Covered panel and method for manufacturing covered panels
AssigneeUnilin BV
InventorsBenjamin CLEMENT, Sam LEDEGEN
Life of this patent
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Abstract
A coated panel has at least a substrate and a top layer applied thereto, The top layer includes at least a decor layer and a translucent or transparent wear layer. The above-mentioned wear layer has a thermally cured acrylate resin or a thermally cured unsaturated polyester resin. Thermal curing partially or completely cures the resin. The acrylate resin or unsaturated polyester resin is at least partially cured by a thermally initiated radical crosslinking reaction. A method for the production of such coated panels, in particular floor panels, is provided according the aforementioned coated panel.
Claims18
Method for the production of coated panels, wherein the coated panels comprise at least a substrate and a top layer applied on the substrate;
- wherein the top layer comprises at least a decor layer and a translucent or transparent wear layer,
- wherein the method comprises at least the steps of:
- providing a coated paper sheet, wherein the coated paper comprises a paper sheet and a gelled acrylate resin coating;
- and
- at least partial curing of the gelled acrylate resin by hot pressing to form at least a part of the wear layer;
- wherein the gelled acrylate resin comprises one or more than one thermoinitiator;
- wherein the pressing is carried out by a structured pressing element;
- wherein in the hot pressing a relief is formed in the top layer;
- wherein the décor layer is provided by the paper sheet;
- wherein a thermally initiated radical crosslinking reaction occurs in the hot pressing.
Method for the production of coated panels, wherein the coated panels comprise at least a substrate and a top layer applied on the substrate;
- wherein the top layer comprises at least a decor layer and a translucent or transparent wear layer,
- wherein the method comprises at least the steps of:
- providing a coated paper sheet, wherein the coated paper comprises a paper sheet and a gelled acrylate resin coating;
- and
- at least partial curing of the gelled acrylate resin by hot pressing to form at least a part of the wear layer;
- wherein the gelled acrylate resin comprises one or more than one thermoinitiator;
- wherein the pressing is carried out by a structured pressing element;
- wherein in the hot pressing a relief is formed in the top layer;
- wherein the décor layer is provided by the paper sheet;
- wherein a thermally initiated radical crosslinking reaction occurs in the hot pressing;
- wherein the paper sheet is a printed paper sheet impregnated with a thermally curing resin;
- wherein the hot pressing is carried out on a stack that comprises at least the substrate and the coated paper sheet;
- and optionally a backing layer;
- wherein the substrate is a wood-based substrate;
- wherein the coated paper sheet comprises an adhesion promotor between the paper sheet and the gelled acrylate resin coating;
- wherein the adhesion is selected from a polyurethane, a polyurethane dispersion, a water-based polyurethane dispersion, a polyurethane dispersion with acrylate functionality, a melamine acrylate or a low-viscosity acrylate primer, or combinations thereof;
- wherein the hot pressing is carried out by means of a short cycle press or by means of a press of the continuous type or by means of a hot press roller;
- wherein the coated paper sheet is laminated onto the substrate in the hot pressing step.
Dependencies are inferred from the claim text.