Wear-resistant panel for building panels and method for producing such wear-resistant panel

Abstract

A method of producing a wear plate (10), the method comprising: providing a first foil (11); applying a second foil (12) over the first foil (11); applying a third foil (13) over the second foil (12); applying a wear-resistant layer (21) to the first foil (11) and / or the second foil (12) prior to applying the second foil (12) over the first foil (11); applying a wear-resistant layer (22) on the second foil (12) and / or the third foil (13) prior to applying the third foil (13) over the second foil (12); and attaching together the first foil (11), the second foil (12) and the third foil (13) by means of heating and pressing to form the wear plate (10), wherein the wear layers (21, 22) are arranged between the first and second foils (11, 12) and between the second and third foils (12, 13).

Description

Field of the Invention

[0001] The present invention relates to the field of building panels, wear-resistant plates for such building panels, and methods of producing such wear-resistant plates and building panels. Background Art

[0002] In recent years, so-called luxury vinyl tiles and planks (LVT) have become increasingly successful. These types of floor panels typically include a thermoplastic core, a thermoplastic decorative layer disposed on the core, a transparent wear-resistant layer on the decorative layer, and a coating applied on the wear-resistant layer. The thermoplastic material is typically PVC. The wear-resistant layer is typically a PVC foil having a thickness of, for example, 0.2 - 0.7 mm. The coating applied on the wear-resistant layer is typically a UV-cured polyurethane coating. The wear-resistant layer and the coating together provide the wear resistance of the floor panel and protect the decorative layer.

[0003] However, when the floor panel is worn, it has been shown that the coating and the wear-resistant layer are relatively easily worn, or at least the wear affects the appearance of the wear-resistant layer, such as having scratches and / or no longer being transparent. Compared with traditional laminated floor panels, the wear resistance of LVT floor panels is poor. However, LVT floors offer several advantages over, for example, laminated floors, such as deep embossing, humidity-related dimensional stability, moisture resistance, and sound absorption properties.

[0004] Therefore, there is a desire to provide an LVT product having improved wear resistance and / or improved appearance characteristics. Summary of the Invention

[0005] An object of at least embodiments of the present inventive concept is to provide an improvement over the known art. This object can be achieved by the technology defined in the appended independent claims; certain embodiments are set forth in the relevant dependent claims.

[0006] In a first aspect of the present inventive concept, there is provided a method of producing a wear-resistant plate, comprising:

[0007] providing a first foil comprising a thermoplastic material;

[0008] applying a second foil comprising a thermoplastic material above the first foil;

[0009] applying a third foil comprising a thermoplastic material above the second foil;

[0010] applying a wear-resistant layer comprising wear-resistant particles on the first foil and / or the second foil before applying the second foil above the first foil;

[0011] applying a wear-resistant layer comprising wear-resistant particles on the second foil and / or the third foil before applying the third foil above the second foil; and

[0012] The first foil, the second foil, and the third foil are attached together by heating and pressing to form a wear-resistant plate, wherein a wear-resistant layer is disposed between the first foil and the second foil and between the second foil and the third foil.

[0013] The wear-resistant layer containing wear-resistant particles can be applied in the form of powder, fluid, paste, sheet, or in the form of a mixture with, for example, an adhesive.

[0014] The wear-resistant layer can be applied by spreading, rolling, or any other suitable application method.

[0015] In one embodiment, before applying the second foil, the wear-resistant layer between the first foil and the second foil is applied to the first foil, for example, by spreading. In an alternative embodiment, before applying the second foil to the first foil, the wear-resistant layer is applied to the second foil, for example, by spreading.

[0016] Furthermore, before applying the third foil, the wear-resistant layer between the second foil and the third foil can be applied to the second foil, for example, by spreading. Alternatively, the wear-resistant layer can be applied to the third foil, for example, by spreading, before applying the third foil to the second foil.

[0017] In one embodiment of the inventive concept, each wear-resistant layer can contain at least 99 wt% of wear-resistant particles, or at least 99.5 wt% of wear-resistant particles.

[0018] In one embodiment, the wear-resistant particles are selected from alumina / aluminum oxide, quartz, diamond, diamond powder, boron nitride, garnet, glass, glass beads, feldspar, silicon carbide, boron carbide, granite, or a combination thereof.

[0019] In one embodiment, the wear-resistant particles are alumina / aluminum oxide particles.

[0020] In another embodiment, after attaching the foils together, the wear-resistant particles disposed between the first foil and the second foil are contained / enclosed / surrounded within the first foil and the second foil at least in a direction substantially parallel to the thickness of the foil or in a direction substantially perpendicular to the longitudinal extension direction of the foil, and the wear-resistant particles disposed between the second foil and the third foil are contained / enclosed / surrounded within the second foil and the third foil at least in a direction substantially parallel to the thickness of the foil or in a direction substantially perpendicular to the longitudinal extension direction of the foil. After attaching the foils together, the wear-resistant particles disposed between the first foil and the second foil can be fixedly enclosed therein, and the wear-resistant particles disposed between the second foil and the third foil can be fixedly enclosed therein. Fixedly enclosing means that the wear-resistant particles cannot move or detach from the foil after the manufacturing process.

[0021] Alternatively, after the foils are attached together, none of the wear-resistant particles disposed between the second foil and the third foil protrude from the third foil.

[0022] The wear-resistant particles may mainly have, i.e., at least 94% of the wear-resistant particles have a particle size within 53 μm to 102 μm, which may correspond to a particle size of 180 according to the well-known FEPA standard.

[0023] In one embodiment, the wear-resistant layer applied between the first foil and the second foil is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0024] Furthermore, the wear-resistant layer applied between the second foil and the third foil may be applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0025] In a preferred embodiment, the amounts of the wear-resistant layers between the first foil and the second foil and between the second foil and the third foil are substantially equal.

[0026] In addition, the total amount of the wear-resistant layers applied between the first foil and the second foil and between the second foil and the third foil may be 10 - 60 g / m 2 、15 - 50 g / m 2 or 20 - 40 g / m 2 .

[0027] In one embodiment, the first foil, the second foil, and / or the third foil comprises any one of 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.

[0028] The foil may comprise at least 50 wt% of a thermoplastic material, at least 60 wt% of a thermoplastic material, or at least 70 wt% of a thermoplastic material.

[0029] The first foil, the second foil, and the third foil may each have a thickness of 20 - 500 μm or 50 - 200 μm. Alternatively, the first foil, the second foil, and the third foil may have a thickness of at least 20 μm or at least 50 μm. In one embodiment, the thickness of each foil is the same. Alternatively, the thicknesses of these foils may be different.

[0030] The average particle size of the wear-resistant particles can be less than the thickness of the top foil, where in this embodiment, the top foil is the third foil. The average particle size of the wear-resistant particles can be greater than the thickness of the third foil. However, during pressing, the wear-resistant particles are pressed into the first and second foils such that the wear-resistant particles do not protrude beyond the upper surface of the third foil after pressing, even though the wear-resistant particles have an average particle size exceeding the thickness of the third foil.

[0031] The ratio between the particle size of the wear-resistant particles and the thickness of the top foil can be less than 1.5:1.

[0032] The ratio between the particle size of the wear-resistant particles and the thickness of the first foil can be less than 1.5:1.

[0033] The ratio between the particle size of the wear-resistant particles and the thickness of the second foil can be less than 1.5:1.

[0034] The ratio between the particle size of the wear-resistant particles and the thickness of the third foil can be less than 1.5:1.

[0035] The ratio between the particle size of the wear-resistant particles and the thickness of any foil can be less than 1.5:1.

[0036] The method can further include applying scratch-resistant particles in the top wear-resistant layer, where in one embodiment, the top wear-resistant layer is between the second and third foils. The scratch-resistant particles can be or include nano-sized silica particles, preferably fused silica particles. The scratch-resistant particles can be or include alumina / aluminum oxide. Having scratch-resistant particles at least in the top wear-resistant layer can reduce the risk of deep scratches on the top surface.

[0037] Furthermore, although the wear-resistant plate as described above includes three foils and two wear-resistant layers, it is possible and sometimes desirable to have additional foils and wear-resistant layers to form such a wear-resistant plate. The method steps of applying the wear-resistant layer and applying the foils shown are then repeated as needed multiple times.

[0038] In one embodiment, the step of attaching the first, second, and third foils together by heating and pressing to form the wear-resistant plate is achieved by a combined heating and pressing process, preferably by a lamination process. The lamination process can be a static process or a continuous process, such as a calendering process.

[0039] In addition, the attachment of the foils to form the wear-resistant plate can be carried out in a single step.

[0040] The step of attaching the foils together can be carried out at a temperature of 50 - 300 °C, such as 50 - 220 °C, such as 75 - 180 °C and a pressure of 1 - 100 bar, such as 1 - 50 bar, such as 1 - 30 bar for 3 - 500 seconds, such as 5 - 300 seconds, such as 5 - 100 seconds.

[0041] In one embodiment, the attachment of the foil may be carried out in a process where heat and pressure are each applied separately.

[0042] Alternatively, the attachment of the foil may be carried out in a process where heat and pressure are applied at least instantaneously simultaneously. The time for applying heat and pressure simultaneously can be as short as 0.1 second.

[0043] The step of attaching the foils together may further include cooling the wear-resistant plate.

[0044] The step of attaching the foils together may further include cooling the wear-resistant plate before releasing the pressure from the wear-resistant plate.

[0045] In another embodiment, the attachment of the foil may be carried out in a static press, such as a Multidaylight press. For such a static press, the time can be much longer than the above examples, such as 10 - 20 minutes or longer. If such a static press is used, the attachment process may further include a cooling process.

[0046] In one embodiment of the inventive concept, the method step of attaching the foils together according to any of the above methods may be a pre - lamination where the wear-resistant plates are not completely laminated together. The complete lamination of the wear-resistant plates is carried out in a subsequent lamination, in which the wear-resistant plates are applied on, for example, a substrate and laminated together to form a building panel. Such a subsequent lamination and the method of forming a building panel are introduced below.

[0047] In a second aspect of the inventive concept, there is provided a method of producing a building panel, the method comprising:

[0048] Providing a substrate;

[0049] Applying the wear-resistant plate produced by any of the above embodiments above the substrate;

[0050] Attaching the substrate and the wear-resistant plate together by heating and pressurizing to form a building panel.

[0051] In one embodiment, the method further includes applying a decorative layer between the substrate and the wear-resistant plate by heating and pressurizing before attaching the substrate and the wear-resistant plate together.

[0052] The decorative layer of the building panel may be a colored powder layer, paper, polymer-based sheet, wood-based sheet, wood veneer, cork-based sheet, or woven or non-woven fabric. The decorative layer may also be a printed layer, such as a printed polymer-based sheet or a printed layer above the substrate.

[0053] In one embodiment, the step of attaching the substrate and the wear-resistant plate together by heating and pressurization to form a building panel is achieved by a combined heating and pressurization process, preferably by a lamination process. The lamination process can be one or more static processes or continuous processes, such as a calendering process.

[0054] In addition, attaching at least the substrate and the wear-resistant plate together to form a building panel can be carried out in a single step.

[0055] The step of attaching at least the substrate and the wear-resistant plate can be carried out at a temperature of 50 - 300 °C, such as 50 - 220 °C, such as 75 - 180 °C and a pressure of 1 - 100 bar, such as 1 - 50 bar, such as 1 - 30 bar for 3 - 500 seconds, such as 5 - 300 seconds, such as 5 - 100 seconds.

[0056] In one embodiment, the attachment of at least the substrate and the wear-resistant plate can be carried out in a process where heat and pressure are applied separately.

[0057] Alternatively, the attachment of at least the substrate and the wear-resistant plate can be carried out in a process where heat and pressure are applied at least instantaneously simultaneously. The time for applying heat and pressure simultaneously can be as short as 0.1 second.

[0058] The step of attaching at least the substrate and the wear-resistant plate together may further include cooling the building panel.

[0059] The step of attaching at least the substrate and the wear-resistant plate together may further include cooling the building panel before releasing the pressure from the building panel.

[0060] In another embodiment, the attachment of at least the substrate and the wear-resistant plate can be carried out in a static press, such as a multi-layer press. For such a static press, the time can be much longer than the above examples, such as 10 - 20 minutes or longer. If such a static press is used, the attachment process may further include a cooling process.

[0061] In a third aspect of the inventive concept, there is provided a method of producing a building panel, the method comprising:

[0062] Providing a substrate;

[0063] Applying a first foil containing a thermoplastic material above the substrate;

[0064] Applying a second foil containing a thermoplastic material above the first foil;

[0065] Applying a third foil containing a thermoplastic material above the second foil;

[0066] Applying a wear-resistant layer containing wear-resistant particles on the first foil and / or the second foil before applying the second foil above the first foil;

[0067] Before applying the third foil above the second foil, apply a wear-resistant layer containing wear-resistant particles on the second foil and / or the third foil; and

[0068] Attach the substrate, the first foil, the second foil, and the third foil together by heating and pressing to form a building panel, wherein the wear-resistant layer is disposed between the first foil and the second foil and between the second foil and the third foil.

[0069] The wear-resistant layer containing wear-resistant particles can be applied in the form of powder, fluid, paste, sheet, or in the form of a mixture with, for example, an adhesive.

[0070] The wear-resistant layer can be applied by spreading, rolling, or any other suitable application method.

[0071] In one embodiment, before applying the second foil, the wear-resistant layer between the first foil and the second foil is applied to the first foil, for example, by spreading. In an alternative embodiment, before applying the second foil to the first foil, the wear-resistant layer is applied to the second foil, for example, by spreading.

[0072] Furthermore, before applying the third foil, the wear-resistant layer between the second foil and the third foil can be applied to the second foil, for example, by spreading. Alternatively, the wear-resistant layer can be applied to the third foil, for example, by spreading before the third foil is applied to the second foil.

[0073] Preferably, each wear-resistant layer can contain at least 99 wt% of wear-resistant particles, or at least 99.5 wt% of wear-resistant particles.

[0074] In one embodiment, the wear-resistant particles are selected from alumina / aluminum oxide, quartz, diamond, diamond powder, boron nitride, almandine, glass, glass beads, feldspar, silicon carbide, boron carbide, granite, or a combination thereof.

[0075] In one embodiment, the wear-resistant particles are alumina / aluminum oxide particles.

[0076] Furthermore, after attaching the foils together, the wear-resistant particles disposed between the first foil and the second foil are at least contained / enclosed / surrounded / encapsulated within the first foil and the second foil in a direction substantially parallel to the thickness of the foils, and the wear-resistant particles disposed between the second foil and the third foil are at least contained / enclosed / surrounded within the second foil and the third foil in a direction substantially parallel to the thickness of the foils. After attaching the foils together, the wear-resistant particles disposed between the first foil and the second foil can be fixedly enclosed therein, and the wear-resistant particles disposed between the second foil and the third foil can be fixedly enclosed therein. Fixedly enclosing means that the wear-resistant particles cannot move or detach from the foils after the manufacturing process.

[0077] Alternatively, after the foils are attached together, none of the wear-resistant particles disposed between the second and third foils protrude from the third foil.

[0078] The wear-resistant particles may mainly have, i.e., at least 94% of the wear-resistant particles have a particle size within 53 μm to 102 μm, which may correspond to a particle size of 180 according to the well-known FEPA standard.

[0079] In one embodiment, the wear-resistant layer applied between the first and second foils is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0080] In addition, the wear-resistant layer applied between the second and third foils may be applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0081] In a preferred embodiment, the amounts of the wear-resistant layers between the first and second foils and between the second and third foils are substantially equal.

[0082] In addition, the total amount of the wear-resistant layers applied between the first and second foils and between the second and third foils may be 10 - 60 g / m 2 、15 - 50 g / m 2 or 20 - 40 g / m 2 .

[0083] In one embodiment, the first foil, the second foil, and / or the third foil comprises any one of 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.

[0084] The foil may comprise at least 50 wt% of a thermoplastic material, at least 60 wt% of a thermoplastic material, or at least 70 wt% of a thermoplastic material.

[0085] Each of the first foil, the second foil, and the third foil may have a thickness of 20 - 500 μm or 50 - 200 μm. Alternatively, the first foil, the second foil, and the third foil may have a thickness of at least 20 μm or at least 50 μm.

[0086] In one embodiment, each foil has the same thickness. Alternatively, the foils may have different thicknesses.

[0087] The average particle size of the wear-resistant particles may be less than the thickness of the topmost foil, which in this embodiment is the third foil. The average particle size of the wear-resistant particles may be greater than the thickness of the third foil. However, during pressing, the wear-resistant particles are pressed into the first and second foils such that the wear-resistant particles do not protrude beyond the upper surface of the third foil after pressing, even though the wear-resistant particles have an average particle size greater than the thickness of the third foil.

[0088] The ratio between the particle size of the wear-resistant particles and the thickness of the topmost foil may be less than 1.5:1.

[0089] The ratio between the particle size of the wear-resistant particles and the thickness of the first foil may be less than 1.5:1.

[0090] The ratio between the particle size of the wear-resistant particles and the thickness of the second foil may be less than 1.5:1.

[0091] The ratio between the particle size of the wear-resistant particles and the thickness of the third foil may be less than 1.5:1.

[0092] The ratio between the particle size of the wear-resistant particles and the thickness of any foil may be less than 1.5:1.

[0093] The method may further include applying scratch-resistant particles in the topmost wear-resistant layer, which in one embodiment is between the second and third foils. The scratch-resistant particles may be or include nano-sized silica particles, preferably fused silica particles. The scratch-resistant particles may be or include alumina / aluminum oxide. Having scratch-resistant particles at least in the topmost wear-resistant layer can reduce the risk of deep scratches on the top surface.

[0094] In one embodiment, the method further includes applying a decorative layer between the substrate and the first foil before attaching at least the substrate and the foil together by heating and pressing.

[0095] The decorative layer of the building panel may be a colored powder layer, paper, polymer-based board, wood-based board, wood veneer, cork-based board, or woven or non-woven fabric. The decorative layer may also be a printed layer, such as a printed polymer-based board or a printed layer above the substrate.

[0096] In one embodiment, the step of attaching the substrate and the wear-resistant plate together by heating and pressing to form a building panel is achieved by a combined heating and pressing process, preferably by a lamination process. The lamination process may be one or more static processes or continuous processes, such as a calendering process.

[0097] In addition, attaching at least the substrate and the wear-resistant plate together to form a building panel can be carried out in a single step.

[0098] The step of attaching at least the substrate and the wear-resistant plate can be carried out at a temperature of 50 - 300 °C, such as 50 - 220 °C, such as 75 - 180 °C and a pressure of 1 - 100 bar, such as 1 - 50 bar, such as 1 - 30 bar for 3 - 500 seconds, such as 5 - 300 seconds, such as 5 - 100 seconds.

[0099] In one embodiment, the attachment of at least the substrate and the wear-resistant plate can be carried out during a process in which heat and pressure are applied separately.

[0100] Alternatively, the attachment of at least the substrate and the wear-resistant plate can be carried out during a process in which heat and pressure are applied instantaneously at least simultaneously. The time for applying heat and pressure simultaneously can be as short as 0.1 second.

[0101] The step of attaching at least the substrate and the wear-resistant plate together may further include cooling the building panel.

[0102] The step of attaching at least the substrate and the wear-resistant plate together may further include cooling the building panel before releasing the pressure from the building panel.

[0103] In another embodiment, the attachment of at least the substrate and the wear-resistant plate can be carried out in a static press, such as a multi-layer press. For such a static press, the time can be much longer than the above examples, such as 10 - 20 minutes or longer. If such a static press is used, the attachment process may further include a cooling process.

[0104] In one embodiment, the substrate 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.

[0105] In one embodiment, the substrate can be foamed.

[0106] In addition, the substrate can be a single-layer substrate or a multi-layer substrate.

[0107] In a fourth aspect of the inventive concept, there is provided a method for producing a building panel, the method comprising:

[0108] providing a substrate;

[0109] applying a first foil containing a thermoplastic material above the substrate;

[0110] applying a second foil containing a thermoplastic material above the first foil;

[0111] Before applying the first foil above the substrate, an abrasion-resistant layer containing abrasion-resistant particles is applied on the substrate and / or the first foil;

[0112] Before applying the second foil above the first foil, an abrasion-resistant layer containing abrasion-resistant particles is applied on the first foil and / or the second foil; and

[0113] The substrate, the first foil, and the second foil are attached together by heating and pressing to form a building panel, wherein the abrasion-resistant layer is disposed between the substrate, the first foil, and the second foil.

[0114] The abrasion-resistant layer containing abrasion-resistant particles can be applied in the form of powder, fluid, paste, sheet, or in the form of a mixture with, for example, an adhesive.

[0115] The abrasion-resistant layer can be applied by spreading, rolling, or any other suitable application method.

[0116] In one embodiment, before applying the first foil, the abrasion-resistant layer between the substrate and the first foil is applied to the substrate, for example, by spreading. In an alternative embodiment, before applying the first foil above the substrate, the abrasion-resistant layer is applied to the first foil, for example, by spreading.

[0117] In addition, before applying the second foil, the abrasion-resistant layer between the first foil and the second foil can be applied to the first foil, for example, by spreading. Alternatively, the abrasion-resistant layer can be applied to the second foil, for example, by spreading, before applying the second foil to the first foil.

[0118] Preferably, each abrasion-resistant layer can contain abrasion-resistant particles in an amount of at least 99 wt%, or at least 99.5 wt%.

[0119] In one embodiment, the abrasion-resistant particles are selected from alumina / aluminum oxide, quartz, diamond, diamond powder, boron nitride, garnet, glass, glass beads, feldspar, silicon carbide, boron carbide, granite, or a combination thereof.

[0120] In one embodiment, the abrasion-resistant particles are alumina / aluminum oxide particles.

[0121] In addition, after the foils are attached together, the wear-resistant particles disposed between the substrate and the first foil can be enclosed therein / the substrate and the first foil at least in a direction substantially parallel to the thickness of the foil, and the wear-resistant particles disposed between the first foil and the second foil can be enclosed therein / the first foil and the second foil at least in a direction substantially parallel to the thickness of the foil. After the foils are attached together, the wear-resistant particles disposed between the substrate and the first foil can be fixedly enclosed therein, and the wear-resistant particles disposed between the first foil and the second foil can be fixedly enclosed therein. Fixedly enclosing means that the wear-resistant particles cannot move or detach from the foil after the manufacturing process.

[0122] Alternatively, after the foils are attached together, none of the wear-resistant particles disposed between the first foil and the second foil protrude from the second foil.

[0123] The wear-resistant particles may mainly have, i.e., at least 94% of the wear-resistant particles have a particle size within 53 μm to 102 μm, which may correspond to a grit size of 180 according to the well-known FEPA standard.

[0124] In one embodiment, the wear-resistant layer applied between the substrate and the first foil is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0125] In addition, the wear-resistant layer applied between the first foil and the second foil can be applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0126] In a preferred embodiment, the amounts of the wear-resistant layers between the substrate and the first foil and between the first foil and the second foil are substantially equal.

[0127] In addition, the total amount of the wear-resistant layers applied between the substrate and the first foil and between the first foil and the second foil can be 10 - 60 g / m 2 、15 - 50 g / m 2 or 20 - 40 g / m 2 .

[0128] In one embodiment, the first foil and / or the second foil comprises any one of polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, and combinations thereof.

[0129] The foil may comprise at least 50 wt% of a thermoplastic material, at least 60 wt% of a thermoplastic material or at least 70 wt% of a thermoplastic material.

[0130] The first and second foils may each have a thickness of 20 - 500 μm or 50 - 200 μm. Alternatively, the first and second foils may have a thickness of at least 20 μm or at least 50 μm.

[0131] In one embodiment, the thickness of each foil is the same. Alternatively, the thicknesses of the foils may be different.

[0132] The average particle size of the wear-resistant particles may be less than the thickness of the topmost foil, where in this embodiment, the topmost foil is the second foil. The average particle size of the wear-resistant particles may be greater than the thickness of the second foil. However, during pressing, the wear-resistant particles may be pressed into the substrate and the first foil such that the wear-resistant particles do not protrude beyond the upper surface of the second foil after pressing, even though the wear-resistant particles have an average particle size exceeding the thickness of the second foil.

[0133] The ratio between the particle size of the wear-resistant particles and the thickness of the topmost foil may be less than 1.5:1.

[0134] The ratio between the particle size of the wear-resistant particles and the thickness of the first foil may be less than 1.5:1.

[0135] The ratio between the particle size of the wear-resistant particles and the thickness of the second foil may be less than 1.5:1.

[0136] The ratio between the particle size of the wear-resistant particles and the thickness of any foil may be less than 1.5:1.

[0137] The method may further comprise applying scratch-resistant particles in the topmost wear-resistant layer, where in one embodiment, the topmost wear-resistant layer is located between the first and second foils. The scratch-resistant particles may be or comprise silica particles of nanoscale size, preferably fused silica particles. The scratch-resistant particles may be or comprise alumina / aluminum oxide. Having scratch-resistant particles at least in the topmost wear-resistant layer may reduce the risk of deep scratches on the top surface.

[0138] In one embodiment, the method further comprises applying a decorative layer between the substrate and the wear-resistant layer before attaching at least the substrate and the foil together by heating and pressing.

[0139] The decorative layer of the building panel may be a colored powder layer, paper, polymer-based board, wood-based board, wood veneer, cork-based board, or woven or non-woven fabric. The decorative layer may also be a printed layer, such as a printed polymer-based board or a printed layer above the substrate.

[0140] In one embodiment, the step of attaching the substrate and the foil together by means of heating and pressing to form a building panel is achieved by a combined heating and pressing process, preferably a lamination process. The lamination process can be one or more static processes or continuous processes, such as a calendering process.

[0141] In addition, the attachment of at least the substrate and the wear-resistant plate together to form a building panel can be carried out in a single step.

[0142] The step of attaching at least the substrate and the wear-resistant plate can be carried out at a temperature of 50 - 300 °C, such as 50 - 220 °C, such as 75 - 180 °C and a pressure of 1 - 100 bar, such as 1 - 50 bar, such as 1 - 30 bar for 3 - 500 seconds, such as 5 - 300 seconds, such as 5 - 100 seconds.

[0143] In one embodiment, the attachment of at least the substrate and the wear-resistant plate can be carried out in a process where heat and pressure are applied separately.

[0144] Alternatively, the attachment of at least the substrate and the wear-resistant plate can be carried out in a process where heat and pressure are applied at least instantaneously simultaneously. The time for applying heat and pressure simultaneously can be as short as 0.1 second.

[0145] The step of attaching at least the substrate and the wear-resistant plate together may further include cooling the building panel.

[0146] The step of attaching at least the substrate and the wear-resistant plate together may further include cooling the building panel before releasing the pressure from the building panel.

[0147] In another embodiment, the attachment of at least the substrate and the wear-resistant plate can be carried out in a static press, such as a multi-layer press. For such a static press, the time can be much longer than the above examples, such as 10 - 20 minutes or longer. If such a static press is used, the attachment process may further include a cooling process.

[0148] In one embodiment, the substrate 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.

[0149] In one embodiment, the substrate can be foamed.

[0150] In addition, the substrate can be a single-layer substrate or a multi-layer substrate.

[0151] In a fifth aspect of the inventive concept, there is provided a wear-resistant plate comprising:

[0152] a first foil containing a thermoplastic material;

[0153] A second foil comprising a thermoplastic material;

[0154] A third foil comprising a thermoplastic material;

[0155] A wear-resistant layer containing wear-resistant particles disposed between the first foil and the second foil; and

[0156] A wear-resistant layer containing wear-resistant particles disposed between the second foil and the third foil.

[0157] In one embodiment of the inventive concept, each wear-resistant layer comprises wear-resistant particles in an amount of at least 99 wt%, or at least 99.5 wt%.

[0158] In one embodiment, the wear-resistant particles are selected from alumina / aluminum oxide, quartz, diamond, diamond powder, boron nitride, almandine, glass, glass beads, feldspar, silicon carbide, boron carbide, granite, or a combination thereof.

[0159] In one embodiment, the wear-resistant particles are alumina / aluminum oxide particles.

[0160] In another embodiment, the wear-resistant particles disposed between the first foil and the second foil are enclosed therein / the first and second foils at least in a direction substantially parallel to the thickness of the foil, and the wear-resistant particles disposed between the second foil and the third foil are enclosed therein / the second and third foils at least in a direction substantially parallel to the thickness of the foil. The wear-resistant particles disposed between the first foil and the second foil can be fixedly enclosed therein, and the wear-resistant particles disposed between the second foil and the third foil can be fixedly enclosed therein. Fixedly enclosing means that the wear-resistant particles cannot move or detach from the foil after the manufacturing process.

[0161] Alternatively, none of the wear-resistant particles disposed between the second foil and the third foil protrude from the third foil.

[0162] The wear-resistant particles may predominantly have, i.e., at least 94% of the wear-resistant particles have a particle size within 53 μm to 102 μm, which may correspond to a particle size of 180 according to the well-known FEPA standard.

[0163] In one embodiment, the wear-resistant layer disposed between the first foil and the second foil is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 of the amount.

[0164] In addition, the wear-resistant layer disposed between the second foil and the third foil can be 5 - 30 g / m 2, in an amount of 7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0165] In a preferred embodiment, the amount of the wear-resistant layer between the first foil and the second foil and between the second foil and the third foil is substantially equal.

[0166] In addition, the total amount of the wear-resistant layer disposed between the first foil and the second foil and between the second foil and the third foil can be 10 - 60 g / m 2 , 15 - 50 g / m 2 or 20 - 40 g / m 2 .

[0167] In one embodiment, the first foil, the second foil, and / or the third foil comprises any one of polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, and combinations thereof.

[0168] The foil may comprise at least 50 wt% of a thermoplastic material, at least 60 wt% of a thermoplastic material, or at least 70 wt% of a thermoplastic material.

[0169] The first foil, the second foil, and the third foil may each have a thickness of 20 - 500 μm or 50 - 200 μm. Alternatively, the first foil, the second foil, and the third foil may have a thickness of at least 20 μm or at least 50 μm.

[0170] In one embodiment, the thickness of each foil is the same. Alternatively, the thicknesses of the foils may be different.

[0171] The average particle size of the wear-resistant particles may be less than the thickness of the topmost foil, in this embodiment, the topmost foil is the third foil. The average particle size of the wear-resistant particles may be greater than the thickness of the third foil. However, during pressing, the wear-resistant particles are pressed into the first foil and the second foil such that the wear-resistant particles do not protrude beyond the upper surface of the third foil after pressing, although the wear-resistant particles have an average particle size exceeding the thickness of the third foil.

[0172] The ratio between the particle size of the wear-resistant particles and the thickness of the topmost foil may be less than 1.5:1.

[0173] The ratio between the particle size of the wear-resistant particles and the thickness of the first foil may be less than 1.5:1.

[0174] The ratio between the particle size of the wear-resistant particles and the thickness of the second foil may be less than 1.5:1.

[0175] The ratio between the particle size of the wear-resistant particles and the thickness of the third foil may be less than 1.5:1.

[0176] The ratio between the particle size of the wear-resistant particles and the thickness of any foil may be less than 1.5:1.

[0177] The wear-resistant plate may further include scratch-resistant particles in the uppermost wear-resistant layer. In one embodiment, the uppermost wear-resistant layer is between the second foil and the third foil. The scratch-resistant particles may be or include nano-sized silica particles, preferably fused silica particles. The scratch-resistant particles may be or include alumina / aluminum oxide. Having scratch-resistant particles at least in the uppermost wear-resistant layer can reduce the risk of generating deep scratches in the top surface.

[0178] In a sixth aspect of the inventive concept, there is provided a building panel including:

[0179] A substrate; and

[0180] A wear-resistant plate according to any of the above embodiments disposed above the substrate.

[0181] In one embodiment, the substrate includes 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.

[0182] In one embodiment, the substrate may be foamed.

[0183] In another embodiment, the building panel further includes a decorative layer disposed between the substrate and the wear-resistant plate.

[0184] The decorative layer of the building panel may be a colored powder layer, paper, polymer-based sheet, wood-based sheet, wood veneer, cork-based sheet, or woven or non-woven fabric. The decorative layer may also be a printed layer, such as a printed polymer-based sheet or a printed layer above the substrate.

[0185] In a seventh aspect of the inventive concept, there is provided a building panel including:

[0186] A substrate;

[0187] A first foil including a thermoplastic material disposed above the substrate;

[0188] A second foil including a thermoplastic material disposed above the first foil;

[0189] A wear-resistant layer including wear-resistant particles disposed between the substrate and the first foil; and

[0190] A wear-resistant layer containing wear-resistant particles disposed between a first foil and a second foil.

[0191] In one embodiment of the inventive concept, each wear-resistant layer contains wear-resistant particles in an amount of at least 99 wt%, or at least 99.5 wt%.

[0192] In one embodiment, the wear-resistant particles are selected from alumina / aluminum oxide, quartz, diamond, diamond powder, boron nitride, almandine, glass, glass beads, feldspar, silicon carbide, boron carbide, granite, or a combination thereof.

[0193] In one embodiment, the wear-resistant particles are alumina / aluminum oxide particles.

[0194] In another embodiment, the wear-resistant particles disposed between the substrate and the first foil are enclosed therein / the substrate and the first foil at least in a direction substantially parallel to the thickness of the foil or in a direction substantially perpendicular to the longitudinal extension direction of the foil, and the wear-resistant particles disposed between the first foil and the second foil are enclosed therein / the first foil and the second foil at least in a direction substantially parallel to the thickness of the foil or in a direction substantially perpendicular to the longitudinal extension direction of the foil. The wear-resistant particles disposed between the substrate and the first foil can be fixedly enclosed therein, and the wear-resistant particles disposed between the first foil and the second foil can be fixedly enclosed therein. Fixedly enclosing means that the wear-resistant particles cannot move or detach from the foil after the manufacturing process.

[0195] Alternatively, none of the wear-resistant particles disposed between the first foil and the second foil protrude from the second foil.

[0196] The wear-resistant particles may mainly have, i.e., at least 94% of the wear-resistant particles have a particle size within 53 μm to 102 μm, which may correspond to a particle size of 180 according to the well-known FEPA standard.

[0197] In one embodiment, the wear-resistant layer disposed between the substrate and the first foil is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 of the amount.

[0198] In addition, the wear-resistant layer disposed between the first foil and the second foil can be applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 of the amount.

[0199] In a preferred embodiment, the amounts of the wear-resistant layers between the substrate and the first foil and between the first foil and the second foil are substantially equal.

[0200] In addition, the total amount of the wear-resistant layer disposed between the substrate and the first foil and between the first foil and the second foil may be 10 - 60 g / m 2 , 15 - 50 g / m 2 or 20 - 40 g / m 2 .

[0201] In one embodiment, the first foil and / or the second foil comprises any one of polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, and combinations thereof.

[0202] The foil may comprise at least 50 wt% of a thermoplastic material, at least 60 wt% of a thermoplastic material or at least 70 wt% of a thermoplastic material.

[0203] The first foil and the second foil may each have a thickness of 20 - 500 μm or 50 - 200 μm. Alternatively, the first foil and the second foil may have a thickness of at least 20 μm or at least 50 μm.

[0204] In one embodiment, the thickness of each foil is the same. Alternatively, the thicknesses of the foils may be different.

[0205] The average particle size of the wear-resistant particles may be less than the thickness of the topmost foil, which in this embodiment is the second foil. The average particle size of the wear-resistant particles may be greater than the thickness of the second foil. However, during pressing, the wear-resistant particles may be pressed into the substrate and the first foil such that the wear-resistant particles do not protrude beyond the upper surface of the second foil after pressing, even though the wear-resistant particles have an average particle size exceeding the thickness of the second foil.

[0206] The ratio between the particle size of the wear-resistant particles and the thickness of the topmost foil may be less than 1.5:1.

[0207] The ratio between the particle size of the wear-resistant particles and the thickness of the first foil may be less than 1.5:1.

[0208] The ratio between the particle size of the wear-resistant particles and the thickness of the second foil may be less than 1.5:1.

[0209] The ratio between the particle size of the wear-resistant particles and the thickness of any foil may be less than 1.5:1.

[0210] The building panel may also include scratch-resistant particles in the uppermost wear layer. In one embodiment, the uppermost wear layer is between a first foil and a second foil. The scratch-resistant particles may be or include nano-sized silica particles, preferably fused silica particles. The scratch-resistant particles may be or include alumina / aluminum oxide. Having scratch-resistant particles at least in the uppermost wear layer can reduce the risk of deep scratches being generated in the top surface. In one embodiment, the substrate 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.

[0211] In one embodiment, the substrate may be foamed.

[0212] In another embodiment, the building panel further includes a decorative layer disposed between the substrate and the wear layer.

[0213] The decorative layer of the building panel may be a colored powder layer, paper, polymer-based sheet, wood-based sheet, wood veneer, cork-based sheet, or a woven or non-woven fabric. The decorative layer may also be a printed layer, such as a printed polymer-based sheet or a printed layer over the substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0214] Embodiments of the inventive concept will be described below: With reference to the accompanying drawings, which illustrate non-limiting embodiments of how the inventive concept may be put into practice.

[0215] Figure 1 is a schematic view of a method of manufacturing a wear-resistant plate according to an embodiment of the inventive concept;

[0216] Figure 2A and 2B is a schematic view of a method of manufacturing a wear-resistant plate according to another embodiment of the inventive concept;

[0217] Figure 3 is a schematic side view of a cross-section of a wear-resistant plate according to an embodiment of the inventive concept;

[0218] Figure 4 is a schematic view of a method of manufacturing a building panel according to an embodiment of the inventive concept;

[0219] Figure 5 is a schematic side view of a cross-section of a building panel according to an embodiment of the inventive concept;

[0220] Figure 6A and 6BSchematic diagram of a method for producing a building panel according to another embodiment of the inventive concept;

[0221] Figure 7 is with Figure 6A and 6B Schematic side view of a cross-section of a building panel produced by the method in;

[0222] Figure 8A and 8B Schematic diagram of a method for producing a building panel according to yet another embodiment of the inventive concept;

[0223] Figure 9 is with Figure 8A and 8B Schematic side view of a cross-section of a building panel produced by the method in; and

[0224] Figure 10 is a graph showing the results of wear tests. DETAILED DESCRIPTION

[0225] Specific embodiments of the inventive concept will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. The terms used in the detailed description of the embodiments shown in the drawings are not intended to limit the invention. In the drawings, like reference numerals denote like elements.

[0226] Generally, in the present disclosure, terms such as "below" or "lower" typically mean closer to the back surface or plane of the panel, while "above" or "upper" means closer to the front surface or plane of the panel. In addition, the thickness direction of the panel is defined as the vertical direction when the panel is lying flat on a surface. The horizontal and vertical directions are definitions applicable when the building panel is lying flat on, for example, a floor. In addition to the horizontal and vertical directions, the description will also refer to a direction parallel to the extension direction of the decorative surface and a direction perpendicular to the extension direction of the decorative surface. When the building panel is lying flat on, for example, a floor, the horizontal direction is the same as the direction parallel to the extension direction of the decorative surface, and the vertical direction is the same as the direction perpendicular to the extension direction of the decorative surface.

[0227] Referring to the accompanying drawings, a method for producing a wear-resistant plate 10 and a building panel 1, as well as such a wear-resistant plate 10 and a building panel 1, are shown. The wear-resistant plate 10 is a plate suitable for, for example, the building panel 1. Such a building panel 1 may be a floor panel, a wall panel, a furniture component, or the like.

[0228] Figure 1 A first possible method for producing the wear-resistant plate 10 is shown. The method includes:

[0229] Provide a first foil 11;

[0230] Apply a first wear-resistant layer 21 on the first foil 11;

[0231] Apply a second foil 12 above the first foil 11;

[0232] Apply a second wear-resistant layer 22 on the second foil 12;

[0233] Apply a third foil 13 above the second foil 12; and

[0234] Attach the first foil 11, the second foil 12 and the third foil 13 together by means of heating and pressing to form a wear-resistant plate 10. The first wear-resistant layer 21 and the second wear-resistant layer 22 are respectively disposed between the first foil 11 and the second foil 12, and between the second foil 12 and the third foil 13.

[0235] As shown in the figure, the first wear-resistant layer 21 and the second wear-resistant layer 22 are spread onto the corresponding foils 11, 12 by spreading devices 31, 32. The wear-resistant layer can be a powder layer, such as a loose powder layer. However, the wear-resistant layer can be applied in the form of powder, fluid, paste, sheet or in the form of a mixture with, for example, an adhesive.

[0236] In addition, the wear-resistant layer can be applied by spreading, rolling or any other suitable application method.

[0237] As shown in the figure, before the second foil 12 is applied above the first foil 11, the first wear-resistant layer 21 is applied to the surface of the first foil 11, wherein after the second foil 12 has been applied above the first foil 11, this surface of the first foil 11 faces the second foil 12. However, in an alternative embodiment, the first wear-resistant layer 21 can be applied to the surface of the second foil 12 before the second foil 12 is applied above the first foil 11, wherein after the second foil 12 has been applied above the first foil 11, this surface of the second foil 12 faces the first foil 11.

[0238] In addition, the second wear-resistant layer 22 is shown as being applied to the surface of the second foil 12 before the third foil 13 is applied above the second foil 12, wherein after the third foil 13 has been applied above the second foil 12, this surface of the second foil 12 faces the third foil 13. However, in some alternative embodiments, the second wear-resistant layer 22 can be applied to the surface of the third foil 13 before the third foil 13 is applied above the second foil 12, wherein after the third foil 13 has been applied above the second foil 12, this surface of the third foil 13 faces the second foil 12.

[0239] In another alternative embodiment, a plurality of foils are pre-spread with a wear-resistant layer. Then, the pre-spread foils are applied to each other in a desired multi-layer form, such as any one of 4-10 layers of foils.

[0240] Although the drawings mainly show an embodiment in which the wear-resistant plate includes three foils and two wear-resistant layers, it is possible and sometimes desirable to have more foils and wear-resistant layers to form such a wear-resistant plate. The method steps of spreading the wear-resistant layer and applying the foils shown are then repeated as many times as desired, for example, to apply any one of 4-10 layers of foils.

[0241] After the foils 11, 12 are attached together, the wear-resistant particles of the wear-resistant layer 21 disposed between the first foil 11 and the second foil 12 are enclosed therein / in the first and second foils at least in a direction substantially parallel to the thickness of the foils 11, 12 or in a direction substantially perpendicular to the longitudinal extension direction of the foils. The same applies to the wear-resistant particles of the wear-resistant layer 22 disposed between the second foil 12 and the third foil 13. After the foils 12, 13 are attached together, the wear-resistant particles of the wear-resistant layer 22 disposed between the second foil 12 and the third foil 13 are enclosed therein / in the second and third foils at least in a direction substantially parallel to the thickness of the foils 12, 13 or in a direction substantially perpendicular to the longitudinal extension direction of the foils. During the manufacturing process, the pressing plate is preferably a flat pressing plate without structural parts, which does not allow the wear-resistant particles to protrude above the uppermost surface of the uppermost foil during pressing, that is, the uppermost surface of the uppermost foil becomes flat after pressing, and there are no unevennesses in the uppermost surface.

[0242] The first wear-resistant layer 21 applied between the first foil 11 and the second foil 12 is applied in an amount of 5-30 g / m 2 preferably in an amount of 7.5-25 g / m 2 or even more preferably in an amount of 10-20 g / m 2 The second wear-resistant layer 22 applied between the second foil 12 and the third foil 13 is applied in an amount of 5-30 g / m 2 preferably in an amount of 7.5-25 g / m 2 or even more preferably in an amount of 10-20 g / m 2 The amounts of the wear-resistant layers 21, 22 between the first foil 11 and the second foil 12 and between the second foil 12 and the third foil 13 are preferably substantially equal. However, in a number of other embodiments, it may be preferred to have different amounts of wear-resistant layers to form the wear-resistant plate 10. For example, compared with other layers, the top wear-resistant layer may include 50% to 75% of the total amount of the wear-resistant layer.

[0243] The total amount of wear-resistant layers 21, 22 applied between foils 11, 12, 13 of the wear-resistant plate 10 is 10 - 60 g / m 2 , preferably 15 - 50 g / m 2 , or even more preferably 20 - 40 g / m 2 .

[0244] Each wear-resistant layer 21, 22 contains wear-resistant particles 24. The wear-resistant particles can be alumina / aluminum oxide particles (AlO3). Each wear-resistant layer 21, 22 contains at least 99 wt% of wear-resistant particles, or at least 99.5 wt% of wear-resistant particles. The remaining amount of the wear-resistant layer can contain, for example, stabilizers, binders, or different product enhancers for improving processability and usability.

[0245] In one embodiment, the wear-resistant layer is not a glass fiber layer, a glass mesh layer, or a glass sail layer. In one embodiment, the wear-resistant layer is not a non-woven fiber layer.

[0246] After foils 11, 12 are attached together, the wear-resistant particles 24 arranged between the first foil 11 and the second foil 12 are enclosed in the first and second foils at least in a direction substantially parallel to the foil thickness, and preferably even fixedly enclosed therein. Fixedly enclosing means that after the manufacturing process, the wear-resistant particles cannot move or detach from foils 11, 12.

[0247] Furthermore, after foils 12, 13 are attached together, the wear-resistant particles 24 arranged between the second foil 12 and the third foil 13 are enclosed in the second and third foils at least in a direction substantially parallel to the foil thickness, and preferably even fixedly enclosed therein. Fixedly enclosing means that after the manufacturing process, the wear-resistant particles cannot move or detach from foils 12, 13. By being enclosed therein, after foils 12, 13 are attached together, at least the wear-resistant particles 24 arranged between the second foil 12 and the third foil 13 do not protrude from the third foil 13, and more specifically, no wear-resistant particles 24 protrude from the upper surface of the third foil 13, where after foils 12, 13 are attached together, the upper surface of the third foil 13 faces away from the second foil 12. As described above, during the manufacturing process, the pressing plate is preferably a flat pressing plate without structural parts, which does not allow wear-resistant particles to protrude above the uppermost surface of the uppermost foil during pressing, that is, the uppermost surface of the uppermost foil becomes flat after pressing, and there are no irregularities in the uppermost surface.

[0248] Each foil 11, 12, 13 of the wear-resistant plate contains a thermoplastic material selected from one or more of 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.

[0249] The first foil 11, the second foil 12, and the third foil 13 each have a preferred thickness of 20 - 300 μm or 50 - 200 μm. Foil with an even greater thickness may be possible, but the preferred range of applications of the wear-resistant plate 10 described herein is as above. The foils 11, 12, 13 forming the wear-resistant plate 10 may have the same or different thicknesses. For example, for building panels assembled into a floor in a domestic environment, it is preferred that the top foil may be thinner, for example 50% thinner, than the foil arranged below, as this can enhance the visual appearance and decoration of the building panel. Another example is that, for example, for building panels assembled into a floor in public and commercial environments, it is preferred that the top foil may be thicker, for example 50% thicker, than the foil arranged below, as this can enhance the wear resistance and surface resistance of the building panel.

[0250] The method step of attaching the foils together can be carried out by a combined pressing and heating process 34 or a process in which pressure and heat are carried out separately. The method step of attaching the foils together is preferably carried out by a lamination or pre-lamination process, which can be a static process or a continuous process. An example of a static process can be a multi-layer press, and an example of a continuous process can be a calendering process with calender rolls, each calendering roll laminating the foils together. In addition, the heating part of such a process 34 can be achieved by a single heating device heating from one direction or a dual heating device heating from two opposite directions.

[0251] The step of attaching the foils together can be carried out at a temperature of 50 - 300 °C, for example 50 - 220 °C, for example 75 °C and 180 °C, and a pressure of 1 - 100 bar, for example 1 - 50 bar, for example 1 - 30 bar for 3 - 500 seconds, for example 5 - 300 seconds, for example 5 - 100 seconds. If the step of attaching the foils together is achieved by a continuous lamination process, the possible process speed can be 1 - 50 m / min, or 2 - 30 m / min.

[0252] The method steps of attaching the foils together can be a pre - lamination, i.e., where the wear - resistant plates are not fully laminated together, and where, compared to the main lamination process of manufacturing the wear - resistant plates and / or building panels, the pre - lamination is defined by lower pressure, lower temperature, and shorter process time. The purpose of this pre - lamination is to lock the particles to the foils without achieving full lamination of the foils, in order to simplify the handling of the wear - resistant plates for the subsequent main lamination process. The full lamination of the wear - resistant plates can be carried out during a subsequent lamination, where the wear - resistant plates are applied on, for example, a substrate and laminated together to form a building panel. The method of this subsequent lamination and forming the building panel is introduced below.

[0253] Figure 2A and 2B shows an alternative embodiment of the method of producing the wear - resistant plate 10, where Figure 2B the steps in Figure 2A are a continuation of the steps shown in Figure 1 The embodiment shown in Figure 2A and 2B differs from Figure 2A and 2B in that there is an additional attachment step between the application of the second foil 12 and the spreading of the second wear - resistant layer 22. That is,

[0254] providing a first foil 11;

[0255] applying a first wear - resistant layer 21 on the first foil 11;

[0256] applying a second foil 12 above the first foil 11;

[0257] attaching the first foil 11 and the second foil 12 together by heating and pressing;

[0258] applying a second wear - resistant layer 22 on the second foil 12,

[0259] applying a third foil 13 above the second foil 12; and

[0260] attaching the third foil 13 to the second foil 12 by heating and pressing to form the wear - resistant plate 10. The first wear - resistant layer 21 and the second wear - resistant layer 22 are respectively disposed between the first foil 11 and the second foil 12 and between the second foil 12 and the third foil 13.

[0261] The method steps of attaching the foils together by means of heating and pressing can be carried out by one or more combined pressing / pressurizing and heating processes 34, 34b or processes where heating and pressing are carried out separately. The method steps of attaching the foils together are preferably carried out by one or more lamination or pre-lamination processes, which can be a static process or a continuous process. Examples of a static process can be a multi-layer press, and an example of a continuous process can be a calendering process with calender rolls, each calendering roll laminating the foil layers together. In addition, the heating part of such processes 34a, 34b can be achieved by a single heating device heating from one direction or a double heating device heating from two opposite directions.

[0262] The step of attaching the foils together can be carried out at a temperature of 50 - 300 °C, for example 50 - 220 °C, for example 75 - 180 °C and a pressure of 1 - 100 bar, for example 1 - 50 bar, for example 1 - 30 bar for 3 - 500 seconds, for example 5 - 300 seconds, for example 5 - 100 seconds. If the step of attaching the foils together is achieved by a continuous lamination process, the possible process speed can be 1 - 50 m / min, or 2 - 30 m / min.

[0263] The method step of attaching the foils together can be a pre-lamination where the wear-resistant plates are not fully laminated together. The full lamination of the wear-resistant plates can be carried out during a subsequent lamination, where the wear-resistant plates are applied on, for example, a substrate and laminated together to form a building panel. This subsequent lamination and the method of forming a building panel are described below.

[0264] Figure 3It is a detailed schematic diagram of the wear-resistant plate 10, which is produced, for example, by any of the aforementioned methods. The wear-resistant plate 10 includes three foils 11, 12, 13 and two wear-resistant layers 21, 22. Each wear-resistant layer 21, 22 is encapsulated / surrounded by two foils 11, 12, 13 disposed therebetween. Each wear-resistant layer 21, 22 contains wear-resistant particles 24. In one embodiment, the wear-resistant particles 24 are completely surrounded / enclosed by the foils 11, 12, 13 at least in a direction substantially parallel to the thickness of the foils. In one embodiment, the wear-resistant particles are completely surrounded / enclosed by the foils 11 and 13 and are preferably fixedly enclosed. Fixedly enclosing means that after the manufacturing process, the wear-resistant particles cannot move or detach from the foils 12, 13. Preferably, no wear-resistant particles 24 protrude from either of the two outer foils (the first foil 11 and the third foil 13). Thus, the wear-resistant plate 10 can be disposed on the substrate 3 of the building panel 1, with the first foil 11 or the third foil 13 facing the substrate 3. As described above, during the manufacturing process, the pressing plate is preferably a flat pressing plate without structural parts, which does not allow the wear-resistant particles to protrude above the uppermost surface of the uppermost foil during pressing, that is, the uppermost surface of the uppermost foil becomes flat after pressing, and there are no irregularities in the uppermost surface.

[0265] As described above, the amounts of the wear-resistant layers 21, 22 between the first foil 11 and the second foil 12 and between the second foil 12 and the third foil 13 are preferably substantially equal. However, in a number of other embodiments, it may be preferred to have different amounts of wear-resistant layers to form the wear-resistant plate 10.

[0266] Although the drawings mainly show an embodiment in which the wear-resistant plate 10 includes three foils and two wear-resistant layers, it is possible and sometimes desirable to have even more foils and wear-resistant layers to form such a wear-resistant plate.

[0267] Figure 4 A method for producing a building panel 1 having such a wear-resistant plate 10 is shown, and the building panel 1 is schematically shown in Figure 5 as follows. The method includes:

[0268] Providing a substrate 3;

[0269] Applying a decorative layer 5;

[0270] Applying the wear-resistant plate 10; and

[0271] Attaching the substrate 3, the decorative layer 5 and the wear-resistant plate 10 together by heating and pressing to form the building panel 1.

[0272] The substrate 3 can be a single-layer substrate or a multi-layer substrate. In addition, the substrate 3 can comprise a polymer-based material, where the polymer-based material can be a thermoplastic material. The thermoplastic material can be selected from the group including the following: polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), polyethylene (PE), polystyrene (PS), polypropylene (PP), polycarbonate (PC), polyvinyl acetate (PVAc), ethylene-vinyl acetate (EVA), polyacrylate methyl methacrylate, polymethyl methacrylate (PMMA), acrylonitrile butadiene styrene (ABS), thermoplastic polyurethane (TPU), and / or combinations thereof. The substrate 3 can comprise a thermoplastic material in an amount of at least 10 wt%, at least 15 wt% or at least 20 wt%. The substrate 3 can comprise a thermoplastic material in an amount of 10-60 wt%, 15-50 wt% or 20-30 wt%.

[0273] The substrate 3 based on a thermoplastic material can comprise 30-90 wt%, 40-85 wt% or 50-80 wt% of a filler. The filler can be an organic filler or an inorganic filler.

[0274] The substrate 3 can further comprise a thermosetting material, such as epoxy resin, polyurethane, crosslinked polyethylene (PEX), aminoplastics, phenoplastics, acrylates, and / or combinations thereof. The substrate 3 based on a thermosetting material can comprise 10-70 wt%, 20-60 wt% or 25-50 wt% of a thermosetting resin, such as aminoplastics, polyurethane, phenoplastics, epoxy resin or acrylate resin.

[0275] The substrate 3 based on a thermosetting material can further comprise 1-70 wt%, 10-70 wt% or 20-70 wt% of a filler. The filler can be an organic filler or an inorganic filler.

[0276] The substrate 3 can further comprise a mineral-based material, such as magnesium oxide (MgO), magnesium chloride (MgCl2), magnesium sulfate (MgSO4) or sand. The substrate 3 based on a mineral-based material can comprise at least 50 wt%, at least 60 wt%, at least 70 wt% or at least 80 wt% of the mineral-based material. The substrate 3 based on these types of mineral materials can further comprise 1-20 wt% or 5-15 wt% of a filler, which is an organic filler or an inorganic filler. Another suitable mineral-based material is, for example, Portland cement. The substrate material based on this type of mineral material can be called a fiber cement board and can further comprise sand and / or 1-20 wt% or 5-15 wt% of a filler.

[0277] The filler of the substrate 3 may include at least one or more of organic fillers, inorganic fillers, or a combination thereof. Examples of organic fillers are wood flour and rice husk. These types of organic fillers are generally low in cost and easily available. The substrate may contain 1-70 wt% organic filler, or 30-70 wt% organic filler. Examples of inorganic fillers are calcium carbonate (CaCO3), barium sulfate (BaSO4), talc, and / or combinations thereof. These types of fillers are particularly cost-effective and easily available.

[0278] The substrate may further contain a plasticizer selected from phthalates, terephthalates, aliphatic compounds, cyclohexanecarboxylates, adipates, trimellitates, polyol esters, and other substances such as DOTP (dioctyl terephthalate), DEHP, DOA, DINP, DOP, ATBC, TOTM, or The substrate material forming the substrate may contain 1-30 wt% or 2-15 wt% of the plasticizer.

[0279] For this type of application, a typical SPC substrate preferably used may contain 10-40 wt%, 15-35 wt% or 20-30 wt% of a thermoplastic material such as PVC. The SPC substrate may further contain 50-90 wt%, 60-80 wt% or 65-75 wt% of an inorganic filler such as chalk. The SPC substrate may further contain 0-20 wt%, 1-15 wt% or 2-10 wt% of additives such as impact modifiers, stabilizers, lubricants, and / or pigments.

[0280] A typical LVT substrate also preferably used for this type of application will have a material content similar to that of the above SPC substrate, i.e., 10-40 wt%, 15-35 wt% or 20-30 wt% of a thermoplastic material, 50-90 wt%, 60-80 wt% or 65-75 wt% of an inorganic filler, and 0-20 wt%, 1-15 wt% or 2-10 wt% of additives, but with 1-20 wt%, 2-15 wt% or 3-10 wt% of a plasticizer added.

[0281] The decorative layer 5 of the building panel 1 may be a colored powder layer, paper, polymer-based sheet, wood-based sheet, wood veneer, cork-based sheet, or woven or non-woven fabric. The decorative layer 5 may also be a printed polymer-based sheet.

[0282] The wear-resistant plate 10 is substantially transparent, such that when the decorative layer 5 is disposed below the wear-resistant layer 10 in the finished building panel 1, its appearance is not affected. The surprising advantage of the wear-resistant plate 10 having two or more wear-resistant layers 21, 22 as described above, compared to a wear-resistant plate having the same amount of wear-resistant particles but disposed in a single layer, is that the opacity of the wear-resistant plate 10 is affected. Scattering the same amount of wear-resistant particles 24 between at least two wear-resistant layers 21, 22 makes the wear-resistant plate less cloudy, i.e., more transparent, compared to having the same amount of wear-resistant particles in a single wear-resistant layer. This means that the appearance of the decorative layer 5 disposed below the wear-resistant plate 10 is improved by having two or more wear-resistant layers 21, 22.

[0283] The method steps of attaching the wear-resistant plate 10, the decorative layer 5, and the substrate 3 together by heating and pressure to form the building panel 1 can be carried out by one or more combined pressing and heating processes 34 or one or more processes in which heating and pressing are carried out separately. The method steps are preferably carried out by one or more lamination or pre-lamination processes, which can be static processes or continuous processes. Examples of static processes can be multi-layer presses, and examples of continuous processes can be calendering processes with calender rolls that laminate foil layers together. In addition, the heating part of such a process 34 can be achieved by a single heating device heating from one direction or a dual heating device heating from two opposite directions.

[0284] The step of attaching the wear-resistant plate 10, the decorative layer 5, and the substrate 3 together to form the building panel 1 can be carried out at a temperature of 50 - 300 °C, such as 50 - 220 °C, such as 75 °C and 180 °C, and a pressure of 1 - 100 bar, such as 1 - 50 bar, such as 1 - 30 bar for 3 - 500 seconds, such as 5 - 300 seconds, such as 5 - 100 seconds. If the step of attaching the foil layers together is achieved by a continuous lamination process, the possible process speed can be 1 - 50 m / min, or 2 - 30 m / min.

[0285] The method step of attaching the foil layers together to form the wear-resistant plate 10 can be a pre-lamination in which the wear-resistant plate is not fully laminated together. The full lamination of the wear-resistant plate can be carried out during a subsequent lamination in which the wear-resistant plate is applied on the substrate 3 and / or the decorative layer 5 and laminated together to form the building panel.

[0286] Figure 4 A method is shown in which the finished wear-resistant plate 10 is disposed on the decorative layer 5 and the substrate 3, while Figure 6A and 6BSchematically shown is a method in which the wear-resistant plate 10 is pressed while forming the building panel 1. All features, characteristics and embodiments of the above method, the substrate 3, the decorative layer 5, the foils 11, 12, 13 and the wear-resistant layers 21, 22 are also applicable to this alternative embodiment of the method for producing the building panel 1.

[0287] As Figure 6A and 6B shown, the method comprises:

[0288] Providing the substrate 3;

[0289] Applying the decorative layer 5 on the substrate 3;

[0290] Applying the first foil 11 on the decorative layer 3;

[0291] Applying the first wear-resistant layer 21 on the first foil 11;

[0292] Applying the second foil 12 above the first foil 11;

[0293] Applying the second wear-resistant layer 22 on the second foil 12;

[0294] Applying the third foil 13 above the second foil 12; and

[0295] Attaching the first foil 11, the second foil 12, the third foil 13, the decorative layer 5 and the substrate 3 together by means of heating and pressing to form the building panel 1. The first wear-resistant layer 21 and the second wear-resistant layer 22 are respectively disposed between the first foil 11 and the second foil 12 and between the second foil 12 and the third foil 13.

[0296] The method steps of attaching the foils 11, 12, 13, the wear-resistant layers 21, 22, the decorative layer 5 and the substrate 3 together by means of heating and pressing to form the building panel 1 can be carried out by one or more combined pressing / pressurizing and heating processes 34 or one or more processes in which the pressurizing and heating are carried out separately. These method steps are preferably carried out by one or more laminating or pre-laminating processes, which can be static processes or continuous processes. Examples of static processes can be multi-layer presses, and examples of continuous processes can be calendering processes with calender rolls that laminate the foils together. In addition, the heating part of such a process 34 can be achieved by a single heating device heating from one direction or a double heating device heating from two opposite directions.

[0297] The steps of attaching the foils 11, 12, 13, the wear-resistant layers 21, 22, the decorative layer 5 and the substrate 3 together to form the building panel 1 can be carried out at a temperature of 50 - 300 °C, such as 50 - 220 °C, such as 75 °C and 180 °C and a pressure of 1 - 100 bar, such as 1 - 50 bar, such as 1 - 30 bar for a time of 3 - 500 seconds, such as 5 - 300 seconds, such as 5 - 180 seconds. If the step of attaching the foils together is achieved by a continuous lamination process, the possible process speed can be 1 - 50 m / min or 2 - 30 m / min.

[0298] If there are multiple processes, the method step of attaching the foils together can be a pre-lamination where the foils are not fully laminated together. The full lamination of the wear-resistant plate can be carried out during a subsequent lamination, in which the pre-laminated wear-resistant plate is applied to the substrate 3 and / or the decorative layer 5 and laminated together to form the building panel 1.

[0299] Figure 7 is made of Figure 6A and 6B Schematic view of the building panel 1 produced by the method shown.

[0300] Figure 8A and 8B shows a further embodiment of the method of producing a building panel 1 according to the inventive concept, and Figure 9 schematically shows such a building panel 1. The difference from the previously described embodiment is that the first wear-resistant layer 21 is directly applied or spread on the decorative layer 5 instead of on the first foil. The first foil 11' of this embodiment is instead applied above the first wear-resistant layer 21. Furthermore, the second wear-resistant layer 22 is then applied or spread onto the first foil 11', and then the second foil 12' is applied above the second wear-resistant layer 22. Then, the second foil 12' will form the topmost layer of the building panel 1, as Figure 8A 、 8B and 9 show. Of course, even more foils and wear-resistant layers can be applied to form a building panel suitable for a specific application, having, for example, any one of a total of 2 - 10 foil layers.

[0301] All the features and characteristics of the above-mentioned substrate, decorative layer, foils and wear-resistant layers also apply to this alternative embodiment.

[0302] Therefore, as Figure 8A and 8B shown, the method includes:

[0303] Providing a substrate 3;

[0304] Applying a first foil 11' above the substrate 3;

[0305] Apply a second foil 12' above the first foil 11'.

[0306] Apply a wear-resistant layer 21 on the substrate 3 and / or the first foil 11' before applying the first foil 11' above the substrate 3.

[0307] Apply a wear-resistant layer 22 on the first foil 11' and / or the second foil 12' before applying the second foil 12' above the first foil 11'; and

[0308] Attach the substrate 3, the first foil 11' and the second foil 12' together by means of heating and pressing to form a building panel 1. The wear-resistant layers 21, 22 are respectively disposed between the substrate 3 and the first foil 11', and between the first foil 11' and the second foil 12'.

[0309] The method steps of attaching the foils 11', 12', the wear-resistant layers 21, 22, the decorative layer 5 and the substrate 3 together to form the building panel 1 can be carried out by one or more combined pressing and heating processes 34 or one or more processes in which pressing and heating are carried out separately. These method steps are preferably carried out by one or more laminating or pre-laminating processes, which can be static processes or continuous processes. Examples of static processes can be multi-layer presses, and examples of continuous processes can be calendering processes with calender rolls that laminate the foils together. In addition, the heating part of such a process 34 can be achieved by a single heating device heating from one direction or a double heating device heating from two opposite directions.

[0310] The step of attaching the foils 11', 12', the wear-resistant layers 21, 22, the decorative layer 5 and the substrate 3 together to form the building panel 1 can be carried out at a temperature of 50 - 300 °C, such as 50 - 220 °C, such as 75 °C and 180 °C, and a pressure of 1 - 100 bar, such as 1 - 50 bar, such as 1 - 30 bar for a time of 3 - 500 seconds, such as 5 - 300 seconds, such as 5 - 100 seconds. If the step of attaching the foils together is achieved by a continuous lamination process, the possible process speed can be 1 - 50 m / min, or 2 - 30 m / min.

[0311] If there are multiple processes, the method steps of attaching the foils together (which can be, in this embodiment, attaching the first foil 11', the second foil 12' and the second wear-resistant layer 22 together before applying the first foil 11', the second foil 12' and the second wear-resistant layer 22 to the substrate 3 having the first wear-resistant layer 21 and possibly the decorative layer 5) can be of a pre-lamination type, where the foils are not fully laminated together. The full lamination of the foils forming the wear-resistant plate can be carried out during a subsequent lamination, in which the pre-laminated wear-resistant plate, the substrate 3 and / or the decorative layer 5 are laminated together to form the building panel 1.

[0312] Multiple embodiments of the present disclosure include wear-resistant plates, such as wear-resistant plates produced by any of the embodiments disclosed herein, wherein the wear-resistant plates have a wear resistance of at least 4000 revolutions, such as at least 4800 revolutions, such as at least 4900 revolutions, such as at least 5600 revolutions, such as at least 5700 revolutions, such as at least 5800 revolutions, such as at least 6000 revolutions, such as at least 6500 revolutions, such as at least 7000 revolutions, such as at least 7400 revolutions, which is obtained from a wear test performed according to the EN13329:2016+A2:2021 standard using a Taber Abraser. To determine the wear resistance, the wear-resistant plate can be on a substrate, such as on a substrate and a decorative layer. The substrate can be based on a thermoplastic material, such as a luxury vinyl tile (LVT), a stone polymer composite (SPC), a wood polymer composite (WPC), or an expanded polymer composite (EPC) substrate or the like. The decorative layer can be based on polyvinyl chloride (PVC), polypropylene (PP), or polyethylene (PE) or the like.

[0313] Examples

[0314] For the following samples, the wear-resistant plates have been produced and obtained with the following components:

[0315] - A standard PVC-based foil with a PHR (parts per hundred rubber) of 28, which is for example from or

[0316] - The wear-resistant layer has at least 99 wt% alumina / aluminum oxide particles.

[0317] For the reference sample, two foils were used, one with a thickness of 0.1 mm and the other with a thickness of 0.2 mm. Different amounts of the wear-resistant layer were applied between the foils.

[0318] For the samples according to the inventive concept, three foils were used, each having the same thickness of 0.1 mm. A wear-resistant layer was applied between the first and the second foils, and a wear-resistant layer was applied between the second and the third foils. The amounts of the wear-resistant layers arranged between the first and the second layers and between the second and the third layers were equal, but the total amount of the wear-resistant layer was different in each sample.

[0319] Before pressing and heating to form sample panels with different types of wear-resistant plates on top, the foils and the wear-resistant layers of the reference samples and the samples according to the inventive concept were respectively arranged above a substrate, which was a substrate based on a thermoplastic material. In addition, a decorative layer was arranged between the substrate and the first foil of the wear-resistant plate. The same type of decorative layer with the same decorative pattern was used for all the following samples.

[0320] Then, the sample panels with the substrate, the decorative layer, and different wear-resistant plates were formed by a continuous pressing device through heating and pressing for 60 seconds. The temperature in the pressing plate of the pressing device was 150 °C, and the pressure was 15 bar.

[0321] Two tests were conducted on each sample, a wear test after the sample panel was formed and a test on the appearance of the decorative layer.

[0322] Test 1 - Wear Test

[0323] According to EN 13329:2016+A2:2021, the wear test was carried out using a Taber abrasion tester. Table 1 gives the results of the reference sample, i.e., the sample with a substrate, a decorative layer, two foils (F), and one wear-resistant layer (WRL) between the foils. Table 2 gives the results of the samples according to the inventive concept, i.e., the samples with a substrate, a decorative layer, three foils, and two wear-resistant layers. A chart comparing the results between the reference sample and the samples according to the inventive concept can be seen in Figure 10 in.

[0324] Table 1: Wear Test - Reference Sample

[0325] Wear Test – Reference Sample Sample Structure with Foil (F) and Wear Resistant Layer (WRL) Number of Revolutions RS1 <![CDATA[F of 0.1 mm + 10 g / m 2 of WRL + F of 0.2 mm]]> 3900 RS2 <![CDATA[F of 0.1mm + 20g / m 2 of WRL + F of 0.2mm]]> 4300 RS3 <![CDATA[F of 0.1mm + 30g / m 2 of WRL + F of 0.2mm]]> 4800 RS4 <![CDATA[F of 0.1 mm + 40 g / m 2 of WRL + F of 0.2 mm]]> 5500

[0326] Table 2: Wear Test - Samples According to the Inventive Concept

[0327]

[0328] The conclusion of the above wear test is that there is no significant difference in the wear resistance characteristics of the building panels between the wear-resistant plates with two foils and one wear-resistant layer and the wear-resistant plates with three foils and two wear-resistant layers. This conclusion was expected but needed to be proven.

[0329] Test 2 - Appearance Test

[0330] The appearance test was carried out by observing the samples RS1 - RS3 and S1 - S5 from different angles of 10°, 30°, 45° and 90° relative to the horizontal plane. Then each sample was rated based on the grades shown in Table 3.

[0331] Table 3: Appearance Test - Grade Definition

[0332]

[0333] The color performance is defined by the decorative layer. As described above, the grades are set according to how the decorative layer appears when the sample is viewed from different angles from the observer's perspective. The difference in rating depends on how the decorative layer, color and pattern are presented to the observer, preferably simulating how the observer perceives the building panel when the building panel is installed as part of, for example, a floor, wall panel or furniture. The reference samples RS1 - RS3 are compared with the samples S1 - S5 according to the inventive concept. Of particular interest is the comparison of different samples having the same total amount of wear-resistant layer, i.e., comparing RS1 with S1, RS2 with S3, RS3 with S4, and RS4 with S5. The grade of each sample can be seen in Table 4 below.

[0334] Table 4: Sample Grades

[0335] Appearance Test - Sample Grade RS1 B RS2 B RS3 B RS4 C S1 A S2 A S3 A S4 A S5 B S6 B

[0336] When comparing the reference samples and the samples according to the inventive concept, the appearance test gave some surprising results. The results tell us that rather than setting a certain amount of wear-resistant layer in one layer, spreading that certain amount of wear-resistant layer between two layers has less impact on the appearance of the decorative layer. One possible explanation for this surprising effect is that when the amount of wear-resistant layer is spread between two layers, fewer or smaller clusters of wear-resistant particles are formed. Another possible explanation for this surprising effect is that since the amount of wear-resistant particles is arranged in at least two layers that are separately arranged between two foils, the concentration of wear-resistant particles in each layer is reduced, resulting in more openings between the particles, i.e., the wear-resistant particles are more dispersed, which allows an increase in the light transmittance of the decorative layer, contributing to more optimized visual properties.

[0337] From the above tests, it can be concluded that when it comes to the appearance of the decorative layer of a building panel and how the observer perceives the building panel without compromising the wear resistance of the wear-resistant plate of the building panel, it is beneficial to have a building panel with multiple wear-resistant layers and more foils, where each wear-resistant layer is arranged between two foils.

[0338] Finally, although the concepts of the present invention have been described above with reference to multiple specific embodiments, the present invention is not limited to the specific forms set forth herein. On the contrary, the present invention is only limited by the appended claims. Within the scope of the appended claims, other embodiments besides the above specific embodiments are equally possible. All embodiments can be used alone or in combination. Angles, dimensions, rounded portions, the spacing between surfaces, etc. are merely examples and can be adjusted within the basic principles of the present invention.

[0339] Item part

[0340] Item 1. A method for producing a wear-resistant plate (10), comprising:

[0341] Providing a first foil (11) comprising a thermoplastic material;

[0342] Applying a second foil (12) comprising a thermoplastic material above the first foil (11);

[0343] Applying a third foil (13) comprising a thermoplastic material above the second foil (12);

[0344] Applying a wear-resistant layer (21) on the first foil (11) and / or the second foil (12) before applying the second foil (12) above the first foil (11);

[0345] Applying a wear-resistant layer (22) on the second foil (12) and / or the third foil (13) before applying the third foil (13) above the second foil (12); and

[0346] Attaching the first foil (11), the second foil (12), and the third foil (13) together by heating and pressing to form a wear-resistant plate (10), wherein the wear-resistant layers (21, 22) are provided between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13).

[0347] Item 2. The method according to Item 1, wherein the wear-resistant layer (21) applied between the first foil (11) and the second foil (12) is spread on the first foil (11) before applying the second foil (12).

[0348] Item 3. The method according to Item 1 or 2, wherein the wear-resistant layer (22) applied between the second foil (12) and the third foil (13) is spread on the second foil (12) before applying the third foil (13).

[0349] Item 4. The method according to any one of the preceding items, wherein each wear-resistant layer (21, 22) comprises wear-resistant particles (24).

[0350] Item 5. The method according to Item 4, wherein each wear-resistant layer (21, 22) comprises at least 99 wt% of wear-resistant particles, or at least 99.5 wt% of wear-resistant particles.

[0351] Item 6. The method according to Item 4 or 5, wherein the wear-resistant particles (24) are alumina / aluminum oxide particles.

[0352] Item 7. The method according to any one of Items 4-6, wherein after the foils (11, 12, 13) are attached together, the wear-resistant particles (24) disposed between the first foil (11) and the second foil (12) are enclosed in the first foil and the second foil, and the wear-resistant particles (24) disposed between the second foil (12) and the third foil (13) are enclosed in the second foil and the third foil.

[0353] Item 8. The method according to any one of Items 4-7, wherein after the foils (11, 12, 13) are attached together, none of the wear-resistant particles (24) disposed between the second foil (12) and the third foil (13) protrude from the third foil (13).

[0354] Item 9. The method according to any one of the preceding items, wherein the wear-resistant layer (21) applied between the first foil (11) and the second foil (12) is applied in an amount of 5-30 g / m 2 、7.5-25 g / m 2 or 10-20 g / m 2 of the amount.

[0355] Item 10. The method according to any one of the preceding items, wherein the wear-resistant layer (22) applied between the second foil (12) and the third foil (13) is applied in an amount of 5-30 g / m 2 、7.5-25 g / m 2 or 10-20 g / m 2 of the amount.

[0356] Item 11. The method according to any one of the preceding items, wherein the amounts of the wear-resistant layers (21, 22) between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13) are substantially equal.

[0357] Item 12. The method according to any one of the preceding items, wherein the first foil (11), the second foil (12) and / or the third foil (13) 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.

[0358] Item 13. The method according to any one of the preceding items, wherein the first foil (11), the second foil (12) and the third foil (13) each have a thickness of 20 - 300 μm or 50 - 200 μm.

[0359] Item 14. A method of producing a building panel (1), comprising:

[0360] providing a substrate (3);

[0361] applying a wear-resistant plate (10) produced by the method according to any one of Items 1 - 11 above the substrate (3);

[0362] attaching the substrate (3) and the wear-resistant plate (10) together by heating and pressing to form a building panel (1).

[0363] Item 15. A method of producing a building panel (1), comprising:

[0364] providing a substrate (3);

[0365] applying a first foil (11) comprising a thermoplastic material above the substrate (3);

[0366] applying a second foil (12) comprising a thermoplastic material above the first foil (11);

[0367] applying a third foil (13) comprising a thermoplastic material above the second foil (12);

[0368] applying a wear-resistant layer (21) on the first foil (11) and / or the second foil (12) before applying the second foil (12) above the first foil (11);

[0369] applying a wear-resistant layer (22) on the second foil (12) and / or the third foil (13) before applying the third foil (13) above the second foil (12); and

[0370] The substrate (3), the first foil (11), the second foil (12) and the third foil (13) are attached together by means of heating and pressing to form a building panel (1), wherein wear-resistant layers (21, 22) are provided between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13).

[0371] Item 16. The method according to item 15, wherein the wear-resistant layer (21) applied between the first foil (11) and the second foil (12) is spread on the first foil (11) before the second foil (12) is applied.

[0372] Item 17. The method according to item 15 or 16, wherein the wear-resistant layer (22) applied between the second foil (12) and the third foil (13) is spread on the second foil (12) before the third foil (13) is applied.

[0373] Item 18. The method according to any one of items 15 - 17, wherein each wear-resistant layer (21, 22) comprises wear-resistant particles (24).

[0374] Item 19. The method according to item 18, wherein each wear-resistant layer (21, 22) comprises at least 99 wt% of wear-resistant particles, or at least 99.5 wt% of wear-resistant particles.

[0375] Item 20. The method according to item 18 or 19, wherein the wear-resistant particles (24) are alumina / aluminum oxide particles.

[0376] Item 21. The method according to any one of items 18 - 20, wherein after the foils (11, 12, 13) are attached together, the wear-resistant particles (24) arranged between the first foil (11) and the second foil (12) are enclosed in the first and second foils, and the wear-resistant particles (24) arranged between the second foil (12) and the third foil (13) are enclosed in the second and third foils.

[0377] Item 22. The method according to any one of items 18 - 21, wherein after the substrate and the foils () are attached together, none of the wear-resistant particles () arranged between the second foil () and the third foil () protrude from the third foil ().

[0378] Item 23. The method according to any one of items 15 - 22, wherein the wear-resistant layer (21) applied between the first foil (11) and the second foil (12) is at 5 - 30 g / m 2, 7.5 - 25 g / m 2 or 10 - 20 g / m 2 in an amount of.

[0379] Item 24. The method according to any one of Items 15 - 23, wherein the wear-resistant layer (32) applied between the second foil (12) and the third foil (13) is in an amount of 5 - 30 g / m 2 , 7.5 - 25 g / m 2 or 10 - 20 g / m 2 in an amount of.

[0380] Item 25. The method according to any one of Items 15 - 24, wherein the amounts of the wear-resistant layers (21, 22) between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13) are substantially equal.

[0381] Item 26. The method according to any one of Items 15 - 25, wherein the first foil (11), the second foil (12) and / or the third foil (13) comprise 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.

[0382] Item 27. The method according to any one of Items 15 - 26, wherein each of the first foil (11), the second foil (12) and the third foil (13) has a thickness of 20 - 300 μm or 50 - 200 μm.

[0383] Item 28. The method according to any one of Items 15 - 27, wherein the substrate (3) 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.

[0384] Item 29. A method for producing a building panel (1), comprising:

[0385] providing a substrate (3);

[0386] applying a first foil (11') comprising a thermoplastic material above the substrate (3);

[0387] applying a second foil (12') comprising a thermoplastic material above the first foil (11');

[0388] Before applying the first foil (11') above the substrate (3), apply an abrasion-resistant layer (21) on the substrate (3) and / or the first foil (11').

[0389] Before applying the second foil (12') on the first foil (11'), apply an abrasion-resistant layer (22) on the first foil (11') and / or the second foil (12'); and

[0390] Attach the substrate (3), the first foil (11') and the second foil (12') together by heating and pressing to form a building panel (1), wherein the abrasion-resistant layers (21, 22) are provided between the substrate (3), the first foil (11') and the second foil (12').

[0391] Item 30. The method according to item 29, wherein the abrasion-resistant layer (21) applied between the substrate (3) and the first foil (11') is spread on the substrate (3) before applying the first foil (11').

[0392] Item 31. The method according to item 29 or 30, wherein the abrasion-resistant layer (22) applied between the first foil (11') and the second foil (12') is spread on the first foil (11') before applying the second foil (12').

[0393] Item 32. The method according to any one of items 29 - 31, wherein each abrasion-resistant layer (21, 22) contains abrasion-resistant particles (24).

[0394] Item 33. The method according to item 32, wherein each abrasion-resistant layer (21, 22) contains abrasion-resistant particles in an amount of at least 99 wt% or at least 99.5 wt%.

[0395] Item 34. The method according to item 32 or 33, wherein the abrasion-resistant particles (24) are alumina / aluminum oxide particles.

[0396] Item 35. The method according to any one of items 32 - 34, wherein after attaching the substrate (3) and the foils (11', 12') together, the abrasion-resistant particles (24) arranged between the substrate (3) and the first foil (11') are enclosed in the substrate and the first foil, and the abrasion-resistant particles (24) arranged between the first foil (11') and the second foil (12') are enclosed in the first foil and the second foil.

[0397] Item 36. The method according to any one of Items 32 - 35, wherein, after attaching the substrate (3) and the foils (11', 12'), none of the wear-resistant particles (24) disposed between the first foil (11') and the second foil (12') protrude from the second foil (12').

[0398] Item 37. The method according to any one of Items 29 - 36, wherein the wear-resistant layer (21) applied between the substrate (3) and the first foil (11') is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0399] Item 38. The method according to any one of Items 29 - 37, wherein the wear-resistant layer (32) applied between the first foil (11') and the second foil (12') is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

[0400] Item 39. The method according to any one of Items 29 - 38, wherein the amounts of the wear-resistant layer (21) between the substrate (3) and the first foil (11') and between the first foil and the second foil (11', 12') are substantially equal.

[0401] Item 40. The method according to any one of Items 29 - 39, wherein the total amount of the wear-resistant layers (21, 22) applied between the substrate (3) and the first foil (11') and between the first foil (11') and the second foil (12') is 10 - 60 g / m 2 、15 - 50 g / m 2 or 20 - 40 g / m 2 .

[0402] Item 41. The method according to any one of Items 29 - 40, wherein the first foil (11') and / or the second foil (12') 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.

[0403] Item 42. The method according to any one of Items 29 - 41, wherein each of the first foil (11') and the second foil (12') has a thickness of 20 - 300 μm or 50 - 200 μm.

[0404] Item 43. The method according to any one of Items 29 - 42, wherein the substrate (3) 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.

[0405] Item 44. An abrasion-resistant plate (10), comprising:

[0406] A first foil (11) comprising a thermoplastic material;

[0407] A second foil (12) comprising a thermoplastic material disposed above the first foil (11);

[0408] A third foil (13) comprising a thermoplastic material disposed above the second foil (12);

[0409] An abrasion-resistant layer (21) disposed between the first foil (11) and the second foil (12); and

[0410] An abrasion-resistant layer (22) disposed between the second foil (12) and the third foil (13).

[0411] Item 45. The abrasion-resistant plate according to Item 44, wherein each abrasion-resistant layer (21, 22) comprises abrasion-resistant particles (24).

[0412] Item 46. The abrasion-resistant plate according to Item 45, wherein each abrasion-resistant layer (21, 22) comprises an amount of abrasion-resistant particles of at least 99 wt% or at least 99.5 wt%.

[0413] Item 47. The abrasion-resistant plate according to Item 45 or 46, wherein the abrasion-resistant particles (24) are alumina / aluminum oxide particles.

[0414] Item 48. The abrasion-resistant plate according to any one of Items 45 - 47, wherein the abrasion-resistant particles (24) disposed between the first foil (11) and the second foil (12) are enclosed in the first and second foils, and the abrasion-resistant particles (24) disposed between the second foil (12) and the third foil (13) are enclosed in the second and third foils.

[0415] Item 49. The wear-resistant plate according to any one of Items 45-48, wherein the wear-resistant particles (24) arranged between the second foil (12) and the third foil (13) do not protrude from the third foil (13).

[0416] Item 50. The wear-resistant plate according to any one of Items 44-49, wherein the wear-resistant layer (21) applied between the first foil (11) and the second foil (12) is in an amount of 5-30 g / m 2 、7.5-25 g / m 2 or 10-20 g / m 2 is applied.

[0417] Item 51. The wear-resistant plate according to any one of Items 44-50, wherein the wear-resistant layer (22) applied between the second foil (12) and the third foil (13) is in an amount of 5-30 g / m 2 、7.5-25 g / m 2 or 10-20 g / m 2 is applied.

[0418] Item 52. The wear-resistant plate according to any one of Items 44-51, wherein the amounts of the wear-resistant layers (21, 22) between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13) are substantially equal.

[0419] Item 53. The wear-resistant plate according to any one of Items 44-52, wherein the total amount of the wear-resistant layers (21, 22) applied between the first foil (11) and the second foil (12) and between the second foil (12) and the third foil (13) is 10-60 g / m 2 、15-50 g / m 2 or 20-40 g / m 2 .

[0420] Item 54. The wear-resistant plate according to any one of Items 44-53, wherein the first foil (11), the second foil (12) and / or the third foil (13) 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.

[0421] Item 55. The wear-resistant plate according to any one of Items 44 - 54, wherein each of the first foil (11), the second foil (12), and the third foil (13) has a thickness of 20 - 300 μm or 50 - 200 μm.

[0422] Item 56. An architectural panel, comprising:

[0423] a substrate (3); and

[0424] the wear-resistant plate (10) according to any one of Items 44 - 56 disposed on the substrate (3).

[0425] Item 57. The architectural panel according to Item 56, wherein the substrate (3) 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.

[0426] Item 58. An architectural panel, comprising:

[0427] a substrate (3);

[0428] a first foil (11') containing a thermoplastic material disposed above the substrate (3);

[0429] a second foil (12') containing a thermoplastic material disposed above the first foil (11');

[0430] a wear-resistant layer (21) disposed between the substrate (3) and the first foil (11'); and a wear-resistant layer (22) disposed between the first foil (11') and the second foil (12').

[0431] Item 59. The architectural panel according to Item 58, wherein each wear-resistant layer (21, 22) comprises wear-resistant particles (24).

[0432] Item 60. The architectural panel according to Item 59, wherein each wear-resistant layer (21, 22) comprises at least 99 wt% of wear-resistant particles, or at least 99.5 wt% of wear-resistant particles.

[0433] Item 61. The architectural panel according to Item 59 or 60, wherein the wear-resistant particles (24) are alumina / aluminum oxide particles.

[0434] Item 62. The building panel according to any one of Items 59 - 61, wherein the wear-resistant particles (24) disposed between the substrate (3) and the first foil (11') are enclosed in the substrate and the first foil, and the wear-resistant particles (24) disposed between the first foil (11') and the second foil (12') are enclosed in the first foil and the second foil.

[0435] Item 63. The building panel according to any one of Items 59 - 62, wherein none of the wear-resistant particles (24) disposed between the first foil (11') and the second foil (12') protrude from the second foil (12').

[0436] Item 64. The building panel according to any one of Items 58 - 63, wherein the wear-resistant layer (21) applied between the substrate (3) and the first foil (11') is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 of the amount.

[0437] Item 65. The building panel according to any one of Items 58 - 64, wherein the wear-resistant layer (22) applied between the first foil (11') and the second foil (12') is applied in an amount of 5 - 30 g / m 2 、7.5 - 25 g / m 2 or 10 - 20 g / m 2 of the amount.

[0438] Item 66. The building panel according to any one of Items 58 - 65, wherein the amounts of the wear-resistant layers (21, 22) between the substrate (3) and the first foil (11') and between the first foil and the second foil (11', 12') are substantially equal.

[0439] Item 67. The building panel according to any one of Items 58 - 66, wherein the total amount of the wear-resistant layers (21, 22) between the substrate (3) and the first foil (11') and between the first foil (11') and the second foil (12') is 10 - 60 g / m 2 、15 - 50 g / m 2 or 20 - 40 g / m 2 .

[0440] Item 68. The building panel according to any one of Items 58 - 67, wherein the first foil (11') and / or the second foil (12') 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.

[0441] Item 69. The building panel according to any one of Items 58 - 68, wherein each of the first foil (11') and the second foil (12') has a thickness of 20 - 300 μm or 50 - 200 μm.

[0442] Item 70. The building panel according to any one of Items 58 - 69, wherein the substrate (3) 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.

Claims

1. A method of producing a wear-resistant plate (10), the method comprising: providing a first foil (11) comprising a thermoplastic material; applying a second foil (12) comprising a thermoplastic material above the first foil (11); applying a third foil (13) comprising a thermoplastic material above the second foil (12); applying a wear-resistant layer (21) comprising wear-resistant particles (24) on the first foil (11) and / or the second foil (12) before applying the second foil (12) above the first foil (11); applying a wear-resistant layer (22) comprising wear-resistant particles (24) on the second foil (12) and / or the third foil (13) before applying the third foil (13) above the second foil (12); and attaching the first foil (11), the second foil (12) and the third foil (13) together by heating and pressing to form the wear-resistant plate (10), wherein the two wear-resistant layers (21, 22) are provided between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13).

2. The method according to claim 1, wherein, Each wear-resistant layer (21, 22) comprises at least 99 wt% or at least 99.5 wt% of wear-resistant particles.

3. The method according to claim 1 or 2, wherein The wear-resistant particles (24) are alumina particles.

4. The method according to any one of the preceding claims, wherein, After attaching the foils (11, 12, 13) together, the wear-resistant particles (24) disposed between the first foil (11) and the second foil (12) are enclosed in the first foil and the second foil, and the wear-resistant particles (24) disposed between the second foil (12) and the third foil (13) are enclosed in the second foil and the third foil.

5. The method according to any one of the preceding claims, wherein, After attaching the foils (11, 12, 13) together, none of the wear-resistant particles (24) disposed between the second foil (12) and the third foil (13) protrude above the upper surface of the third foil (13).

6. The method according to any one of the preceding claims, wherein, The wear-resistant layer (21) applied between the first foil (11) and the second foil (12) is applied in an amount of 5 - 30 g / m 2 , 7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

7. The method according to any one of the preceding claims, wherein, The wear-resistant layer (22) applied between the second foil (12) and the third foil (13) is applied in an amount of 5 - 30 g / m 2 , 7.5 - 25 g / m 2 or 10 - 20 g / m 2 .

8. The method according to any one of the preceding claims, wherein, The amounts of the wear-resistant layers (21, 22) between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13) are substantially equal.

9. The method according to any one of the preceding claims, wherein The first foil (11), the second foil (12) and the third foil (13) each have a thickness of 20 - 300 μm or 50 - 200 μm.

10. A method of producing a building panel (1), the method comprising: providing a substrate (3); applying a wear-resistant plate (10) produced according to any one of claims 1 - 9 above the substrate (3); attaching the substrate (3) and the wear-resistant plate (10) together by heating and pressing to form the building panel (1).

11. The method according to claim 10, further comprising: Before attaching the substrate (3), the decorative layer (5) and the wear-resistant plate (10) together by heating and pressing to form the building panel (1), the decorative layer (5) is applied between the substrate (3) and the wear-resistant plate (10).

12. A method for producing a building panel (1), the method comprising: Providing a substrate (3); Applying a first foil (11) comprising a thermoplastic material above the substrate (3); Applying a second foil (12) comprising a thermoplastic material above the first foil (11); Applying a third foil (13) comprising a thermoplastic material above the second foil (12); Before applying the second foil (12) above the first foil (11), applying a wear-resistant layer (21) comprising wear-resistant particles (24) on the first foil (11) and / or the second foil (12); Before applying the third foil (13) above the second foil (12), applying a wear-resistant layer (22) comprising wear-resistant particles (24) on the second foil (12) and / or the third foil (13); and Attaching the substrate (3), the first foil (11), the second foil (12) and the third foil (13) together by heating and pressing to form the building panel (1), wherein the wear-resistant layers (21, 22) are provided between the first foil and the second foil (11, 12) and between the second foil and the third foil (12, 13).

13. The method according to claim 12, further comprising: Before attaching the substrate (3), the decorative layer (5) and the foils (11, 12, 13) together by heating and pressing to form the building panel (1), applying the decorative layer (5) between the substrate (3) and the first foil (11).

14. A method for producing a building panel (1), the method comprising: Providing a substrate (3); Applying a first foil (11') comprising a thermoplastic material above the substrate (3); Applying a second foil (12') comprising a thermoplastic material above the first foil (11'); Before applying the first foil (11') above the substrate (3), applying a wear-resistant layer (21) comprising wear-resistant particles (24) on the substrate (3) and / or the first foil (11'); Before applying the second foil (12') above the first foil (11'), applying a wear-resistant layer (22) comprising wear-resistant particles (24) on the first foil (11') and / or the second foil (12'); and Attaching the substrate (3), the first foil (11') and the second foil (12') together by heating and pressing to form the building panel (1), wherein the two wear-resistant layers (21, 22) are provided between the substrate (3), the first foil (11') and the second foil (12').

15. The method according to claim 14, further comprising: Before attaching the substrate (3), the decorative layer (5) and the foils (11’, 12’) together by means of heating and pressing to form the building panel (1), the decorative layer (5) is applied between the substrate (3) and the wear-resistant layer (21).

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