine. The so-called "White Mountain" occurs frequently. This is an area on the melamine surface where inclusions are concentrated. It primarily occurs in deep indentations or where structures are formed. The melamine surface of such laminate panels is known to produce a clicking sound during use. Several solutions to this problem are known from the prior art. WO 03/016655 discloses the application of a soundproof layer, such as a cork layer, under a melamine layer. It is known from WO 2010/088769 to provide a flexible monomer coating on a melamine layer. WO 2009/101217 and WO 2010/070474 provide examples of laminate panels in which the top layer is composed mainly of polyvinyl chloride (PVC) instead of melamine resin. WO 2010/070474 discloses a panel having a printed decorative layer that can be formed on a substrate and finished with a transparent PVC layer. Furthermore, a method of finishing panels with a printed decorative layer using UV-cured or electron-beam cured acrylate resins is known from WO 01/47726. This process is difficult to integrate into existing methods for laminate panel production, requires complex material logistics and machinery, and leads to high costs. For example, electron beam curing requires an inert atmosphere capable of performing processing at the plate level, and this technology is applied to smaller panels or sheets in physically enclosed lead spaces primarily to neutralize harmful gamma rays. These lead-encapsulated components are thicker than 2.5 mm and very heavy. The photoinitiators required for curing by UV radiation have a detrimental effect on the quality of the resulting surface. Molecules used as photoinitiators are under increasing pressure due to the health risks associated with them for humans. In panels where the top layer consists entirely of polyvinyl chloride (PVC), a loss of scratch resistance is observed compared to conventional melamine surfaces. Additionally, the PVC layer must be constructed to be significantly thicker than the melamine layer to achieve similar wear resistance. The characteristics and thickness of the PVC layer provide a plastic-like appearance to the floor panels, particularly when attempting to mimic products such as wood, stone, or ceramics. The relief achievable from the PVC layer is not sharp, compromising the realistic appearance of the resulting imitation. In panels where the top layer is obtained from UV-cured or electron-beam-cured acrylate, as in WO 01/47726, advantageous surface properties are achieved. The relief obtainable from such a top layer is limited in that a structural film must be applied, for example, as in EP2019735. To better explain the features of the present invention, several preferred examples are described below with reference to the attached drawings, without being limited in any way. FIG. 1 illustrates a perspective view of a coated panel having the features of the present invention, more specifically a floor panel. Figure 2 shows a larger scale section along line II-II of Figure 1. FIG. 3 is a schematic diagram of several steps of a method having the features of the present invention. Figures 4 and 5 illustrate the sound measurement results of a panel having the features of the present invention. FIG. 6 illustrates a method having the features of the present invention. FIG. 1 shows a coated panel (1). In this case, it is a rectangular floor panel comprising at least a substrate (2), and an upper layer (3) applied to the substrate having a decorative layer (4) and a translucent or transparent wear layer (5). The wear layer (5) comprises a thermosetting acr