Countertop panel

Abstract

A countertop panel (100) characterized in that it comprises: - a core (1) comprising a parallelepiped shape defining a top surface, a bottom surface and a side face; - a top sheet (2) and a bottom sheet (3) bonded to the top and bottom surfaces of the core (1), respectively, by a sheet adhesive (5); - an edge (4) bonded to the side face of the core by an edge adhesive (6); wherein the core (1) comprises a density between 80 - 300 kg / m 3 , at least a level 5 (UNE EN ISO 19712-3:2013 and UNE EN ISO 4586-2:2009) of impact resistance, a peel resistance between 7 - 10 kg / m, and 0.5 - 5% water absorption in continuous cycles; wherein the sheet adhesive (5) is a hygroscopic polyurethane hot melt adhesive comprising: a viscosity, Brookfield (ASTM D3236) between 2,500 - 6,000 mPas at 140 °C, a curing time between 1 - 4 days, an open time (DV Method) between 120 - 220 seconds and a solidification time (DV Method) between 90 - 150 seconds; and wherein the edge banding adhesive (6) is a hygroscopic polyurethane hot melt adhesive comprising a viscosity, Brookfield (ASTM D3236) between 50,000 - 60,000 mPas at 140 °C and a curing time between 1 - 4 days.

Description

Countertop panel Technical field of the invention The present invention falls within the field of interior design. Specifically, it relates to a countertop panel that can be used as furniture in kitchens, bathrooms, contract furniture, etc. Background of the invention Furniture is the set of furnishings; they are objects that serve to facilitate the uses and activities common in homes, offices and other types of premises. Among the various elements of the furniture are the countertop panels. Depending on where the panel is installed, it must have certain characteristics. For example, a countertop panel in a kitchen creates a useful surface for the user. This surface may be used for supporting small appliances, food preparation, washing dishes, cooking, etc. It is essential that the countertop surface has good hygienic properties to prevent the proliferation of microorganisms. For its part, bathroom furnishings, similar to those in the kitchen, require the use of countertops resistant to the proliferation of microorganisms, so that optimal hygiene is maintained. Finally, contract furniture is identified by its initial design for institutional or corporate clients, both public and private, although it can also be used by individuals. Contract furniture is designed for greater durability due to repeated use, for example, in the hotel and restaurant sector, offices, and also the furniture found in city parks. Therefore, the function of these panels can be quite varied. The development of versatile panels, capable of supporting multiple requirements, where maintenance and product resistance are key characteristics in the development of a countertop panel, so as to achieve greater durability of the final product, is one of the main objectives of the sector. Currently, there are materials, such as porcelain or ceramic, that allow for countertop panels with adaptable qualities suitable for developing numerous market solutions. However, these solutions are heavy and complex, which can substantially increase their cost. Alternatively, other solutions have been developed, made up of multiple elements, which result in a compact product. These products feature a sandwich-type structure. That is, these solutions consist of a central element or core. This core is the main structure or support. It is generally rectangular in shape, where the width and length of the panel are substantially greater than the thickness of the core. Thus, a first main surface, or top surface, can be defined, where, in use, a user can place other elements, and a second main surface, or bottom surface, opposite and parallel to the top surface. Numerous materials are used for developing the core. This material must possess good physical and chemical properties, as it is the main material of the countertop panel. This core is covered by other elements. The first layer of this covering is a laminate or sheet. This type of covering is applied to the top or bottom surface. In addition to improving the panel's technical properties, these sheets can also be used as design elements for the countertop panel, allowing it to visually resemble other panels. A second cladding element is a side cladding or edge banding, arranged to cover the side faces of the panel. Again, this cladding can modify the exterior design of the finished countertop panel. Generally, these elements are attached to the panel core using an adhesive. Unfortunately, it has been found that the durability of the coatings used for these types of panels can be compromised. The conditions of use (temperature, humidity, impacts, etc.) can affect the bonding of these elements and seriously compromise the structure of the countertop panel. Thus, numerous solutions exist for the development of this type of laminated furniture, each tailored to individual needs. However, currently available solutions present at least one of the following limitations: - High cost - High weight - Low abrasion resistance - Low resistance to radiated heat - Low fire resistance - Low water resistance - Weak element union - Low panel resistance - Low durability of the components Therefore, it is necessary to develop new solutions relating to countertop panels used in the construction and decoration sector, which ensure a lightweight and economical product, with high resistance and durability. Summary of the invention The object of the present invention is to provide a solution to the problems currently existing at the time, by developing a new countertop panel. A countertop panel comprises: - a core, comprising a parallelepiped shape that defines an upper surface, a lower surface and a side face; - an upper plate and a lower plate, joined by an iron adhesive to the upper and lower surfaces, respectively, of the core; - an edge, attached to the side face of the core by an edge adhesive; Unlike previous solutions, the core according to the present invention must possess certain characteristics. Thus, the core comprises: - a density between 8.- 300 kg / m3, - at least a level 5, according to the UNE EN ISO 19712-3:2013 and UNE EN ISO 4586-2:2009 standards, for impact resistance - Water absorption in continuous cycles in the range between 0.5 - 5% - A peeling resistance between 7 - 10 kg / m Thus, an example of a material that provides these characteristics is a core made of a thermoplastic material based on polyethylene terephthalate, which also allows for easy handling with current machinery in the sector. Furthermore, this compound is a recyclable material, which can benefit the sustainability of the resulting product. The sheet adhesive is a hygroscopic polyurethane hot melt adhesive comprising: For its part, the edgebanding adhesive is a hygroscopic polyurethane hot melt adhesive comprising: Unlike other solutions in the sector, this countertop panel features a structure that increases the durability of the resulting panel while maintaining the properties of a countertop suitable for kitchens, bathrooms, or contract furniture. Specifically, this solution improves the bond between these elements, which initially exhibit a weak and unstable connection under external stress. Additionally, the structure employed in the development of this invention reduces the final weight of the panel, enhancing its applications. The described structure maintains high resistance to abrasion, heat, fire, and water, resulting in excellent characteristics for its use as a countertop panel, making it competitive with other current solutions. Therefore, the countertop panel according to the present invention provides an economical and resistant solution with high durability, resulting in an economical and feasible alternative to current countertop panel solutions in kitchens, bathrooms or other types of furniture. In the figures of the present invention, reference is made to the following set of elements: 100 Countertop Panel 1 Core 2 Top plate 3 Bottom plate 4 Song 5 Iron-on adhesive 6 Edge banding adhesive Brief description of the figures Figure 1 shows a schematic of an embodiment of a countertop panel according to the present invention. Detailed description of the invention As stated, the object of the present invention is to provide a new countertop panel. As shown in Figure 1, the countertop panel (100) according to the present invention comprises: - a nucleus (1), - an upper plate (2) and a lower plate (3), joined to the core (1) by a plate adhesive (5), and - an edge (4), attached to the core (1) by an edge adhesive (6). The core (1) requires a density between 8 and 300 kg / m³, at least level 5 impact resistance according to UNE EN ISO 19712-3:2013 and UNE EN ISO 4586-2:2009, a peel resistance between 7 and 10 kg / m³, and between 0.5 and 5% water absorption in continuous cycles. Additionally, the core has a compressive strength between 0.5 and 6 MPa and a compressive modulus between 50 and 300 MPa. Thus, the core (1) can be made of a thermoplastic material based on polyethylene terephthalate (PET). Specifically, the polyethylene terephthalate used is either extruded or in the form of recyclable PET flakes. In this way, a 100% recycled and recyclable product can be achieved. This core (1) has dimensions similar to a parallelepiped. Thus, two main surfaces can be defined, a top surface and a bottom surface, and a lateral surface or face, smaller than the main surfaces. Unlike other materials, polyethylene terephthalate (PET) offers good durability over time, with excellent strength and toughness properties. PET is resistant to high humidity and temperature, making it suitable for use in both outdoor spaces and indoor areas such as kitchens and bathrooms. Additionally, it is characterized by its high resistance to constant stress and wear thanks to its rigidity and hardness. In a particular embodiment, the core (1) of the countertop panel (199) is constructed from, for example, one of the variants of the Divinycell® PR series (PR80, PR100, PR150, PR200) ​​from DIAB International AB. These variants are acceptable depending on the final degree of twist of the resulting panel, which will be defined according to its end use. These variants can be defined according to the following characteristics: density, thermal resistance temperature, compressive strength, compression modulus, shear stress, shear modulus, shear stress and shear modulus. According to the present invention, the countertop panel comprises an upper plate and a lower plate, covering the corresponding upper and lower surfaces of the countertop panel core. In a particular embodiment, the top plate (3) and the bottom plate (4) have a thickness between 0.8 and 12 mm, preferably 3–4 mm. The thickness of these plates (3, 4) allows for acceptable strength, especially torsion and tension, in the resulting panel. A thickness below this range would result in a more malleable product, while a greater thickness would increase the weight and cost of the final product. In another specific application, these panels are made of a phenolic material. This type of material allows for the development of a panel with the characteristics described above. Phenolic materials are compounds made of natural resins and polymers. The phenolic compound has moisture-resistant and antibacterial properties, making it ideal for countertop panels where hygiene is a key factor. Alternatively, the boards (3, 4) can be made of wood, high-pressure laminate (HPL), melamine, melamine-coated paper, Kraft paper, laminated offset paper, or laminated wood. The choice of material depends on the product's end use. For example, in applications requiring lower abrasion or heat resistance, melamine or offset paper can be used. In conclusion, modifying the material of the top and bottom boards allows for a wider range of products, aesthetically resembling other conventional products on the market. Other materials such as stone (natural or artificial), silica or silicate surfaces, and cement or cementitious surfaces are discarded due to the high cost or weight they would add to the resulting countertop panel. These materials are heavier, making them difficult to use with current machinery in the sector, and when handled, for example, by cutting or shaping them, they can release silicates, increasing the risk of health problems or resulting in a poor appearance. Additionally, these materials have low adhesion to other materials, which hinders their application as a construction material for the slabs according to the present invention. Other alternative materials have lower torsional and impact resistance, which limits their application capabilities and makes them difficult to adapt to residential use.For example, a lot of dirt can be generated when working with these materials inside the home. Specifically, in one embodiment of the present invention, the top sheet (3) of the countertop panel (100) is made of a decorative laminate based on thermosetting resins. This type of sheet provides excellent characteristics to the resulting panel. Additionally, this type of sheet can be surface-coated with a fingerprint-resistant varnish, achieving a matte surface, in accordance with EN 438:2016. Additionally, the countertop panel (100) comprises an edge (4) intended to cover the side face of the countertop panel. In a particular embodiment, the edge (4) is made of ABS material. This material provides a superior aesthetic finish compared to other materials. In addition to the aesthetic improvement, this material offers greater impact resistance, thus enhancing the overall strength of the panel in the event of an occasional impact to the edge. Specific examples of edgebanding used according to the present invention are edgebanding (4) based on polyvinyl chloride (PVC) or acrylonitrile butadiene styrene (ABS). Unlike other materials available in the industry, these materials provide the ability to aesthetically close the sandwich panel, and can be processed using existing machinery. PVC is an excellent insulator, so a PVC edge (4) offers high thermal resistance, which can be relevant in some countertop panel applications. Meanwhile, an ABS edge (4) offers high hardness and impact resistance, ideal for protecting the central core of the countertop panel. Due to the low adhesion between the elements of the countertop panel (100), a specific adhesive is required. Surprisingly, bonding the core (1) to a board (2, 3) requires a substantially different adhesive than bonding the core (1) to the edge (4). Thus, a first adhesive, or board adhesive (5), and a second adhesive, or edgebanding adhesive (6), can be defined. The first adhesive or sheet adhesive (5) is a polyurethane hot melt adhesive. It is a hygroscopic adhesive, enabling its application in humid environments. Specifically, this adhesive (5) exhibits good speed, a long open time (120–220 seconds, according to the D&V method), and high specific adhesion to materials such as glass, metals, plastics, composites, and ABS. Additionally, the sheet adhesive (5) according to the present invention has a medium setting time (90–150 seconds, according to the D&V method) and low viscosity (Brookfield viscosity - ASTM D3236: in the range of 2,500–6,000 mPas at 140°C). These characteristics allow this adhesive to be used as a sheet adhesive (5) efficiently and economically. Additionally, the curing time of this sheet adhesive is within a range of 1 to 4 days, at a temperature between 15 and 20 ºC and normal relative humidity. The curing time depends on ambient temperature and humidity conditions. This sheet metal adhesive requires specific usage conditions: - Ambient and material temperature: above 11 - 18 °C - Application head temperature: 70 - 190 °C - Nozzle temperature: 70 - 190 °C In one particular embodiment, the sheet adhesive (5) has a Brookfield viscosity of 4,500 mPas at 140ºC, with an open time in the range of 150 - 180 seconds, a solidification time of 100 - 120 seconds, and a cross-linking time of approximately 3 days. Additionally, when gluing materials without moisture, for example: PVC / PVC or PVC / AI, the ambient humidity should be above 30%, preferably above 50%. The second adhesive, or edgebanding adhesive (6), is a hygroscopic polyurethane hot melt adhesive. Unlike the sheet adhesive, the edgebanding adhesive has a high viscosity (Browfield viscosity - ASTM D3236: in the range of 50,000 - 60,000 mPas at 140ºC) and a curing time of between 1 and 4 days. In one particular embodiment, the edgebanding adhesive has a Brookfield viscosity of 60,000 mPas at 140ºC and a curing time of approximately 3 days. Example 1 In one particular embodiment, the present solution has been implemented with the following components: - A Divinycell PR100 core, with dimensions 305-130 and a thickness of 20 mm, - A top sheet of high-pressure decorative laminate (HPL) with a thickness of 2 mm, - A bottom sheet made of 2 mm thick high-pressure decorative laminate (HPL), - An edge made of 2 mm thick ABS, - The sheet adhesive is a hygroscopic polyurethane hot melt adhesive comprising: a viscosity, Brookfield (ASTM D3236) between 2,500 - 6,000 mPas at 140 ºC, a curing time between 1 - 4 days, an open time (DV Method) between 120 - 220 seconds and a solidification time (DV Method) between 90 - 150 seconds, and - The edgebanding adhesive is a hygroscopic polyurethane hot melt adhesive comprising a viscosity, Brookfield (ASTM D3236) between 50,000 - 60,000 mPas at 140 ºC and a curing time between 1 - 4 days. The process for obtaining this countertop panel includes: - to arrange a core, - glue an upper and lower sheet onto the corresponding upper and lower surfaces of the core using sheet adhesive, and - glue an edge onto the side face of the core using an edgebanding adhesive. The board can be bonded by applying board adhesive, at least partially, to the top and bottom surfaces of the core and then contacting the top and bottom boards with the adhesive applied to the corresponding surface of the core. Alternatively, the board adhesive can be applied to the inner face of the board, and this assembly can then be made to contact the corresponding top or bottom surface of the board to be bonded. This process can be used similarly for edge banding. The edge banding adhesive can be applied to the side of the core or alternatively to the inside of the edge, and then the adhesive can be applied to the other element to be bonded. Therefore, the present invention succeeds in overcoming the current limitations in the development of countertop panels, by providing an economical solution with excellent resistance and durability properties, which allows its flexible use in the development of kitchens, bathrooms or contract furniture, where the necessary conditions are highly variable.

Claims

1. A countertop panel (100) characterized in that it comprises: - a core (1) comprising a parallelepiped shape defining a top surface, a bottom surface and a side face; - a top sheet (2) and a bottom sheet (3) bonded to the top and bottom surfaces of the core (1), respectively, by a sheet adhesive (5); - an edge (4) bonded to the side face of the core by an edge adhesive (6); wherein the core (1) comprises a density between 80 - 300 kg / m3, at least a level 5 (UNE EN ISO 19712-3:2013 and UNE EN ISO 4586-2:2009) of impact resistance, a peel resistance between 7 - 10 kg / m, and 0.5 - 5% water absorption in continuous cycles; where the sheet adhesive (5) is a hygroscopic polyurethane hot melt adhesive comprising: a viscosity, Brookfield (ASTM D3236) between 2,500 - 6.

1. The countertop panel according to claim 1, wherein the core is made of a thermoplastic material based on polyethylene terephthalate.

2. The countertop panel according to claim 1, wherein the adhesive (5) has a Brookfield viscosity of 4,500 mPas at 140°C, a curing time of 1-4 days, an open time (DV Method) of 120-220 seconds, and a solidification time (DV Method) of 90-150 seconds; and wherein the edgebanding adhesive (6) is a hygroscopic polyurethane hot melt adhesive comprising a Brookfield viscosity (ASTM D3236) of 50,000-60,000 mPas at 140°C and a curing time of 1-4 days.

3. The countertop panel according to claim 1, wherein the core is made of a thermoplastic material based on polyethylene terephthalate.

4. The countertop panel according to claim 1, wherein the iron-on adhesive (5) comprises a curing time of 3 days.

5. The countertop panel according to claim 1, wherein the iron-on adhesive (5) comprises an open time in the range of 150–180 seconds. 6.The countertop panel according to claim 1, wherein the board adhesive (5) has a setting time in the range of 100–120 seconds.

7. The countertop panel according to claim 1, wherein the edgebanding adhesive (6) has a Brookfield viscosity of 60,000 mPas at 140°C.

8. The countertop panel according to claim 1, wherein the edgebanding adhesive (6) has a curing time of 3 days.

9. The countertop panel according to claim 1, wherein the top (2) or bottom (3) board has a thickness in the range of 0.8–12 mm.

10. The countertop panel according to claim 1, wherein the top (2) or bottom (3) board of the countertop panel (100) is made of phenolic material, wood, high-pressure laminate (HPL), melamine, melamine paper, Kraft paper, laminated offset paper, or laminated wood.

11. The countertop panel according to claim 1, wherein the edge (4) of the countertop panel (100) is made of PVC or ABS.