Floor panel and method for manufacturing floor panels
AssigneeUnilin, Bvba
InventorsFrank Loncke, Luc Vanhastel, Laurent Meersseman
Life of this patent
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Abstract
A floor panel has a substrate and a decorative layer of wood veneer having a thickness of 1 millimeter or less provided on the substrate. The substrate has an average density of more than 750 kilograms per cubic meter. The decorative layer is provided on the substrate by means of a layer on the basis of thermosetting resin situated between the substrate and the decorative layer. A method for manufacturing such floor panels including a structured veneer surface that can be obtained according to the arrangement of the aforementioned floor panel.
Claims19
A floor panel with a substrate and a provided thereon decorative layer of wood veneer having a thickness of 1 millimeter or less, wherein said substrate has an average density of more than 750 kilograms per cubic meter;
- wherein said decorative layer is provided on the substrate by means of a layer on the basis of thermosetting resin situated between the substrate and the decorative layer;
- wherein said floor panel is provided with lower edge regions on one or more edges and wherein said wood veneer extends in one piece from on the surface of the substrate over said lower edge regions;
- wherein said lower edge region forms a bevel or chamfer, wherein the wood veneer extends over the lower edge region at least up to a point, wherein the veneer surface is situated on a level in a horizontal plane which intersects said substrate:
- wherein the wood veneer defines a thickness tapering over the chamfer from a first thickness at the surface of the substrate to a second thickness at the lower edge regions, the second thickness being less than the first thickness.
A method for manufacturing floor panels, wherein these floor panels comprise at least a substrate and a provided thereon decorative layer of wood veneer, wherein the method comprises at least the following steps:
- the step of providing a base plate having an average density of 750 kilograms per cubic meter or more;
- the step of composing a stack which comprises at least the structured base plate, a resin layer on the basis of thermosetting resin and one or more wood veneers;
- the step of pressing said stack in a heated press, wherein said resin layer is hardened, such that said veneers are adhered to the base plate;
- the step of dividing the pressed whole into panels, of which panels said floor panels can be formed;
- the step of finishing said panels to form said floor panels;
- wherein said floor panel is provided with lower edge regions on one or more edges and wherein said wood veneer extends in one piece from on the surface of the substrate over said lower edge regions;
- wherein said lower edge region forms a bevel or chamfer, wherein the wood veneer extends over the lower edge region at least up to a point, wherein the veneer surface is situated on a level in a horizontal plane which intersects said substrate:
- wherein the wood veneer defines a thickness tapering over the chamfer from a first thickness at the surface of the substrate to a second thickness at the lower edge regions, the second thickness being less than the first thickness.
A method for manufacturing floor panels, wherein these floor panels comprise at least a substrate and a provided thereon decorative layer of wood veneer, wherein the method comprises at least the following steps:
- the step of providing a base plate having an average density of 750 kilograms per cubic meter or more;
- the step of composing a stack comprising at least the base plate, a glue layer or resin layer, and one or more wood veneers;
- the step of pressing said stack in a press, wherein said base plate is deformed, such that the upper surface of said base plate shows a structure, and that said wood veneers at least partially follow the contour of the structured upper surface of the base plate;
- the step of dividing the pressed whole into panels, of which panels the aforementioned floor panels can be formed;
- the step of finishing said panels to form said floor panels;
- wherein said floor panel is provided with lower edge regions on one or more edges and
- wherein said wood veneer extends in one piece from on the surface of the substrate over said lower edge regions;
- wherein said lower edge region forms a bevel or chamfer, wherein the wood veneer extends over the lower edge region at least up to a point, wherein the veneer surface is situated on a level in a horizontal plane which intersects said substrate:
- wherein the wood veneer defines a thickness tapering over the chamfer from a first thickness at the surface of the substrate to a second thickness at the lower edge regions, the second thickness being less than the first thickness.
Dependencies are inferred from the claim text.