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WO2016151435A1 - Procédé pour fabriquer un panneau décoratif et panneau décoratif - Google Patents

Procédé pour fabriquer un panneau décoratif et panneau décoratif Download PDF

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Publication number
WO2016151435A1
WO2016151435A1 PCT/IB2016/051476 IB2016051476W WO2016151435A1 WO 2016151435 A1 WO2016151435 A1 WO 2016151435A1 IB 2016051476 W IB2016051476 W IB 2016051476W WO 2016151435 A1 WO2016151435 A1 WO 2016151435A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
resin
decorative
veneer
decorative panel
Prior art date
Application number
PCT/IB2016/051476
Other languages
English (en)
Inventor
Frank Loncke
Laurent Meersseman
Original Assignee
Unilin, Bvba
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
Priority claimed from BE2015/5173A external-priority patent/BE1022850B1/nl
Application filed by Unilin, Bvba filed Critical Unilin, Bvba
Publication of WO2016151435A1 publication Critical patent/WO2016151435A1/fr

Links

Classifications

    • 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
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
    • B27N7/005—Coating boards, e.g. with a finishing or decorating 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/042—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of wood
    • 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
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/06—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • 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
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • 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
    • B32B27/10—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 paper or cardboard
    • 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
    • B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/043—Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B2037/1253—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives curable adhesive
    • 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
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • 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
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls
    • 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
    • B32B2451/00—Decorative or ornamental articles
    • 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
    • B32B2607/00—Walls, panels

Definitions

  • This invention relates to a method for manufacturing a decorative panel and a decorative panel which can be obtained by such method.
  • the invention relates to decorative panels, such as floor panels, which comprise a top or decorative layer based on wood.
  • decorative panels such as floor panels, which comprise a top or decorative layer based on wood.
  • Such panels are widely known, for example, from WO 2010/122514.
  • floor panels In the case of floor panels, one talks about ready to install, prefabricated or composed parquet, in English also indicated as “Engineered Wood Parquet", or about veneer parquet.
  • Composed parquet panels usually comprise at least a substrate, a wood layer provided thereon, and a wood-based backing layer on the underside of the substrate.
  • the wood layer situated on the upper side functions as a top and decorative layer and mostly is realized from hardwood. However, it may be treated further at its upper side, for example, for influencing the appearance thereof and/or for improving the surface quality thereof, for example, by means of coloring, providing a wear-resistant and waterproof transparent lacquer, and so on.
  • the wood-based backing layer mostly consists of a one-piece thin layer of a cheap and mostly soft wood species.
  • Such parquet panels are sensitive to indentations by impact and may be sensitive to scratches. Due to their even worse mechanical features, soft wood species are unsuitable as a top layer for such panels.
  • the substrate of a composed parquet panel is composed of a plurality of crosswise-directed strips of wood.
  • Such substrate is also called a lamella core.
  • the lamellas mostly consist of soft wood, such as spruce (English: spruce) or hevea.
  • HDF High Density Fiberboard
  • elongated panels it is also known to replace the lamellas at the short sides by strips of another material, such as HDF (High Density Fiberboard) or plywood, in order to increase the strength at these edges. Examples thereof are described in DE 101 63 435, WO 2010/122514 and WO 2007/141605.
  • embodiments of composed parquet panels are known wherein the entire substrate is replaced by a single continuous wood fiberboard, more particularly a MDF or HDF board, for example, as described in DE 201 21 836.
  • the present invention relates to a method for manufacturing a decorative panel, preferably a floor panel, wherein the method comprises the following steps:
  • thermosetting resin By using thermosetting resin, it is obtained that a harder layer of hardened resin will form between the two wood layers. When, during use of the panel, wear would be formed through the first layer, the underlying layer becomes visible, however, still is protected by the resin.
  • the resin may penetrate into one or both veneer layers, such that these layers will be hardened internally.
  • the resin possibly locally but still better substantially entirely, penetrates at least the aforementioned first layer, namely the layer situated closest to the surface of the decorative panel, and possibly the second layer, too. It is clear that in this manner a still further improvement of the wear resistance is obtained.
  • the method offers the possibility of applying decorative top layers on the basis of softer wood species, such as spruce wood, in high-wear applications, such as in floor panels, or furniture panels, such as counter tops. Further, the method may also lead to an improvement of the mechanical features, such as impact resistance and wear resistance, with the common wood species, such as oak.
  • the pressing together preferably leads to a density increase of one or more of the respective veneer layers.
  • a density increase may lead to an increased impact resistance.
  • thermosetting resin one may start from various ingredients.
  • a polycondensation resin for example, a resin based on melamine, melamine formaldehyde, urea, urea formaldehyde or phenol formaldehyde.
  • pMDI Polymeric Methylene Diphenyl di-lsocyanate
  • other types of formaldehyde-free resins for example, based on starch, proteins or carbohydrates, such as sugars.
  • the thermosetting resin may also comprise various additives, such as flowing agents, hardening agents and/or plasticizers.
  • the aforementioned intermediate layer relates to a separate layer, namely a layer which is separate from a veneer layer.
  • a separate layer can be realized by various possibilities, a number of important possibilities of which will be listed herein below.
  • the resin is provided at least by means of a carrier sheet, wherein this carrier sheet then preferably is simultaneously also pressed between the two veneer layers concerned and thus remains present in the final decorative top layer.
  • a carrier sheet may be, for example, a paper sheet, namely preferably a paper sheet with a dry weight of 50 grams per square meter or less, preferably 10 to 30 grams per square meter.
  • a paper sheet with a dry weight of more than 10 grams per square meter is applied, such that sufficient resin can be deposited by means of the respective carrier sheet.
  • a paper sheet which consists of alpha- cellulose and preferably is unfilled.
  • Such paper sheet is known from the laminate technology as overlay paper.
  • This paper shows the advantage that it can become transparent when being pressed. This is the case, for example, when a melamine- . based resin is applied as the thermosetting resin.
  • the resin preferably is provided on and/or in the carrier sheet by means of techniques which are known as such from the laminate technology, for example, by means of impregnating the carrier sheet in a resin bath, spraying resin onto the paper surface, applying resin by means of grid rollers and so on.
  • the resin is impregnated in the carrier sheet, for example, paper sheet.
  • the carrier sheet for example, paper sheet.
  • the presence of resin in the core of the carrier sheet leads to a better splitting resistance in the pressed whole of the decorative top layer.
  • paper is chosen having a relatively open or porous structure, for example, paper with an average air resistance, as measured by the Gurley method (Tappi T460), of less than 30 or still better of less than 25 seconds.
  • the resin of the intermediate layer is provided at least by means of a strewing operation and/or the resin of the intermediate layer is provided as a powder.
  • a powder Preferably, use is made of resin particles having an average size of less than 1 millimeter, and still better smaller than 500 micrometers.
  • the inventor has found that the use of powder resin allows adding resin into the intermediate layer with a better accuracy, or higher resolution, than in the case of the aforementioned first possibility. Moreover, a more transparent intermediate resin layer is obtained. Such layer will also be less prominently present as a line when the decorative layer is observed from the side.
  • a combination of a plurality of techniques is applied for providing the resin of the intermediate layer.
  • the aforementioned first and second possibilities be combined, or still other techniques can be applied, such as providing a portion of the resin in liquid condition on a surface of one or more of the aforementioned veneer layers.
  • the resin of the intermediate layer, directly before pressing is in a B- stage, or is in this B-stage when being applied.
  • the so-called B-stage is an intermediate stage of the hardening process in which certain thermosetting resins may be.
  • Such B-stage a certain cross-linking already has occurred, however, the hardening reaction is not yet completed, such that the resin still can be heated for flowing before the final hardening, which is irreversible.
  • Such B-stage may occur, for example, with the already above-mentioned melamine-, urea- and phenol- containing resins, and in particular with melamine formaldehyde resins.
  • the resin is provided in the intermediate layer in B-stage, a smooth production of the top layer can be performed. The final flow and hardening allows that the veneer layers are interconnected and that the resin possibly penetrates into one or more of the veneer layers during pressing.
  • the resin may be in the aforementioned B-stage.
  • the resin which has been provided on the carrier sheet in liquid form, then, for example, is treated in an oven before it is provided between the veneer layers and/or before it is pressed.
  • the resin of the intermediate layer shows a residual moisture content of less than 10 percent, for example, of approximately 7 percent.
  • a low residual moisture content is advantageous during pressing and reduces the risk of the occurrence of defects in the decorative top layer. To wit, excess water may lead to that the veneer layers are affected and/or that the decorative layer will burst open due to an excessive vapor pressure in the intermediate resin layer.
  • the aforementioned intermediate layer comprises wear-resistant particles, for example, particles of aluminum oxide, silicon oxide or silicon carbide.
  • the particles preferably show an average particle size situated between 20 and 200 micrometers.
  • aluminum oxide is applied.
  • thermosetting resin on the basis of melamine or melamine formaldehyde, in view of the fact that aluminum has a refractive index which is approximately equal to that of the resin.
  • the particles even when they should have an average particle size of more than 80 micrometers, can hardly be noticed.
  • the aforementioned wear-resistant particles preferably are provided by means of the same carrier sheet, for example, at least in that they are blended into the resin and/or at least in that they are blended into paper mass in the paper production.
  • a carrier sheet is used of which the paper mass substantially is free from wear- resistant particles, however, wherein on the underside of the carrier sheet a resin layer is provided which comprises wear-resistant particles.
  • the underside of the carrier sheet the side is meant which, in the final decorative panel, is provided for being directed towards the underside of the panel.
  • said intermediate layer comprises colorants, such as dyes or stains (English: dyes or stains), which preferably may penetrate into one or more of the aforementioned veneer layers during the pressing thereof.
  • colorants such as dyes or stains (English: dyes or stains)
  • the decorative top layer shows a coloration which is spread over the thickness thereof. Namely, it is simpler to color or to penetrate two veneer layers of half the thickness with stains or dyes, than one veneer layer of full thickness.
  • a deeper coloration of the decorative top layer leads to less conspicuous traces of wear.
  • the respective veneer layers may have been colored prior to the press treatment.
  • the present invention is not limited to composing a decorative top layer of only two veneer layers with an intermediate resin layer, but that more than two veneer layers, for example, 4 to 9 veneer layers, preferably each time with such intermediate resin layer, can be applied.
  • a decorative top layer is obtained having a thickness of 2.5 millimeters or more, for example, up to 4.5 millimeters.
  • the aforementioned two veneer layers have a different thickness, wherein preferably the first veneer layer, which is intended for lying closer to the surfaced of the decorative panel or which forms this surface, is the thinnest.
  • a first of the aforementioned veneer layers has a thickness of one millimeter or less, for example, 0.4 to 0.8 millimeters
  • a second of the aforementioned veneer layers has a thickness of one and a half millimeter or more, for example, 2 to 3 millimeters.
  • the decorative top layer of the panel can be formed by means of only two veneer layers with intermediate resin layer.
  • thermosetting resin due to the limited thickness of the surface veneer, or the first veneer layer, a good penetration of the thermosetting resin and possible coloration of this layer can be obtained.
  • the intermediate resin layer certainly in the cases wherein it comprises a paper sheet and/or wear-resistant particles, then forms a performant wear layer for the underlying thicker veneer.
  • the underlying veneer may be penetrated at least superficially by means of the resin of the intermediate resin layer.
  • the aforementioned two veneer layers originate from the same piece of massive wood and are pressed in the same succession and with the same orientation as in the piece of massive wood from which they are obtained.
  • they are mutually aligned in horizontal direction.
  • they horizontally, in mutual respect have the same or strongly similar position as in the piece of massive wood from which they originate.
  • veneer layers are applied which are obtained by sawing massive wood. By sawing, the wood structure is preserved better than in the case of cutting off or peeling.
  • the present invention also relates to a decorative panel which is obtained by means of a method of the invention.
  • the invention in an independent manner, also relates to a decorative panel, wherein this decorative panel comprises at least a substrate material and a provided thereon decorative top layer, with the characteristic that the aforementioned top layer consists at least of two wooden veneer layers pressed on top of each other by means of thermosetting resin.
  • the aforementioned thermosetting resin forms a separate layer between the aforementioned veneer layers.
  • the aforementioned two veneer layers are at least separated by a paper sheet, for example, a similar paper sheet preferably impregnated with hardened resin, as this is the case in the above-mentioned first possibility for the method of the invention.
  • the aforementioned decorative layer comprises at least wear-resistant particles in a position between the aforementioned two veneer layers. It is clear that to this aim the wear-resistant particles can be applied which are mentioned in the scope of the method of the invention.
  • both veneer layers show a similar coloration.
  • the aforementioned two veneer layers are of different thickness, wherein a first veneer layer shows a thickness of 1 millimeter or less, whereas a second, underlying veneer layer shows a thickness of 1.5 millimeters or more.
  • the aforementioned two veneer layers originate from the same piece of massive wood and are situated in the decorative top layer in the same succession and orientation as in this piece of massive wood. Still better, they are also horizontally aligned or approximately horizontally aligned as in the original piece of massive wood.
  • the veneer layers relate to sawn veneer layers.
  • sawn veneer layers With the intention of better showing the characteristics of the invention, an example without any limitative character is described herein below.
  • the resin layer respectively consists of an overlay paper impregnated with melamine resin and having a residual moisture content of 7%.
  • the dry paper weight is 22 grams per square meter, and the applied resin in dry weight is 60 grams per square meter.
  • the resin comprises 10 grams per square meter of aluminum oxide particles having an average particle size of 90 micrometers.
  • the resin is in the so- called B-stage.
  • the oak veneer layers are pressed together with the intermediate overlay papers with a pressure of 20 bar and a temperature of 200°C, during 20 seconds.
  • the wear-resistant particles namely, the aluminum oxide particles
  • the wear-resistant particles are situated on that side of the overlay paper that is facing away from the final surface of the decorative top layer.
  • the impact of the resulting decorative top layer each time is tested in accordance with EN 438-2:2004.
  • Relevant for the impact resistance is the diameter of the impact of a steel ball.
  • the wear resistance is evaluated by the depth of the wear mark obtained in the Taber test after 2000 cycles. The results are represented below in tabular form.
  • the results show that the impact resistance and wear resistance considerably increases by applying the method of the invention.
  • the results further show that the resin of the intermediate layer to a certain extent penetrates into the upper veneer layer, in view of the fact that a significant difference in the depth of the wear mark already is obtained before the first veneer layer is worn away completely, namely within the first 0.5 millimeters underneath the surface.
  • the inventors have found that, when the first 0.5 millimeters are worn through, the increase of the depth of the wear mark in the top layer of the example is strongly reduced, whereas the wear of the standard oak top layer continues unabatedly. In this case, this is due to the presence of the intermediate resin layer, paper layer and wear-resistant particles, which protect the underlying veneer layer.
  • Figure 1 in perspective represents a decorative panel according to the invention
  • Figures 2 and 3 at a larger scale, represent a cross-section according to the lines ll-ll and Ill-Ill indicated in figure 1 ;
  • Figure 4 in a view similar to that of figure 3, represents a variant;
  • Figure 5 represents how the floor panels of figure 8 can be coupled for forming a floating floor covering;
  • Figure 6 at a larger scale, represents a view on the area indicated by F6 in figure 2.
  • Figure 1 represents a decorative panel, more particularly a floor panel 1 , in accordance with the invention.
  • the panel 1 is rectangular and oblong and comprises a pair of opposite short edges 2-3 and a pair of opposite long edges 4-5.
  • the decorative top layer 6 is formed by composed veneer 7.
  • the decorative panel 1 comprises a substrate material 8 on which the composed veneer 7 is provided, for example, glued or otherwise attached thereto.
  • the substrate material 8 consists of a so-called lamella core, wherein this core comprises a plurality of adjoining lamellas 9, which are oriented crosswise to the length of the floor panel 1.
  • lamellas 9 are made of softwood, for example, spruce wood or hevea.
  • the outermost lamellas 9A- 9B, which form the short edges 2-3, can be made of a different material, such as MDF/HDF or plywood (English: plywood). Such material allows a better processing for, for example, forming mechanical coupling means 10 therein by means of milling.
  • a backing layer 11 is provided, for example, glued or otherwise attached to the lamella core.
  • Such backing layer 11 preferably is made of a wooden veneer layer having a thickness of at least 50 percent of the decorative top layer. According to a variant, for the backing layer 11 a composed veneer 7 can be applied similar to that of the top layer.
  • Figures 2 and 3 represent that both pairs of opposite edges 2-3-4-5 are provided with mechanical coupling means 10, which substantially are realized as a tongue 12 and a groove 13 bordered by an upper lip 14 and a lower lip 5, wherein the tongue 12 and the groove 12 substantially are responsible for the locking in a vertical direction V, and wherein the tongue 12 and the groove 13 are provided with additional locking parts 16-17, which substantially are responsible for the locking in a horizontal direction H.
  • the locking parts comprise a protrusion 16 on the underside of the tongue 12 and a recess 17 in the lower groove lip 15.
  • the coupling means 10 represented in figures 2 and 3 allow at least a coupling by means of a rotational movement W around the respective edges 2-3-4-5 and/or a coupling by means of a sliding movement S towards each other, in a substantially horizontal manner, of the edges 2-3-4-5 to be coupled.
  • Figures 4 and 5 represent a variant with a pair of short edges 2-3, which allow obtaining a coupling at least by means of a downward movement D.
  • An edge 2 is provided with a male coupling part 18, whereas the other edge 3 is provided with a female coupling part 19.
  • the male coupling part 18 is pressed into the female coupling part 19 in order to be locked there in the vertical direction V, as a result of a pair of cooperating protrusions 20 and recesses 21.
  • the recess 21 partially is formed by a resilient element 22 present in the female coupling part 19.
  • Figure 6 represents a detail of the composed structure of the composed veneer 7 which forms the decorative surface 6.
  • the composed veneer 7 in this case is formed by two veneer layers 23A-23B provided on top of each other, with an intermediate layer 24 of hardened thermosetting resin. Further, the composed veneer 7 shows a structure on the decorative surface 6, wherein the latewood 25 is more prominent as a protruding portion 26.
  • the two veneer layers 23A-23B have a different thickness, wherein the first veneer layer 23A, which is situated closer to the decorative surface 6, is thinner than the underlying veneer layer 23B.

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Floor Finish (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé pour fabriquer un panneau décoratif, lequel procédé comprend les étapes suivantes : l'étape consistant à disposer un matériau de substrat (8) ; l'étape consistant à fabriquer une couche supérieure décorative (7) ; l'étape consistant à disposer la couche supérieure décorative et le matériau de substrat l'un au-dessus de l'autre ; et lequel est caractérisé en ce que, pour fabriquer la couche supérieure décorative (7), au moins deux couches de contreplaqué en bois (23A - 23B) sont pressées l'une contre l'autre avec une couche intermédiaire (24) de résine thermodurcissable. Un autre objet de la présente invention concerne un panneau décoratif (1) qui peut être obtenu à l'aide de ce procédé.
PCT/IB2016/051476 2015-03-20 2016-03-16 Procédé pour fabriquer un panneau décoratif et panneau décoratif WO2016151435A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201562135780P 2015-03-20 2015-03-20
US62/135,780 2015-03-20
BE2015/05173 2015-03-23
BE2015/5173A BE1022850B1 (nl) 2015-03-20 2015-03-23 Werkwijze voor het vervaardigen van een decoratief paneel en decoratief paneel.

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WO2017188883A1 (fr) * 2016-04-25 2017-11-02 Välinge Innovation AB Élément plaqué et procédé de production d'un tel élément plaqué
CN108705621A (zh) * 2018-07-25 2018-10-26 嘉善大王椰整体橱柜有限公司 一种抗开裂的免漆生态板及其制作工艺
US10286633B2 (en) 2014-05-12 2019-05-14 Valinge Innovation Ab Method of producing a veneered element and such a veneered element
US10576715B2 (en) 2015-07-10 2020-03-03 Aladdin Manufacturing Corporation Flooring board with a thin veneer wood aesthetic and durable surface
EP3315687B1 (fr) * 2016-10-31 2020-05-27 Tarkett GDL S.A. Planche de parquet en bois avec système de connexion par lamelle de contre-plaqué et kit de planches
US10981362B2 (en) 2018-01-11 2021-04-20 Valinge Innovation Ab Method to produce a veneered element
US10988941B2 (en) 2014-01-10 2021-04-27 Valinge Innovation Ab Method of producing a veneered element
US11072156B2 (en) 2013-11-27 2021-07-27 Valinge Innovation Ab Method for producing a floorboard
US11167533B2 (en) 2018-01-11 2021-11-09 Valinge Innovation Ab Method to produce a veneered element and a veneered element
US11313123B2 (en) 2015-06-16 2022-04-26 Valinge Innovation Ab Method of forming a building panel or surface element and such a building panel and surface element
US11597187B2 (en) 2019-01-09 2023-03-07 Valinge Innovation Ab Method to produce a veneer element and a veneer element
US12005693B2 (en) 2019-09-03 2024-06-11 Unilin Bv Stone plastic composite (SPC) floor comprising decorative surface
EP3921148B1 (fr) * 2019-02-04 2024-08-07 Unilin, BV Panneau de plancher et son procédé de fabrication

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DE10163435C1 (de) 2001-12-21 2003-02-06 Johannes Schulte Parkettdiele
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Cited By (24)

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US11072156B2 (en) 2013-11-27 2021-07-27 Valinge Innovation Ab Method for producing a floorboard
US11485126B2 (en) 2013-11-27 2022-11-01 Valinge Innovation Ab Method for producing a floorboard
US11890847B2 (en) 2014-01-10 2024-02-06 Välinge Innovation AB Method of producing a veneered element
US11370209B2 (en) 2014-01-10 2022-06-28 Valinge Innovation Ab Method of producing a veneered element
US11318726B2 (en) 2014-01-10 2022-05-03 Valinge Innovation Ab Wood fibre based panel with a surface layer
US10988941B2 (en) 2014-01-10 2021-04-27 Valinge Innovation Ab Method of producing a veneered element
US10286633B2 (en) 2014-05-12 2019-05-14 Valinge Innovation Ab Method of producing a veneered element and such a veneered element
US11313123B2 (en) 2015-06-16 2022-04-26 Valinge Innovation Ab Method of forming a building panel or surface element and such a building panel and surface element
US10576715B2 (en) 2015-07-10 2020-03-03 Aladdin Manufacturing Corporation Flooring board with a thin veneer wood aesthetic and durable surface
WO2017188883A1 (fr) * 2016-04-25 2017-11-02 Välinge Innovation AB Élément plaqué et procédé de production d'un tel élément plaqué
US11904588B2 (en) 2016-04-25 2024-02-20 Välinge Innovation AB Veneered element and method of producing such a veneered element
EA038727B1 (ru) * 2016-04-25 2021-10-11 Велинге Инновейшн Аб Облицованный шпоном элемент и способ изготовления такого облицованного шпоном элемента
US10828881B2 (en) 2016-04-25 2020-11-10 Valinge Innovation Ab Veneered element and method of producing such a veneered element
EP3315687B1 (fr) * 2016-10-31 2020-05-27 Tarkett GDL S.A. Planche de parquet en bois avec système de connexion par lamelle de contre-plaqué et kit de planches
US11167533B2 (en) 2018-01-11 2021-11-09 Valinge Innovation Ab Method to produce a veneered element and a veneered element
US11738540B2 (en) 2018-01-11 2023-08-29 Välinge Innovation AB Method to produce a veneered element and a veneered element
US11850829B2 (en) 2018-01-11 2023-12-26 Välinge Innovation AB Method to produce a veneered element and a veneered element
US10981362B2 (en) 2018-01-11 2021-04-20 Valinge Innovation Ab Method to produce a veneered element
CN108705621A (zh) * 2018-07-25 2018-10-26 嘉善大王椰整体橱柜有限公司 一种抗开裂的免漆生态板及其制作工艺
US11597187B2 (en) 2019-01-09 2023-03-07 Valinge Innovation Ab Method to produce a veneer element and a veneer element
US11975508B2 (en) 2019-01-09 2024-05-07 Välinge Innovation AB Method to produce a veneer element and a veneer element
EP3921148B1 (fr) * 2019-02-04 2024-08-07 Unilin, BV Panneau de plancher et son procédé de fabrication
US12134900B2 (en) 2019-02-04 2024-11-05 Unilin Bv Floor panel and method for manufacturing the same
US12005693B2 (en) 2019-09-03 2024-06-11 Unilin Bv Stone plastic composite (SPC) floor comprising decorative surface

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