WO2006126930A1

WO2006126930A1 - A decorative laminate

Info

Publication number: WO2006126930A1
Application number: PCT/SE2006/000572
Authority: WO
Inventors: Christina Eriksson; Hans Persson; Jan-Ingvar Nygren
Original assignee: Pergo (Europe) Ab
Priority date: 2005-05-23
Filing date: 2006-05-18
Publication date: 2006-11-30
Also published as: DE102005023661B4; DE102005023661A1

Abstract

A floor panel intended for use as a floor covering material whereby a plurality of said floor panels are joined together to form said floor covering. The floor panel comprises an upper decorative and abrasion resistant layer, an intermediate damping layer and a carrying core. The floor panel further constitutes edges, said edges having a joint geometry so as to allow a plurality of such floor panels to be joined together. The joint geometry have a feature selected from the group consisting of; tongue, groove, undercut, protrusion, girder, web, lower cheek, upper cheek, resilient portion, hook, grapnel, claw and a combination thereof. The upper decorative and abrasion resistant layer comprises a decorative layer and an uppermost wear layer. The intermediate damping layer comprises an elastic material, said elastic material being bonded to the upper side of the carrying core and to which elastic material the upper decorative and abrasion resistant layer is bonded.

Description

A decorative laminate.

BACKGROUND OF THE INVENTION ■

1. Field of the invention

The present invention relates to a decorative laminate with an integrated damping layer intended to decrease the sound-level.

2. Description of related prior art

Products coated with thermosetting laminate are common nowadays. They are foremost used where the demands on abrasion resistance are great, but also where resistance towards different chemicals and moisture are demanded. As example of such products can be mentioned floors, floor headings, work tops, desk tops and wall panels.

The thermosetting laminate most often consists of a number of base sheets with decor sheet arranged closest to the surface. The decor sheet can be provided with a desired decor or pattern. Such thermosetting laminates are very hard in order to withstand the wear they are exposed to. This will unfortunately lead to a high noise level when hard objects are retarded suddenly by the laminate surface, such as hard heels, keys and coins towards a laminate surface. There are also other type of laminates where high noise levels may be perceived as uncomfortable.

It is desirable to be able to muffle the sound level in rooms with a floor surface of laminate, specially in areas where shoes normally are used.

SUMMARY OF THE INVENTION

It has, through the present invention, been made possible to meet the above mentioned desires and a decorative laminate with a lower noise level has been achieved. Accordingly, the invention relates to a decorative laminate. The invention is characterised in that the laminate comprises an upper decorative and preferably abrasion resistant layer, an intermediate damping layer and a carrying core, the intermediate damping layer being constituted of an elastic material.

The definition of the phrase laminate as used in the present invention should be understood the wider sense of the word, implying that a laminate constitutes two or more strata of materials. These materials may have different mechanical properties such as, but not limited thereto; opacity, density, elastic module, elastic compression module, material composition, thermal conductivity, electrical conductivity, abrasion resistance etc.

The intermediate damping layer suitably have a thickness in the range 0.2 - 4 mm. The damping layer is further being expanded to contain cavities. Said intermediate damping layer have an average density in the range 300 - 900 kg / m³. The upper decorative and preferably abrasion resistant layer have a thickness of at least 10% of the thickness of the intermediate damping layer.

According to one embodiment of the invention the intermediate damping layer have a thickness in the range 0.3 - 3 mm. The damping layer is expanded to contain cavities. The intermediate damping layer have an average density in the range 300 - 800 kg / m³. The upper decorative and preferably abrasion resistant layer have a thickness of at least 15% of the thickness of the intermediate damping layer.

According to one embodiment of the invention the intermediate damping layer have a thickness in the range 0.7 - 1.3 mm.

The intermediate damping layer is preferably constituted of an elastic material. This material may be constituted of a natural material such as cork and rubber or a synthetic material like thermoelastic materials and elastomeres. Some natural materials like for example cork are ^"by nature expanded to contain cavities, while some other materials like synthetic elastomeres are expanded to contain cavities during the manufacturing of said materials.

The intermediate damping layer is suitably constituted of polyurethane which has proven to have the desired properties to withstand increased temperatures necessary for some specific lamination procedures.

According to one embodiment of the invention the intermediate damping layer has a density in the range 450 - 650 kg / m³.

The laminate according to the present invention is advantageously used for floor covering purpose wherein the laminate comprises a plurality of edges of which at least two opposite edges are provided with means for joining. The means for joining are suitably provided on all edges. These means for joining suitably have a cross-section geometry so construed as to allow mechanical locking, whereby a plurality of said decorative laminates can be locked together to form said floor covering without having to use glue.

It is, however, understood that a laminate according to the present invention may be used in other applications as well, the following being examples thereof, not excluding other uses; wall panels, ceiling panels, table tops, wok tops, door panels and furniture.

According to one embodiment of the invention the upper decorative and preferably abrasion resistant layer comprises at least one decor paper layer, at least one overlay paper layer and optionally one or more base paper layer where at lest one of the paper layers are impregnated with a thermosetting resin. The overlay paper layer is then suitably impregnated with melamine formaldehyde resin and provided with small hard particles having an average particle size in the range 1 - 150 μm. The small hard particles are suitably selected from the group consisting of aluminium oxide, silicon oxide and silicon carbide.

According to one embodiment of the invention the decorative and preferably abrasion resistant layer comprises one base paper layer, one decor paper layer and at least one overlay paper layer while the intermediate damping layer has a thickness in the range 0.7 - 1 mm and a density in the range 500 - 650 kg / m³.

According to another embodiment of the invention the decorative and abrasion resistant layer comprises one decor paper layer and at least one overlay paper layer while the intermediate damping layer has a thickness in the range 0.7 - 1 mm and a density in the range 500 - 650 kg / m³.

The intermediate damping layer may, according to one embodiment of the invention, be provided with through holes having a diameter in the range 0.5 - 2 mm, said holes being applied to an amount in excess of 500 holes / m².

According to yet another embodiment of the invention the decorative and abrasion resistant layer comprises one decor paper layer and at least one overlay paper layer while the intermediate damping layer has a thickness in the range 1.2 - 2 mm and a density in the range 500 - 650 kg / m³.

According to yet another embodiment the decorative and abrasion resistant layer comprises at least two base paper layer, one decor paper layer and at least one overlay paper layer while the intermediate damping layer has a thickness in the range 1 - 2 mm and a density in the range 450 - 650 leg / m³.

As discussed earlier in the present application the intermediate damping layer is suitably constituted of polyurethane.

As an alternative to thermosetting laminates as described above it is, according to the present invention, alternatively possible to utilise other material combinations for the decorative and abrasion resistant wear layer.

According to one embodiment of such an alternative, the decorative and abrasion resistant layer is comprises a wood veneer and at least one overlay paper. The at least one overlay paper is here suitably impregnated with thermosetting resin. This thermosetting resin is then preferably selected from the group consisting of; melamine formaldehyde resin, urea formaldehyde resin, acrylic resin or a combination thereof.

According to another embodiment of the present invention the wood veneer is provided with at least one impregnated overlay paper on its upper side and at least one backing paper on its lower side, said backing paper being selected from the group consisting of; Kraft paper, overlay paper and a combination thereof. The backing paper is then suitably impregnated with a thermosetting resin selected from the group consisting of; melamine formaldehyde resin, urea formaldehyde resin, phenol formaldehyde resin and combinations thereof.

According to yet another embodiment of the present invention the decorative and abrasion resistant wear layer comprises a wood veneer and a UV curing lacquer or an EB curing lacquer. The wood veneer may suitably further comprise a backing paper on its lower side, said backing paper being selected from the group consisting of; Kraft paper, overlay paper and a combination thereof. This backing paper is then suitably impregnated with a thermosetting resin selected from the group consisting of; melamine formaldehyde resin, urea formaldehyde resin, phenol formaldehyde resin and combinations thereof.

Also according to these embodiments the intermediate damping layer is suitably constituted of polyurethane as described above even if other materials listed herein are possible to utilise.

The carrying core used in the present invention is suitably constituted by materials like a solid wood board, a particle board, a fibre board, an oriented strand board, a board based on polymers such as polyurethane or a fibre cement board. It is of course possible to utilise other suitable materials.

According to an embodiment of the present invention the decorative and abrasion resistant layer has a thickness in the range 0.1 mm - 0.7 mm, preferably 0.15 mm - 0.5 mm.

According to one embodiment of the present invention, the decorative and abrasion resistant layer has a density in the range 1250 - 1500 kg / m³.

The intermediate damping layer suitably has an elasticity compression coefficient in the range 0.5 - 4 Mpa, preferably 0.7 - 3 Mpa.

The intermediate damping layer and the decorative and abrasion resistant layer is suitably joined with the . carrying core by means of glue, heat and pressure. This glue is suitably selected from; melamine formaldehyde, urea formaldehyde, phenol formaldehyde, hot-melt glue and combinations thereof. It is accordingly possible to use different bonding agents selectively depending on which layers that are to be bonded. The different layers may be joined together in a static, discontinuous, laminate press or in a continuous laminate press which utilises press belts.

Although it is advantageous from a logistical point of view to join all layers in a one step laminating process, it is possible and may show equally advantageous to separate the lamination process into a series of steps. It is for example possible to laminate the decorative and abrasion resistant layer in a first step and then to join that with the intermediate damping layer and the carrying core. It is also possible to laminate the intermediate damping layer and the decorative and abrasion resistant layer in a first step and then to laminate this to the carrying core in a second step. A third alternative is to bond the intermediate damping layer to the carrying core and to laminate this to the decorative and abrasion resistant layer in a second lamination step.

It is known that polymeric materials, especially under dry conditions, help generate undesired static charges which may cause unpleasant discharges when one touch a metal object like a door handle. This charging may, according to a special embodiment of the invention, be counteracted by having the intermediate damping layer comprising a conductive material. The conductive material is suitably constituted of carbon black, carbon fibre, magnetite or a vacuum metallized layer. The conductivity is preferably better than 500 kΩcm.

As discussed earlier the intermediate damping layer and/or the decorative and abrasion resistant layer is suitably joined with the carrying core by means of hot-melt glue, heat and pressure. According to one alternative embodiment of the invention the glue comprises a conductive material. The conductive material is then suitably constituted of carbon black, magnetite or carbon fibre. Also here the conductivity is preferably better than 500 kΩcm. The invention also relates to a floor covering material comprising a plurality of floor panels. Thus, a floor panel intended for use as a floor covering material whereby a plurality of said floor panels are joined together to form said floor covering. The invention is characterised in that the floor panel comprises an upper decorative and abrasion resistant layer, an intermediate damping layer and a carrying core. The floor panel constitutes edges, said edges having a joint geometry so as to allow a plurality of such floor panels to be joined together. The joint geometry have a feature selected from the group consisting of; tongue, groove, undercut, protrusion, girder, web, lower cheek, upper cheek, resilient portion, hook, grapnel, claw and a combination thereof. The upper decorative and abrasion resistant layer comprises a decorative layer and an uppermost wear layer. The intermediate damping layer comprises an elastic material, said elastic material being bonded to the upper side of the carrying core and to which elastic material the upper decorative and abrasion resistant layer is bonded.

According to one embodiment of the invention the joints further comprises an additive selected from the group consisting of; glue, pre-applied glue determined to become activate during assembly, wax, oil, lacquer, polymer and combinations thereof.

According to one embodiment of the invention the decorative and abrasion resistant layer, comprises materials selected from the group consisting of; decor paper, wood veneer, decor foil, overlay paper, lacquer, UV-curing lacquer, radiation curing lacquer, thermosetting resin, underlay paper and combinations thereof. According to one embodiment of the invention the carrying core comprises a material selected from the group consisting of; fibre board, particle board, oriented strand board, plywood, massive wood, fibre cement board and polymer based boards. Polymer based boards may for example comprise a polyolefin like polyethylene and polypropylene and also a filler. The filler may be a fibrous material like cellulose but also particles of for example wood or minerals like lime may be used.

The damping layer suitably comprises pores. The damping layer suitably has a density in the range 300 - 900 kg / m³. The damping layer is furthermore so constituted that it preferably has the capability of withstanding 180 ⁰C for a period of 1 minute without radical softening or loosing its chemical or mechanical structure. The damping layer is according to one embodiment of the invention constituted of polyurethane. The damping layer suitably has a density in the range 500 - 700 kg / m³. According to one embodiment of the invention the damping layer has a thickness in the range 0.5 - 5 mm. The thickness of the decorative and abrasion resistant layer is preferably at least one tenth, but not more than nine tenth, the thickness of the damping layer.

As described above in selected embodiments of the invention the decorative and abrasion resistant layer comprises thermosetting laminate which preferably comprises one or more decor papers which possibly is /are impregnated with melamine-formaldehyde resin. The decor paper may according to other embodiments be replaced by wood veneer or a decor foil. It further comprises and one or more overlay sheets impregnated with melamine formaldehyde resin- arranged on top of the decor papers. The thermosetting laminate may further comprise one or more conventional resin impregnated underlay papers, arranged under the decor paper or decor papers, wood veneer or decor foil, which underlay papers preferably contains phenol-formaldehyde resin. The different layers are laminated together under increased pressure and increased temperature. This is suitably achieved in a one step process so that the intermediate damping layer, the different layers of the decorative and abrasion resistant thermosetting laminate and possibly also the carrying core, are joined and cured at the same time. At least one of the sheets impregnated with thermosetting resin, preferably the outermost, is provided with hard particles of for example silicon oxide, aluminium oxide and/or silicon carbide with an average size of 1 -100 μm, preferably around 5 - 60 μm.

EMBODIMENT EXAMPLE

A decorative laminate in the form of a floor covering material consisting of a plurality of floor panels were joined together via tongue and groove joints, said joints being provided with snapping webs allowing the panels to be locked together without use of glue. The floor panels were comprised from bottom to top of; backing felt, a 7.8 mm thick MDF board, a 0.8 mm thick intermediate polyurethane layer having an average density of 625 kg / m², a Kraft paper layer, a decor paper layer and an overlay paper layer was tested for impact strength and sound reduction.

The impact resistance was tested with small ball in accordance with EN 438/part2. The minimum requirements was determined to 8N. The test result showed impact resistance of more than 16N. The sound reduction was tested in accordance with EPLF 021029-3 of Nov. 2004.

The test result received was <55 sone. For the sake of comparison a standard laminate shows figures >65 sone while a laminate with rear side sound reduction show figures >58 sone. Accordingly the present invention show a radical improvement on sound reduction with a fully acceptable level^' of impact resistance.

It is understood that undesired noise will be reduced when using laminates according to the present invention. However, also desired properties like ergonomic ones will be improved. This is especially noted on floor covering materials like discussed above where the damping layer also will have a cushioning effect when one walks on such a floor.

Claims

WE CLAIM

1. A decorative laminate, wherein the laminate comprises an upper decorative and preferably abrasion resistant layer, an intermediate damping layer and a carrying core, the intermediate damping layer being constituted of an elastic material.

2. A decorative laminate according to claim 1 , wherein the intermediate damping layer have a thickness in the range 0.2 - 4 mm.

3. A decorative laminate according to claim 1, wherein the damping layer is expanded to contain cavities.

4. A decorative laminate according to claim 1, wherein the intermediate damping layer further having an average density in the range 300 - 90.0 kg / m³.

5. A decorative laminate according to claim 1, wherein the upper decorative and preferably abrasion resistant layer have a thickness of at least 10% of the thickness of the intermediate damping layer.

6. A decorative laminate according to claim 2, wherein the intermediate damping layer have a thickness in the range 0.3 - 3 mm.

7. A decorative laminate according to claim 6, wherein the intermediate damping layer further having an average density in the range 300 - 800 kg / m³.

8. A decorative laminate according to claim 6, wherein the upper decorative and preferably abrasion resistant layer have a thickness of at least 15% of the thickness of the intermediate damping layer.

9. A decorative laminate according to claim 6, wherein the intermediate damping layer have a thickness in the range 0.7 - 1.3 mm.

10. A decorative laminate according to claim 9, wherein the intermediate damping layer have a thickness in the range 0.7 - 1.3 mm.

11. A decorative laminate according to any of the claims 1 - 10, wherein the intermediate damping layer is constituted of polyurethane.

12. A decorative laminate according to any of the claims 1 - 10, wherein the intermediate damping layer has a density in the range 450 - 650 kg / m³.

13. A decorative laminate according to any of the claims 1 - 10 wherein the laminate is used for floor covering purpose wherein the laminate comprises a plurality of edges of which at least two opposite edges are provided with means for joining.

14. A decorative laminate according to claim 13 wherein said means for joining are provided on all edges.

15. A decorative laminate according to claim 14 wherein said means for joining have a cross-section geometry so constructed as to allow mechanical locking whereby a plurality of said decorative laminates can be locked together to form said floor covering without having to use glue.

16. A decorative laminate according to any of the claims 2 - 5, wherein the upper decorative and preferably abrasion resistant layer comprises at least one decor paper layer, at least one overlay paper layer and optionally one or more base paper layer, that at lest one of the paper layers are impregnated with thermosetting resin.

17. A decorative laminate according to claim 16, wherein the overlay paper layer is impregnated with melamine formaldehyde resin and provided with small hard particles having an average particle size in the range 1 - 150 μm, the small hard particles being selected from the group consisting of aluminium oxide, silicon oxide and silicon carbide.

18. A decorative laminate according to claim 16, wherein the decorative and preferably abrasion resistant layer comprises one base paper layer, one decor paper layer and at least one overlay paper layer while the intermediate damping layer has a thickness in the range 0.7 - 1 mm and a density in the range 500 - 650 kg / m³.

19. A decorative laminate according to any of the claims 2 - 5, wherein the decorative and abrasion resistant layer comprises one decor paper layer and at least one overlay paper layer while the intermediate damping layer has a thickness in the range 0.7 - 1 mm and a density in the range 500 - 650 kg / m³.

20. A decorative laminate according to claim 18, wherein the intermediate damping layer is provided with through holes having a diameter in the range 0.5 - 2 mm, said holes being applied to an amount in excess of 500 holes / m².

21. A decorative laminate according to any of the claims 2 - 5, wherein the decorative and abrasion resistant layer comprises at least two base paper layer, one decor paper layer and at least one overlay paper layer while the intermediate damping layer has a thickness in the range 1 - 2 mm and a density in the range 450 - 650 kg / m³.

22. A decorative laminate according to any of the claims 18 - 21, wherein the intermediate damping layer is constituted of polyurethane.

23. A decorative laminate according to any of the claims 2 - 5 wherein the decorative and abrasion resistant layer is comprises a wood veneer and at least one overlay paper.

24. A decorative laminate according to claim 23 wherein the at least one overlay paper is impregnated with thermosetting resin.

25. A decorative laminate according to claim 24 wherein the thermosetting resin is selected from the group consisting of; melamine formaldehyde resin, urea formaldehyde resin, acrylic resin or a combination thereof.

26. A decorative laminate according to claim 23 wherein the wood veneer is provided with at least one impregnated overlay paper on its upper side and at least one backing paper on its lower side, said backing paper being selected from the group consisting of; Kraft paper, overlay paper and a combination thereof.

27. A decorative laminate according to claim 26 wherein the backing paper is impregnated with a thermosetting resin selected from the group consisting of; melamine formaldehyde resin, urea formaldehyde resin, phenol formaldehyde resin and combinations thereof.

28. A decorative laminate according to any of the claims 2 - 5 wherein the decorative and abrasion resistant wear layer comprises a wood veneer and a UV curing lacquer.

29. A decorative laminate according to claim 28 wherein the wood veneer further comprises a backing paper on its lower side, said backing paper being selected from the group consisting of; Kraft paper, overlay paper and a combination thereof.

30. A decorative laminate according to claim 29 wherein the backing paper is impregnated with a thermosetting resin selected from the group consisting of; melamine formaldehyde resin, urea formaldehyde resin, phenol formaldehyde resin and- combinations thereof.

31. A decorative laminate according to any of the claims 23 - 30, wherein the intermediate damping layer is constituted of polyurethane.

32. A decorative laminate according to any of the claims 1 - 8, wherein the carrying core is constituted by a particle board.

33. A decorative laminate according to any of the claims 1 - 8, wherein the carrying core is constituted by a fibre board.

34. A decorative laminate according to any of the claims 1 - 8, wherein the carrying core is constituted by an oriented strand board.

35. A decorative laminate according to any of the claims 1 - 8, wherein the carrying core is constituted by a board based on polymers such as polyurethane.

36. A decorative laminate according to any of the claims 1 - 8, wherein the carrying core is constituted by a fibre cement board.

37. A decorative laminate according to claim 11, wherein the thermosetting laminate has a thickness in the range 0.1 mm - 0.7 mm, preferably 0.15 mm - 0.5 mm.

38. A decorative laminate according to claim 37, wherein the thermosetting laminate has a density in the range 1250 - 1500 kg / m³.

39. A decorative laminate according to any of the claims 1 - 8, wherein the intermediate damping layer has elasticity compression coefficient in the range 0.5 - 4 Mpa, preferably 0.7 - 3 Mpa.

40. A decorative laminate according to any of the claims 1 - 8, wherein the intermediate damping layer and the decorative and abrasion resistant layer is joined with the carrying core by means of glue, heat and pressure.

41. A decorative laminate according to any of the claims 1 - 8, wherein the intermediate damping layer further comprises a conductive material.

42. A decorative laminate according to claim 41 , wherein the conductive material is constituted of carbon black.

43. A decorative laminate according to claim 41, wherein the conductive material is constituted of carbon fibre.

44. A decorative laminate according to claim 41, wherein the conductive material is constituted of magnetite.

45. A decorative laminate according to claim 41, wherein the conductive material is constituted of a vacuum metallized layer.

46. A decorative laminate according to claim 41, wherein a conductivity is better than 500 kΩcm.

47. A decorative laminate according to any of the claims 1 - 8, wherein the intermediate damping layer and/or the decorative and abrasion resistant layer is joined with the carrying core by means of hot-melt glue, heat and pressure.

48. A decorative laminate according to claim 47, wherein the glue comprises a conductive material. ^■

49. A decorative laminate according to claim 47, wherein the conductive material is constituted of carbon black.

50. A decorative laminate according to claim 47, wherein the conductive material is constituted of carbon fibre.

51. A process according to claim 47, wherein a conductivity is better than

500 kΩcm.

52. A floor panel intended for use as a floor covering material whereby a plurality of said floor panels are joined together to form said floor covering, wherein said floor panel comprises an upper decorative and abrasion resistant layer, an intermediate damping layer and a carrying core, that said floor panel constitutes edges, said edges having a joint geometry so as to allow a plurality of such floor panels to be joined together, said joint geometry having a feature selected from the group consisting of; tongue, groove, undercut, protrusion, girder, web, lower cheek, upper cheek, resilient portion, hook, grapnel, claw and a combination thereof, that the upper decorative and abrasion resistant layer comprises a decorative layer and an uppermost wear layer, that the intermediate damping layer comprises an elastic material, said elastic material being bonded to the upper side of the carrying core and to which elastic material the upper decorative and abrasion resistant layer is bonded.

53. A floor panel according to claim 52 wherein the joints further comprises an additive selected from the group consisting of; glue, pre-applied glue determined to become activate during assembly, wax, oil, lacquer, polymer and combinations thereof.

54. A floor panel according to claim 52 wherein the decorative and abrasion resistant layer comprises materials selected from the group consisting of; decor paper, wood veneer, decor foil, overlay paper, lacquer, UV-curing lacquer, radiation curing lacquer, thermosetting resin, underlay paper and combinations thereof.

55. A floor panel according to claim 52 wherein the carrying core comprises a material selected from the group consisting of; fibre board, particle board, oriented strand board, plywood, massive wood, fibre cement board and polymer based boards.

56. A floor panel according to claim 52 wherein the damping layer comprises pores.

57. A floor panel according to claim 56 wherein the damping layer has a density in the range 300 - 900 kg / m³.

58. A floor panel according to claim 56 wherein the damping layer has the capability of withstanding 180 ⁰C for a period of 1 minute without softening or

loosing its chemical structure.

59. A floor panel according to claim 58 wherein the damping layer is constituted of polyurethane.

60. A floor panel according to claim 59 wherein the damping layer has a density in the range 500 - 700 kg / m³.

61. A floor panel according to claim 56 wherein the damping layer has a thickness in the range 0.5 - 5 mm.

62. A floor panel according to claim 56 wherein the thickness of the decorative and abrasion resistant layer is at least one tenth, but not more than nine tenth, the thickness of the damping layer.