Partially cured coated sheet

Patent metadata

Field	Value
Publication number	US-12384940-B2
Application number	US-202418774383-A
Country	US
Kind code	B2
Filing date	Jul 16, 2024
Priority date	May 8, 2020
Publication date	Aug 12, 2025
Grant date	Aug 12, 2025

Abstract

A sheet includes a support layer and a coating layer on a side of the support layer. The coating layer is partially cured. The coating layer has carbon-carbon double bonds. The relative amount of carbon-carbon double bonds is higher at the surface of the coating layer than at the contact surface of the coating layer with the support layer. Methods are disclosed to manufacture such sheets; and to produce a decorative panel using such sheets.

First claim

The invention claimed is:

1. A method for producing a decorative panel,
wherein the method comprises the step of providing a sheet,
wherein the sheet comprises a support layer and a coating layer, wherein the coating layer is provided on a side of the support layer, wherein the coating layer is partially cured, wherein the coating layer comprises carbon-carbon double bonds, wherein the relative amount of carbon-carbon double bonds is higher at the surface of the coating layer than at the contact surface of the coating layer with the support layer;
wherein the method comprises the step of providing a substrate;
wherein the method comprises the step of applying the sheet onto the substrate, wherein the support layer of the sheet is provided at the side of the substrate;
wherein the method comprises the step of hot pressing the sheet onto the substrate by using temperature and pressure, thereby laminating the sheet onto the substrate; and thereby providing a three-dimensional structure onto the surface of the coating layer of the sheet by means of hot pressing with a structured press element wherein a thermal curing of the coating layer is performed.

2. The method of claim 1 , wherein the sheet is unwound from a roll.

3. The method of claim 1 , wherein the support layer of the sheet contacts the substrate.

4. The method of claim 1 , wherein the coating layer comprises one or more than one type of thermo-initiator.

5. The method of claim 1 , wherein the coating layer comprises a first group of thermo-initiators and a second group of thermo-initiators,
wherein the first group of thermo-initiators provides between 10% by weight and 50% by weight of the combination of the first group of thermo-initiators and the second group of thermo-initiators,
wherein the second group of thermo-initiators provides between 50% by weight and 90% by weight of the combination of the first group of thermo-initiators and the second group of thermo-initiators;
wherein the thermo-initiators of the first group of thermo-initiators have a one hour half-life temperature which is at least 10° C. lower than the thermo-initiators of the second group of thermo-initiators.

6. The method as in claim 1 , wherein the coating layer comprises one or more than one of acrylate, methacrylate or unsaturated polyester.

7. The method as in claim 1 , wherein the coating layer comprises one or more or combinations selected from urethane acrylate, epoxy acrylate or polyester acrylate.

8. The method of claim 1 , wherein the support layer comprises a decorative print.

9. The method of claim 1 , wherein the structured press element is a short cycle press or a multidaylight press comprising structured press plates.

10. The method of claim 1 , wherein the coating layer has a weight between 20 and 400 gram per square meter.

11. The method of claim 1 , wherein the hot pressing is carried out at a temperature between 120 to 220° C.; and at a pressure between 10 to 80 bar.

12. The method of claim 1 , wherein the support layer of the sheet comprises a décor layer, wherein the décor layer shows a printed wood pattern, and wherein the hot pressing provides the decorative panel with a relief in register with the printed wood pattern.

13. The method of claim 1 , wherein the support layer comprises a printed sheet of paper.

14. The method of claim 13 , wherein the sheet of paper is a melamine impregnated paper, or wherein the sheet of paper is an acrylate impregnated sheet of paper.

15. The method of claim 13 , wherein the sheet of paper comprises at one or at both sides an adhesion promoting layer.

16. The method of claim 15 , wherein the adhesion promoting layer is provided by a polyurethane comprising acrylate functional groups or by a polyurethane layer being devoid of double carbon-carbon bonds, by a melamine acrylate or by an acrylate primer.

17. The method of claim 1 , wherein the substrate is selected from
a substrate comprising an MDF or HDF board or a wood particle board;
a substrate comprising a core, wherein the core comprises a thermoplastic polymer comprising filling material, wherein the filling material is provided by one or more of stone particles or chalk;
a mineral based substrate;
a substrate comprising a magnesium oxide panel;
a fiber cement board; or
a mineral fiber board.

Assignees

• Unilin Bv

Inventors

• Clement Benjamin
• Ledegen Sam
• Seynaeve Marijn

Classifications

• C09J2433/006

  in the substrate · CPC title

• C09J2400/283

  in the substrate · CPC title

• C09D135/02

  Homopolymers or copolymers of esters (C09D135/06, C09D135/08 take precedence) · CPC title

• C09D133/14

  of esters containing halogen, nitrogen, sulfur or oxygen atoms in addition to the carboxy oxygen · CPC title

• C09D4/00

  Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond {; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16} · CPC title