Method to produce a thermoplastic wear resistant foil

Patent metadata

Field	Value
Publication number	US-2016016391-A1
Application number	US-201514790850-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 and a second thermoplastic material form on the first foil, and adhering the first foil to the second thermoplastic binder and the wear resistant particles 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 wear resistant particles and a second thermoplastic material on the first foil, and adhering the first foil to the second thermoplastic material and the wear resistant particles to form a wear resistant foil.

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

3 . The method according to claim 1 , wherein the wear resistant particles and the second thermoplastic material are applied as a mix.

4 . The method according to claim 1 , wherein the second thermoplastic material is applied powder form.

5 . The method according to claim 1 , wherein the second thermoplastic material ( 5 ) is applied in molten form.

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

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

8 . The method according to claim 1 , wherein the second thermoplastic material comprises polyvinyl chloride (PVC) or polyurethane (PU).

9 . The method according to claim 1 , wherein the first foil, the second thermoplastic material and the wear resistant particles are adhered to each other by pressing, preferably without an adhesive.

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

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

12 . The method according to claim 1 , wherein a thickness of a layer formed by the second thermoplastic material and the wear resistant particles is less than 75 μm after being adhered to each other.

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 wear resistant particles and a second thermoplastic material on the first foil, and adhering the core to the first foil and to the second thermoplastic material and the wear resistant particles to form a building panel.

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

16 . The method according to claim 14 , wherein the wear resistant particles and the second thermoplastic material are applied as a mix.

17 . The method according to claim 14 , wherein the second thermoplastic material is applied powder form.

18 . The method according to claim 14 , wherein the second thermoplastic material is applied in molten form.

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

21 . The method according to claim 14 , wherein the second thermoplastic material comprises polyvinyl chloride (PVC) or polyurethane (PU).

22 . The method according to claim 14 , wherein the first foil, the second thermoplastic material and the wear resistant particles are adhered to each other by pressing, preferably without an adhesive.

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

24 . The method according to claim 11 , wherein the wear resistant particles have an average particle size of less than 45 μm.

25 . The method according to claim 14 , wherein a thickness of a layer formed by the second thermoplastic material and the wear resistant particles is less than 75 μm after adhered to each other.

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

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 ( 21 ) is HDF, MDF, particleboard, OSB, Wood Plastic Composite (WPC), 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 wear resistant foil, comprising
providing a carrier, applying wear resistant particles and a second thermoplastic material on the carrier, and adhering the wear resistant particles and the second thermoplastic material to each other to form a wear resistant foil.

32 . The method according to claim 31 , wherein the wear resistant particles are enclosed by the second thermoplastic material after being adhered to each other.

33 . The method according to claim 31 , wherein the wear resistant particles and the second thermoplastic material are applied as a mix.

34 . The method according to claim 31 , wherein the second thermoplastic material is applied in powder form.

35 . The method according to claim 31 , wherein the second thermoplastic material is applied in molten form.

36 . The method according to claim 31 , wherein the second thermoplastic material comprises polyvinyl chloride (PVC) or polyurethane (PU).

37 . The method according to claim 31 , wherein the second thermoplastic material and the wear resistant particles are adhered to each other by pressing.

38 . The method according to claim 31 , wherein the wear resistant particles have an average particle size of less than 45 μm.

39 . The method according to claim 31 , wherein a thickness of a layer formed by the second thermoplastic material and the wear resistant particles is less than 7

Assignees

• Valinge Innovation Ab

Inventors

• Lundblad Christer
• Hakansson Niclas
• Ziegler Goran

Classifications

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title

• B32B2307/412

  Transparent · CPC title

• B32B19/045

  of synthetic resin · CPC title

• B32B2250/02

  2 layers · CPC title

• B32B2264/10

  Inorganic particles · CPC title