• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    PANEL UNDERSTANDING A COMPOSITE POLYMERIC LAYER AND A METHOD OF MANUFACTURING SUCH PANEL. The present invention relates to a panel (1) comprising a polymeric composite layer (4) and a cover layer which is laminated to the polymeric composite layer (4), wherein the cover layer comprises a polymeric film (5) .
    公开号:BR112012033640B1
    申请号:R112012033640-1
    申请日:2011-06-30
    公开日:2020-11-10
    发明作者:Bruno Paul Louis Vermeulen
    申请人:Unilin, Bvba；
    IPC主号:
    专利说明:

    [0001] The invention relates to a panel, in particular a floor panel, which comprises a polymeric composite layer and a cover layer which is laminated to the polymeric composite layer.
    [0002] Such a panel is known in the art and includes WPC as a polymeric compound. WPC is composed of plastic wood and is composed of polymeric material and a natural fiber, for example, from any source of wood. The polymeric material can be one or more polymers having a polyolefin group, such as polyethylene. Other polymeric materials include polypropylene, polyvinyl chloride (PVC), PVC cup-polymer, or the like. In a known panel, a covering layer, for example, a sheet of paper including a heart pattern, is attached to the WPC layer by means of glue. In order to achieve a high quality of fixation, a relatively expensive glue has to be applied.
    [0003] It is an object of the present invention to provide a low cost panel comprising a polymeric composite layer and a laminated cover layer thereto.
    [0004] In order to achieve this objective, the covering layer comprises a polymeric film.
    [0005] The advantage of the panel, according to the invention, is that a strong adhesion can be achieved between the polymeric composite layer and the polymeric film, in particular in the case of a polymeric composite layer containing a non-polar polymer, without the need to use expensive glue. A polymeric film appears to be more compatible with a polymeric composite layer in terms of adhesion than a conventional sheet of paper. One of the non-polar polymers is polypropylene, for example. In practice, the polymeric film can be provided with a decoration pattern, which is printed on the film, for example. It is noted that the polymeric compound can be a mixture of one or more polymeric materials and non-polymeric materials, or partially polymeric material. Examples of non-polymeric materials or partially polymeric materials are chalk and carpet residue, jute, styrene butadiene (latex), but a lot of alternative materials are conceivable. The polymeric compound can additionally contain a coupling agent to improve the cohesion of the material. Alternative additives are elastomers or materials having a high load-absorbing capacity. This can also improve the adhesion properties with the polymeric film or characteristics similar to UV resistance, moisture resistance and bending resistance. The polymeric film can be produced from a mixture of different polymers or a simple polymer. Preferably, the polymer film is free of non-polymeric materials that are contained in the polymeric composite layer. In general, the polymeric composite layer can be a polymeric compound and a non-polymeric compound substance whereby the polymeric film is substantially free of this non-polymeric compound substance. However, a smaller portion of the polymeric film may contain a non-polymer compound substance. The polymeric composite layer and / or the polymeric film may contain a mixture of polymers. The compound substance can be natural fibers or unnatural fibers, particles, or the like.
    [0006] The polymeric composite layer can be a WPC layer that is produced from plastic wood composite (WPC), and the cover layer can be a non-WPC polymeric film.
    [0007] In a practical embodiment, the film has a thickness of less than 1500 pm and, preferably, less than 500 pm. Before lamination, the film may be a continuous sheet. The polymeric film is thinner than the polymeric composite layer; in practice, one can also talk about a core of polymeric compound to which the polymeric film is laminated.
    [0008] The polymeric film can be produced from, among others, PVC, polyethylene, XPS (polystyrene), polypropylene, polyester, polypropylene, mixtures thereof, or other polymers, or the like. These materials are compatible with one or more polymers contained in various types of polymeric composite layer and types of WPC layer in terms of adhesion. Preferably, both the polymeric composite layer and the polymeric film contain a polymer of similar type.
    [0009] In a preferred embodiment, the polymeric film is fused to the polymeric composite layer, as this appears to create an optimal adhesion between the polymeric film and the polymeric composite layer. This means that in a contact area between the polymeric film and the polymeric composite layer, an anterior molten portion of at least one of the polymeric film and the polymeric composite layer functions as glue. In the panel according to the invention, the previous molten portion is cured. In this case, no additional glue is needed.
    [0010] In order to create a high level of wear resistance of the panel, the polymeric film is covered by a layer of ionomer resin, preferably selected from the group known as Surlyn®. An ionomer resin is a polymer comprising repeating units of both electrically neutral repeating units and a fraction of ionized units. Surlyn® is a commercial thermoplastic ionomer resin that was introduced by DuPont ™ in the 1960s. Surlyn® can be used in commercial extrusion / coextrusion, blown film, cast film, and extrusion coating equipment designed for polyethylene resins. Other characteristics of Surlyn® are sealing performance, formability, clarity, oil / grease resistance, and high heat stretch resistance, which makes the material very suitable for application in the field of floor panels.
    [0011] The ionomer resin layer may be a sheet which is laminated to the polymeric film by means of a bonding layer between the ionomer resin layer and the polymeric film, in which the bonding layer is preferably selected from the group known as Bynel®. Bynel® is a commercial adhesive resin that was introduced by DuPont ™, too. Alternatively, a copolymer of ethylene and methacrylic acid, for example, Nucrel® from DuPont ™, is also conceivable.
    [0012] In the embodiments as described hereinafter, a decoration pattern, such as a natural wood pattern, can be provided in the polymeric film. Alternatively, a decoration pattern is provided directly on the polymeric composite layer. In this case, the polymeric film itself can be an ionomer resin film that is directly provided in the decorated polymeric composite layer, or by means of a bonding layer, as mentioned here before.
    [0013] In the case of providing a decoration pattern on the polymeric film, the pattern can be provided by a digitally controlled inkjet printer. Preferably, the printing process is adapted to the properties of the polymeric film. For example, the viscosity of the paint and the droplet size can be varied, or the polymeric film is prepared by corona treatment, plasma treatment, or by applying a primer. Alternatively, the decoration pattern can be printed in a conventional manner, for example, by embossing printing, contact printing, or non-contact printing.
    [0014] The invention is also related to a panel, comprising a polymeric composite layer, in which an upper face of the polymeric composite layer is provided with a decoration pattern and covered by an ionomer resin layer. In this case, the ionomer resin layer can be formed from a sheet, extruded layer, or the like. In a specific embodiment, the polymeric composite layer is a WPC layer produced from plastic wood composite (WPC).
    [0015] The panel, according to the invention, can be a floor panel, ceiling panel, wall panel, or the like.
    [0016] The invention is also related to a method of manufacturing a laminated panel, including the steps of: providing a polymeric composite layer having a top face that has a temperature above its melting temperature, providing a polymeric film, placing the polymeric film on the upper side of the polymeric composite layer, and pressing of the polymeric composite layer and the polymeric film together. Preferably, the temperature, pressure and time of this process are selected such that the original structure of a large part of the polymeric film remains substantially the same.
    [0017] The upper face can be heated before providing the polymeric composite layer in order to prepare it to receive the polymeric film. Heat can be created by means of infrared radiation. It is also conceivable to increase the temperature by alternative heating means, for example, by using a laser.
    [0018] Alternatively, the polymeric composite layer is manufactured by melting a polymeric granulate layer and pressing the molten layer, in which the polymeric composite layer is provided for placing the polymeric film on its upper face before the upper face is cooled below its melting temperature. In this case, it is not necessary to heat the polymeric composite layer again after having made it, before placing the polymeric film on its upper face.
    [0019] The invention is also related to a method of fabricating a panel, including the steps of melting a layer of polymeric granulate, providing a polymeric layer on the upper face of the polymeric composite layer, and pressing the polymeric composite layer and of the polymeric layer together. If the polymeric layer is provided in the liquid phase on the upper face, it can be distributed on the surface of the polymeric composite layer, and smoothing the surface. If the polymeric layer is provided in the solid phase, for example, a sheet or film, it will melt together with the polymeric composite layer and smooth the surface. This is advantageous, since the outer surface of a polymeric composite layer can be thicker without the polymeric layer.
    [0020] The polymeric film can be prepared by applying a surface tension treatment, preferably a corona discharge treatment, then providing an ink pattern on the polymeric film, then applying a surface tension treatment, preferably a discharge treatment corona, then applying a bonding layer and subsequently applying an ionomer layer before or after placing the polymeric film on the upper face of the polymeric composite layer. The ionomer layer can be Surlyn®, as described here before. Alternative surface tension treatment includes plasma treatment, pyrolysis treatment, flame pyrolysis treatment, UV treatment, ozone treatment, or the like. Among the successive steps as mentioned here, there may be intermediate steps. In a preferred embodiment, a primer to promote adhesion of olefinic resins is applied to the polymeric film before providing the ink pattern and / or before applying the ionomer layer. The primer is intended to improve the adhesion characteristics and also to intensify the diffusion and bonding of the paint. In practice, the primer can be applied for an amount of 0.2 g / m2, for example. Preferably, the primer is an aqueous resin, for example, Mica A-131-X. Mica A-131-X is a simple component, composed of aqueous resin designed to promote adhesion of olefinic resins to various support films and papers in the extrusion and lamination coating.
    [0021] Applying a primer before applying a bonding layer provides additional adhesion with the bonding layer. An appropriate bonding layer is selected from the group known as Bynel®, being developed by DuPont ™, or it can be a mixture of Fusabond M603 and Elvax315LG in a ratio of 40% / 60% or 30% / 70%, for example , but different reasons are conceivable. In general, the part of Fusabond M603 can vary between 20 and 50% in the mixture.
    [0022] One or more layers of polyurethane can be applied on top of the ionomer layer.
    [0023] The polymeric film can be prepared by a coextrusion process resulting in a lamination layer to the polymeric composite layer.
    [0024] The polymeric film can be provided with a surface texture before or after placing the polymeric film on the upper face of the polymeric composite layer, for example, by embossing.
    [0025] The invention is also related to a method of making a film as a separate product, starting with providing a polymeric layer and including one or more of the steps as described here before.
    [0026] The invention will hereinafter be elucidated with reference to very schematic drawings showing embodiments of the invention by way of example.
    [0027] Fig. 1 is an exploded cross-sectional view of an embodiment of the panel according to the invention.
    [0028] Fig. 2 is an illustrative view of processing steps, showing an embodiment of a method of fabricating a panel according to the invention.
    [0029] Fig. 3 is a similar view according to Fig. Of an alternative embodiment.
    [0030] Fig. 4 is a view similar to the bottom of Fig. 3 of another alternative embodiment.
    [0031] Fig. 5 is a similar view according to Fig. 2 of yet another alternative embodiment.
    [0032] Fig. 1 shows separate layers of an embodiment of a panel 1 according to the invention. Panel 1 is a laminate comprising several layers. The total thickness of this embodiment of panel 1 is about 5.5 mm, but alternative sizes are possible. From the bottom side to the top side of panel 1 of Fig. 1, you can see a bottom soft layer 2 of about 1 mm, a layer of WPC or core 3 of about 3 mm, a soft top layer 4 about 1 mm, a polymeric non-WPC 5 film of about 250 pm, a bonding layer 6 of about 50 pm, and an ionomer resin layer 7 of about 200 pm. The thicknesses mentioned are only examples, and alternative values are possible. It is noted that instead of WPC, an alternative polymeric compound can be applied. The polymeric compound can be produced from a polymer and a compound substance such as carpet residue, chalk, or the like. It is also possible, for example, that the carpet waste itself contains one or more polymers such that the polymeric compound can be produced from carpet waste containing polymer, possibly added with one or more additional polymers. In addition, a coupling agent for improved cohesion can be contained in the polymeric compound. It is also noted that the non-WPC polymeric film can be replaced with a polymeric film that is substantially free of any compound substance.
    [0033] The lower soft layer 2 and the upper soft layer 4 are fixed on both sides of the WPC core 3 for reasons of comfort in this embodiment, but the soft layers 2, 4 can be omitted. The upper and lower soft layers 2, 4 can be flexible to improve sound dampening. Various types of soft layers 2, 4 are possible, such as foam, wood veneer, and the like. In the embodiment shown in Fig. 1, the upper and lower soft layers 2, 4 are produced from soft WPC.
    [0034] The core of WPC 3 and / or the soft layers of WPC 2, 4 comprise a non-polar polymer, for example, polypropylene. The non-WPC 5 polymeric film is produced from polypropylene, but alternative materials are conceivable, for example, PVC or polyethylene. It appears that a much stronger fixation can be understood between the non-polar layer of WPC 4, in this case the upper soft layer of WPC 4, and the polymeric film of non-WPC 5 than between a non-polar layer of WPC and a sheet of paper on conventional panels including a layer of WPC.
    [0035] The non-WPC polymeric film 5 can be provided with a decoration pattern, for example, by printing an ink pattern on the film 5.
    [0036] In the embodiment of Fig. 1, the ionomer resin layer 7 forms a protective layer, such as a wear resistant top layer in conventional laminated panels. It is naturally possible to apply another type of wear resistant layer than the ionomer resin layer 7. Preferably, the ionomer resin layer 7 has a high level of transparency in order to maintain a non-WPC polymeric film decoration pattern 5 visible. An appropriate material is selected from the group known as Surlyn® being developed by DuPont ™. Additionally, the ionomer resin layer can be covered with a polyurethane coating, or similar, in order to improve abrasion and scratch resistance. Such a coating may have a thickness of 5 - 30 pm, but a thinner or thicker coating is conceivable. Alternatively or in addition to a polyurethane coating, the ionomer resin layer can be covered with a UV top coat, or a varnish that can be cured by an electron beam, possibly added with wear resistant particles. In addition, the upper side of panel 1 can be subjected to a plasma treatment. Plasma treatment may comprise applying a material, for example, in the form of a metal coating or film, metal oxides, metal nitrides, and mixtures thereof, such as aluminum oxide, silicon oxide, tin oxide and / or indium oxide, titanium oxide, zirconium dioxide, tantalum oxide, chromium oxide, aluminum nitride, boron nitride, silicon nitride, titanium nitride, and zirconium nitride.
    [0037] Bonding layer 6 is applied for adhesion to the ionomer resin layer 7 to the non-WPC polymeric film 5. An appropriate bonding layer is selected from the group known as Bynel®, being developed by DuPont ™, also . Alternative materials that are suitable as a layer are Nucrel® 0609HSA, Elvax® 3165LG, Fusabond® M 603 from DuPont ™, or mixtures thereof.
    [0038] Panel 1, as shown in Fig. 1, can be produced by heating an upper face of the upper soft layer of WPC 4 to a temperature that is higher than its melting temperature, then placing the polymeric film of non-WPC 5 on the molten top face, and by pressing the polymeric non-WPC 5 film on the top layer of WPC 4. The top face of the top layer of WPC 4 can be heated by means of infrared radiation, but alternative heating means are conceivable . It is conceivable that the total stack of layers 5, 6, 7 is pressed to the layers of WPC 2, 3, 4 simultaneously if the stack of layers 2, 3, 4 already forms a base panel. The bonding layer 6 can be applied to the polymeric non-WPC film 5 by means of a coextrusion process. The polymeric non-WPC film 5 and the ionomer resin layer 7 can be supplied in rolls. Alternatively, the bonding layer can be applied to the polymeric film 5 in which a decoration pattern is provided. It is also possible that during or after the process of providing a decoration pattern to the polymeric film, a primer or adhesion layer is provided on the polymeric film 5. In this case, the Bynel® layer can be omitted.
    [0039] In a specific embodiment, the stack of layers 5, 6, 7 is prepared by the following successive steps: providing the polymeric film 5, applying a surface tension treatment to an upper surface of the polymeric film 5, for example, a treatment corona discharge, provide an ink pattern on the polymeric film 5, for example, by digital printing and / or conventional printing, again apply a surface tension treatment, for example, a corona discharge treatment, apply the bonding layer 6, and applying the ionomer layer 7. The binding layer 6 and the ionomer layer 7 can be selected from the group known as Bynel® and Surlyn®, respectively. This process can be a coextrusion process. The resulting film 5, 6, 7 can be attached to a single film or sheet to the soft layer 4, or to the layers of WPC 2, 3, 4 if the layer stack 2, 3, 4 already forms a base panel. Before providing the ink pattern and / or before applying the ionomer layer 7, a primer to promote adhesion of olefinic resins can be applied to the polymeric film 5.
    [0040] It is noted that alternative surface tension treatments can be applied, such as plasma treatment, pyrolysis treatment, flame pyrolysis treatment, UV treatment, ozone treatment, or the like. In addition, pattern printing can be performed by contact printing or non-contact printing.
    [0041] It is also possible to fuse the polymeric film of non-WPC 5 to the upper layer of WPC 4 directly after manufacturing the core of WPC 3 and the lower WPC and upper soft layers of WPC 2, 4. The layers of WPC 2, 3 , 4 can be manufactured by melting the WPC granulate layers and pressing the melted layers together. Such a method is described in WO 2008/122668.
    [0042] Before cooling the layers of WPC 2, 3, 4 below, the melting temperature of at least the upper soft layer of WPC 4 and possibly before pressing the layers of WPC 2,3,4 together, the polymeric film of non-WPC 5 can be placed on the molten top of the top layer of WPC 4. It is noted that if the polymeric film of non-WPC 5 is placed on a layer of WPC that is still very hot, film 5 can melt, which it is undesirable.
    [0043] Nevertheless, in an alternative method of fabricating a panel, a polymeric film is deliberately melted into the polymeric composite layer. In this case, a polymeric sheet, for example, polypropylene, PVC, polyester, or the like, can be supplied to the melted granular layer of the polymeric compound. The polymeric film melts and, as a result, after pressing, the panel obtains a smooth surface on the side where the polymeric sheet is provided and melted. This is advantageous if the polymeric composite layer has a coarse surface due to the inhomogeneous mixture of the polymer and a composite substance. In addition, the polymeric layer fused to the polymeric composite layer can also improve the stability and hardness of the resulting panel and additionally improves the adhesion of another polymeric film on it. It is also possible to provide a fused polymeric layer or film on the back side of the polymeric composite layer, which can function as an equilibrium layer. It is noted that instead of applying a polymeric sheet, the polymeric material can be provided in the granules of the polymeric compound by spraying it in a liquid phase. In the case of applying a polymeric sheet, it can have a specific weight of 10-500 g / m2.
    [0044] It is possible to use a press including an embossed press plate in order to create a panel 1 having an embossed upper surface. The lamination process can be continuous or discontinuous. In addition, the polymeric film 5 and / or the ionomer resin layer 7 can be embossed before lamination or after lamination of layers 5, 7 to the polymeric composite layer. "Embossing can be done by using a textured cap, or by using a textured pressing plate, or by using a pressing plate on which a releasable textured press layer is present".
    [0045] In addition, panel 1 can be provided with locking means for fixing panels to each other in order to form a floor, for example. In addition, panel 1 can be provided on at least two and preferably all edges with locking means. Preferably, the locking means also includes a mechanical locking system for locking the adjacent floor panels not only in a direction perpendicular to the surface of the panels, but also in a direction parallel to the surface and perpendicular to the respective side of the panel 1. However, the invention is not limited to this as a whole. All locking systems, including the use of a tongue and groove, as well as adhesives, are involved by the invention.
    [0046] Fig. 2 illustrates an embodiment of a method of manufacturing a panel 1 according to the invention. On the left side of Fig. 2, a polymeric granulate is supplied by a collector 8 and applied to a conveyor belt 9 such that a layer 10 of polymeric granules occurs and is transported by the conveyor belt 9. The layer 10 is transported to a double belt press 11 where it is heated, cast and pressed. When the pressed layer 10 leaves the double belt press 11, at least one upper surface of the layer 10 is not yet cooled below its melting temperature.
    [0047] In a next stage of the process, the polymeric film 5 is provided from a roll 12 and placed on the top surface of the pressed layer 10. Since the top surface is in a molten or partially molten state, no additional glue has to be added. The polymeric composite layer 10, including the polymeric film 5, is guided through a double belt laminator 13 where they are fixed together under high pressure.
    [0048] Next, a corona discharge treatment is applied by a corona discharge device 14. This surface tension treatment creates a polymeric film surface 5 that is suitable for receiving a primer at a primer 15 application station.
    [0049] The primer can be an aqueous resin, for example, Mica A-131-X.
    [0050] In a next stage, the bonding layer 6 is extruded in a bonding layer 16 extrusion coating. This step is followed by the application of the ionomer layer 7, via an ionomer layer extrusion coating 17. The The resulting layer is treated by calender rolls 18. It is conceivable to co-extrude additional layers for additional characteristics, for example, an anti-wear and / or anti-scratch layer, an anti-static layer, a water-impermeable layer, such as a PE layer of about 10 pm, possibly having different layer thicknesses. The calender rolls 18 can be made of Teflon or silicone.
    [0051] On top of the wear-resistant layer, particles are diffused by a diffusion device 19 at the right end of the process as shown in Fig. 2. The upper surface is provided with a texture by an embossing drum 20. The The resulting panel can be cut into pieces and provided with locking means, such as tongues and grooves.
    [0052] Fig. 3 illustrates another embodiment of the method that is similar to the embodiment as illustrated in Fig. 2 until the primer application station 15. After applying the primer, a decoration pattern is printed on the upper surface of the polymeric film 5 by a digital printer 21. Conventional contact printing devices, such as flexo, engraved cylinders, or the like, or non-contact printing devices, such as inkjet, toner, or the like, or a combination of these, are conceivable.
    [0053] After the printing stage, the upper surface of the intermediate product is treated again by a second corona discharge device 22 and a second primer application station 15a. Subsequently, the bonding layer 6 is extruded by the bonding layer extrusion coater 16 and the ionomer layer 7 is applied by the ionomer layer extrusion coater 17. The resulting layer is also treated by the calender rolls 18 and provided with particles resistant to wear by the diffusion device 19. The upper surface is provided with a texture by the embossing drum 20.
    [0054] Fig. 4 illustrates an alternative step of providing the upper surface with a texture. In this case, a textured release layer 21 is guided on a roll 22. The roll 22 may have a flat surface that guides the flat back side of the release layer 21. The advantage of the textured release layer 21 is that anti-wear particles in the portion the top of the ionomer layer 7 which is embossed will mainly impact the release layer 21. This minimizes any wear on the roller 22.
    [0055] Fig. 5 illustrates yet another alternative embodiment. In this case, there is a printing unit 23 comprising a filler, primer and base coatings. The printing unit 23 applies several layers to the pressed layer 10. The topmost layer is suitable for printing an ink pattern on it.
    [0056] The topmost layer may comprise thinner particles, for example, in the size range of 20-500 pm. As a result, a smooth top surface is obtained. A suitable powder appears to be Dupont ™ Abcite® material, but alternative materials are conceivable. Abcite is derived from Surlyn. The finer particles can be colored such that a smooth colored surface is obtained, which is ready to print a decorative pattern on it. It is possible that the printing unit 23 applies at least one layer of powder, for example, Abcite® from Dupont ™, on the top surface of layer 10 which is still in a molten or partially molten state. This leads to a smooth surface on which a decoration pattern can be printed and which can be covered with additional layers as described here before.
    [0057] In order to improve the fixation of the powder layer or the polymeric layer 5 to the upper surface of layer 10, at least an upper portion of layer 10 can be prepared in a special way, for example, by reducing or omitting the ratio of compound substance in layer 10. Due to a higher polymer ratio in the upper portion of layer 10, it is easier to melt the powder or polymeric layer 5 to the upper surface of layer 10. In the case of heating the upper surface of layer 10 , will be more reactive to the heat source if the ratio of polymers in the upper portion of layer 10 is increased.
    [0058] The invention is not limited to the embodiments as described above and shown in the drawings, which can be varied in various ways without departing from the scope of the invention. For example, the top soft layer can be removed such that the non-WPC polymeric film is attached directly to the WPC core. It is also possible that a very thin layer is present between the WPC core and the non-WPC polymeric film that is necessary to produce the WPC core, but which is of such a thickness that it cannot adversely affect a strong adhesion between the core of the WPC WPC and non-WPC polymeric film. In addition, an upper face of the WPC 3 core can be provided with a decoration pattern and directly covered by the ionomer resin layer 7, consequently eliminating the non-WPC polymeric film 5 and the upper soft layer of WPC 4. It is noticed that the panel according to the invention can be flexible or rigid, or between them. Similarly, the method according to the invention can lead to such a panel.
    权利要求:
    Claims (10)
    [0001]
    1. Panel (1), comprising a polymeric composite layer (4) and a cover layer that is laminated to the polymeric composite layer (4), characterized in that the cover layer comprises a polymeric film (5) having a thickness less than 1500 pm and provided with a decoration pattern that is printed on it, in which the polymeric film (5) is fused to the polymeric composite layer (4), in which the polymeric film (5) is produced in a polymer selected from the list consisting of PVC, polyethylene, polystyrene (XPS), polypropylene, polyester, and polypropylene, where in a contact area between the polymeric film (5) and the polymeric composite layer (4) of a previously melted portion of at least one of the polymeric film (5) and the polymeric composite layer acts as glue.
    [0002]
    2. Panel (1), according to claim 1, characterized by the fact that the decoration pattern is printed by a digitally controlled inkjet printer, recording printing, contact printing or non-contact printing.
    [0003]
    3. Panel (1) according to claim 1 or 2, characterized by the fact that the polymeric composite layer is a layer of WPC (4) produced from plastic wood composite (WPC), and the covering layer is a polymeric non-WPC film (5), or the polymeric composite layer is a composite of a polymer and a non-polymeric composite substance whereby the polymeric film (5) is free of said non-polymeric composite substance.
    [0004]
    Panel (1) according to any one of claims 1 to 3, characterized in that the polymeric film (5) has a thickness of less than 500 pm.
    [0005]
    Panel (1) according to any one of claims 1 to 4, characterized in that the polymeric film (5) is covered by a layer of ionomer resin (7).
    [0006]
    6. Method of manufacturing a laminated panel, characterized by the fact that it includes the steps of: providing a polymeric composite layer (4, 10) and having a top face that has a temperature above its melting temperature, providing a polymeric film (5) having a thickness of less than 1500 pm, in which the polymeric film (5) is produced from a polymer selected from the list consisting of PVC, polyethylene, polystyrene (XPS), polypropylene, polyester, and polypropylene , place the polymeric film (5) on the top face of the polymeric composite layer (4, 10), and press the polymeric composite layer (4, 10) and the polymeric film (5) together, in which a decoration pattern is printed on the polymeric film (5), in which the polymeric film (5) is fused to the polymeric composite layer (4), in which in a contact area between the polymeric film (5) and the polymeric composite layer (4) of a molten portion previously of at least one of the film polymeric (5) and the polymeric composite layer acts as glue.
    [0007]
    Method according to claim 6, characterized by the fact that the upper face is heated before providing the polymeric composite layer (4), preferably by means of infrared radiation.
    [0008]
    8. Method according to claim 6, characterized by the fact that the polymeric composite layer (4) is produced by melting a layer of polymeric granulate and pressing the molten layer, in which the polymeric composite layer (4) it is provided for placing the polymeric film (5) on its upper face before the upper face is cooled below its melting temperature.
    [0009]
    Method according to any one of claims 6 to 8, characterized in that the polymeric film (5) is prepared by applying a surface tension treatment, preferably a corona discharge treatment, then providing a pattern of ink on the polymeric film (5), then applying a surface tension treatment, preferably a corona discharge treatment, then applying a bonding layer (6), then applying an ionomer layer (7), before or after placement of the polymeric film (5) on the upper face of the polymeric composite layer (4).
    [0010]
    10. Method according to claim 9, characterized by the fact that a primer to promote adhesion of olefinic resins is applied to the polymeric film (5) before providing the ink pattern and / or before applying the ionomer layer or the bonding layer (6).
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    同族专利:
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    CA2804100C|2019-10-08|
    PL3354457T3|2021-06-28|
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    法律状态:
    2017-06-20| B25A| Requested transfer of rights approved|Owner name: UNILIN, BVBA (BE) |
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-10-08| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-06-30| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-11-10| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 30/06/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    EP10167988.4|2010-06-30|
    EP10167988A|EP2402153A1|2010-06-30|2010-06-30|A panel comprising a polymeric composite layer and a method of manufacturing a panel|
    EP10190253.4|2010-11-05|
    EP10190253|2010-11-05|
    PCT/EP2011/061017|WO2012001109A1|2010-06-30|2011-06-30|A panel comprising a polymeric composite layer and a method of manufacturing such panel|
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