Method to produce a thermoplastic wear resistant foil

Patent metadata

Field	Value
Publication number	US-2016016390-A1
Application number	US-201514790774-A
Country	US
Kind code	A1
Filing date	Jul 2, 2015
Priority date	Jul 16, 2014
Publication date	Jan 21, 2016
Grant date	—

Abstract

A method to produce a wear resistant foil, including providing a first foil including a first thermoplastic material, applying wear resistant particles on the first foil, applying a second foil including a second thermoplastic material on the first foil, and adhering the first foil and the second foil to each other to form a wear resistant foil.

First claim

1 . A method to produce a wear resistant foil, comprising
providing a first foil comprising a first thermoplastic material, applying a second foil comprising a second thermoplastic material on the first foil, applying wear resistant particles on the first foil and/or on the second foil prior to applying the second foil on the first foil, and adhering the first foil to the second foil with the wear resistant particles therebetween for forming the wear resistant foil.

2 . The method according to claim 1 , wherein the wear resistant particles are enclosed by the first and the second foil after being adhered to each other.

3 . The method according to claim 1 , wherein the first thermoplastic material comprises polyvinyl chloride (PVC).

4 . The method according to claim 1 , wherein the second thermoplastic material comprises polyurethane (PU).

5 . The method according to claim 1 , wherein the first thermoplastic material comprises polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

6 . The method according to claim 1 , wherein the second thermoplastic material comprises polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

7 . The method according to claim 1 , wherein the wear resistant particles comprise aluminium oxide.

8 . The method according to claim 1 , wherein the wear resistant particles have an average particle size of less than 45 μm.

9 . The method according to claim 1 , wherein the first and the second foil are adhered to each other by pressing.

10 . The method according to claim 1 , wherein the wear resistant particles are applied on the first foil.

11 . The method according to claim 1 , wherein the second foil is formed by an extrusion process such as extrusion coating and/or extrusion lamination on the first foil.

12 . The method according to claim 1 , wherein a thickness of the second foil is less than 75 μm.

13 . The method according to claim 1 , wherein the wear resistant foil is substantially transparent.

14 . A method to produce a building panel, comprising
providing a core, applying a first foil comprising a first thermoplastic material on the core, applying a second foil comprising a second thermoplastic material on the first foil, applying wear resistant particles on the first foil and/or on the second foil prior to applying the second foil on the first foil, and adhering the core, the first foil and the second foil to each other to form the building panel.

15 . The method according to claim 14 , wherein the wear resistant particles are enclosed by the first and the second foil after being adhered to each other.

16 . The method according to claim 14 , wherein the first thermoplastic material comprises polyvinyl chloride (PVC).

17 . The method according to claim 14 , wherein the second thermoplastic material comprises polyurethane (PU).

18 . The method according to claim 14 , wherein the first thermoplastic material comprises polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

19 . The method according to claim 14 , wherein the second thermoplastic material comprises polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

20 . The method according to claim 14 , wherein the wear resistant particles comprise aluminium oxide.

21 . The method according to claim 14 , wherein the wear resistant particles have an average particle size of less than 45 μm.

22 . The method according to claim 14 , wherein the core, the first foil and the second foil are adhered to each other by pressing.

23 . The method according to claim 14 , wherein the wear resistant particles are applied on the first foil.

24 . The method according to claim 14 , wherein the second foil ( 2 ) is formed by an extrusion process.

25 . The method according to claim 14 , wherein a thickness of the second foil is less than 75 μm after pressing.

26 . The method according to claim 14 , wherein the first foil, the second foil and the wear resistant particles form a wear resistant foil being substantially transparent.

27 . The method according to claim 14 , wherein the core comprising a third thermoplastic material.

28 . The method according to claim 27 , wherein the third thermoplastic material comprises polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

29 . The method according to claim 14 , wherein the core is a wood-based board, a Wood Plastic Composite (WPC), a thermoplastic board or a mineral board.

30 . The method according to claim 14 , further comprising arranging a decorative layer on the core.

31 . A method to produce a building panel, comprising
providing a core, applying a second foil comprising a second thermoplastic material on the core, applying wear resistant particles on the core and/or on the second foil prior to the second foil is being applied on the core, and adhering the core and the second foil together to form a building panel.

32 . The method according to claim 31 , wherein the wear resistant particles are enclosed by the second foil and the core.

33 . The method according to claim 31 , wherein the second thermoplastic material comprises polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or a combination thereof.

34 . The method according to claim 31 , wherein the core is a thermoplastic core, a Wood Plastic Composite (WPC), a wood-based board or a mineral board.

35 . The method according to claim 33 , wherein the wear resistant particles have an average particle size of less than 45 μm.

36 . The method according to claim 33 , wherein a thickness of the second foil is less than 75 μm after pressing.

37 . The method according to claim 33 , wherein the core and the second foil are adhered to each other by pressing.

38 . The method according to claim 33 , wherein the wear resistant particles are applied on the core.

39 . The method according to claim 33 , wherein the second foil is formed by an extrusion process.

40 . A building panel, compris

Assignees

• Valinge Innovation Ab

Inventors

• Lundblad Christer
• Hakansson Niclas
• Ziegler Goran

Classifications

• B32B21/12

  next to a particulate layer · CPC title

• B32B37/12

  characterised by using adhesives · CPC title

• B32B19/045

  of synthetic resin · CPC title

• B29C48/15

  incorporating preformed parts or layers, e.g. extrusion moulding around inserts · CPC title

• B29K2627/06

  PVC, i.e. polyvinylchloride · CPC title