Mineral board and decorative mineral panel

Abstract

A method for manufacturing a decorative panel (1) comprises the steps of providing a mineral board, preferably a magnesium oxide based board; applying a thermoset resin (17) onto the surface of the mineral board; partially curing the thermoset resin; applying a resin-impregnated printed paper sheet (18) onto the partially cured thermoset resin; and applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board.

Description

[0001] Mineral board and decorative mineral panel

[0002] The invention relates to mineral boards, e.g. magnesium oxide boards, and decorative panels comprising such board as carrier. The invention further relates to methods for making such mineral boards.

[0003] Decorative panels comprising a mineral board as carrier and a decorative top layer on the mineral board are known. Examples of such panels having a magnesium oxide based board are described in WO2021 / 165769A1 and in WO 2021 / 165812A1.

[0004] It is an objective of the invention to provide improved mineral boards for use in the production of decorative panels comprising such mineral boards as carrier material. It is an objective of the invention to provide decorative panels comprising a mineral board as carrier material that show improved properties and / or can be manufactured more easily or in a more reliable manner. It is a further objective to provide methods for making such mineral boards for use in the production of decorative panels.

[0005] The first aspect of the invention relates to a method for manufacturing a decorative panel. The method comprises the steps of providing a mineral board; applying a thermoset resin onto the surface of the mineral board; partially curing the thermoset resin; applying a resin-impregnated printed paper sheet onto the partially cured thermoset resin; and applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board.

[0006] It is a benefit of this method that excellent adhesion is created between the resin- impregnated printed paper sheet and the mineral board thanks to the presence of the partially cured thermoset resin layer when laminating by means of a press operation the resin-impregnated printed paper sheet onto the mineral board. If the resin-impregnated printed paper sheet comprises a resin that condensates during the lamination step, problems with the occurrence of condensation moisture due to the chemical curing reaction are prevented.

[0007] Preferably, the mineral board is or comprises a magnesium oxide based board. Meant is that the board comprises a magnesium oxide cement matrix; e.g. a MOS (magnesium oxy sulphate) or a MOC (magnesium oxy chloride) matrix.

[0008] A preferred method according to the first aspect of the invention is characterized in that in the step of applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board, the thermoset resin and the resin of the resin-impregnated printed paper sheet are cured. The curing provides an effective adhesion between the different layers in the laminate that is formed.

[0009] The thermoset resin applied onto the surface of the mineral board is preferably selected from melamine resin, melamine formaldehyde resin, urea formaldehyde resin, polyurethane resin (e.g. a water based polyurethane dispersion) or phenol formaldehyde resin. Such resins have shown to provide excellent adhesion results. Polyurethane is particularly preferred because of it adheres well to a broad range of substrates.

[0010] The second aspect of the invention relates to a method for manufacturing a decorative panel. The method comprises the steps of

[0011] - providing a mineral board;

[0012] - drying the mineral board to a moisture content below 7 wt%, and preferably below 5 wt%, and preferably below 4 wt%, more preferably below 3 wt%, more preferably higher than 2 wt%;

[0013] - applying a resin-impregnated printed paper sheet onto the mineral board; and

[0014] - applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board.

[0015] It is a benefit of the method of the second aspect of the invention that issues with condensation moisture originating from the resin of the resin-impregnated printed paper sheet are prevented during the lamination process. This is especially beneficial when the mineral board comprises cellulosic fillers, e.g. wood fibers or wood dust. Cellulosic fillers at the surface of the mineral board can absorb condensation moisture and create bond sites for the resin of the resin-impregnated paper sheet, but only if the moisture content is sufficiently low such that there is room for the cellulosic material to absorb the condensation moisture without steam being created which would be negative for the adhesion.

[0016] The moisture content of the mineral board should not be too low however, as it would mean that water molecules are driven out of the mineral cement crystals (e.g. out of the magnesium oxide cement crystals), which would mean an unwanted weakening of the mineral board.

[0017] Optionally, any embodiment of the method of the second aspect of the invention can be as in any embodiment of the first aspect of the invention.

[0018] Preferably, in the method according to the second aspect of the invention, the mineral board is or comprises a magnesium oxide based board. Meant is that the board comprises a magnesium oxide cement matrix; e.g. a MOS (magnesium oxy sulphate) or a MOC (magnesium oxy chloride) matrix.

[0019] A preferred method of the second aspect is characterized in that the step of drying the mineral board is performed by using IR (infrared) heat, preferably by using electrical IR-lamps or by IR radiating gas burners or by using hot air.

[0020] The use of IR-heat is particularly preferred, as it provides an energy efficient way of drying the mineral board to the required moisture level.

[0021] In a preferred method according to the first aspect of the invention as well as according to the second aspect of the invention, the drying operation is performed after applying the thermoset resin onto the surface of the mineral board. This embodiment provides the synergistic benefits of the first aspect and the second aspect of the invention, resulting in even better adhesion in the laminate made.

[0022] The third aspect of the invention relates to a method for manufacturing a decorative panel. The method comprises the steps of

[0023] - providing a mineral board;

[0024] - applying a resin-impregnated printed paper sheet onto the mineral board; and

[0025] - applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board; wherein the resin-impregnated printed paper sheet comprises at one side a polyurethane layer or an acrylate layer, wherein the resin-impregnated printed paper sheet is applied onto the mineral board such that the polyurethane layer or the acrylate layer contacts the mineral board.

[0026] It is a benefit of the third aspect of the invention that improved adhesion is obtained of the resin-impregnated printed paper sheet to the mineral board. The polyurethane layer or the acrylate layer provide for the improved adhesion, as it acts as an adhesion layer.

[0027] Preferably, in the method according to the third aspect of the invention, the mineral board is or comprises a magnesium oxide based board. Meant is that the board comprises a magnesium oxide cement matrix; e.g. a MOS (magnesium oxy sulphate) or a MOC (magnesium oxy chloride) matrix.

[0028] Optionally, any embodiment of the method of the third aspect of the invention can be as in any embodiment of the first aspect of the invention and / or as in any embodiment of the second aspect of the invention.

[0029] The fourth aspect of the invention relates to a method for manufacturing a decorative panel, wherein the method comprises the steps of providing a mineral board; applying a resin-impregnated printed paper sheet onto the mineral board; and applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board. The mineral board is locally impregnated with a resin. With “locally” is meant that over a certain area - but not over the full area - of the surface of the mineral board, the mineral board is impregnated with a resin.

[0030] It is a benefit of the fourth aspect of the invention that edges of the mineral board - e.g. after sawing the board to smaller board units - are provided at least over part of the thickness of the mineral board (and preferably over the full thickness of the mineral board) with a resin that will seal the edges over at least part - and preferably over the full thickness - of the mineral board.

[0031] Preferably ,the mineral board is locally impregnated with a resin through the full thickness of the mineral board. This is beneficial for the production of panels - e.g. decorative panels - that will be water resistant, as water or moisture at the edges will not have negative consequences.

[0032] Preferably, in the method according to the fourth aspect of the invention, the mineral board is or comprises a magnesium oxide based board. Meant is that the board comprises a magnesium oxide cement matrix; e.g. a MOS (magnesium oxy sulphate) or a MOC (magnesium oxy chloride) matrix.

[0033] Optionally, any embodiment of the method of the fourth aspect of the invention can be as in any embodiment of the first aspect of the invention, and / or as in any embodiment of the second aspect of the invention, and / or as in any embodiment of the third aspect of the invention.

[0034] A preferred embodiment of the fourth aspect of the invention is characterized in that the board is cut at the location locally impregnated with resin, such that the edges of the board originating from the cutting are at least over a part of the thickness of the mineral board - and preferably over the full thickness of the mineral board - sealed by the resin. The boards resulting from this embodiment can be used for the production of water resistant panels, as harmful consequences from water or moisture at the edges are prevented thanks to the sealing of the edges. A preferred embodiment of the fourth aspect of the invention is characterized in that the resin with which the mineral board is locally impregnated comprises or consists of polymeric methylene diphenyl diisocyanate, polyurethane or combinations thereof.

[0035] In embodiments of the first aspect, the second aspect, the third aspect or the fourth aspect of the invention, the resin of the resin-impregnated printed paper sheet can preferably be selected from a urea formaldehyde resin, a melamine resin, a melamine formaldehyde resin, an acrylic resin, or combinations thereof.

[0036] Preferred embodiments of the first aspect, the second aspect, the third aspect or the fourth aspect of the invention are characterized in that the method comprises the step of applying a second resin-impregnated paper sheet onto the resin-impregnated printed paper sheet. In the step of applying pressure at increased temperatures wherein the resin- impregnated printed paper sheet is laminated onto the mineral board, also the second resin-impregnated paper sheet is laminated onto the mineral board.

[0037] It is a benefit that a wear layer can be provided on the mineral board.

[0038] Preferably, the second resin-impregnated paper sheet provides after the lamination step a transparent or translucent layer.

[0039] Preferably, the resin of the second resin-impregnated paper sheet is a melamine resin or a melamine formaldehyde resin.

[0040] The resin-impregnated paper sheet can comprise wear resistant particles, preferably corundum. The presence of the wear resistant particles improves the wear resistance of the wear layer.

[0041] Preferred embodiments of the first aspect, the second aspect, the third aspect or the fourth aspect of the invention are characterized in that in the step of applying pressure at increased temperatures, the surface of the decorative panel is provided with a texture. The texture can be provided in register with the printed decor of the resin-impregnated printed paper sheet.

[0042] Such embodiments allow to provide the mineral board with an appealing decorative surface, e.g. the imitation of a wood surface.

[0043] The fifth aspect of the invention relates to a mineral board, characterized in that the mineral board comprises one or more than selected from the list of:

[0044] - wood fibers and / or wood dust, wherein the wood fibers and / or the wood dust comprise a coating, preferably wherein the coating is selected from the list of silicone, silane or siloxane, or combinations thereof;

[0045] - glass fibers, wherein the glass fibers are provided with a coating or spin finish, preferably wherein the coating is selected from the list of silicone, silane or siloxane, or combinations thereof;

[0046] - basalt fibers, wherein the basalt fibers are provided with a coating or spin finish; preferably wherein the coating is selected from the list of silicone, silane or siloxane, or combinations thereof.

[0047] The coating provides the wood fibers, the glass fiber of the basalt fibers with hydrophobic properties. This is beneficial for producing a mineral board which is resistant to water and moisture.

[0048] Preferably, The mineral board of the fifth aspect of the invention is a magnesium oxide based board.

[0049] The sixth aspect of the invention relates to a mineral board characterized in that the mineral board comprises wood fibers and / or wood dust. The wood fibers or wood dust comprise a coating. The coating is selected from an acrylic coating, a polyurethane dispersion (PUD), an isocyanate coating such as a methylene diphenyl diisocyanate (MDI) coating or a polymeric diphenyl diisocyanate (pMDI) coating, an epoxy coating, a vinyl ester coating, a bio-based coating -e.g. based upon sugar, lignin, flour and / or hyperbranched polyamides-, a styrene butadiene coating, an acrylate coating -such as an emulsion of acrylate or a styrene acrylate, a latex modified acrylate-, an epoxy resin, an alkyd resin -such as an polyurethane modified alkyd-, a silicon containing coating -such as polysiloxanes, polydimethylsiloxane-.

[0050] It is a benefit of such mineral board that it has good water resistant properties, as water and vapor absorption by the wood fibers and / or wood dust is minimized or even fully prevented by the coating on the wood fibers and / or wood dust.

[0051] The mineral board of the sixth aspect of the invention preferably is a magnesium oxide based board and / or a board according to any embodiment of the fifth aspect of the invention.

[0052] The coating preferably encapsulates the wood fibers and / or the wood dust. This embodiment provides even better water and moisture resistant properties as the wood fibers and / or dust can no longer absorb moisture.

[0053] The seventh aspect of the invention relates to a mineral board characterized in that the mineral board comprises one or more additives selected from

[0054] - silanes, preferably hydrophobic silanes;

[0055] - siloxanes, preferably hydrophobic siloxanes;

[0056] - metallic soaps, e.g. salts of fatty acids, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps;

[0057] - silicates, preferably silicates with hydrophobic properties, e.g. Li-silicates;

[0058] - hydrophobic silica, preferably silica comprising a hydrophobic group chemically bonded to its surface, more preferably wherein the hydrophobic group is selected from alkyl or polydimethylsiloxane chains.

[0059] These additives provide the board with hydrophobic properties, such that the water resistance of the mineral board is improved.

[0060] Siloxanes and hydrophobic silica are particularly preferred because of their outstanding hydrophobic properties. The one or more additives in the mineral board are preferably distributed over the full volume of the mineral board. Such embodiment provides good water resistance to the full volume of the mineral board.

[0061] The mineral board of the seventh aspect of the invention preferably is a magnesium oxide based board, and / or a board according to any embodiment of the fifth aspect, and / or the sixth aspect of the invention.

[0062] The eighth aspect of the invention relates to a mineral board, characterized in that the mineral board comprises fillers selected from one of more than one of wood fibers, wood dust, glass fibers or basalt fibers; wherein a top layer of the mineral board comprises a higher percentage by weight of the fillers than the central section of the mineral board.

[0063] The higher percentage by weight of the fillers in the top layer will result in more presence of the fillers at the top surface of the mineral board. This higher presence if beneficial as the fillers provide bonding opportunities when laminating a layer onto the mineral board. When lamination a resin-impregnated paper sheet (e.g. a paper sheet impregnated with melamine formaldehyde resin), the melamine formaldehyde resin can bond to the fillers, e.g. to the hydroxyl groups of wood fibers or wood dust. The result is better adhesion of the layer laminated to the mineral board.

[0064] Preferably, the top layer of the mineral board comprises relative to the weight of the layer 10 wt% more fillers than the central section of the mineral board.

[0065] Optionally the fillers can be provided with a coating. Such coating can increase the adhesion.

[0066] The mineral board of the eighth aspect of the invention preferably is a magnesium oxide based board, and / or a board according to any embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect of the invention. A preferred embodiment of the eighth aspect of the invention is characterized in that the mineral board has a layered construction, with an upper layer, a central layer and a bottom layer. The central layer is provided between - and preferably contacting - the upper layer and the bottom layer. The upper layer of the mineral board comprises a higher percentage by weight of the fillers - and preferably of wood-based fillers (e.g. wood fibers and / or wood dust) - than the central section of the mineral board.

[0067] A preferred mineral board according to the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, or the eighth aspect of the invention is characterized in that the mineral board is free from a reinforcing fiberglass web.

[0068] Such embodiment is preferred as it allows to have a more homogeneous composition throughout the mineral board, which facilitates the manufacturing process of the mineral board.

[0069] A preferred mineral board according to the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, or the eighth aspect of the invention is characterized in that the mineral board comprises a magnesium oxide cement based matrix, wherein the magnesium oxide cement is a magnesium oxy chloride cement.

[0070] Such embodiments are preferred as the presence in the board of the magnesium oxy chloride cement means that the board comprises a very stable magnesium oxide cement matrix.

[0071] A preferred mineral board according to the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, or the eighth aspect of the invention is characterized in that the mineral board comprises a magnesium oxide cement based matrix, wherein the magnesium oxide cement is a magnesium oxy sulphate.

[0072] Such embodiments are preferred as the formation of such magnesium oxide cement based matrix can be controlled more easily when manufacturing the board. A preferred mineral board according to the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention is characterized in that the mineral board comprises a magnesium oxide cement based matrix, wherein the magnesium oxide cement is a combination of magnesium oxy chloride cement and of magnesium oxy sulphate cement.

[0073] Such embodiments are preferred as a stable magnesium oxide cement matrix is obtained the formation of which can be controlled easily when manufacturing the board.

[0074] A preferred magnesium oxide cement matrix comprises one or more of

[0075] - MgO - MgC12 - H2O in a 5-1-13 mol ratio; or

[0076] - MgO - MgSO4 - H2O, in a 9-1-21, 5-1-14, 9-1-20 or 5-1-12 mol ratio.

[0077] A preferred magnesium oxide cement matrix comprises one or more of a 5Mg(OH2).MgSO4.7H2O crystal structure, a 5Mg(OH2).MgC12.8H2O crystal structure; or a 8Mg(OH2).MgC12.8H2O crystal structure; or combinations thereof.

[0078] A preferred mineral board according to the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention is characterized in that the density of the mineral board is at least 1300 kg / m3, preferably at least 1350 kg / m3. Thanks to the high density, the resistance to water of the board is better. The board is more compacted, leaving less voids for water the enter the board.

[0079] A mineral board as in any embodiment of the fifth aspect, the sixth aspect, the seventh aspect, or the eighth aspect can be used in embodiments of the first aspect, the second aspect, the third aspect or the fourth aspect of the invention.

[0080] The ninth aspect of the invention relates to package. The package comprises at least one

[0081] - and preferably a plurality of - mineral board(s). The package is characterized in that it comprises a water tight packaging material. The mineral boards are packed in the water tight packaging material. The moisture content of the mineral boards is less then 7 wt%, preferably less than 5 wt% and preferably more than 2 wt%. The package comprising mineral boards of the ninth aspect of the invention has the benefit that a partially cured thermoset resin impregnated paper can be thermally pressed with good lamination quality onto the mineral board, as the low level of moisture content of the mineral boards is maintained thanks to the water tight packaging material.

[0082] The moisture content of the mineral boards is preferably more than 2 wt%, as a lower moisture content would mean that crystallization water of the mineral board has been removed, resulting in lower mechanical properties of the mineral board.

[0083] The package preferably comprises a multitude of stacked mineral boards.

[0084] The mineral boards in the package of the ninth aspect of the invention can be magnesium oxide based boards, preferably magnesium oxide boards according to any embodiment of the fifth aspect, and / or of the sixth aspect, and / or of the seventh aspect, and / or of the eighth aspect of the invention.

[0085] A preferred package is characterized in that the water tight packaging material comprises a plastic foil and / or that the water tightness of the packaging material is provided by a plastic foil.

[0086] The tenth aspect of the invention relates to a decorative panel. The decorative panel comprises a mineral board and a top layer. The top layer comprises a resin-impregnated printed paper sheet. The decorative panel comprises one or more than one layer of resin- impregnated paper sheets between the mineral board and the resin-impregnated printed paper sheet.

[0087] It is a benefit of the decorative panel of the tenth aspect of the invention that improved adhesion is obtained between the mineral board and the resin-impregnated printed paper sheet. It is a further benefit of the invention that the decorative panel can be provided with deeper embossments at its surface. Mineral boards are essentially non-compressible. The provision of the one or more than one layer of resin-impregnated paper sheets creates a layer in the board that allows to be deeper embossed, e.g. in the thermal press lamination operation.

[0088] The presence of the one or more than one layer of resin-impregnated paper sheets also allows to provide the decorative panel with a pressed bevel. Mineral boards are essentially non-compressible. The provision of the one or more than one layer of resin- impregnated paper sheets creates a layer in the board that allows a bevel to be pressed in the board.

[0089] Preferably, the paper weight (meaning without the resin) of each of the one or more than one layer of resin-impregnated paper sheets is between 100 and 200 gram per square meter.

[0090] Preferably, the weight of each of the one or more than one layer of resin-impregnated paper sheets is between 200 and 440 gram per square meter.

[0091] Preferably, at least two and preferably less than five, more preferably less than four layers, of resin-impregnated paper sheets are provided. Such embodiments provide optimal performance in terms of embossment and pressed bevel that can be provided, without unduly increasing material and production costs.

[0092] The use of three layers of resin-impregnated paper sheets has shown to be optimal.

[0093] Preferably, the paper sheets of the one or more than one layer of resin-impregnated paper sheets are Kraft paper sheets.

[0094] Preferably, the paper sheets of the one or more than one layer of resin-impregnated paper sheets are unprinted paper sheets. A preferred embodiment of the tenth aspect is characterized in that the resin of the resin- impregnated paper sheets is selected from urea formaldehyde resin, melamine resin, melamine formaldehyde resin, polyurethane resin (e.g. a water based polyurethane dispersion) or phenol formaldehyde resin, or a combination of melamine formaldehyde and phenol formaldehyde resin.

[0095] Melamine formaldehyde resin and a combination of melamine formaldehyde and phenol formaldehyde resin are particularly preferred because of their excellent performance.

[0096] The use of phenol formaldehyde resin, in itself or in combination e.g. with melamine formaldehyde resin is beneficial for its water resistance properties.

[0097] A preferred embodiment of the tenth aspect is characterized in that the decorative panel comprises an edge, wherein the edge is provided with a bevel. At the bevel, the thickness of the combination of the top layer and the one or more than one layer of resin- impregnated paper sheets is lower than outside the bevel.

[0098] It is a benefit of such embodiments that the decorative panel can have been provided with a pressed bevel, which is facilitated thanks to the compressibility of the one or more than one layer of resin-impregnated paper sheets.

[0099] A preferred embodiment of the tenth aspect is characterized in that the decorative panel comprises an edge. The edge is provided with a pressed bevel, wherein the thickness of the combination of the top layer and the one or more than one layer of resin-impregnated paper sheets is reduced at the bevel.

[0100] The presence of the one or more than one layer of resin-impregnated paper sheets facilitates the production of a pressed bevel, and provides the opportunity to make a deeper bevel, as the mineral board has little compressibility.

[0101] The mineral board of the decorative panel of the tenth aspect of the invention can be a magnesium-oxide based board; and / or preferably a mineral board as in any of the embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention.

[0102] The eleventh aspect of the invention relates to a decorative panel. The decorative panel comprises a mineral board and a top layer. The top layer comprises a resin-impregnated printed paper sheet. The decorative panel comprises one or more than one layer of resin- impregnated bottom paper sheets. The one or more than one layer of resin-impregnated bottom paper sheets are laminated to the mineral board at the opposite side of the side comprising the top layer.

[0103] It is a benefit that the bottom paper sheets provide for a balancing layer, certainly if at the upper side of the decorative panel one or more than one resin-impregnated paper sheets have been laminated. Furthermore, the bottom paper sheets prevent damage to the bottom lip of a female coupling part that can be provided at the edge of the decorative panel, for coupling with a male coupling part at an edge of another such panel.

[0104] The one or more than one layer of resin-impregnated paper sheets preferably are Kraft paper sheet and / or are preferably unprinted paper sheets.

[0105] Preferably more than one, and preferably less than four, resin-impregnated bottom paper sheets are provided.

[0106] The mineral board of the decorative panel of the eleventh aspect of the invention can be a magnesium-oxide based board; and / or preferably a mineral board as in any of the embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention.

[0107] The decorative panel of the eleventh aspect of the invention can be a decorative panel as in any embodiment of the tenth aspect of the invention.

[0108] A preferred embodiment of the eleventh aspect of the invention is characterized in that the resin of the resin-impregnated paper sheets is selected from urea formaldehyde resin, melamine resin, melamine formaldehyde resin, polyurethane resin (e.g. a water based polyurethane dispersion) or phenol formaldehyde resin, or a combination of melamine formaldehyde and phenol formaldehyde resin.

[0109] The twelfth aspect of the invention relates to a decorative panel . The decorative panel of the twelfth aspect comprises a mineral board and a top layer. The top layer comprises a resin-impregnated printed paper sheet. The resin-impregnated printed paper sheet comprises at its side directed to the mineral board a layer of polyurethane.

[0110] It is a benefit of this embodiment that an excellent bonding is provided between the mineral board and the resin-impregnated printed paper sheet.

[0111] The mineral board of the decorative panel of the twelfth aspect of the invention can be a magnesium-oxide based board; and / or preferably a mineral board as in any of the embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention.

[0112] The decorative panel of the twelfth aspect of the invention can be a decorative panel as in any embodiment of the tenth aspect of the invention and / or as in any embodiment of the eleventh aspect of the invention.

[0113] The thirteenth aspect of the invention relates to a decorative panel. The decorative panel comprises a mineral board and a top layer. The decorative panel comprises a resin layer. The decorative panel comprises an edge provided with a bevel. The bevel is a pressed bevel provided by compression of at least the resin layer.

[0114] The presence of the resin layer allows the provision of a pressed bevel, as the resin layer is compressible wherein the mineral board is not much compressible.

[0115] A pressed bevel has the benefit that a printed decor of the top layer is also provided in the pressed bevel. The resin layer is preferably present over the full surface of the decorative panel.

[0116] However, the resin layer can be present at least at the bevel, but not over the full surface of the decorative panel.

[0117] Preferably, the resin layer does not comprise a paper layer.

[0118] The mineral board of the decorative panel of the thirteenth aspect of the invention can be a magnesium-oxide based board; and / or preferably a mineral board as in any of the embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention.

[0119] The decorative panel of the thirteenth aspect of the invention can be a decorative panel as in any embodiment of the tenth aspect of the invention, and / or as in any embodiment of the eleventh aspect of the invention, and / or as in any embodiment of the twelfth aspect of the invention.

[0120] A preferred embodiment of the thirteenth aspect of the invention is characterized in that the top layer comprises a printed decor, preferably provided on a - more preferably resin impregnated - paper sheet. The resin layer is provided on top of the printed decor.

[0121] A preferred embodiment of the thirteenth aspect of the invention is characterized in that the top layer comprises a printed decor, preferably provided on a - more preferably resin impregnated - paper sheet. The resin layer is provided between the printed decor and the mineral board. Such embodiments have the benefit that the visible decor provided by the printed decor is not disturbed - also not in the pressed bevel - by the resin layer.

[0122] The resin layer of the thirteenth aspect of the invention can e.g. be a acrylic resin (e.g. a UV-curing acrylic resin) or a polyester resin (e.g. an unsaturated polyester resin). A preferred embodiment of the thirteenth aspect of the invention is characterized in that the bevel is at least partly, and preferably entirely, provided in a chamfer provided in the mineral board. Such embodiments facilitate the production of the pressed bevel.

[0123] Preferably, the resin layer is provided in the chamfer, and preferably not over the full surface of the mineral board.

[0124] Such embodiment facilitate the production of the pressed bevel, while keeping the amount of resin layer required to a minimum.

[0125] The chamfer can have been provided in the mineral board by means of a machining operation, or by using a structured press element when pressing the ingredients of the board.

[0126] The fourteenth aspect of the invention relates to a decorative panel. The decorative panel comprises a mineral board and a top layer. The decorative panel comprises an edge, wherein the edge is provided with a bevel. The bevel is at least partly, and preferably entirely, provided in a chamfer provided - preferably by a machining operation - in the mineral board.

[0127] It is a benefit of the invention that the creation of a bevel can be facilitated. Mineral boards are not well compressible, making the provision of a pressed bevel difficult or impossible without taking additional measures. A chamfer can be mechanically provided in the board before laminating the top layer onto the mineral board. The chamfer can even be provided in the mineral board by milling a groove in a mineral board and sawing the board at the groove, thereby providing two mineral boards each with a chamfer at an edge.

[0128] A resin layer can be applied at the chamfer (preferably this resin layer is not applied on the full surface of the mineral board) after which the top layer can be laminated to the mineral board. In the hot pressure lamination process, a bevel can be pressed at the chamfer, by comprising the resin layer in the chamfer. The mineral board of the decorative panel of the fourteenth aspect of the invention can be a magnesium-oxide based board; and / or preferably a mineral board as in any of the embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention.

[0129] The decorative panel of the fourteenth aspect of the invention can be a decorative panel as in any embodiment of the tenth aspect of the invention and / or as in any embodiment of the eleventh aspect of the invention, and / or as in any embodiment of the twelfth aspect of the invention, or / as in any embodiment of the thirteenth aspect of the invention.

[0130] The fifteenth aspect of the invention relates to a decorative panel. The decorative panel comprises a mineral board and a top layer. The top layer comprises a printed decor. A resin layer is provided between the decor layer and the mineral board.

[0131] It is a benefit that the resin layer of the fifteenth aspect of the invention provided sound dampening properties to the decorative panel when walked upon when used as floor covering.

[0132] Preferably, the resin layer is a foam resin layer. This has the benefit that improved sound dampening is obtained.

[0133] The printed decor is preferably provided on a paper sheet, more preferably the paper sheet is a resin impregnated paper sheet.

[0134] The resin layer can be a polyurethane layer, preferably a foamed polyurethane layer. Such layers provide improved sound dampening properties.

[0135] The resin layer can be a layer comprising or consisting of polyvinyl butyral. Such layer comprising polyvinyl butyral (PVB) can comprises cellulosic of lignocellulosic particles, e.g. wood fibers or wood chips. The presence of such particles can further improve the sound dampening properties and improve the bonding between the resin layer and the top layer of the decorative panel. E.g. a top layer comprising melamine formaldehyde resin will bond better. It is also possible to use an adhesion layer, e.g. a polyurethane layer for improving the lamination strength between the top layer and the resin layer (e.g. a polyvinyl butyral comprising resin layer).

[0136] The mineral board of the decorative panel of the fifteenth aspect of the invention can be a magnesium-oxide based board; and / or preferably a mineral board as in any of the embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention.

[0137] The decorative panel of the fifteenth aspect of the invention can be a decorative panel as in any embodiment of the tenth aspect of the invention, and / or as in any embodiment of the eleventh aspect of the invention, and / or as in any embodiment of the twelfth aspect of the invention, and / or as in any embodiment of the thirteenth aspect of the invention, and / or as in any embodiment of the fourteenth aspect of the invention.

[0138] The sixteenth aspect of the invention relates to a decorative panel. The decorative panel comprises a mineral board and a top layer. The decorative panel is rectangular: square or oblong. The decorative panel comprises at least at two opposite edges coupling parts for coupling the decorative panel with a second such decorative panel at their respective side edges; wherein in coupled condition a locking is provided in the direction perpendicular to the surface of the coupled layered panels; as well as a locking is provided in the direction perpendicular to the coupled side edges and parallel to the surface of the coupled layered panels. The coupling parts comprise at one of the two opposite edges a male coupling part. The coupling parts comprise at the other one of the two opposite edges a female coupling part.

[0139] A preferred embodiment of the sixteenth aspect of the invention is characterized in that the two opposite edges comprise an impregnation layer and / or a coating layer at least partially sealing the edges at least over a part of their surface - and preferably over their full surface - from liquid water absorption and / or from absorption of water vapor from the atmosphere. Such embodiments provide decorative panels that can be installed into a covering - e.g. a floor covering - that is less prone to negative effects that could be caused by water or moisture uptake by the decorative panels, as the impregnation or coating layer prevents ingress of water or moisture in the decorative panels. This way, if the mineral board is a magnesium oxide based board, the magnesium oxide based cement will not be negatively affected by water or moisture and will retain its integrity.

[0140] The impregnation layer and / or the coating layer of the sixteenth aspect of the invention preferably comprises a methylene difenyl diisocyanate (MDI), a silicone, a siloxane, an alkyd, an acrylate, a methacrylate, a fluorinated acrylate, a fluorinated methacrylate, a fluorinated acrylate copolymer, at (per)fluoroalkyl (meth)acrylate, a (per)fluoroalky (meth)acrylate copolymer, an epoxy rein, a fluorinated epoxy resin, a styrene acrylate, a urethane acrylate, a polyurethane modified alkyd, a fluor modified alkyd, a styrene butadiene co-polymer, a polyurethane (preferably a hydrophobic polyurethane), or combinations thereof.

[0141] A preferred combination for use in the sixteenth aspect of the invention is a composition comprising an alkyd and a polyurethane (preferably a hydrophobic polyurethane). Such compositions have shown to provide excellent water proofing properties to the decorative panel.

[0142] A preferred combination for use in the sixteenth aspect of the invention is a composition comprising an alkyd and a fluorinated acrylate (preferably a hydrophobic polyurethane). Such compositions have shown to provide excellent water proofing properties to the decorative panel.

[0143] A preferred embodiment of the sixteenth aspect of the invention is characterized in that the impregnation layer and / or the coating layer comprises a hydrophobic polymer, being for example a hydrophobic polycarbodiimide, a hydrophobic polyurethane or a hydrophobic acrylate polymer, wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms; preferably wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms.

[0144] Such embodiment provide excellent water proofing properties to the decorative panel.

[0145] Preferably, the impregnation layer and / or coating layer provides a film on the edges. The provision of a film of the edges is beneficial for improved tightness of the edges to water vapor, eliminating the impact of high moisture content in the air on the decorative panels.

[0146] The impregnation layer and / or coating layer of the sixteenth aspect of the invention can comprise a metallic soap, preferably a salt of a fatty acid, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps. Such embodiments provide improved water resistance properties to the edges of the decorative panel, and consequently to the full decorative panel.

[0147] A preferred embodiment of the sixteenth aspect of the invention is characterized in that at the two opposite edges the mineral board is impregnated from its top side at least over part of its thickness - and preferably over its full thickness - with an impregnation agent from the distal end of the coupling part to beyond the proximal end of the coupling part.

[0148] The impregnation can be performed before milling the coupling parts at the edges of the panel. The impregnation can be even be performed before cutting a larger board into panels, the edges of which can be provided with coupling parts. The board can be cut in an impregnated section, such that both edges at the cut line comprise such impregnation. Such approach has the benefit of a good impregnation over a certain depth as seen from the edge of the panel.

[0149] The impregnation in embodiments of the sixteenth aspect of the invention can preferably comprise a metallic soap, more preferably a salt of a fatty acid, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps. Such embodiments provide the decorative panel with further improved resistance to negative effects of moisture. A preferred embodiment of the sixteenth aspect of the invention is characterized in that the male coupling part comprises a tongue; and that the female coupling part comprises a groove, wherein the groove is bordered by an upper lip and by a lower lip. Preferably, the lower lip extends more distal than the upper lip. Such embodiments provide better coupling of the decorative panels, e.g. in a floor covering.

[0150] A preferred embodiment of the sixteenth aspect of the invention is characterized in that the coupling parts are configured as on the one hand a tongue and on the other hand a groove bordered by an upper lip and a lower lip. The tongue and the groove provide in coupled condition a locking in the direction perpendicular to the surface of the coupled layered panels. The tongue and the groove comprise locking parts. The locking parts provide in coupled condition a locking in the direction perpendicular to the coupled side edges and parallel to the surface of the coupled layered panels.

[0151] Preferably, the locking parts comprise a protrusion at the lower lip and a corresponding recess at the bottom of the tongue.

[0152] A preferred embodiment of the sixteenth aspect of the invention is characterized in that the coupling can be performed by means of an angling movement of the respective side edges of the decorative panels to be coupled.

[0153] The coupling parts can be substantially provided in the mineral board. Such embodiments simplify the construction of the decorative panel.

[0154] The mineral board of the decorative panel of the sixteenth aspect of the invention can be a magnesium-oxide based board; and / or preferably a mineral board as in any of the embodiment of the fifth aspect, and / or the sixth aspect, and / or the seventh aspect, and / or the eighth aspect of the invention.

[0155] The decorative panel of the sixteenth aspect of the invention can be a decorative panel as in any embodiment of the tenth aspect of the invention, and / or as in any embodiment of the eleventh aspect of the invention, and / or as in any embodiment of the twelfth aspect of the invention, and / or as in any embodiment of the thirteenth aspect of the invention, and / or as in any embodiment of the fourteenth aspect of the invention; and / or as in any embodiment of the fifteenth aspect of the invention.

[0156] A preferred embodiment of the tenth aspect, and / or the eleventh aspect, and / or the twelfth aspect, and / or the thirteenth aspect, and / or the fourteenth aspect, and / or the fifteenth aspect, and / or the sixteenth aspect of the invention is characterized in that the top layer comprises a resin-impregnated printed paper sheet, and that the resin of the resin- impregnated printed paper sheet is selected from a melamine resin, a melamine formaldehyde resin, or an acrylic resin. The use of such resins provides good durability to the decorative panel.

[0157] A preferred embodiment of the tenth aspect, and / or the eleventh aspect, and / or the twelfth aspect, and / or the thirteenth aspect, and / or the fourteenth aspect, and / or the fifteenth aspect, and / or the sixteenth aspect of the invention is characterized in that the top layer comprises a wear layer.

[0158] The wear layer preferably comprises a resin impregnated paper sheet, optionally comprising wear resistant particles such as corundum.

[0159] The wear layer can comprise or consist of a lacquer layer, e.g. an acrylic lacquer layer. The lacquer layer optionally comprises wear resistant particles such as corundum.

[0160] The seventeenth aspect of the invention relates to a method for manufacturing a mineral board. The method comprises the steps of:

[0161] - applying a magnesium oxide cement comprising mixture onto a carrier, e.g. onto a moving belt;

[0162] - scattering wood fibers and / or wood dust on top of the mixture;

[0163] - optionally compressing the mixture onto which the wood fibers and / or wood dust has been scattered, wherein the wood fibers and / or wood dust are pressed into the surface of the mixture; and

[0164] - curing the magnesium oxide cement. This method provides a mineral board the upper surface of which comprises wood fibers and / or wood dust at its surface. This is beneficial, at it increases the adhesion potential of a top layer comprising a thermoset resin (e.g. a melamine formaldehyde resin) onto this upper surface of the mineral board, as the wood fibers and / or wood dust provide sites for a bond with the thermoset resin when laminating the top layer using pressure and increased temperature onto the mineral board during with the thermoset resin of the top layer is cured.

[0165] The mineral board obtained in the method of the seventeenth aspect of the invention preferably is a magnesium oxide based board.

[0166] The mineral board obtained in the method of the seventeenth aspect of the invention preferably is a mineral board as in any embodiment of the fifth aspect, and / or of the sixth aspect, and / or of the seventh aspect, and / or of the eighth aspect of the invention.

[0167] A preferred embodiment of the method of the seventeenth aspect of the invention is characterized in that the wood fibers and / or wood dust are coated, preferably coated with an uncured or partially cured thermoset resin, even more preferably coated with a resin that reacts with melamine formaldehyde resin. Such embodiments have the benefit that the ability for excellent adhesion with a top layer comprising a thermoset resin is further improved.

[0168] A preferred embodiment of the method of the seventeenth aspect of the invention is characterized in that the magnesium oxide cement comprising mixture comprises fillers, preferably selected from one or more of wood fibers and / or wood dust (more preferably wherein the wood fibers and / or the wood dust comprise a coating); glass fibers (more preferably wherein the glass fibers are provided with a coating or spin finish), or basalt fibers (more preferably wherein the basalt fibers are provided with a coating or spin finish). Such embodiments provide a mineral board with improved mechanical properties, e.g. with better ductility. Preferably, the magnesium oxide cement comprising mixture applied onto the carrier is a dry mixture, more preferably applied onto the carrier by means of scattering.

[0169] Using a dry mixture allows better dosing and application of the ingredients of the mixture. The moisture content of the mixture can be optimally selected, and no drying is required, such that the optimal crystal structures in the final magnesium oxide cement based board can be obtained.

[0170] Preferably, the scattering of wood fibers and / or wood dust on top of the mixture is performed by scattering a second mixture comprising a magnesium oxide cement and wood fibers and / or wood dust. Such embodiments have the benefit that the wood fibers and / or wood dust at the surface of the mineral board are better bonded into the mineral board.

[0171] More preferably, the magnesium oxide cement comprising mixture comprises wood fibers and or wood dust; wherein in the mixture the weight percentage of wood fibers and wood dust is lower than in the second mixture. This embodiment ensures that the surface of the mineral board comprises a higher weight percentage of wood fibers and / or wood dust, beneficial for adhesion with a thermoset resin comprising top layer during thermal lamination of the top layer onto the mineral board during which the thermoset resin of the top layer is cured.

[0172] With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, several preferred embodiments are described, with reference to the accompanying drawings, wherein: figure 1 schematically and in perspective represents a portion of a floor covering, which consists of floor panels according to an example of the invention; figure 2, in top view, represents a floor panel from the floor covering of figure 1; figure 3 represents a cross-section according to lines III-III of figure 2, of embodiments of panels according to aspects of the invention; figure 4 shows an example of a decorative panel according to aspects of the invention; figures 5-11 represent cross-sections according to lines III-III of figure 2, of embodiments of panels according to aspects of the invention; figure 12 shows a package of mineral boards according to aspects of the invention; figure 13 shows a method according to aspects of the invention for producing a decorative panel; figure 14 shows a method according to aspects of the invention for producing a decorative panel; and figure 15 shows a method according to aspect of the invention for manufacturing a mineral board.

[0173] Same reference numerals have the same meaning in the different figures.

[0174] Figure 1 shows a floor covering comprising floor panels 1 according to embodiments of the invention. Figure 2, in top view, represents a floor panel from the floor covering of figure 1

[0175] The floor panels 1 comprise a first pair of opposite edges 2, 3, as well as a second pair of opposite edges 4, 5. The exemplary floor panels are rectangular and oblong.

[0176] The floor panels 1 are configured at their edges such that they can be mutually coupled according to the so-called fold-down principle, which is a principle known as such and which consists in that such floor panels 1 can be coupled to each other at the first pair of edges 2, 3 by means of a turning movement R. The floor panels are configured such that in coupled condition at their first pair of opposite edges 2, 3 a locking in vertical direction as well as in horizontal direction is obtained, this latter perpendicular to the respective edges.

[0177] In the example, the floor panels can also be coupled to each other at the second pair of opposite edges 4, 5. The floor panels are configured such that in coupled condition at their second pair of opposite edges 4, 5 a locking in vertical direction as well as in horizontal direction is obtained, this latter perpendicular to the respective edges. As represented in figure 3 and figures 5 to 11, such floors panel 1 can be provided with coupling parts 6, 7 at their first pair of edges 2, 3.

[0178] As can be seen in figure 3, the coupling parts 6, 7 of the first pair of edges 2, 3 are provided by a male coupling part 6 and a female coupling part 7.

[0179] The male coupling part comprises a tongue 9. The female coupling part 7 comprises a groove 10, which is bordered by an upper lip 11 and by a lower lip 12. The lower lip 11 extends more distal than the upper lip 12. The tongue 9 and the groove 10 provide in coupled condition a locking in the direction perpendicular to the surface of the coupled layered panels.

[0180] The tongue 9 and the groove 10 comprise locking parts 13, 14 providing in coupled condition a locking in the direction perpendicular to the coupled side edges and parallel to the surface of the coupled layered panels. In the example shown, the locking parts 13, 14 comprise a protrusion 13 at the lower lip 12, and a corresponding recess 14 at the bottom of the tongue 9. The locking parts 13, 14 provide in coupled condition a locking in the direction perpendicular to the coupled first pair of opposite edges 2, 3 and parallel to the surface of the coupled layered panels.

[0181] Figure 3 shows an example of a decorative floor panel 1 according to aspects of the invention. The panel 1 comprises a mineral board 16 acting as core of the panel. The mineral board can be a magnesium oxide based board, preferably comprising wood fibers. On top of the mineral board 16, a layer of thermoset resin 17 (e.g. a polyurethane resin, but not limited thereto) is provided. A resin impregnated printed paper sheet 18 is provided, providing the decor of the decorative floor panel. The resin of the resin impregnated printed paper sheet 18 can e.g. be a melamine formaldehyde resin. A wear layer 19 can be applied to the decorative panel. The wear layer 19 can comprise a resin (e.g. a melamine formaldehyde resin) impregnated paper sheet and / or a lacquer layer (e.g. an acrylic lacquer layer). The wear layer 19 can comprise wear resistance increasing particles, such as corundum. The layer of thermoset resin 17 improves the adhesion between the mineral board 16 and the resin impregnated printed paper sheet 18.

[0182] The layer of thermoset resin 17 can have been applied onto the mineral board 16; and / or at the bottom of the resin impregnated printed paper sheet 18. The layer of thermoset resin 17 can also have been applied as a separate sheet, e.g. as a resin sheet or as a paper sheet impregnated with the resin.

[0183] The adhesion between the resin impregnated paper sheet 18 and the mineral board 16 - with the layer of thermoset resin 17 in between - can have been provided by a thermal pressing operation, in which optionally a texture is provided to the surface of the decorative floor panel 1.

[0184] The panel 1 can comprise a second layer of thermoset resin 21 at the bottom of the mineral board 16. The resin of the second layer of thermoset resin 21 can be the same resin (e.g. polyurethane resin) as the layer of thermoset resin 17. The panel comprises at its bottom a balance layer 22, which can comprise a resin (e.g. a melamine formaldehyde resin) impregnated sheet of paper. The second layer of thermoset resin 21 is provided for improving the adhesion between the mineral board 16 and the balance layer 22. The second layer of thermoset resin 21 can have been applied as a resin layer at the bottom of the mineral board 16, and / or applied at the upper side of the balance layer 22, or can have been provided in the thermal pressing process in which the layers are laminated to each other as a separate sheet, e.g. a resin sheet or a paper sheet impregnated with resin.

[0185] Figure 4 shows a detail of an exemplary embodiment according to the invention wherein the panel comprises a layer of thermoset resin 17 on top of the mineral board 16. The layer of thermoset resin 17 is provided by a sheet of paper 24 impregnated with a thermosetting resin, e.g. with a polyurethane resin, applied to the sheet of paper 24 as a polyurethane dispersion subsequently dried. The decor layer 18 is provided by a printed sheet of paper 26 impregnated with a thermosetting resin, e.g. a melamine formaldehyde resin. In the example of figure 4, the wear layer 19 comprises a sheet of paper 29 impregnated with resin (e.g. impregnated with melamine formaldehyde resin); the wear layer 19 can optionally comprise wear resistance increasing particles such as corundum.

[0186] Figure 5 shows an example of a decorative floor panel 1 according to aspects of the invention. The panel 1 comprises a mineral board 16 (e.g. a magnesium oxide board) acting as core of the panel. The mineral board can be a magnesium oxide based board, preferably comprising wood fibers. The panel comprises a top layer 31. The top layer comprises a resin-impregnated printed paper sheet 18 providing the decor layer of the panel. The decorative panel comprises three resin-impregnated Kraft paper sheets 32 (however, there can be less or more than three of such sheets present) between the mineral board 16 and the resin-impregnated printed paper sheet 18. The top layer 31 optionally comprises a wear layer 19, e.g. a wear layer as explained earlier in this document.

[0187] The resin of the three resin-impregnated Kraft paper sheets 32 can e.g. be selected from urea formaldehyde resin, melamine resin, melamine formaldehyde resin, polyurethane resin (e.g. a water based polyurethane dispersion) or phenol formaldehyde resin. The use of phenol formaldehyde resin is preferred however, because of its low cost, its excellent adhesion properties and its excellent resistance to moisture.

[0188] The panel 1 comprises at its edges 2, 3 a bevel 34. The bevels 34 are pressed bevels, wherein the thickness of the combination of the top layer and the three resin-impregnated Kraft paper sheets 32 is reduced at the bevel 34.

[0189] At the bottom of the panel 1, a number of resin-impregnated sheets 35 - preferably the same type and number as the resin impregnated sheets provided at the upper side of the panel - can be laminated onto the mineral board 16.

[0190] Figure 6 shows an example of a decorative floor panel 1 according to aspects of the invention. The decorative panel comprises a mineral board 16 (e.g. a magnesium oxide board) and a top layer 31. The top layer can comprise a resin-impregnated printed paper sheet 18 providing the decor layer of the panel. The top layer 31 optionally comprises a wear layer 19, e.g. a wear layer as explained earlier in this document.

[0191] The panel 1 comprises a resin layer 37. Figure 6 shows the resin layer 37 between the resin-impregnated printed paper sheet 18 providing the decor layer and the mineral board 16. It is also possible that the resin layer 37 is provided above and preferably on top of the decor layer. The opposite edges 2, 3 of the decorative panel 1 are provided with a bevel, by compressing at least the resin layer 37.

[0192] Such resin layer 37 is helpful to provided a pressed bevel, as mineral boards are normally not compressible as is the case when the board is e.g. a high density wood fiber board (HDF).

[0193] Figure 7 shows an example of a decorative floor panel 1 according to aspects of the invention. The decorative floor panel of figure 6 is to a large extent similar as the decorative floor panel shown in figure 5. The floor panel of figure 6 has in addition a chamfer 38 milled at the opposite edges 2, 3 of the mineral board. This facilitates the provision of bevel, e.g. a pressed bevel as in figure 5.

[0194] Figure 8 shows an example of a decorative floor panel 1 according to aspects of the invention. The decorative floor panel of figure 7 is to a large extent similar to the floor panel shown in figure 7, with the difference that the resin layer 37 of figure 7 is a foam layer 39 in figure 8. Such foam layer 39 provides a sound dampening to the decorative panel. As shown in figure 8, such foam layer 39 is beneficial for providing a pressed bevel 34 to the panel, whether or not in combination with a milled chamfer 38 in the mineral board (figure 8 shows a panel having a milled chamfer in the mineral board, however, this is an optional feature). The foam layer 39 can also be used in decorative floor panels not having a bevel, for providing sound dampening properties to the floor panel.

[0195] Figure 9 shows an example of a decorative floor panel 1 according to aspects of the invention. The decorative panel comprises a mineral board 16 (e.g. a magnesium oxide board). The top layer can comprise a resin-impregnated printed paper sheet 18 providing the decor layer of the panel. The top layer 31 comprises a wear layer 19, e.g. a wear layer as explained earlier in this document.

[0196] The mineral board 16 comprises a magnesium oxide based cement and fillers, e.g. wood fibers. The mineral board 16 of figure 9 has a layered construction, with an upper layer 41, a central layer 42 and a bottom layer 43. The central layer 42 is provided between and contacting the upper layer 41 and the bottom layer 43. The upper layer 41 of the mineral board 16 comprises a higher percentage by weight of wood fibers than the central layer 42 of the mineral board.

[0197] Figure 10 shows an example of a decorative floor panel 1 according to aspects of the invention. The two opposite edges 2, 3 of the panel comprise an impregnation layer 44. The impregnation layer 44 is provided for sealing the edges from liquid water absorption and / or from absorption of water vapor from the atmosphere. In the example shown in figure 10, the impregnation layer 44 has been obtained by impregnating the mineral board 16 (e.g. a magnesium oxide board) from its top side over its full thickness prior to cutting the board into panels and prior to milling the coupling parts 6, 7.

[0198] In the example, the impregnation has been performed through the full thickness of the mineral board 16 and such that the impregnation layer 44 extends - after milling the coupling parts 6, 7 to the panel - from the distal end of the coupling part to beyond the proximal end of the coupling part. This way, the full profile of the coupling parts 6, 7 is provided with the impregnation agent used, thereby sealing the full profile of the coupling parts 6, 7 from water absorption from liquid water or water vapor.

[0199] It is also possible to impregnate the mineral board (16) from its upper side only over a part of the thickness of the board.

[0200] The impregnation agent used to obtain the impregnation layer 44 can comprise a methylene difenyl diisocyanate (MDI), a silicone, a siloxane, an alkyd, an acrylate, a methacrylate, a fluorinated acrylate, a fluorinated methacrylate, a fluorinated acrylate copolymer, at (per)fluoroalkyl (meth)acrylate, a (per)fluoroalky (meth)acrylate copolymer, an epoxy rein, a fluorinated epoxy resin, a styrene acrylate, a urethane acrylate, a polyurethane modified alkyd, a fluor modified alkyd, a styrene butadiene copolymer, or combinations thereof. The impregnation agent can comprise a metallic soap, preferably a salt of a fatty acid, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps.

[0201] Figure 11 shows an example of a decorative floor panel 1 according to aspects of the invention. The decorative floor panel 1 of figure 11 has been provided at its edges 2, 3 with an impregnation layer 45. In addition, also a film 46 is provided on the edges 2, 3. It is not necessary however that an impregnation layer 45 and a film 46 are provided, it is also possible according to the invention to provide either an impregnation layer 45 or a film 46 for sealing the edges from water absorption. The impregnation agent used to provide the impregnation layer 45 and / or the film 46 can comprise a methylene difenyl diisocyanate (MDI), a silicone, a siloxane, an alkyd, an acrylate, a methacrylate, a fluorinated acrylate, a fluorinated methacrylate, a fluorinated acrylate copolymer, at (per)fluoroalkyl (meth)acrylate, a (per)fluoroalky (meth)acrylate copolymer, an epoxy rein, a fluorinated epoxy resin, a styrene acrylate, a urethane acrylate, a polyurethane modified alkyd, a fluor modified alkyd, a styrene butadiene co-polymer, or combinations thereof. The impregnation layer 45 and / or the film 46 can optionally comprise a metallic soap, preferably a salt of a fatty acid, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps.

[0202] Figure 12 shows a package of mineral boards according to aspects of the invention. The package shown comprises a plurality of stacked mineral boards 16 (e.g. magnesium oxide based boards) packed in a water tight packaging material 48. The mineral boards 16 packed in the water tight packaging material 48 have a moisture content of less then 7 wt%, preferably less than 5 wt%. The water tight packaging material 48 can e.g. be a plastic foil.

[0203] Figure 13 shows a method according to aspects of the invention for producing a decorative panel. The method comprises the step of providing a mineral board 16, e.g. a magnesium oxide based board. A thermoset resin 50 (e.g. a polyurethane dispersion) is applied onto the surface of the mineral board, thereby obtaining a resin layer 17 on the mineral board 16. The thermoset resin is partially cured in step 51.

[0204] A resin-impregnated printed paper sheet 18 is positioned on partially cured resin layer 17. A resin (e.g. a melamine formaldehyde resin) impregnated paper sheet 19 which will form a wear layer in the final panel is positioned onto the resin-impregnated printed paper sheet 18. The resin of the resin-impregnated printed paper sheet 18 can be a melamine formaldehyde resin.

[0205] In a single daylight press 53 pressure is applied at increased temperatures such that the wear layer 19 and the resin-impregnated printed paper sheet 18 are laminated onto the mineral board 16 with the help of the resin layer 17. In the thermal pressing operation, the resin of the resin layer 17, the resin of the resin-impregnated printed paper sheet 18 and the resin of the resin impregnated paper sheet 19 are cured.

[0206] The press element used can be a structured press element, such that the surface of the decorative panel is provided with a structured (embossed) surface. The embossments can be made in register with the decor of the resin-impregnated printed paper sheet 18. The press element can also provide a pressed bevel to the decorative panel.

[0207] Optionally, a balance layer 22 is also introduced in the press at the bottom of the mineral board 16. The balance layer 22 can comprise a resin (e.g. a melamine formaldehyde resin) impregnated sheet of paper. In the thermal pressing operation, the balance layer 22 is laminated onto the mineral board 16.

[0208] The method shown in figure 13 can be used for manufacturing a decorative panel shown in figures 3 - 11.

[0209] Figure 14 shows a method according to aspects of the invention for producing a decorative panel. The method comprises the step of providing a mineral board 16, e.g. a magnesium oxide based board. The mineral board 16 is led through a drying section 55 in which the mineral board is dried to a moisture content below 7 wt%, and preferably below 5wt%. The drying section can e.g. comprise IR-dryers, e.g. electrical IR-lamps or IR radiating gas burners.

[0210] A resin-impregnated printed paper sheet 18 is positioned on the dried mineral board 16. A resin (e.g. a melamine formaldehyde resin) impregnated paper sheet 19 which will form a wear layer in the final panel is positioned onto the resin-impregnated printed paper sheet 18. The resin of the resin-impregnated printed paper sheet 18 can be a melamine formaldehyde resin.

[0211] In a single daylight press 53 pressure is applied at increased temperatures such that the wear layer 19 and the resin-impregnated printed paper sheet 18 are laminated onto the mineral board 16. In the thermal pressing operation, the resin of the resin-impregnated printed paper sheet 18 and the resin of the resin impregnated paper sheet 19 are cured.

[0212] The press element used can be a structured press element, such that the surface of the decorative panel is provided with a structured (embossed) surface. The embossments can be made in register with the decor of the resin-impregnated printed paper sheet 18. The press element can also provide a pressed bevel to the decorative panel.

[0213] Optionally, a balance layer 22 is introduced also in the press at the bottom of the mineral board 16. The balance layer 22 can comprise a resin (e.g. a melamine formaldehyde resin) impregnated sheet of paper. In the thermal pressing operation, the balance layer 22 is laminated onto the mineral board 16.

[0214] The drying operation on the mineral board 16 improves the quality of adhesion of the resin-impregnated printed paper sheet 18 to the mineral board 16 in that problems with condensing water from the resin of the resin-impregnated printed paper sheet 18 are largely prevented.

[0215] Figure 15 shows a method according to aspects of the invention for manufacturing a mineral board. A dry magnesium oxide cement comprising mixture 57 is applied by means of a scattering device 58 onto a carrier 59, e.g. onto a moving belt. The magnesium oxide cement comprising mixture can comprises fillers, preferably selected from one or more of wood fibers and / or wood dust (the wood fibers and / or the wood dust can comprise a coating); glass fibers (the glass fibers can be provided with a coating or spin finish), or basalt fibers (the basalt fibers can be provided with a coating or spin finish).

[0216] Wood fibers 61 and / or wood dust is scattered by means of a scattering device 62 on top of this mixture 57. Optionally, the wood fibers and / or wood dust can have been coated, preferably with an uncured or partially cured thermoset resin, with a resin that reacts with melamine formaldehyde resin.

[0217] A compression device, e.g. a compression roller 63, can be provided for compressing the mixture 57 onto which the wood fibers 61 and / or wood dust has been scattered, such that the wood fibers and / or wood dust are pressed into the surface of the mixture 57. The mixture can be further compressed in a double-belt press. After curing, a magnesium oxide based board is obtained.

[0218] The features of the different embodiments and figures can be combined with each other, as long as the features are not contradictory to each other.

[0219] The present invention is in no way limited to the embodiments described as an example or represented in the figures, on the contrary it can be realized in various forms and dimensions, without leaving the scope of the invention.

Claims

Claims1 Method for manufacturing a decorative panel (1), wherein the method comprises the steps of- providing a mineral board (16) - preferably a magnesium oxide based board- applying a thermoset resin (17) onto the surface of the mineral board;- partially curing said thermoset resin;- applying a resin-impregnated printed paper sheet (18) onto said partially cured thermoset resin; and- applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board.2.- Method as in claim 1, characterized in that in the step of applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet (18) is laminated onto the mineral board (16), the thermoset resin and the resin of the resin- impregnated printed paper sheet are cured.3.- Method as in any of the preceding claims 1 - 2, characterized in that the thermoset resin (17) is selected from melamine resin, melamine formaldehyde resin, urea formaldehyde resin, polyurethane resin (e.g. a water based polyurethane dispersion) or phenol formaldehyde resin.4.- Method for manufacturing a decorative panel - optionally a method as in any of the preceding claims -, wherein the method comprises the steps of- providing a mineral board (16) - preferably a magnesium oxide based board -;- drying the mineral board (16) to a moisture content below 7 wt%, and preferably below 5 wt%, and preferably below 4 wt%, more preferably below 3 wt%, more preferably higher than 2 wt%;- applying a resin-impregnated printed paper sheet (18) onto said mineral board; and- applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet (18) is laminated onto the mineral board.5.- Method as in claim 4, characterized in that the step of drying the mineral board (16) is performed by using IR-heat, preferably by using electrical IR-lamps or by IR radiating gas burners or by using hot air.6.- Method as in any of the preceding claims 1 - 3 and as in any of the preceding claim 4 - 5; characterized in that said drying is performed after applying the thermoset resin (17) onto the surface of the mineral board.7.- Method for manufacturing a decorative panel (1) - optionally a method as in any of the preceding claims - , wherein the method comprises the steps of- providing a mineral board (16) - preferably a magnesium oxide based board- applying a resin-impregnated printed paper sheet (18) onto said mineral board; and- applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board; wherein the resin-impregnated printed paper sheet comprises at one side a polyurethane layer or an acrylate layer , wherein the resin-impregnated printed paper sheet is applied onto said mineral board such that the polyurethane layer or the acrylate layer contacts the mineral board.8.- Method for manufacturing a decorative panel - - optionally a method as in any of the preceding claims- , wherein the method comprises the steps of- providing a mineral board (16) - preferably a magnesium oxide based board -;- applying a resin-impregnated printed paper sheet (18) onto said mineral board; and- applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board; wherein the mineral board is locally impregnated with a resin (44), preferably through the full thickness of the mineral board.9.- Method as in claim 8, characterized in that the board is cut at the location (44) locally impregnated with resin, such that the edges (2, 3) of the board originating fromsaid cutting are at least over a part of the thickness of the mineral board - and preferably over the full thickness of the mineral board - sealed by said resin.10.- Method as in any of the preceding claims 7 - 9, characterized in that the resin with which the mineral board is locally impregnated comprises or consists of polymeric methylene diphenyl diisocyanate, polyurethane or combinations thereof.11.- Method as in any of the preceding claims, characterized in that the resin of the resin-impregnated printed paper sheet (18) is selected from a urea formaldehyde resin, a melamine resin, a melamine formaldehyde resin, an acrylic resin, or combinations thereof.12.- Method as in any of the preceding claims, characterized in that the method comprises the step of applying a second resin-impregnated paper sheet (29) onto the resin-impregnated printed paper sheet (18); wherein in the step of applying pressure at increased temperatures wherein the resin-impregnated printed paper sheet is laminated onto the mineral board, also the second resin-impregnated paper sheet is laminated onto the mineral board.13.- Method as in claim 12, characterized in that the resin of the second resin- impregnated paper sheet (29) is a melamine resin or a melamine formaldehyde resin.14.- Method as in any of the preceding claims 11 - 13, characterized in that the resin- impregnated paper sheet (29) comprises wear resistant particles, preferably corundum.15.- Method as in any of the preceding claims, characterized in that in the step of applying pressure at increased temperatures, the surface of the decorative panel is provided with a texture, preferably a texture in register with the printed decor of the resin- impregnated printed paper sheet16.- Mineral board (16) - preferably a magnesium oxide based board -, characterized in that the mineral board comprises one or more than selected from the list of:- wood fibers and / or wood dust, wherein the wood fibers and / or the wood dust comprises a coating, preferably wherein the coating is selected from the list of silicone, silane or siloxane, or combinations thereof;- glass fibers, wherein the glass fibers are provided with a coating or spin finish, preferably wherein the coating is selected from the list of silicone, silane or siloxane, or combinations thereof;- basalt fibers, wherein the basalt fibers are provided with a coating or spin finish; preferably wherein the coating is selected from the list of silicone, silane or siloxane, or combinations thereof.17.- Mineral board (16) - preferably a magnesium oxide based board, and / or preferably a mineral board as in claim 16 -, characterized in that the mineral board comprises wood fibers and / or wood dust, wherein the wood fibers or wood dust comprises a coating, wherein the coating is selected from an acrylic coating, a polyurethane dispersion (PUD), an isocyanate coating such as a methylene diphenyl diisocyanate (MDI) coating or a polymeric diphenyl diisocyanate (pMDI) coating, an epoxy coating, a vinyl ester coating, a bio-based coating -e.g. based upon sugar, lignin, flour and / or hyperbranched polyamides-, a styrene butadiene coating, an acrylate coating -such as an emulsion of acrylate or a styrene acrylate, a latex modified acrylate-, an epoxy resin, an alkyd resin -such as an polyurethane modified alkyd-, a silicon containing coating -such as polysiloxanes, polydimethylsiloxane-.18.- Mineral board (16) as in claim 17, characterized in that the coating encapsulates the wood fibers and / or the wood dust.19.- Mineral board (16) - preferably a magnesium oxide based board, and / or preferably a mineral board as in any of the preceding claims 16 - 18 -, characterized in that the mineral board comprises one or more additives selected from- silanes, preferably hydrophobic silanes;- siloxanes, preferably hydrophobic siloxanes;- metallic soaps, e.g. salts of fatty acids, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps;- silicates, preferably silicates with hydrophobic properties, e.g. Li-silicates;- hydrophobic silica, preferably silica comprising a hydrophobic group chemically bonded to its surface, more preferably wherein the hydrophobic group is selected from alkyl or polydimethylsiloxane chains.20.- Mineral board (16) - preferably a magnesium oxide based board, and / or preferably a mineral board as in any of the preceding claims 16 - 19 -, characterized in that the mineral board comprises fillers selected from one of more than one of wood fibers, wood dust, glass fibers or basalt fibers; wherein a top layer of the mineral board comprises a higher percentage by weight of said fillers than the central section of the mineral board; preferably wherein the top layer of the mineral board comprises relative to the weight of the layer 10 wt% more fillers than the central section of the mineral board.21.- Mineral board as in claim 20, characterized in that the mineral board has a layered construction, with an upper layer (41), a central layer (42) and a bottom layer (43), wherein the central layer is provided between - and preferably contacting - the upper layer and the bottom layer, wherein the upper layer of the mineral board comprises a higher percentage by weight of said fillers - and preferably of wood-based fillers (e.g. wood fibers and / or wood dust) - than the central section of the mineral board.22.- Mineral board as in any of the preceding claims 16 - 21, characterized in that the mineral board (16) is free from a reinforcing fiberglass web.23.- Mineral board as in any of the preceding claims 16 - 22, characterized in that the mineral board (16) comprises a magnesium oxide cement based matrix, wherein the magnesium oxide cement is a magnesium oxy chloride cement or a magnesium oxy sulphate cement or combinations thereof.24.- Mineral board (16) as in claim 23, characterized in that the magnesium oxide cement matrix comprises one or more of- MgO - MgC12 - H2O in a 5-1-13 mol ratio; or- MgO - MgSO4 - H2O, in a 9-1-21, 5-1-14, 9-1-20 or 5-1-12 mol ratio.25.- Mineral board (16) as in claim 23, characterized in that the magnesium oxide cement matrix comprises a 5Mg(OH2).MgSO4.7H2O crystal structure; or in that the magnesium oxide cement comprises a 5Mg(OH2).MgC12.8H2O crystal structure; or in that the magnesium oxide cement comprises a 8Mg(OH2).MgC12.8H2O crystal structure; or combinations thereof.26.- Mineral board (16) as in any of the preceding claims 16 - 25, characterized in that the density of the mineral board is at least 1300 kg / m3, preferably at least 1350 kg / m3.27.- Package, wherein the package comprises at least one - and preferably a plurality of - mineral board(s) (16), - preferably (a) magnesium oxide based board(s), more preferably (a) magnesium board(s) as in any of the preceding claims 16 - 26 -, characterized in that the package comprises a water tight packaging material (48), wherein the at least one mineral board is packed in the water tight packaging material, wherein the moisture content of the at least one mineral board is less then 7 wt%, preferably less than 5 wt% and preferably more than 2 wt%.28.- Package as in claim 27, characterized in that the water tight packaging material comprises a plastic foil and / or that the water tightness of the packaging material is provided by a plastic foil.29.- Decorative panel, characterized in that the decorative panel (1) comprises a mineral board (16) - preferably a magnesium-oxide based board, and / or preferably a mineral board as in any of the preceding claims 16 - 26, - and a top layer (31); wherein the top layer comprises a resin-impregnated printed paper sheet (18); wherein the decorative panel comprises one or more than one layer of resin-impregnated paper sheets (32) - preferably Kraft paper sheets, preferably unprinted paper sheets - between the mineral board (16) and the resin-impregnated printed paper sheet (18).30.- Decorative panel as in claim 29, characterized in that the resin of the resin- impregnated paper sheets (32) is selected from urea formaldehyde resin, melamine resin, melamine formaldehyde resin, polyurethane resin (e.g. a water based polyurethane dispersion) or phenol formaldehyde resin, or a combination of melamine formaldehyde and phenol formaldehyde resin.31.- Decorative panel as in any of the preceding claims 29 - 30, characterized in that the decorative panel (1) comprises an edge (2, 3), wherein the edge is provided with a bevel (34), wherein at the bevel, the thickness of the combination of the top layer and the one or more than one layer of resin-impregnated paper sheets is lower than outside said bevel.32.- Decorative panel as in any of the preceding claims 29 - 31, characterized in that the decorative panel (1) comprises an edge (2, 3), wherein the edge is provided with a bevel (34), wherein the bevel is a pressed bevel, wherein the thickness of the combination of the top layer and the one or more than one layer of resin-impregnated paper sheets is reduced at the bevel.33.- Decorative panel - characterized in that the decorative panel (1) comprises a mineral board (16) - preferably a magnesium-oxide based board, and / or preferably a mineral board as in any of the preceding claims 16 - 26, - and a top layer (31); optionally the decorative panel (1) is a decorative panel as in any of the preceding claims 29 - 32, characterized in that the top layer (31) comprises a resin-impregnated printed paper sheet; wherein the decorative panel comprises one or more than one layer of resin-impregnated bottom paper sheets (35) - preferably Kraft paper sheets, preferably unprinted paper sheets -, wherein the one or more than one layer of resin-impregnated bottom paper sheets (35) are laminated to the mineral board (16) at the opposite side of the side comprising the top layer (31).34.- Decorative panel (1) as in claim 33, characterized in that the resin of the resin- impregnated paper sheets (35) is selected from urea formaldehyde resin, melamine resin, melamine formaldehyde resin, polyurethane resin (e.g. a water based polyurethanedispersion) or phenol formaldehyde resin, or a combination of melamine formaldehyde and phenol formaldehyde resin.35.- Decorative panel - optionally a decorative panel (1) as in any of the preceding claims 29 - 34, characterized in that the decorative panel (1) comprises a mineral board (16)- preferably a magnesium-oxide based board, and / or a mineral board as in any of the preceding claims 16 - 26 - and a top layer (31); wherein the top layer (31) comprises a resin-impregnated printed paper sheet (18); wherein the resin-impregnated printed paper sheet comprises at its side directed to the mineral board a layer of polyurethane.36.- Decorative panel - optionally a decorative panel as in any of the preceding claims 29 - 35, wherein the decorative panel (1) comprises a mineral board (16) - preferably a magnesium-oxide based board, and / or a mineral board as in any of the preceding claims 16 - 26 - and a top layer (31), characterized in that the decorative panel comprises a resin layer (37); wherein the decorative panel comprises an edge (2, 3), wherein the edge is provided with a bevel (34), wherein the bevel is a pressed bevel provided by compression of at least the resin layer (37).37.- Decorative panel as in claim 36, characterized in that the top layer (31) comprises a printed decor, preferably provided on a - more preferably resin impregnated - paper sheet (18), wherein the resin layer (37) is provided on top of the printed decor.38.- Decorative panel as in any of the preceding claims 36 - 37, characterized in that the top layer (31) comprises a printed decor, preferably provided on a - more preferably resin impregnated - paper sheet, wherein the resin layer is provided between the printed decor and the mineral board.39.- Decorative panel as in any of the preceding claims 36 - 38, characterized in that said bevel (34) is at least partly, and preferably entirely, provided in a chamfer (38) provided in the mineral board (16).40.- Decorative panel - optionally a decorative panel as in any of the preceding claims 29 - 39, wherein the decorative panel (1) comprises a mineral board (16) - preferably a magnesium-oxide based board, and / or a mineral board as in any of the preceding claims 16 - 26 - and a top layer (31); characterized in that the decorative panel comprises an edge (2, 3), wherein the edge is provided with a bevel (34), wherein said bevel is at least partly, and preferably entirely, provided in a chamfer (38) provided - preferably by a machining operation - in the mineral board (16).41.- Decorative panel - optionally a decorative panel as in any of the preceding claims 29 - 40, wherein the decorative panel (1) comprises a mineral board (16) - optionally a mineral board as in any of the preceding claims 16 - 26 - and a top layer (31); characterized in that the top layer (31) comprises a printed decor, preferably provided on a - more preferably resin impregnated - paper sheet (18), wherein a resin layer (37) is provided between the decor layer and the mineral board.42.- Decorative panel - optionally a decorative panel as in any of the preceding claims 29 - 41, wherein the decorative panel comprises a mineral board (16) - preferably a magnesium-oxide based board, and / or a mineral board as in any of the preceding claims 16 - 26 - and a top layer (31); wherein the decorative panel (1) is rectangular - square or oblong -, wherein the decorative panel comprises at least at two opposite edges (2, 3) coupling parts (6, 7) for coupling the decorative panel with a second such decorative panel at their respective side edges (2, 3); wherein in coupled condition a locking is provided in the direction perpendicular to the surface of the coupled layered panels; as well as a locking is provided in the direction perpendicular to the coupled side edges and parallel to the surface of the coupled layered panels; wherein the coupling parts (6, 7) comprise at one of said two opposite edges a male coupling part (6); wherein the coupling parts comprise at the other one of said two opposite edges a female coupling part (7).43.- Decorative panel as in claim 42, characterized in that the two opposite edges comprise an impregnation layer (44, 45) and / or a coating layer at least partially sealingthe edges at least over a part of their surface - and preferably over their full surface - from liquid water absorption and / or from absorption of water vapor from the atmosphere.44.- Decorative panel as in claim 43, characterized in that the impregnation layer (44) and / or the coating layer comprise a methylene difenyl diisocyanate (MDI), a silicone, a siloxane, an alkyd, an acrylate, a methacrylate, a fluorinated acrylate, a fluorinated methacrylate, a fluorinated acrylate copolymer, at (per)fluoroalkyl (meth)acrylate, a (per)fluoroalky (meth)acrylate copolymer, an epoxy rein, a fluorinated epoxy resin, a styrene acrylate, a urethane acrylate, a polyurethane modified alkyd, a fluor modified alkyd, a styrene butadiene co-polymer, a polyurethane (preferably a hydrophobic polyurethane), or combinations thereof, e.g. a composition comprising an alkyd and a polyurethane (preferably a hydrophobic polyurethane), or a composition comprising an alkyd and a fluorinated acrylate (preferably a hydrophobic polyurethane).45.- Decorative panel as in any of the preceding claims 43 - 44, characterized in that the impregnation layer and / or the coating layer comprises a hydrophobic polymer, being for example a hydrophobic polycarbodiimide, a hydrophobic polyurethane or a hydrophobic acrylate polymer, wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms; preferably wherein the hydrophobic polymer comprises an aliphatic hydrocarbon group preferably with 6 to 34 carbon atoms.46.- Decorative panel as in claims 43 - 45, characterized in that the impregnation layer(45) and / or coating layer provides a film (46) on the edges (2, 3).47.- Decorative panel as in any of the preceding claims 43 - 46, characterized in that the impregnation layer (44, 45) and / or coating layer comprises a metallic soap, preferably a salt of a fatty acid, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps.48.- Decorative panel as in any of the preceding claims 43 - 45, characterized in that at the two opposite edges (2, 3) the mineral board (16) is impregnated from its top side at least over part of its thickness - and preferably over its full thickness - with animpregnation agent (44) - preferably methylene diphenyl diisocyanate (MDI) or polyurethane, more preferably a hydrophobic polyurethane - from the distal end of the coupling part to beyond the proximal end of the coupling part (6, 7).49.- Decorative panel as in any of the preceding claims 48, characterized in that the impregnation agent (44, 45) comprises a metallic soap, preferably a salt of a fatty acid, e.g. stearates or laurates, e.g. Ca, Mg, Zn or Al metallic soaps.50.- Decorative panel as in any of the preceding claims 42 - 49, characterized in that the male coupling part (6) comprises a tongue (9); and that the female coupling part (7) comprises a groove (10), wherein the groove is bordered by an upper lip (11) and by a lower lip (12); preferably wherein the lower lip (12) extends more distal than the upper lip (H).51.- Decorative panel as in any of the preceding claims 42 - 50, characterized in that the coupling parts (6, 7) are configured as on the one hand a tongue (9) and on the other hand a groove (10) bordered by an upper lip (11) and a lower lip (12); wherein the tongue and the groove provide in coupled condition a locking in the direction perpendicular to the surface of the coupled layered panels; wherein the tongue and the groove comprise locking parts (13, 14), wherein the locking parts provide in coupled condition a locking in the direction perpendicular to the coupled side edges and parallel to the surface of the coupled layered panels; preferably the locking parts comprise a protrusion (13) at the lower lip (12) and a corresponding recess (14) at the bottom of the tongue (9).52.- Decorative panel as in any of the preceding claims 42 - 51, characterized in that said coupling can be performed by means of an angling movement (R) of the respective side edges of the decorative panels to be coupled.53.- Decorative panel as in any of the preceding claims 42 - 52, characterized in that the coupling parts (6, 7) are substantially provided in the mineral board (16).54.- Decorative panel as in any of the preceding claims 29 - 53, characterized in that the top layer (31) comprises a resin-impregnated printed paper sheet (18), and that the resin of the resin-impregnated printed paper sheet is selected from a melamine resin, a melamine formaldehyde resin, or an acrylic resin.55.- Decorative panel as in any of the preceding claims 29 - 54, characterized in that the top layer (31) comprises a wear layer (19); preferably the wear layer comprises a resin impregnated paper sheet, optionally comprising wear resistant particles such as corundum, or preferably the wear layer comprises or consists of a lacquer layer - e.g. an acrylic lacquer layer - optionally comprises wear resistant particles such as corundum.56.- Method for manufacturing a mineral board, preferably a magnesium oxide based board, more preferably a mineral board as in any of the preceding claims 16 - 26, characterized in the method comprising the steps of- applying a magnesium oxide cement comprising mixture (57) onto a carrier (59), e.g. onto a moving belt;- scattering wood fibers (61) and / or wood dust on top of said mixture (57);- optionally compressing the mixture onto which the wood fibers and / or wood dust has been scattered, wherein the wood fibers and / or wood dust are pressed into the surface of the mixture;- curing the magnesium oxide cement.57.- Method as in claim 56, characterized in that the wood fibers and / or wood dust are coated, preferably with an uncured or partially cured thermoset resin, more preferably coated with a resin that reacts with melamine formaldehyde resin.58.- Method as in any of the preceding claims 56 - 57, characterized in that the magnesium oxide cement comprising mixture (57) comprises fillers, preferably selected from one or more of wood fibers and / or wood dust (preferably wherein the wood fibers and / or the wood dust comprises a coating); glass fibers (preferably wherein the glass fibers are provided with a coating or spin finish), or basalt fibers (preferably wherein the basalt fibers are provided with a coating or spin finish).59.- Method as in any of the preceding claims 56 -58, characterized in that the magnesium oxide cement comprising mixture (57) applied onto the carrier is a dry mixture, preferably applied onto the carrier by means of scattering.60.- Method as in any of the preceding claims 56 - 59, characterized in that said scattering of wood fibers (61) and / or wood dust on top of said mixture (57) is performed by scattering a second mixture comprising a magnesium oxide cement and wood fibers (61) and / or wood dust.61.- Method as in claim 60, characterized in that the magnesium oxide cement comprising mixture (57) comprises wood fibers (61) and or wood dust; wherein in said mixture the weight percentage of wood fibers (61) and wood dust is lower than in said second mixture.

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