# US 9,434,206 B2 · Method for producing a decorated wall, ceiling or floor panel > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,434,206 B2 - Document ID: US9434206B2 - Status: Granted - Kind: B2 - Application number: 14/236,297 - Filed: 2012-07-27 - Published: 2014-07-17 - Granted: 2016-09-06 - Earliest claimed: 2011-08-02 - Assignees: Surface Technologies GmbH & Co. KG - Applicants: Egon Hoff - Inventors: Egon Hoff - Web page: https://patentgrep.com/patent/US9434206B2 ## CPC - B44C 5/04: Ornamental plaques, e.g. decorative panels, decorative veneers - B44C 5/0461: {used as wall coverings} - B44C 5/0476: {with abrasion resistant properties} - E04C 2/26: composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups {(of cement and mineral fibres E04C2/04)} - E04F 13/0866: {composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence)} - E04F 15/02188: {for use in wet rooms} - E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)} - B32B 27/00: Layered products comprising {a layer of} synthetic resin {(fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18)} - C09J 4/00: Adhesives based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond {; adhesives, based on monomers of macromolecular compounds of groups C09J183/00 - C09J183/16} - Y10T 156/1089: of discrete laminae to single face of additional lamina - Y10T 156/1093: with covering of discrete laminae with additional lamina - Y10T 428/2481: including layer of mechanically interengaged strands, strand-portions or strand-like strips - B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)} - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract For simpler production of a waterproof, decorated wall, ceiling or floor panel with improved quality, the invention proposes a process involving the following steps: provision of a panel-shaped carrier and a non-woven fabric, application of an adhesive to one surface of the carrier or to a surface of the non-woven fabric, lamination of the non-woven fabric by means of the applied adhesive to the surface of the carrier, impregnation of the non-woven fabric with a liquid means, hardening of the impregnating agent, application of a sealing layer as a liquid composition and hardening of the sealing layer and/or application of a top layer as a liquid composition and hardening of the top layer. ## Claims ### Claim 1 Method for producing a decorated wall, ceiling or floor panel, comprising the steps of: a) providing a plate-shaped carrier and a non-woven fabric; b) applying an adhesive to a surface of the carrier or a surface of the non-woven fabric; c) laminating the non-woven fabric by means of the applied adhesive to the surface of the carrier; d) impregnating the non-woven fabric with an impregnation agent, wherein the impregnating is performed by a rubber roller which has a shore (A) hardness of 20 to 40 and the rubber roller protrudes from the carrier in the direction of the roller axis by at least 20 mm; and e) curing the impregnation agent; wherein the carrier is a plastic carrier and the non-woven fabric is a print base paper; and printing a décor onto the paper between steps c) and d). ### Claim 2 (depends on 1) Method according to claim 1, comprising the further process steps: f) applying a wearing layer and curing the wearing layer; and/or g) applying a top layer and curing the top layer. ### Claim 3 (depends on 1) Method according to claim 1, characterized in that the non-woven fabric is a decorative paper. ### Claim 4 (depends on 1) Method according to claim 1, characterized in that the adhesive is a hot melt adhesive. ### Claim 5 (depends on 4) Method according to claim 4, characterized in that the hot melt adhesive is a reactive hot melt adhesive. ### Claim 6 (depends on 1) Method according to claim 1, characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components are adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation. ### Claim 7 (depends on 1) Method according to claim 1, characterized in that the impregnation agent consists of at least two components and impregnating step (d) comprises successively impregnating the two components into the non-woven fabric. ### Claim 8 (depends on 1) Method according to claim 1, characterized in that at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator. ### Claim 9 (depends on 1) Method according to claim 1, characterized in that the composition for producing the wearing layer includes particles of a solid with a Mohs hardness of at least 6. ### Claim 10 (depends on 1) Method according to claim 1, characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer include components adapted to be cross-linked by heat and the curing step is implemented by heating. ### Claim 11 (depends on 1) Method according to claim 1, characterized in that the carrier is cut between steps c) and d), and the carrier is sealed watertightly at lateral surfaces. ### Claim 12 (depends on 1) Decorated wall, ceiling or floor panel produced by a method according to claim 1. ### Claim 13 (depends on 2) Method according to claim 2, characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation. ### Claim 14 (depends on 2) Method according to claim 2, characterized in that the impregnation agent consists of at least two components and impregnating step (d) comprises successively impregnating the two components into the non-woven fabric. ### Claim 15 (depends on 2) Method according to claim 2, characterized in that at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator. ### Claim 16 (depends on 1) Method according to claim 1, characterized in that the composition for producing the wearing layer includes particles of a solid with a Mohs hardness of at least 6. ### Claim 17 (depends on 2) Method according to claim 2, characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation; the impregnation agent consists of at least two components and impregnating step (d) comprises successively impregnating the two components into the non-woven fabric; at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator. ### Claim 18 (depends on 15) Method according to claim 15, characterized in that the composition for producing the wearing layer includes particles of a solid with a Mohs hardness of at least 6. ### Claim 19 (depends on 1) Method according to claim 1 wherein the rubber roller protrudes from the carrier in the direction of the roller axis by between 20 mm and 100 mm. ### Claim 20 (depends on 1) Method according to claim 1, characterized in that the impregnation agent consists of at least two components which are blended together before step (d) impregnating into the non-woven fabric. ### Claim 21 (depends on 2) Method according to claim 2, characterized in that the impregnation agent consists of at least two components which are blended together before step (d) impregnating into the non-woven fabric. ### Claim 22 (depends on 2) Method according to claim 2, characterized in that the impregnation agent, the composition for producing the wearing layer and/or the composition for producing the top layer comprise components adapted to be cross-linked by radiation and each curing step is implemented by means of electromagnetic radiation; the impregnation agent consists of at least two components which are blended together before step (d) impregnating into the non-woven fabric at least one of the compositions for the impregnation agent, the wearing layer or the top layer includes at least a polyester acrylate, an epoxy acrylate and a photoinitiator.