Decorative panel

Patent metadata

Field	Value
Publication number	US-12338625-B2
Application number	US-202418432781-A
Country	US
Kind code	B2
Filing date	Feb 5, 2024
Priority date	Oct 7, 2021
Publication date	Jun 24, 2025
Grant date	Jun 24, 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; and

at least one coating layer,
wherein the at least one 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 at least one 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; and
wherein the at least one coating layer comprises at least one polyurethane resin and/or at least one acrylic resin.

2. The panel according to claim 1 , wherein the decorative layer comprises a printed pattern, a digitally printed pattern provided via printing process and/or a decorative thermoplastic foil or film comprising PP, PET, and/or PVC.

3. The panel according to claim 1 , wherein the at least one coating layer comprises antimicrobial, antivirus, antibacterial and/or antifungus agents.

4. The panel according to claim 1 , wherein the at least one coating layer comprises at least one bottom coating layer and at least one upper coating layer, wherein the at least one bottom coating layer comprises a polyurethane resin, and the at least one upper coating layer comprises an acrylic resin.

5. The panel according to claim 4 , wherein the at least one upper coating layer and/or the at least bottom coating layer comprises a plurality of abrasion resistant particles.

6. The panel according to claim 5 , wherein the abrasion resistant particles are-selected, from the group comprising aluminium oxide, corundum, silicon carbide, titanium dioxide, titanium oxide, diamond particles, or combinations thereof.

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

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

9. The panel according to claim 8 , wherein the coating layer comprises abrasion resistant particles in the range of 0.5 to 5 wt %.

10. The panel according to claim 1 , wherein the 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 is excimer cured.

12. The panel according to claim 1 , wherein the coating layer is substantially transparent.

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

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

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

16. The panel according to claim 1 , wherein the at least one decorative layer comprises a thermoplastic film or a ply of cellulose.

17. The panel according to claim 1 , wherein the 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; and
at least one decorative layer; and

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, and
b) applying at least one coating layer upon the upper surface of the substrate, wherein the coating layer is a crosslinkable coating layer and comprises at least one polyurethane resin and/or at least one acrylic resin;
c) 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 layer comprises a printed pattern, a digitally printed pattern provided via printing process and/or a decorative thermoplastic foil or film comprising PP, PET, and/or PVC.

20. The method according to claim 18 , wherein the 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 , wherein the coating layer is applied with a quantity of less than 100 g/m2.

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

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

24. The method according to claim 18 , wherein the coating layer comprises a plurality of abrasion resistant particles selected from aluminium 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