Decorative panel

Patent metadata

Field	Value
Publication number	US-12312807-B2
Application number	US-202418432766-A
Country	US
Kind code	B2
Filing date	Feb 5, 2024
Priority date	Oct 7, 2021
Publication date	May 27, 2025
Grant date	May 27, 2025

Abstract

The invention relates to a decorative panel, comprising at least one substrate comprising an upper surface and a bottom surface and two pairs of opposing side edges, wherein the substrate comprises at least one core layer and at least one decorative layer and the panel comprising at least one coating layer, wherein the coating layer is provided upon the upper surface of the substrate, wherein both the upper surface of the substrate and the upper coating surface of the coating layer have a predetermined Shore D hardness.

First claim

The invention claimed is:

1. A decorative panel, the panel comprising:
at least one substrate comprising an upper surface and a bottom surface, wherein the substrate comprises:
at least one core layer; and
at least one decorative layer, wherein the at least one decorative layer comprises at least one printed pattern; and

at least one coating layer,
wherein the coating layer is provided upon the upper surface of the substrate;
wherein the upper surface of the substrate has a Shore D hardness of at least 80 and wherein the coating layer has a Shore D hardness of at least 85,
wherein the core layer has a Vicat softening temperature of at least 80 degrees Celsius.

2. The panel according to claim 1 , wherein the printed pattern is at least partially digitally printed.

3. The panel according to claim 1 , wherein the printed pattern is at least partially printed via laser printing, digital printing, inkjet printing, rotogravure printing, electronic line shaft rotogravure printing, automatic plastic printing, offset printing, flexography, and/or rotary printing.

4. The panel according to claim 1 , wherein the decorative layer comprises a decorative thermoplastic foil or film comprising PP, PET, and/or PVC or a ply of cellulose.

5. The panel according to claim 1 , wherein the decorative layer forms an integral part of the core layer and/or wherein the upper surface of the core laver is provided with the at least one printed pattern.

6. The panel according to claim 1 , wherein the at least one coating layer is directly provided upon the decorative layer of the substrate.

7. The panel according to claim 1 , wherein the at least one coating layer is applied with a weight of 5-100 g/m2.

8. The panel according to claim 1 , comprising a plurality of coating layers.

9. The panel according to claim 1 , wherein the at least one coating layer has a Shore D hardness of at least 90 and/or wherein the upper surface of the substrate has a Shore D hardness of at least 85.

10. The panel according to claim 1 , wherein the at least one coating layer comprises at least one thermosetting resin and/or wherein the coating layer comprises at least one crosslinkable prepolymer and at least one photo-initiator.

11. The panel according to claim 1 , wherein the at least one coating layer comprises a plurality of abrasion resistant particles selected, from aluminum oxide, corundum, silicon carbide, titanium dioxide, titanium oxide, diamond particles, or combinations thereof.

12. The panel according to claim 11 , wherein the at least one coating layer comprises abrasion resistant particles in the range of 0.5 to 5 wt %.

13. The panel according to claim 1 , wherein the at least one coating layer is substantially transparent.

14. The panel according to claim 1 , wherein the at least one coating layer comprises at least one polyurethane resin, and/or at least one acrylic resin.

15. The panel according to claim 1 , wherein the at least one coating layer has a thickness in the range of 0.01 mm to 0.30 mm.

16. The panel according to claim 1 , wherein a surface roughness of the at least one coating layer is at least 3 um Ra.

17. The panel according to claim 1 , wherein the at least one core layer comprises at least one pair of opposite side edges, and wherein each pair of opposite side edges is provided with one or more complementary coupling parts.

18. A method for producing a decorative panel, comprising the steps of:
a) providing at least one substrate comprising an upper surface and a bottom surface and two pairs of opposing side edges, wherein the substrate comprises at least one core layer, wherein the upper surface of the substrate has a Shore D hardness of at least 80, and wherein the core layer has a Vicat softening temperature of at least 80 degrees Celsius,
b) printing at least one decorative pattern upon the core layer such that at least one decorative layer is formed,
c) applying at least one coating layer upon the upper surface of the substrate, wherein the coating layer is a crosslinkable coating layer; and
d) curing said coating layer such that a crosslinked coating layer having a Shore D hardness of at least 85 is obtained.

19. The method according to claim 18 , wherein the decorative pattern is at least partially digitally printed.

20. The method according to claim 18 , wherein the at least one coating layer comprises at least one crosslinkable prepolymer and at least one photo-initiator and/or wherein the coating layer comprises at least one thermosetting resin.

21. The method according to claim 18 , comprising the step of applying a texture to the upper surface of the substrate.

22. The method according to claim 18 , wherein the curing step is an UV curing step and/or excimer curing step.

23. The method according to claim 18 , wherein the at least one coating layer comprises a plurality of abrasion resistant particles selected from aluminum oxide, silicon carbide, titanium dioxide, titanium oxide, and/or diamond particles, or combinations thereof.

Assignees

• Champion Link Int Corp

Inventors

• Baert Thomas Luc Martine
• Van Poyer Tom
• Boon Sven

Classifications

• B32B2451/00

  Decorative or ornamental articles · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title

• B05D3/067

  Curing or cross-linking the coating · CPC title

• C08J7/046

  Forming abrasion-resistant coatings; Forming surface-hardening coatings · CPC title

• E04F2201/043

  with tongues and grooves being formed by projecting or recessed parts of the panel layers · CPC title