Decorative panel and method for producing a panel

Abstract

The invention relates to a decorative panel, in particular a floor panel, a wall panel or a ceiling panel, comprising at least one core layer comprising a core upper surface and a core bottom surface, where the core layer comprises a composite material comprising at least one mineral material and at least one polymer, and at least one top layer, the top layer comprises at least one resin-impregnated paperboard layer, in which the core layer has a predetermined Vicat softening temperature, and in which the core upper surface of the core layer has a predetermined Shore D hardness, thereby obtaining a panel having good water resistance and scratch resistance.

Description

[0001] This application is a divisional application of patent application No. 2021115196698, filed on December 13, 2021, entitled "Decorative Panel and Method for Manufacturing Panel". Technical Field

[0002] This invention relates to decorative paneling, particularly floor paneling, wall paneling, or ceiling paneling. The invention also relates to a method for manufacturing decorative paneling. Background Technology

[0003] A flooring project was investigated in an attempt to combine the advantages of a thermoplastic core material (water resistance) and a thermosetting resin-impregnated cellulose top layer (scratch resistance). Difficulties arise when attempting to fully bond the different layers without delamination or requiring a rather complex manufacturing process. Thermoplastic composite cores typically cannot withstand the pressure and heat required to cure the uncured resin impregnated in the top layer, nor the heat required to activate the hardener present in the polymer adhesive that binds the core and top layer together. Thermoplastic cores, such as polyvinyl chloride (PVC), are known to soften or even completely melt at high temperatures; for example, PVC has a low Vicat softening temperature of approximately 65°C and a melting point of approximately 150°C. When attempting to manufacture according to existing techniques, this deformation of the core leads to uneven thickness, breakage of the rigid top layer, etc. Since thermosetting resins, such as melamine resin-impregnated top layers, are known to cure only at temperatures above 150°C, it is necessary to improve the viscosity and stiffness of the core at high temperatures. In addition, the bonding of the thermosetting top layer to the thermoplastic core requires the use of an adhesive layer containing thermosetting resin and polymer adhesive or epoxy resin, which requires heat above 150 degrees Celsius for activation. Summary of the Invention

[0004] The object of the present invention is to at least partially limit or eliminate the aforementioned disadvantages of known processes for manufacturing panels, or at least to provide alternative solutions to the prior art.

[0005] This invention relates to a decorative panel, particularly a floor panel, wall panel, or ceiling panel, comprising: - At least one core layer, the core layer comprising a top surface and a bottom surface and preferably including two pairs of opposing side edges, wherein the core layer comprises a composite material containing at least one mineral material and / or at least one polymer; and - At least one top layer, the top layer comprising at least one resin-impregnated cardboard layer; At least one of the cardboard layers is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive; The Vicat softening temperature of the core layer is at least 80 degrees Celsius, preferably at least 85 degrees Celsius, and / or the Shore D hardness of the core surface of the core layer is at least 85. Detailed Implementation

[0006] The panel according to the invention has several advantages over panels according to the prior art. Combining a core layer comprising at least one mineral material and at least one polymer, and a top layer comprising at least one resin-impregnated paperboard layer, wherein the at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin and / or optionally at least one polymeric adhesive, and wherein the Vicat softening temperature of the core layer is at least 80 degrees Celsius, preferably at least 85 degrees Celsius, and / or wherein the Shore D hardness of the core surface of the core layer is at least 85, the panel not only has the water-repellent benefits of PVC paneling but also the beneficial scratch resistance of paneling with resin-impregnated paper facing. Preferably, using a core layer with a Vicat softening temperature of at least 80 degrees Celsius and a core surface of the core layer with a Shore D hardness of at least 85 at ambient temperature and / or 23 degrees Celsius results in a relatively high hardness for the core layer, while the core composition has the ability to maintain this hardness when heated (e.g., during the attachment of one or more top layers). Therefore, the combination of these technical features prevents deformation of the core layer during manufacturing, use, and / or processing. This technical effect was unexpectedly discovered because those skilled in the art would not consider the synergistic effect between the core layer's hardness and the Vicat softening point to actively contribute to the lamination of the paper layers at high temperatures. Those skilled in the art might consider either one as a contributing feature, but not the synergistic effect of the aforementioned features. The panel according to the invention also has the benefit of a relatively good shrinkage rate, thus preventing the panel's characteristic deformation during hot pressing, for example. This can be explained at least in part by using a core layer comprising a composite material containing at least one mineral material and at least one polymer, and having a Vicat softening temperature of at least 80 degrees Celsius and / or a Shore D hardness of at least 85. The use of at least one mineral material in the core layer to impart sufficient rigidity, advantageously above 4000 MPa MOE and 22 MPa MOR, thereby ensuring the panel's dimensional stability and toughness. It is conceivable that when necessary, or (for example) when a locking mechanism requires flexibility (advantageously below 9000 MPa and 36 Nm MOR) to achieve engagement of the locking mechanism, at least one polymer can be used in the core layer to impart flexible properties to the panel. The core layer according to the invention can provide rigidity and strength to allow (for example) suspension mounting, and is also suitable for providing a substantially flat surface, allowing the top layer to be effectively attached to that surface. The core layer according to the invention is specifically configured and suitable for thermal bonding processes. The aforementioned at least one top layer comprises at least one resin-impregnated cardboard layer, wherein the at least one cardboard layer is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive, such that the top layer can be (for example) directly attached to the core layer by applying heat and / or pressure without the need for an intermediate adhesive layer, while the top layer has substantially good strength and scratch resistance.

[0007] When referring to the Vicat softening temperature, it can also refer to the softening temperature. The top layer can also be called a decorative top layer. The top layer has at least one resin-impregnated paperboard layer. The top layer is typically a cured resin-impregnated paperboard layer. Within the scope of this invention, at least one paperboard layer can also be a cellulose- and / or lignocellulose-based board layer. For example, it is conceivable to use lignocellulose as pulp and dry it to form the board layer. When at least one polymeric adhesive is used, the at least one polymeric adhesive can also be called a polymeric adhesive and / or a polymerized viscous compound. When referring to the core layer, the layer can also be called a carrier layer, carrier panel, carrier, core, and / or panel core.

[0008] Preferably, at least one resin-impregnated paperboard layer is in direct contact with the core surface of the core layer. Therefore, at least one resin-impregnated paperboard layer is directly attached to the core surface of the core layer. Preferably, at least one paperboard layer impregnated with a resin composition comprising at least one polymeric adhesive is in direct contact with the core surface of the core layer. Because of the combination of a paperboard layer impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive and the core layer according to the invention, the two layers can be attached together without the need for an adhesive layer between them. For example, this attachment can be accomplished via thermal bonding, such as by applying heat and / or pressure. Therefore, the use of an adhesive layer between the top layer and the core layer can be omitted.

[0009] In a preferred embodiment, at least one resin-impregnated paperboard layer comprises at least one polymeric adhesive, preferably at least 1% by weight, and more preferably at least 5% by weight. It is also conceivable that at least one resin-impregnated paperboard layer comprises a polymeric adhesive ranging from 1% to 20% by weight, preferably from 2.5% to 15% by weight, and more preferably from 5% to 10% by weight. When using a polymeric adhesive, the polymeric adhesive used in one or more resin-impregnated paperboard layers can be crucial for the bonding between the top and core layers. For example, it is conceivable that at least one polymeric adhesive is grafted into the top layer. It is also conceivable that the resin composition comprises at least 1% by weight, and preferably at least 5% by weight. It is also conceivable that the resin composition comprises a polymeric adhesive ranging from 1% to 20% by weight, preferably from 2.5% to 15% by weight, and more preferably from 5% to 10% by weight. For example, it is conceivable that at least one polymeric adhesive in the resin composition includes polyurethane, polyester, and / or polyepoxide, such as, but not limited to, epoxy resin. At least one polymeric adhesive of the resin composition may be, for example, polyurethane, polyester and / or polyepoxide.

[0010] Thermosetting resins may include, for example, phenolic resins, melamine resins, and / or formaldehyde resins. Thermosetting resins may also include, for example, melamine-formaldehyde resins.

[0011] In a preferred embodiment, the cellulose content of at least one resin-impregnated paperboard layer is at least 40 grams by weight, preferably at least 70 grams. It is also conceivable that the weight of at least one top paperboard layer is at least 25 grams, preferably at least 40 grams, more preferably at least 70 grams. The weight of the paper or resin-impregnated paper can, for example, be in the range of 70 to 80 grams. The resin loading of at least one resin-impregnated paperboard layer is preferably at least 90%, more preferably at least or substantially 100%. Substantially fully resin-impregnated paper is beneficial for the water resistance and scratch resistance of the top layer.

[0012] As for the core layer, preferably, at least one polymer of the composite material is a thermoplastic polymer, and / or at least one polymer of the composite material is an elastomer. It is conceivable that at least one thermoplastic or elastomer polymer may be used in the core layer to impart flexible properties to the panel when necessary, for example, when flexibility is required to achieve engagement of the locking mechanism. The at least one polymer of the composite material may, for example, be selected from the group consisting of polyvinyl chloride (PVC), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), polyethylene (PE), polyurethane (PU), acrylonitrile butadiene styrene copolymer (ABS), and / or copolyester (CPE).

[0013] More preferably, at least one mineral material in the composite material is a magnesium-based mineral material, particularly selected from the group consisting of magnesium oxide (MgO), magnesium chloride (MgCl or MOC cement), and / or oxymagnesium sulfate (MOS cement). It is also conceivable that at least one mineral material in the composite material includes calcium carbonate (CaCO3), chalk, clay, calcium silicate, and / or talc. These materials are known to provide good rigidity to the core layer.

[0014] In one advantageous embodiment, the ratio of mineral material to polymer in the core layer composite is at least 3:1. This relatively large percentage of mineral material provides the core layer with good rigidity and dimensional stability, while the polymer portion is sufficient to provide the desired level of flexibility. This composition is also beneficial for achieving the desired shrinkage rate, particularly less than 0.05%. The mineral material content can also positively influence the minimum Shore D hardness required for the core surface of the core layer. The Shore D hardness of the core surface of the core layer is preferably at least 85. It is also conceivable that the Shore D hardness of the core surface of the core layer is in the range of 85 to 95. A mineral material to polymer ratio of at least 3:1 in the core layer also results in a relatively high surface energy in the core layer, which is positive for the bonding between the core layer and the top layer according to the invention.

[0015] Adding at least one Vicat modifier, particularly to the composite material of the core layer, can further improve the material properties of the core layer. The composite material of the core layer may, for example, contain at least one additive configured to increase the Vicat softening temperature. The Vicat softening temperature of the core layer is preferably at least 80 degrees Celsius. It is also conceivable that the Vicat softening temperature is at least 82 degrees Celsius, at least 83 degrees Celsius, at least 84 degrees Celsius, or at least 85 degrees Celsius. It is also conceivable that the Vicat softening temperature of the core layer is in the range of 80 degrees Celsius to 95 degrees Celsius, or in the range of 85 degrees Celsius to 95 degrees Celsius. The Vicat softening temperature of the core layer may also be substantially 90 degrees Celsius. Optionally, the Vicat softening temperature of the core layer may be higher than 95 degrees Celsius. It is also conceivable that the Vicat softening temperature of the composite material is at least 80 degrees Celsius, preferably at least 85 degrees Celsius. At least one additive may include, for example, acrylonitrile-styrene-acrylate copolymer (ASA), acrylonitrile-butadiene-styrene copolymer (ABS), thermosetting systems, and / or epoxy systems. At least one additive may also be a Vicat modifier or a Vicat modifier.

[0016] In one alternative embodiment, at least one polymer of the composite material may be a thermosetting polymer. Therefore, it is also conceivable that at least one polymer of the core layer composite material includes at least one phenolic resin, melamine resin, and / or formaldehyde resin. The resin used may, for example, be a thermosetting resin. It is also advantageous when the core layer composite material contains at least one thermosetting resin and / or at least one polymeric adhesive. For example, it is conceivable that when the composite material contains at least one thermosetting resin and / or at least one polymeric adhesive, this is equivalent to using at least one thermosetting resin and / or at least one polymeric adhesive in the resin composition of at least one resin-impregnated paperboard layer in the top layer.

[0017] In an advantageous embodiment of the panel, the surface energy of the core upper surface of the core layer is at least 50 dyn / cm. This property allows the resin-impregnated sheet layers to bond well. Thermoplastics such as PVC, PET, PP, etc., typically have considerably low surface energies of less than 50 dyn / cm, and often even less than 40 dyn / cm, making core layers made from these materials unsuitable for direct bonding of resin paper. A surface energy of the core layer below the desired value can cause delamination of one or more resin-impregnated sheet layers of the top layer, especially when the panel is exposed to water and / or heat for a period of time. For example, it is conceivable to increase the surface energy of the core layer by treating the surface with plasma or corona. A proper synergy between surface energy and roughness can positively contribute to preventing delamination. Particularly preferably, the (surface) roughness (Ra) of the core layer is at least 0.5 μm. More preferably, the roughness of the core layer is at least 1 μm. Thus, the roughness of the core upper surface of the core layer can be at least 0.5 μm, preferably at least 1 μm. These properties enable proper bonding between the upper core layer and the top layer (especially the resin composition of the top layer).

[0018] The core layer's elastic modulus or stiffness can be, for example, at least 3500 MPa, especially when tested according to EN310 or ASTM D790. The core layer thickness is preferably between 3 mm and 9 mm, more preferably between 4 mm and 5.5 mm, or between 5.5 mm and 7 mm. In an advantageous embodiment, the core layer density is at least 1200 kg / m³. 3 And preferably at least 1400 kg / m 3 Another possibility is that the core layer has a density of 1600 kg / m³. 3 Up to 2100 kg / m 3 Within the range.

[0019] It is also conceivable that the Shore D hardness of the core bottom surface of the core layer is at least 85 or in the range of 85 to 95. This is particularly advantageous when a backing layer is used. A panel according to the invention may include at least one backing layer comprising at least one resin-impregnated paperboard layer, wherein the at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive. It is conceivable that the backing layer is essentially equivalent to the top layer. Therefore, any of the top layers can also serve as a backing layer attached to the core bottom surface of the core layer. If a backing layer is used, the backing layer can be directly attached to the core bottom surface of the core layer. The backing layer can be, for example, a balancing layer. The core bottom surface of the core layer can have the same properties as the core top surface. In a preferred embodiment, the weight of the backing layer is greater than the weight of the top layer. For example, it is conceivable that the weight of the backing layer is at least 70 grams, preferably at least 100 grams, more preferably at least 120 grams. The relatively heavy backing layer is beneficial for its balancing function. The total paper weight and / or resin loading of the backing layer may, for example, be at least the same as or higher than the total paper weight and / or resin loading of the top layer. Therefore, it is conceivable that the panel includes at least one backing layer, which is preferably attached to the bottom surface of the lower core layer and is substantially different from the top layer. The backing layer can provide protection for the core layer, and thus similarly for the panel. The bottom surface of the backing layer may, for example, include an adhesive layer. It is also conceivable that the backing layer is a balancing layer, preferably configured to stabilize and / or protect the panel. The balancing layer can, for example, prevent cupping, warping, and / or bending of the panel. The balancing layer may also be referred to as a stabilizing layer. The presence of the backing layer can also contribute to the acoustic performance of the panel, as the backing layer can have sound damping characteristics and / or facilitate panel installation. Furthermore, the backing layer can form a moisture barrier. The backing layer may also be made of a polymeric material, such as, but not limited to, polyurethane. It is also conceivable that the panel includes any combination of any of the possible examples of the backing layers described above. Additionally, the backing layer may also be a sound-absorbing layer. This sound-absorbing backing layer can contribute to the acoustic properties of the panel. This backing layer can also be referred to as an acoustic layer. The backing layer can be composed of a foamed layer of ethylene-vinyl acetate copolymer (EVA), irradiated cross-linked polyethylene (IXPE), expanded polypropylene (XPP), and / or expanded polystyrene (XPS), preferably a low-density foamed layer. However, it is also conceivable that the backing layer includes non-woven fibers, such as natural fibers like hemp or cork; and / or recycled / recyclable materials, such as PET. If a backing layer is used, its density is preferably 65 kg / m³. 3 and 300 kg / m 3 Between, the optimal value is 80 kg / m 3 and 150 kg / m 3 between.

[0020] At least one top layer may include at least one decorative layer. For example, it is conceivable that the top layer is a decorative top layer. It is also conceivable that at least one cardboard layer is decorative paper. The panel may optionally include at least one abrasion layer. The abrasion layer may form part of the top layer or form the entire top layer. At least one resin-impregnated cardboard layer may be a substantially transparent board layer. It is also conceivable that at least one top layer includes multiple resin-impregnated cardboard layers, wherein at least one cardboard layer, and preferably each cardboard layer, is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive. In the case of using multiple resin-impregnated cardboard layers, it is advantageous that at least the bottom board layer (attached to the upper core layer) comprises at least one polymeric adhesive. Since the polymeric adhesive is an important component of the bond between the top layer and the core layer, it is preferable that at least the bottom layer of the multiple or one board layer that is in contact with the core surface is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive.

[0021] It is conceivable that a top layer comprising at least one or more resin-impregnated paperboard layers has several compositions. For example, it is conceivable that at least one paperboard layer is decorative paper. It is also conceivable that at least one paperboard layer is reinforcing paper. It is also conceivable to use transparent paperboard layers. In the case of employing multiple layers, different types of paper can be used. For example, in a conceivable embodiment, the top layer comprises, from top to bottom, at least a first transparent paperboard layer of at least 50 g and at least a second decorative paperboard layer of at least 70 g, the first transparent paperboard layer being impregnated with at least one thermosetting resin and containing a plurality of abrasion-resistant particles and / or at least one antibacterial agent, and the second decorative paperboard layer being impregnated with at least one thermosetting resin and / or at least one polymeric adhesive.

[0022] In conceivable embodiments, the top layer comprises a plurality of abrasion-resistant particles. The abrasion-resistant particles are preferably selected from the group consisting of alumina, corundum, silicon carbide, titanium dioxide, titanium oxide, and / or diamond particles. For example, it is conceivable that the abrasion-resistant particles are dispersed in the resin composition of the top layer. In the case of using an abrasion-resistant layer, it is also conceivable that the abrasion-resistant layer comprises a plurality of abrasion-resistant particles. In this case, the abrasion-resistant particles can be dispersed in the abrasion-resistant layer, for example. In the case where the top layer comprises a plurality of resin-impregnated paperboard layers, it is preferable that at least one layer comprises a plurality of abrasion-resistant particles, more preferably at least the upper layers of these layers comprise the abrasion-resistant particles. Alternatively, it is also conceivable that the abrasion-resistant particles are applied to an uncured or semi-cured resin composition such that, after cross-linking between layers, the abrasion-resistant particles can be applied to multiple layers.

[0023] The top layer may also include at least one resin-impregnated paperboard layer containing at least one antimicrobial agent, preferably zinc oxide (ZnO) and / or silver nanoparticles. It is also conceivable that the resin composition impregnating at least one paperboard layer contains at least one antimicrobial agent, preferably a metal oxide such as titanium dioxide (TiO2), zinc oxide (ZnO), or isothiazolinone, zinc pyrithione, thiabendazole, and / or silver nanoparticles. The presence of at least one antimicrobial agent can be advantageous in cases where floor paneling or floor coverings made from such paneling are required for commercial, industrial, or areas with high hygiene standards. In the case of a wear-resistant layer or cover layer, it is also conceivable that the antimicrobial agent is present in the wear-resistant layer or cover layer. The antimicrobial agent can form an integral part of the top layer. Paneling comprising a top layer containing at least one antimicrobial agent generally provides much better protection against bacteria, fungi, parasites, and / or viruses compared to paneling covered with an antimicrobial agent.

[0024] It is advantageous to bond at least one top layer and at least one core layer by providing heat and / or pressure. At least one top layer and at least one core layer can be bonded, for example, via thermal bonding. Thermal bonding is advantageous because the intermediate adhesive layer used between the top layer and the core layer can be omitted. The use of the core layer and top layer according to the invention allows for the application of a thermal bonding process.

[0025] In a preferred embodiment, the panel includes two pairs of opposing side edges, wherein at least one pair of opposing side edges, and preferably each pair of opposing side edges, is provided with complementary coupling members. The core layer of the panel according to the invention may include at least one pair of opposing (side) edges, said pair of opposing (side) edges including complementary coupling members configured for mutual coupling of adjacent panels. The coupling members may form part of the core layer. The coupling members of the panel may, for example, be interlocking coupling members, which are preferably configured to provide both horizontal and vertical locking. Interlocking coupling members are coupling members that require elastic deformation, engagement, or movement in multiple directions to couple or decouple the components from each other. Any suitable interlocking coupling member known in the art may be used. One non-limiting example is an embodiment in which the first edge of the first pair of opposing edges includes a first coupling member, and wherein the second edge of the first pair of opposing edges includes a complementary second coupling member, the coupling members enabling multiple panels to be coupled to each other; wherein the first coupling member includes a lateral tenon extending substantially parallel to the plane defined by the panel, and wherein the second coupling member includes a groove configured to receive at least a portion of the lateral tenon of another panel, the groove being defined by an upper tenon and a lower tenon. It is conceivable that the complementary coupling members require a downward scissor movement or to lock together by horizontal movement upon engagement. It is also conceivable that the interconnecting coupling members include a tenon and a groove, wherein the tenon is disposed on one side edge of a pair of opposing side edges, and the groove is disposed on the other side edge of the same pair of opposing side edges, or on an adjacent side relative to the tenon. Such coupling mechanism designs are known in the art and have proven highly suitable for panels used in floor coverings such as floating floors. In another embodiment, the interconnecting coupling mechanism may have an interlocking feature that prevents any free movement (movement) of the interconnecting panels. This interlocking feature may be a protrusion and a corresponding recess on corresponding opposite side edges, with adjacent panels interlocking with each other via the aforementioned protrusion and recess. It is conceivable to provide reinforcements in the interlocking coupling components to increase strength and prevent breakage during panel installation. For example, complementary or interlocking coupling components can be reinforced with materials such as (but not limited to) fiberglass mesh, reinforcing sheets, carbon fibers, carbon nanotubes, ceramics, glass, arrays of metal or non-metal rods, or polymeric compounds integrally formed in the core layer. It is also conceivable to add a micron- or nano-technology reinforcing coating to the surface of the interlocking coupling components. Panels according to the invention and / or panels obtained via the method according to the invention are suitable for floor, wall, or ceiling coverings preferably characterized by a locking mechanism. Thus, the “suspended” covering can be assembled by connecting the individual panels to each other on all four sides without the need for adhesives.

[0026] The invention also relates to alternative embodiments in which the decorative paneling, particularly floor paneling, wall paneling, or ceiling paneling, comprises at least one core layer and at least one top layer; the core layer comprises a core upper surface and a core bottom surface and two pairs of opposing side edges, wherein the core layer contains at least one thermoplastic binder and at least one filler, and the top layer comprises at least one resin-impregnated paperboard layer, wherein the at least one paperboard layer is impregnated with at least one resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive, wherein the Vicat softening temperature of the core layer is at least 80 degrees Celsius, preferably at least 85 degrees Celsius, and / or wherein the Shore D hardness of the core upper surface of the core layer is at least 85. The core layer may also contain at least one additive, such as the additives described in this invention. The core layer may be a mineral composite material comprising at least one thermoplastic material.

[0027] When measured according to ISPO 23999, for example, the shrinkage rate of the panel according to the invention can be less than 0.15%, and in particular less than 0.05%.

[0028] The present invention also relates to a method for manufacturing decorative panels, particularly floor panels, wall panels, or ceiling panels, especially decorative panels according to any one of the embodiments of the present invention, the method comprising the following steps: a) Provide at least one core layer, the core layer including a core upper surface and a core bottom surface, wherein the core layer comprises a composite material containing at least one mineral material and / or at least one polymer, wherein the softening temperature of the core layer is at least 80 degrees Celsius, preferably at least 85 degrees Celsius, and / or wherein the Shore D hardness of the core upper surface of the core layer is at least 85; b) At least one top layer is provided on the core surface of the core layer, the top layer comprising at least one resin-impregnated paperboard layer, wherein the at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive; c) Apply a pressure of at least 12 MPa and a heat of at least 130 degrees Celsius to the upper surface of the top layer for a first predetermined time; d) Reduce the temperature to below 40 degrees Celsius while maintaining a pressure of at least 12 MPa for a second predetermined time.

[0029] The method according to the invention enables the provision of panels according to the invention in a relatively simple and commercially attractive manner. The core layer employed has relatively high rigidity, while the core composition has the ability to maintain this rigidity during heating and during the attachment of one or more top layers. The method according to the invention further solves the problems of thermal expansion of the core layer under heat and thermal shrinkage of the resin-impregnated cardboard layer under heat due to the selected characteristics. Therefore, undesirable warping and / or cupping of the final article can be prevented. Preferred predetermined time intervals depend on several factors. The first predetermined time is preferably in the range of 30 to 60 minutes, more preferably in the range of 40 to 50 minutes. The second predetermined time may, for example, be in the range of 5 to 30 minutes, preferably in the range of 10 to 20 minutes. It is also conceivable that the first and / or second predetermined time is in the range of 40 to 45 minutes. Preferably, pressure and / or heat are applied via at least one embossing element. For example, the embossing element may be an embossed plate. Using an embossing element can provide a predetermined surface structure on the upper surface of the top layer, which may be desirable for technical and / or aesthetic reasons. The temperature applied during step c) is preferably in the range of 130°C to 150°C. However, it is also conceivable that the temperature applied during step c) is higher than 150°C. It is conceivable that the core surface of the core layer be subjected to heat treatment, sandblasting, and / or corona treatment prior to step c). Such treatment can further increase, for example, the surface energy of the core layer, which can have a positive impact on the bonding process. The method may also include heat treatment at a temperature of at least 90°C and a substantially constant pressure of at least 1 MPa for at least 1 minute, which may be referred to as step e). Alternatively or additionally, the core layer may be heat-treated prior to step c) for, for example, at a temperature of at least 90°C and a substantially constant pressure of at least 1 MPa for at least 1 minute.

[0030] The method may also include providing and / or attaching at least one backing layer, such as in one embodiment of the present invention. The method may also include the step of processing at least two edges of the panel, said at least two edges being provided with complementary coupling members.

[0031] The invention will now be described in more detail with reference to the following non-limiting provisions.

[0032] 1. A decorative panel, particularly a floor panel, wall panel, or ceiling panel, comprising: - At least one core layer, the core layer comprising a top surface and a bottom surface, wherein the core layer comprises a composite material preferably containing at least one mineral material and / or at least one polymer; and - At least one top layer, the top layer comprising at least one resin-impregnated cardboard layer; At least one of the cardboard layers is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive; The Vicat softening temperature of the core layer is at least 80 degrees Celsius, and / or the Shore D hardness of the core surface of the core layer is at least 85.

[0033] 2. The panel according to Clause 1, wherein at least one resin-impregnated cardboard layer is in direct contact with the core surface of the core layer.

[0034] 3. The panel according to any one of the foregoing clauses, wherein at least one resin-impregnated cardboard layer comprises at least 1% by weight of polymer adhesive, preferably at least 5% by weight of polymer adhesive.

[0035] 4. The panel according to any one of the preceding clauses, wherein at least one polymeric adhesive of the resin composition comprises polyurethane, polyester and / or polyepoxide.

[0036] 5. The panel according to any one of the preceding clauses, wherein the weight of at least one resin-impregnated cardboard layer is at least 40 grams, preferably at least 70 grams.

[0037] 6. The panel according to any one of the preceding clauses, wherein the resin loading of at least one resin-impregnated paperboard layer is substantially 100%.

[0038] 7. The panel according to any one of the preceding clauses, wherein at least one polymer of the composite material is a thermoplastic polymer, and / or at least one polymer of the composite material is a thermosetting polymer.

[0039] 8. The panel according to any one of the preceding clauses, wherein at least one polymer of the composite material is selected from the group consisting of: polyvinyl chloride, polypropylene, polyethylene terephthalate, polystyrene, polyethylene, polyurethane, acrylonitrile butadiene styrene copolymer and / or copolyester.

[0040] 9. The panel according to any one of the preceding clauses, wherein at least one mineral material of the composite material is a magnesium-based mineral material, particularly selected from the group consisting of magnesium oxide, magnesium chloride and / or oxymagnesium sulfate.

[0041] 10. The panel according to any one of the preceding clauses, wherein at least one mineral material of the composite material comprises calcium carbonate, chalk, clay, calcium silicate and / or talc.

[0042] 11. The panel according to any one of the preceding clauses, wherein the ratio of the mineral material to the polymer in the composite material is at least 3:1.

[0043] 12. The panel according to any one of the preceding clauses, wherein the composite material further comprises at least one additive configured to increase the Vicat softening temperature.

[0044] 13. The panel according to Clause 12, wherein the additives include acrylonitrile-styrene-acrylate copolymer, acrylonitrile-butadiene-styrene copolymer, thermosetting systems and / or epoxy systems.

[0045] 14. The panel according to any one of the preceding clauses, wherein the surface energy of the core upper surface of the core layer is at least 50 dyn / cm.

[0046] 15. The panel according to any one of the preceding clauses, wherein the roughness of the core surface of the core layer is at least 0.5 μm, preferably at least 1 μm.

[0047] 16. The panel according to any one of the preceding clauses, wherein the thickness of the core layer is between 3 mm and 9 mm, preferably between 4 mm and 5.5 mm, or between 5.5 mm and 7 mm.

[0048] 17. The panel according to any one of the preceding clauses, wherein the density of the core layer is at least 1400 kg / m³. 3 .

[0049] 18. The panel according to any one of the preceding clauses, wherein the Shore D hardness of the core bottom surface of the core layer is at least 85.

[0050] 19. The panel according to any one of the preceding clauses includes at least one backing layer, the backing layer including at least one resin-impregnated cardboard layer, wherein the at least one cardboard layer is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive.

[0051] 20. The panel as described in Clause 19, wherein the weight of the backing layer is greater than the weight of the top layer.

[0052] 21. The panel according to any one of the preceding clauses, wherein the top layer comprises at least one decorative layer, and / or wherein the top layer comprises at least one wear-resistant layer.

[0053] 22. The panel according to any one of the preceding clauses, wherein at least one top layer comprises a plurality of resin-impregnated cardboard layers, wherein at least one cardboard layer is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive.

[0054] 23. The panel according to any one of the preceding clauses, wherein the top layer comprises a plurality of wear-resistant particles, the wear-resistant particles being particularly selected from the group consisting of alumina, corundum, silicon carbide, titanium dioxide, titanium oxide and / or diamond particles.

[0055] 24. The panel according to any one of the preceding clauses, wherein the top layer comprises at least one resin-impregnated cardboard layer, the at least one resin-impregnated cardboard layer containing at least one antimicrobial agent, preferably zinc oxide and / or silver nanoparticles.

[0056] 25. The panel according to any one of the preceding clauses, wherein the top layer and the core layer are bonded by thermal bonding.

[0057] 26. The panel according to any one of the preceding clauses, wherein the panel comprises two pairs of opposing side edges, wherein at least one pair of opposing side edges is provided with complementary coupling members, and preferably each pair of opposing side edges is provided with complementary coupling members.

[0058] 27. A method for manufacturing decorative panels, particularly floor panels, wall panels, or ceiling panels, especially decorative panels according to any one of the preceding clauses, the method comprising the following steps: a) Provide at least one core layer, the core layer including a core upper surface and a core bottom surface, wherein the core layer comprises a composite material containing at least one mineral material and at least one polymer, wherein the softening temperature of the core layer is at least 80 degrees Celsius, preferably at least 85 degrees Celsius, and / or wherein the Shore D hardness of the core upper surface of the core layer is at least 85; b) At least one top layer is provided on the core surface of the core layer, the top layer comprising at least one resin-impregnated paperboard layer, wherein the at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin and / or at least one polymeric adhesive; c) Apply a pressure of at least 12 MPa and a heat of at least 130 degrees Celsius to the upper surface of the top layer for a first predetermined time; d) Reduce the temperature to below 40 degrees Celsius while maintaining a pressure of at least 12 MPa for a second predetermined time.

[0059] 28. The method according to Clause 27, wherein the first predetermined time is in the range of 30 to 60 minutes, preferably in the range of 40 to 50 minutes, and / or wherein the second predetermined time is in the range of 5 to 30 minutes, preferably in the range of 10 to 20 minutes.

[0060] 29. The method according to Clause 27 or 28, wherein pressure and / or heat are applied via at least one embossing element.

[0061] 30. The method according to any one of clauses 27 to 29, wherein the temperature applied during step c) is in the range of 130 degrees Celsius to 150 degrees Celsius.

[0062] 31. The method according to any one of Clauses 27 to 30, wherein prior to step c), the core surface of the core layer is subjected to heat treatment, sandblasting, and / or corona treatment.

[0063] 32. The method according to any one of Clauses 27 to 31, comprising step d) heat treatment at a temperature of at least 90 degrees Celsius and a substantially constant pressure of at least 1 MPa for at least 1 minute.

[0064] Obviously, the present invention is not limited to the examples described, but many variations are possible within the scope of the appended claims, as will be apparent to those skilled in the art. It is not necessary to describe in detail all conceivable combinations of the above-described inventive concepts, as those skilled in the art will understand that many inventive concepts can be (re)combined to achieve a particular application.

[0065] The verb “comprising” and its variations as used in this patent publication should be understood not only to mean “comprising”, but also to mean the terms “including”, “substantially composed of”, “formed by”, and their variations.

Claims

1. A decorative panel, said panel comprising: - At least one core layer, the core layer comprising a top core surface and a bottom core surface, wherein the core layer comprises a composite material containing at least one mineral material and at least one polymer, the ratio of the mineral material to the polymer being at least 3:1; and - At least one top layer, said top layer comprising at least one resin-impregnated cardboard layer; At least one of the cardboard layers is impregnated with a resin composition comprising at least one thermosetting resin; The Vicat softening temperature of the core layer is at least 80 degrees Celsius, and The Shore D hardness of the upper surface of the core layer is at least 85.

2. The panel according to claim 1, wherein at least one resin-impregnated cardboard layer is in direct contact with the core upper surface of the core layer.

3. The panel according to claim 1, wherein the at least one resin-impregnated cardboard layer comprises at least 1% by weight of a polymeric adhesive.

4. The panel according to claim 3, wherein at least one polymeric adhesive of the resin composition comprises polyurethane, polyester and / or polyepoxide.

5. The panel according to claim 1, wherein at least one resin-impregnated cardboard layer weighs at least 40 grams.

6. The panel according to claim 1, wherein the resin loading of the at least one resin-impregnated cardboard layer is at least 100%.

7. The panel according to claim 1, wherein at least one polymer of the composite material is selected from polyvinyl chloride, polypropylene, polyethylene terephthalate, polystyrene, polyethylene, polyurethane, acrylonitrile butadiene styrene copolymer and / or copolyester.

8. The panel according to claim 1, wherein at least one mineral material of the composite material is a magnesium-based mineral material selected from magnesium oxide, magnesium chloride and / or oxymagnesium sulfate.

9. The panel of claim 1, wherein the composite material further comprises at least one additive configured to increase the Vicat softening temperature, wherein the at least one additive comprises an acrylonitrile-styrene-acrylate copolymer, an acrylonitrile-butadiene-styrene copolymer, a thermosetting system, and / or an epoxy system.

10. The panel according to claim 1, wherein the surface energy of the upper surface of the core layer is at least 50 dyn / cm.

11. The panel according to claim 1, wherein the roughness of the upper surface of the core layer is at least 0.5 μm.

12. The panel of claim 1, comprising at least one backing layer, the backing layer comprising at least one resin-impregnated cardboard layer, wherein the at least one cardboard layer is impregnated with a resin composition comprising at least one thermosetting resin.

13. The panel of claim 1, wherein the top layer comprises a plurality of wear-resistant particles, the wear-resistant particles being particularly selected from alumina, corundum, silicon carbide, titanium dioxide, titanium oxide and / or diamond particles.

14. The panel of claim 1, wherein the panel comprises two pairs of opposing side edges, wherein at least one pair of opposing side edges is provided with complementary coupling members.

15. A method for manufacturing a decorative panel according to claim 1, the method comprising the steps of: a) Provide at least one core layer, the core layer comprising a core upper surface and a core bottom surface, wherein the core layer comprises a composite material containing at least one mineral material and at least one polymer, wherein the softening temperature of the core layer is at least 80 degrees Celsius, and wherein the Shore D hardness of the core upper surface of the core layer is at least 85; b) At least one top layer is provided on the upper surface of the core layer, the top layer comprising at least one resin-impregnated paperboard layer, wherein the at least one paperboard layer is impregnated with a resin composition comprising at least one thermosetting resin; c) Apply a pressure of at least 12 MPa and a heat of at least 130 degrees Celsius to the upper surface of the top layer for a first predetermined time; d) Reduce the temperature to below 40 degrees Celsius while maintaining a pressure of at least 12 MPa for a second predetermined time.

16. The method of claim 15, wherein the first predetermined time is in the range of 30 minutes to 60 minutes, and / or wherein, The second predetermined time is in the range of 5 to 30 minutes.

17. The method of claim 15, wherein the temperature applied during step c) is in the range of 130 degrees Celsius to 150 degrees Celsius.

18. The method of claim 15, wherein prior to step c), the core surface of the core layer is subjected to heat treatment, sandblasting, and / or corona treatment.

19. The method of claim 15, further comprising step e) heat treatment at a temperature of at least 90 degrees Celsius and a substantially constant pressure of at least 1 MPa for at least 1 minute.