Panels, in particular floor panels, ceiling panels or wall panels, and use of additional layers in laminated multilayer structures of panels

Abstract

A panel, in particular a floor panel, ceiling panel or wall panel, having a laminated multilayer structure, comprising: a core layer; a decorative layer above the core layer; a transparent top layer on the decorative layer; and an intermediate layer located between the decorative layer and the top layer, the intermediate layer being transparent and being essentially made of a protective material comprising a polyurethane composition, which is a reaction product of a polyester polyol, a polyether polyol and an isocyanate. Use of an additional layer in the laminated multilayer structure of a panel, in particular a floor panel, ceiling panel or wall panel, wherein the additional layer is preferably transparent and being essentially made of a protective material comprising a polyurethane composition, which is a reaction product of a polyester polyol, a polyether polyol and an isocyanate.

Description

[0001] According to a first aspect, the invention relates to a panel, in particular a floor panel, a ceiling panel or a wall panel. In a second aspect, the invention relates to the use of an additional layer in a laminated multilayer structure of a panel.

[0002] In the field of construction, panels using laminated multilayer structures are well known. They have proven to be highly versatile for covering surfaces such as floors, walls and ceilings. In particular, it is attractive to use laminated multilayer structures comprising:

[0003] - core layer,

[0004] - a decorative layer on top of said core layer,

[0005] - A transparent top layer over said decorative layer.

[0006] A recent development is to carry out a specific modification of the top side of the top layer of such a panel once the multilayer structure has been formed, which is known as embossing. In embossing, the top side of the top layer is provided with a relief that imitates the natural top surface perceived, for example, from a wooden panel. A special type of embossing is registered embossing, which provides a relief corresponding to the decorative layer, for example, a decorative image corresponding to the surface of a wooden panel with a grain pattern.

[0007] When producing such panels, the embossing of the top layer can be performed by several techniques, such as compression, milling or chemical etching of the top layer. After the relief has been embossed on the top surface, further finishing steps may be required, such as fine grinding or sanding the embossed surface.

[0008] It has been found that during embossing and / or finishing of the top layer of the panel, the integrity or appearance of the underlying decorative layer may be negatively affected and may even be damaged.

[0009] It is therefore an object of the present invention to further ensure that in the production of laminated multilayer panels as described above, embossing and finishing steps of the top layer are prevented from possibly altering the integrity or appearance of the underlying decorative layer.

[0010] The present invention provides

[0011] Panels, in particular floor panels, ceiling panels or wall panels,

[0012] It has a laminated multi-layer structure, including:

[0013] - core layer,

[0014] - a decorative layer on top of said core layer,

[0015] - a transparent top layer on said decorative layer, and

[0016] - an intermediate layer, which is located between the decorative layer and the top layer,

[0017] The intermediate layer is transparent and is substantially made of a protective material including a polyurethane composition which is a reaction product of a polyester polyol, a polyether polyol, and an isocyanate.

[0018] It has been found that the specific protective material of the intermediate layer has a sufficiently high hardness to protect the decorative layer from any wear or indentation during embossing and finishing of the top layer of the panel.

[0019] In the context of the panel according to the invention, the terms "above" and "on" relate to the direction the panel faces after use on a floor or the like. The term "substantially" includes that at least 75 wt.% (75 weight%), preferably at least 90 wt.%, most preferably 100 wt.% of the intermediate layer is made of protective material.

[0020] The decorative layer may contain a (printed) decorative image on the upper side of the decorative layer, which decorative image is visible when the panel is used as a floor panel, ceiling panel or wall panel. The intermediate layer has a satisfactory transparent quality so that the visibility of the decorative image is not affected by the intermediate layer.

[0021] In the panel according to the invention, the individual layers of the generally laminated multilayer structure are connected to one another directly or indirectly.

[0022] Preferably, the polyurethane composition of the panel of the present invention is a thermosetting polymer material, and in particular, the polyurethane composition is a cross-linked polymer.

[0023] Thermosetting polymer materials are also known in the art as hot melt adhesives, where thermal curing typically occurs over a thermal trajectory of 100-160°C.

[0024] When the panel is produced, the intermediate layer may be applied in a hot-melt state so as to be securely attached to adjacent layers of the panel.

[0025] In the panel of the present invention, the polyester polyol preferably has a weight average molecular weight Mw in the range of 500 to 20,000, and preferably comprises a polyester polyol having a linear monomer having 5 to 8 carbon atoms.

[0026] The polyester polyols may include polyester diols, such as polyesters formed by reacting hexanediol with adipic acid.

[0027] Furthermore, in the panel of the present invention, the polyether polyol preferably has a weight average molecular weight Mw in the range of 400 to 10,000, and preferably includes a branching monomer having 2 to 5 carbon atoms.

[0028] The polyether polyol may include a polyether diol, such as polypropylene glycol.

[0029] In the panel according to the invention, it is particularly preferred that the isocyanate is a diisocyanate and / or a triisocyanate, preferably methylene diphenyl diisocyanate.

[0030] With regard to the protective material, the following preferred weight percentages apply:

[0031] - the protective material contains 5-50wt.% of reacted polyester polyol;

[0032] - The protective material contains 10-40wt.% of reacted polyether polyol;

[0033] - The protective material contains 5-20 wt.% of reacted isocyanate.

[0034] It is further preferred that the protective material comprises a filler material as an additive, such as microfibers and / or aluminum oxide, preferably in the range of 0.2-5 wt. % relative to the protective material.

[0035] This type of filler material further contributes to the required hardness of the protective material and thus enhances the wear resistance of the protective material.

[0036] In the panel according to the invention, it is preferred that the intermediate layer is directly attached to the decorative layer and / or to the top layer.

[0037] Therefore, the desired visibility of the decorative layer can be achieved most conveniently.

[0038] In the panel according to the invention, it is preferred that the top side of the top layer is embossed with a relief, which relief preferably corresponds to the decorative image of the decorative layer.

[0039] It is also preferred that, in the panel according to the present invention, the middle layer has a thickness of 20 to 80 g / m 2 Weight.

[0040] Such a basis weight determines the thickness of the intermediate layer in a range that achieves optimal protection of the decorative layer and optimal visibility of the decorative layer.

[0041] In the panel according to the invention it is advantageous if the intermediate layer is colourless. Thus, the appearance of the decorative layer is not altered by any colour tint on the top side of the panel.

[0042] In the panel according to the present invention, it is preferred that the intermediate layer has a relatively low reflectivity of 4%, 3%, 2% or less.

[0043] Such an interlayer has a reflectance value comparable to that of glass, or can even be lower than that of glass. In the art, the reflectance value is also referred to as the reflection coefficient of a material.

[0044] Due to this reflection value of the intermediate layer, an optimal visibility of the underlying decorative layer is achieved, since a relatively high amount of light is transmitted, while only a small amount of light is reflected.

[0045] In the present invention, it is further preferred that the intermediate layer has a relatively low refractive index, preferably between 1.0 and 1.3.

[0046] Further preferred features of the panel according to the invention include:

[0047] The panel includes a backing layer attached to an underside of the core layer;

[0048] Panel thickness is 3 to 10 mm;

[0049] The panel is flat and has a rectangular profile with four side edges.

[0050] In another preferred embodiment, a panel according to the invention comprises a first panel edge comprising a first coupling profile and a second panel edge, the first panel edge being preferably opposite the first panel edge, the second panel edge comprising a second coupling profile, the second coupling profile being designed to engage with the first coupling profile of an adjacent panel by interlocking in horizontal and vertical directions, wherein the first coupling profile and the second coupling profile are preferably configured such that two such panels can be coupled to each other by means of a lowering movement.

[0051] This type of panel allows a flat surface to be fully covered with multiple interconnected panels, resulting in an overall solid panel coverage.

[0052] In addition to or as an alternative to the above-mentioned first and second coupling profiles, the panel may further comprise at least one third coupling profile and at least one fourth coupling profile located at a third panel edge and a fourth panel edge, respectively, wherein the third coupling profile comprises:

[0053] - a lateral tongue extending in a direction substantially parallel to the upper side of the core,

[0054] - at least one second downward flank located at a distance from said lateral tongue, and

[0055] - a second downward groove formed between said lateral tongue and said second downward flank,

[0056] Wherein, the fourth connection profile comprises:

[0057] - a third groove configured to receive at least a portion of the lateral tongue of the third coupling profile of an adjacent panel, the third groove being defined by an upper lip and a lower lip, wherein the lower lip is provided with an upward locking element,

[0058] Wherein, the third connecting profile and the fourth connecting profile are configured so that two of the panels can be connected to each other by a rotational movement, wherein, in the connected state: at least a portion of the lateral tongue of the first panel is inserted into the third groove of the adjacent second panel, and wherein at least a portion of the upward locking element of the second panel is inserted into the second downward groove of the first panel.

[0059] In a second aspect, the invention relates to the use of an additional layer in a laminated multilayer structure of a panel, in particular a floor panel, a ceiling panel or a wall panel,

[0060] The additional layer is preferably transparent and is substantially made of a protective material comprising a polyurethane composition which is a reaction product of a polyester polyol, a polyether polyol and an isocyanate.

[0061] The use of such an additional layer forms a protective layer protecting the laminated structure of the panel from any high impact techniques generated during the production of the panel, such as embossing in relief on the top layer of the panel.

[0062] When using an additional layer according to the present invention, it is preferred that the polyurethane composition is a thermosetting polymer material, wherein preferably the polyurethane composition is a cross-linked polymer.

[0063] This preferred type of polyurethane composition has a suitable hardness for the intended function of the additional layer, ie a hardness high enough to protect the laminated multilayer structure from any abrasion or indentation during production of the panel.

[0064] Generally, the use according to the invention may comprise preferred features with respect to the panel and the corresponding additional layer, which features correspond to the preferred features already described above with respect to the panel and the corresponding intermediate layer according to the first aspect of the invention.

[0065] In particular, when using the additional layer according to the present invention, it is preferred that the laminated multilayer structure of the panel comprises:

[0066] - core layer,

[0067] - a decorative layer on top of said core layer,

[0068] - a transparent top layer above said decorative layer,

[0069] And the additional layer is used as an intermediate layer between the decorative layer and the top layer.

[0070] As mentioned above, this intermediate layer is most effective in protecting the decorative layer from any wear or indentation during the production of the panel.

[0071] Generally, it is preferred that the additional layer according to the second aspect of the invention is applied in the panel according to the first aspect of the invention. Example

[0072] The present invention will be further described by means of certain preferred embodiments shown in the accompanying drawings, in which:

[0073] Figure 1 shows a cross section of a laminated multilayer structure of a panel according to the invention;

[0074] Figure 2 and 3 Two types of joint coupling profiles suitable for use with a panel according to the invention are shown in cross section.

[0075] Figure 1 Schematically shown is a cross section of a laminated multilayer structure of a panel 100, which is composed of a plurality of layers directly connected to each other. These layers include a backing layer 101, a core layer 102, a decorative layer 103 having a decorative image, an intermediate layer 104, and an embossed top layer 105. The embossed top layer contains depressions 106 and protrusions 107, so that a relief is formed on the top surface of the top layer, which relief corresponds to the pattern of the decorative image facing upward from the decorative layer 105. The intermediate layer 104 is formed of a protective material according to the present invention and is transparent and colorless.

[0076] Figure 2 and Figure 3 Two types of joint connection profiles 401A, 401B are shown, respectively. 402A, 402B, which are two interconnected panels 400A, 400B according to the present invention. Panels 400A and 400B include an embossed top layer 410. As a whole, each panel has a Figure 1 The laminated multilayer structure (however, its Figure 2 and 3 Not shown in further detail).

[0077] Figure 2 Panels 400A and 400B are shown, which respectively include a first panel edge 440A having a first connecting profile 401A and a second panel edge 440B opposite to the first panel edge 440A, the second panel edge including a second connecting profile 401B, which is designed to engage with the first connecting profile 401A of an adjacent panel in horizontal and vertical directions by interlocking, wherein the first connecting profile 401A and the second connecting profile 401B are configured so that two panels of such panels can be connected to each other by means of a descending movement.

[0078] Figure 3 Panels 400A and 400B are shown, which respectively comprise a third coupling profile 402A and a fourth coupling profile 402B at a third panel edge 441A and a fourth panel edge 441B, respectively. The third coupling profile 402A and the fourth coupling profile 402B are configured such that the two panels 440A, 440B can be coupled to each other by a rotational movement, wherein, in the coupled state, at least a portion of a lateral tongue 404B of a first panel is inserted into a groove 404A of an adjacent second panel, and wherein at least a portion of an upward locking element 406A of the second panel is inserted into a second downward groove 406B of the first panel.

[0079] It should be noted that the invention is not limited to the examples shown and described above, but that several variations are possible within the scope of the appended claims, as will be clear to a person skilled in the art.

[0080] The verb "to comprise" and its conjugations used in the specification should be understood to mean not only "to include" but also the phrases "to include", "consisting essentially of", "formed of" and their conjugations.

Claims

1. A panel (100) having a laminated multi-layer structure, the multi-layer structure comprising: A core layer (102), a decorative layer (103) above the core layer, a transparent top layer (105) on the decorative layer, and an intermediate layer (104), the intermediate layer being located between the decorative layer and the top layer, The intermediate layer (104) is transparent and is made of a protective material comprising a polyurethane composition, which is a reaction product of a polyester polyol, a polyether polyol and an isocyanate, wherein the polyurethane composition is a thermosetting polymer material and the polyurethane composition is a cross-linked polymer, wherein the grammage of the intermediate layer (104) is 20 to 80 g / m 2 , wherein the protective material comprises microfibers and / or aluminum oxide as additives in the range of 0.2-5 wt. % relative to the protective material, And wherein the intermediate layer (104) is directly connected to the decorative layer and / or to the top layer.

2. The panel according to claim 1, wherein the panel is a floor panel, a ceiling panel or a wall panel.

3. The panel according to claim 1, wherein the respective layers of the laminated multilayer structure are directly or indirectly connected to each other. 4 . The panel according to claim 1 , wherein the polyester polyol has a weight average molecular weight Mw of 500-20,000 and comprises a polyester polyol containing a linear monomer having 5-8 carbon atoms. The panel according to claim 1 , wherein the weight average molecular weight Mw of the polyether polyol is 400-10000, and the polyether polyol comprises a branched monomer having 2-5 carbon atoms. The panel according to claim 1 , wherein the isocyanate is a diisocyanate and / or a triisocyanate.

7. The panel according to claim 6, wherein: The isocyanate is methylene diphenyl diisocyanate.

8. The panel according to claim 1, wherein the protective material comprises 5-50 wt% of reacted polyester polyol.

9. The panel according to claim 1, wherein the protective material contains 10-40 wt% of reacted polyether polyol.

10. The panel of claim 1, wherein the protective material comprises 5-20 wt% of reacted isocyanate.

11. The panel according to claim 1, wherein the top side of the top layer (105) is embossed with a relief (106, 107), which corresponds to the decorative image (103) of the decorative layer.

12. The panel according to claim 1, wherein the intermediate layer (104) is colorless.

13. The panel according to claim 1, wherein the intermediate layer (104) has a relatively low reflectivity of 4%, 3%, 2% or less.

14. The panel according to claim 1, comprising a first panel edge (440A) comprising a first joining profile (401A) and a second panel edge (440B), the first panel edge being opposite to the first panel edge, the second panel edge comprising a second joining profile (401B), the second joining profile being designed to engage in horizontal and vertical directions by interlocking with the first joining profile (401A) of an adjacent panel, wherein The first coupling profile (401A) and the second coupling profile (401B) are configured such that two such panels (400A, 400B) can be coupled to each other by means of a lowering movement.

15. The panel according to claim 1, comprising at least one third joining profile (402A) and at least one fourth joining profile (402B) located at a third panel edge (441A) and a fourth panel edge (441B), respectively, wherein the third joining profile (402A) comprises: a lateral tongue extending in a direction substantially parallel to the upper side of the core layer, at least one second downward flank located at a distance from said lateral tongue, and a second downward groove formed between the lateral tongue and the second downward flank, wherein the fourth coupling profile (402B) comprises: a third groove configured to receive at least a portion of the lateral tongue of the third coupling profile of an adjacent panel, the third groove being defined by an upper lip and a lower lip, wherein the lower lip is provided with an upward locking element, wherein the third connecting profile (402A) and the fourth connecting profile (402B) are configured such that two of the panels (400A, 400B) can be connected to each other by a rotational movement, wherein, in the connected state: at least a portion of the lateral tongue (404B) of the first plate (400B) is inserted into the third groove (404A) of the adjacent second plate (400A), and wherein at least a portion of the upward locking element (406A) of the second plate (400A) is inserted into the second downward groove (406B) of the first plate (400B).

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