Floor panel and method for manufacturing such floor panels

Abstract

Floor panel, of the type consisting of a laminate panel which comprises at least a printed decorative layer (8) and a top layer (9) forming the upper surface (10) of the floor panel (1), more particularly a so-called overlay, whereby this top layer (9), or, thus, overlay, is realized on the basis of a thermosetting resin, characterized in that in the upper side (11) of the floor panel (1), indentations (12) are formed and in that at last in a number of these indentations (12), a component (13) is provided, which is obtained in that it has been provided in those indentations (12) after the provision of the indentations (12).

Description

[0001] 1. Field of the Invention[0002] This invention relates to a floor panel, as well as to a method for manufacturing such floor panel.[0003] In particular, the invention relates to so-called laminate panels for forming a floor covering.[0004] It is known that in such laminate panels for floors, the appearance of wood, more particularly parquetry or the like, or the appearance of stones or ceramic tiles, is imitated by providing the floor panels, in the proximity of their upper surface, with a decorative layer printed with a pattern, for example, a wood pattern or tile pattern, over which a transparent synthetic layer is provided.[0005] Usually, the printed decorative layer consists of printed paper, whereas the clear synthetic layer normally consists of a synthetic resin or one or more transparent or clear resin-impregnated material layers, for example, paper layers, in which possibly also products can be incorporated in order to enlarge, for example, the wear and tear resistanc...

AI Technical Summary

Problems solved by technology

This technique has the disadvantage that it is complex and, consequently, time-consuming and that it must be performed rather precisely, in consideration of the fact that two layers must be provided on top of each other and care must be taken in particular that the intermediate hardening is performed to a proper degree.

Another disadvantage consists in that one always has to work with at least two top layers, which can exert a disadvantageous influence on the clearness with which the pattern of the printed decorative layer finally is visible, and by which the pattern, formed by the paint in the indentations, is softened.

Thus, the complex and rather expensive procedure described in the German DE 29 26 983 is less suitable for producing larger volumes at a minimum cost price, as desirable in the production of floor panels.

This known technique requires particularly expensive equipment for, during pressing the laminate panels, simultaneously performing a printing action, which renders this technique thus little suitable for the production of floor panels.

As the colour product is provided during the formation of the indentations, as well as is formed by means of a printing process, moreover an appearance similar to printed matter is obtained, which renders the imitation effect less than optimum, at least for certain applications.

Further, it is also known to apply techniques whereby the application of colour products on certain locations in recesses is coupled specifically to particular surface treatments, as a consequence of which the typical characteristics of the normal panel surface can not be guaranteed any longer.

Practice has shown that in such specific application, it is difficult to arrive at a good imitation of a really coloured wooden floor.

The pure paper itself as such is white, however, after impregnation with resin and after pressing the overlay, it becomes almost colourless.

So, for example, it is known that it is difficult to realize very light decors, for example, so-called "crus", as well as very dark decors in a proper manner, as with the techniques known up to now, whereby the decor is determined substantially by the printed decorative layer, the richness of the obtained decor often is

Images