Panel and method for manufacturing a panel

Patent metadata

Field	Value
Publication number	US-11865827-B2
Application number	US-202017593780-A
Country	US
Kind code	B2
Filing date	Mar 25, 2020
Priority date	Mar 25, 2019
Publication date	Jan 9, 2024
Grant date	Jan 9, 2024

Abstract

A panel has a substrate, and a top layer provided thereon. The top layer comprises at least a melamine resin and a binder. The binder is selected from the group comprising: polyacrylates based binder, polyvinyl acetate-based binder, polyester based, acrylic copolymers-based binder or urethane based binder.

First claim

The invention claimed is:

1. A method for manufacturing a panel comprising the following steps of:
providing a substrate;
providing a top layer comprising a binder and a melamine-based resin, wherein the top layer is provided on top of the substrate; and
curing the melamine-based resin directly on top of the substrates;
wherein the top layer comprises a binding layer comprising the binder and wherein the top layer comprises at least a melamine-based layer; and
wherein the binding layer is interposed between the substrate and the melamine-based layer.

2. The method of claim 1 , wherein the binder is selected from a group consisting of: polyacrylates based binder, polyvinyl acetate-based binder, polyester based, acrylic copolymers based binder or urethane based binder.

3. The method according to claim 2 , wherein the binder is urethane based.

4. The method according to claim 3 , wherein the urethane-based binder comprises a urethane based acrylic copolymers dispersion in water.

5. The method according to claim 1 , wherein the binding layer comprises a décor.

6. The method according to claim 1 , wherein the binding layer comprises a printed carrier having a décor and being impregnated with the binder.

7. The method according to claim 1 , wherein the top layer comprises a layer having a mixture of the melamine-based resin and of the binder.

8. The method according to claim 1 , wherein the top layer comprises a water absorbing substance.

9. The method according to claim 8 , wherein the water absorbing substance is selected from a group consisting of: wood fibers, cellulose fibers, paper or mineral particles.

10. The method according to claim 1 , wherein the substrate is substantially made of a synthetic material.

11. The method according to claim 1 , wherein the method comprises a step of providing the binder on top of the substrate that comprises providing a carrier impregnated with the binder.

12. The method according to claim 1 , wherein the curing step is a hot pressing step.

13. The method of claim 12 , wherein the hot pressing step is performed at a temperature comprised between 140° C. and 220° C.

14. The method of claim 12 , wherein the step of hot pressing is performed for a pressing comprised between 10 and 60 seconds.

15. A method for manufacturing a panel comprising the following steps:
providing a substrate;
providing a top layer comprising a binder and a melamine-based resin, wherein the top layer is provided on top of the substrate; and
curing the melamine-based resin directly on top of the substrate;
wherein the top layer comprises a binding layer comprising the binder and wherein the top layer comprises at least a melamine-based layer;
wherein the binding layer is interposed between the substrate and the melamine-based layer;
wherein the binder is urethane based;
wherein the substrate is substantially made of a synthetic material.

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Clement Benjamin
• Ledegen Sam
• Meirlaen José

Classifications

• B32B37/24 Primary

  with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) · CPC title

• A47B96/206

  with laminates comprising planar, continuous or separate layers · CPC title

• B32B3/06 Primary

  for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking} · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• B32B5/18

  characterised by features of a layer {of} foamed material · CPC title