Methods for manufacturing panels and panel obtained hereby

Patent metadata

Field	Value
Publication number	US-9259959-B2
Application number	US-201013501626-A
Country	US
Kind code	B2
Filing date	Sep 15, 2010
Priority date	Oct 14, 2009
Publication date	Feb 16, 2016
Grant date	Feb 16, 2016

Abstract

A method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on the substrate, the top layer includes at least two material layers, amongst which a print, the method may involve applying the two material layers, such that the print is performed directly on the substrate and the print forms at least a portion of a printed decor. At least one of the two material layers may include a mixture having at least a thermally curing component and a radiation-curing component.

First claim

The invention claimed is:

1. A method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on the substrate, the top layer including at least two material layers, wherein at least one of the material layers is a print, the method comprising:
applying the two material layers, such that the print is performed directly on the substrate and the print forms at least a portion of a printed decor;
wherein at least one of the two material layers includes a mixture of at least a thermally curing component and a radiation-curing component;
wherein the mixture is obtained by forming a border zone on the substrate;
wherein the border zone is formed by providing a first one of the components on the substrate, and then providing a second one of the components on the first one of the components; and
wherein at least a portion of the mixture is created during its application on the substrate.

2. The method of claim 1 , wherein the thermally curing component is a synthetic resin.

3. The method of claim 2 , wherein the synthetic resin cures by polycondensation.

4. The method of claim 3 , wherein the synthetic resin contains melamine.

5. The method of claim 1 , wherein the radiation-curing component is a UV- or electron beam-curing lacquer.

6. A method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on the substrate, the top layer including at least two material layers, wherein at least one of the material layers is a print, the method comprising:
applying the two material layers, such that the print is performed directly on the substrate and the print forms at least a portion of a printed decor;
wherein at least one of the two material layers includes a mixture having at least a synthetic resin component and a lacquer component;
wherein the mixture is obtained by forming a border zone on the substrate;
wherein the border zone is formed by providing a first one of the components on the substrate, and then providing a second one of the components on the first one of the components; and
wherein at least a portion of the mixture is created during its application on the substrate.

7. The method of claim 6 , wherein the synthetic resin is selected from the group consisting of urea formaldehyde, melamine, melamine formaldehyde, methane diphenyl diisocyanate, phenol formaldehyde, resorcinol formaldehyde and resorcine phenol formaldehyde.

8. The method of claim 6 , wherein the lacquer is selected from the group consisting of urushiol-based lacquer, nitrocellulose lacquer, acrylic lacquer, water-based lacquer, UV-curing lacquer and electron beam-curing lacquer.

9. The method of claim 6 , wherein the mixture further comprises cellulose.

10. The method of claim 6 , wherein the print is performed using UV inks.

11. The method of claim 6 , further comprising curing the two material layers.

12. A method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on the substrate, the top layer including at least two material layers, wherein at least one of the material layers is a print, the method comprising:
applying the two material layers, such that the print is performed directly on the substrate and the print forms at least a portion of a printed decor;
wherein at least one of the two material layers includes a mixture of at least a thermally curing component and a radiation-curing component;
wherein the mixture is obtained by forming a border zone on the substrate;
wherein the border zone is formed by providing a first one of the components on the substrate, and then providing a second one of the components on the first one of the components; and
wherein the material layer including the mixture is provided on the substrate prior to the print.

13. The method of claim 12 , wherein the thermally curing component is a synthetic resin.

14. The method of claim 13 , wherein the synthetic resin cures by polycondensation.

15. The method of claim 14 , wherein the synthetic resin contains melamine.

16. The method of claim 12 , wherein the radiation-curing component is a UV-or electron beam-curing lacquer.

17. A method for manufacturing panels of the type which is at least composed of a substrate and a top layer provided on the substrate, the top layer including at least two material layers, wherein at least one of the material layers is a print, the method comprising:
applying the two material layers, such that the print is performed directly on the substrate and the print forms at least a portion of a printed decor;
wherein at least one of the two material layers includes a mixture having at least a synthetic resin component and a lacquer component;
wherein the mixture is obtained by forming a border zone on the substrate;
wherein the border zone is formed by providing a first one of the components on the substrate, and then providing a second one of the components on the first one of the components;
and wherein the material layer including the mixture is provided on the substrate prior to the print.

18. The method of claim 17 , wherein the synthetic resin is selected from the group consisting of urea formaldehyde, melamine, melamine formaldehyde, methane diphenyl diisocyanate, phenol formaldehyde, resorcinol formaldehyde and resorcine phenol formaldehyde.

19. The method of claim 17 , wherein the lacquer is selected from the group consisting of urushiol-based lacquer, nitrocellulose lacquer, acrylic lacquer, water-based lacquer, UV-curing lacquer and electron beam-curing lacquer.

20. The method of claim 17 , wherein the mixture further comprises cellulose.

21. The method of claim 17 , wherein the print is performed using UV inks.

22. The method of claim 17 , further comprising curing the two material layers.

Assignees

• Clement Benjamin
• Maesen Christophe
• Flooring Ind Ltd Sarl

Inventors

• Clement Benjamin
• Maesen Christophe

Classifications

• E04F15/02

  Flooring or floor layers composed of a number of similar elements (of webs E04F15/16) · CPC title

• Y10T428/24521

  with component conforming to contour of nonplanar surface · CPC title

• Y10T428/24868

  Translucent outer layer · CPC title

• B44C5/043 Primary

  containing wooden elements · CPC title

• B44C5/04

  Ornamental plaques, e.g. decorative panels, decorative veneers · CPC title