Method for manufacturing decorative panels

Abstract

Method for manufacturing decorative panels, wherein said panels (1) at least comprise a substrate (2) and a decorative top layer (3) comprising a decoration and a transparent or translucent wear layer (5) applied over said decoration, wherein said method at least comprises - the step of providing a sheet (6-6A) comprising at least a first composition (7) for forming a portion of said transparent or translucent wear layer (5); and - the step of applying said sheet (6-6A) on said substrate (2); characterized in that said first composition (7) comprises a water-based radiation curable lacquer, a water-based acrylic or water-based polyurethane dispersion, or a mixture of a water-based radiation curable lacquer and one or more of a water-based acrylic and water-based polyurethane dispersion.

Description

[0001] Method for manufacturing decorative panels

[0002] The present invention relates to a method for manufacturing decorative panels.

[0003] In particular, the invention relates to decorative panels, for which furniture panels, laminate floor panels, parquet floor panels, and floor panels based on synthetic material are known examples.

[0004] More specifically, the invention relates to panels with a substrate and a decorative top layer applied thereto, wherein the decorative top layer comprises a decoration, for example in the form of a decor layer having a printed pattern. Such floor panels are widely known per se, for example from WO 97 / 47834. The floor panels disclosed in said document relate among others to floor panels with a substrate that is composed of an HDF board with a laminate layer pressed directly onto it, wherein the laminate layer comprises one or more paper sheets impregnated with melamine resin, preferably including a paper sheet with a printed pattern in for example a wood or stone motif, specifically a so-called decorative paper. The above-mentioned melamine resin forms among others a transparent or translucent wear layer above the decorative paper, but the transparency or translucency leaves much to be desired. On the underside of the substrate a backing layer or balancing layer may be provided, wherein said backing or balancing layer may also be based on a paper sheet impregnated with melamine resin. This backing layer provides a compensating effect for residual tensile stresses present in the cured and shrunk melamine resin of the top layer. It is possible to form structures in the melamine surface at the same time of curing the melamine resin during the pressing operation. Pressing defects, such as so-called white mountains, may occur. These are zones in which inclusions are concentrated in the melamine surface. These primarily occur at sites in which deep indentations or structures are realized.

[0005] It is known that the melamine surface of such a laminate panel gives rise to ticking sounds for example while walking over a floor consisting of such laminate panels. Multiple solutions to this problem are known from the prior art. WO 03 / 016655 discloses the application of a sound-damping layer such as a cork layer under the melamine layer. It is known from WO 2010 / 088769, among other documents, to provide the melamine layers with a coating of a flexible monomer. WO 2009 / 101217 and WO 2010 / 070474 give examples of laminate panels wherein the top layer is composed, instead of melamine resin, mainly of polyvinyl chloride (PVC). WO 2010 / 070474 discloses panels with a printed decor layer that can be formed on the substrate and is finished with a transparent PVC layer.

[0006] Furthermore, a method is known from WO 01 / 47726 of finishing panels with a printed decor layer with a UV (ultraviolet) curing or electron beam curing acrylate resin. This process is difficult to integrate into existing methods for the production of laminate panels and requires complex material logistics, complex machines, and leads to a high cost.

[0007] In panels in which the top layer is composed entirely of polyvinyl chloride (PVC), a loss of scratch resistance is observed in comparison to the conventional melamine surface. In addition, the PVC layer must be configured to be considerably thicker than a melamine layer in order to obtain comparable wear resistance. The nature and thickness of the PVC layer give rise to a plastic-like appearance of the floor panel, especially in cases where imitation of a product such as wood, stone or ceramic is intended. The relief that can be obtained in a PVC layer is unsharp, which detracts from the realistic appearance of the imitation obtained.

[0008] In panels in which the top layer is obtained from UV cured or electron beam cured acrylate, such as in WO 01 / 47726, favorable surface properties are achieved. The relief that can be obtained in such a top layer is limited in that structural films must be applied, for example such as in EP2019735.

[0009] WO 2020 / 095196 and WO 2021 / 224843 disclose an alternative composition for a translucent or transparent wear layer to be applied over the decoration of a decorative panel. In accordance with WO’ 196 a thermally cured acrylate resin or unsaturated polyester resin is applied. In accordance with WO’483, an acrylate resin may be partially cured using UV radiation and / or thermal energy in order to provide a stable surface before being used in a thermal lamination process, such as in a pressing operation at elevated temperature with a structured press element. The acrylate resin comprises reactive diluents that may bring about a residual tackiness after the partial curing operation. The conditions for obtaining a non-tacky surface in partial curing while maintaining a sufficient ability for further curing are difficult to set and may vary greatly with slight modifications of the composition and / or amount of the acrylate resin, the color of the decoration and the type of pigments used in the decoration. A dark decoration partially absorbs the curing radiation, while a light decoration may partially reflect the curing radiation and lead to a more pronounced curing with the same amount of radiation. The partial curing may be accompanied with VOC emissions in the production environment.

[0010] The present invention in the first place aims to provide an alternative method for manufacturing decorative panels, wherein, in accordance with preferred embodiments, a solution is offered for one or more of the problems with the methods of the prior art.

[0011] With this aim, the present invention - according to the first aspect of the invention - is a method for manufacturing decorative panels, wherein said panels at least comprise a substrate and a decorative top layer comprising a decoration and a transparent or translucent wear layer applied over said decoration, wherein said method at least comprises

[0012] - the step of providing a sheet (which can be a sheet obtained by or obtainable by a method according to the third aspect of the invention) comprising at least a first composition for forming a first portion of said transparent or translucent wear layer; and

[0013] - the step of applying said sheet on said substrate; with as a characteristic that said first composition comprises a water-based radiation curable lacquer, preferably a water-based ultra-violet curable lacquer. Alternatively, said first composition comprises a water-based lacquer, such as a water-based acrylic dispersion or water-based polyurethane dispersion, or a mixture of a water-based radiation curable lacquer and one or more water-based lacquers, for example a mixture of a water-based radiation curable lacquer and one or more of a water-based acrylic and water-based polyurethane dispersion.

[0014] The first composition preferably will provide the surface layer of the decorative panel.

[0015] The water-based lacquer of said first composition can be at least partially or wholly dried by exposure to the ambient environment, convective streams of e.g. air, or by heating for example in a hot air oven. A non-tacky surface can be created in this way and / or by combining the drying with a partial curing by radiation, in the case of a water-based radiation curable lacquer. The partial curing by drying, and optionally radiation, may be accompanied by a moderate amount of VOC emissions, or without VOC emissions, and is less dependent on the color of any underlying decoration. The obtained non-tacky surface may allow for stacking of several such sheets, or for providing such dried and potentially partially cured sheets from a roll, without having problems of unstacking or unrolling due to a sticky surface. At the same time a B-stage, or partial curing, may be obtained that allows for further curing while or after applying said sheet on said substrate. On top of that an anti-fingerprint effect and a good scratch resistance may be obtained even when the final transparent or translucent wear layer is mat. The final curing of such first composition may bring about less shrinking than for example a melamine based layer and result in a more stable decorative panel overall.

[0016] In the case of a water-based radiation curable lacquer, radiation using a relatively short wavelength, for example a radiation having a wavelength between 80 and 450 nm (and more preferably less than 400 nm), is preferred. Such wavelengths can be attained using UV-C or excimer radiation. These short wavelengths bring about a good partial cure of the surface of the first composition after thermal drying. These shortwave lengths tend to mainly cure the surface and do not materially alter the curing of potentially deeper lying compositions, or parts of the first composition. It is important to maintain reactivity in these deeper lying compositions or parts for the subsequent step of applying said sheet on said substrate, for example by means of a heated press operation, wherein, preferably also impressions are formed in said transparent or translucent wear layer. It is remarked that the heat created by the lamps used for the radiation may, in some case, suffice for drying the first composition, while at the same time bringing about a surface cure.

[0017] It is clear that said first composition is preferably at least available at a surface of said sheet, i.e. at the surface of the actual sheet material and preferably not, or at least not exclusively, in the core of such sheet material.

[0018] Said decoration may comprise a printed pattern, for example a printed pattern applied to said sheet. Alternatively, said decoration may comprise a wood veneer, a cork layer, or a pattern obtained through a technique other than a printing technique, for example through scattering of colored particles.

[0019] The decoration may comprise a uniformly colored pattern, such as e.g. provided with a paper sheet colored in the mass.

[0020] Preferably, said sheet is one of a paper sheet and a thermoplastic foil

[0021] In the case of a thermoplastic foil, this may be a foil of polyvinyl chloride, polypropylene, polyethylene or polyethylene terephthalate. Preferably said foil has a thickness of 350 micrometer or less, or even of 200 micrometer or less.

[0022] In the case of a paper sheet, preferably this is a paper sheet having a Gurley value, as measured according to TAPPI T460, of below 30 seconds, preferably below 25 seconds, more preferably below 15 seconds. The moderate Gurley value provides for a high enough ability to absorb any impregnation fluids in the core of the paper. A sufficient impregnation ability of the core is desirable to minimize the risk of paper splitting in the finished decorative panel. Preferably said paper sheet comprises an impregnation composition at least in the core of said paper sheet. Said impregnation fluid may be a thermosetting resin, such as melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, phenol formaldehyde, polyurethane dispersion. Said impregnation fluid may be an acrylic resin. Said impregnation fluid may be a mixture of an acrylic resin and one or more of the thermosetting resins mentioned above. It is especially with impregnation fluids comprising oligomers, for example of an acrylate resin, that the Gurley value is preferred to be sufficiently low, for example below 20 seconds. Preferably said paper sheet has a raw paper surface weight of 15 to 250 grams per square meter. Preferably, when available, said impregnation fluid has at least the same weight, or even at least double the weight, as said raw paper surface weight. Said paper sheet may be provided with a printed pattern as afore stated. In such case said paper sheet preferably has a weight of at least 50 grams per square meter, or at least 60 grams per square meter. Herein the lower paper weights, i.e. from 50 to 90 grams per square meter, are best suited and preferably applied for manufacturing decorative floor panels, while the higher paper weights, i.e. from 90 to 250 grams per square meter are best suited and preferably applied for manufacturing furniture panels. The paper sheets having a surface weight of 15 to 50 grams per square meter are preferably used as so-called overlays, i.e. as transparent wear layers applied over a decoration that is provided on the substrate or an underlying sheet. Such paper sheet is then preferably also provided with an impregnation fluid at least in the core of the paper sheet. It is of course not excluded to provide the bottom of such low weight paper sheet with a printed pattern, for example instead of using a separate printed pattern underneath such overlay.

[0023] Preferably, said first composition is free or essentially free from reactive diluent, for example with an amount of diluent below 1 wt%, preferably as defined on solid matter in the first composition.

[0024] A preferred method is characterized in that the first composition comprises reactive diluents. The presence of the reactive diluents has the benefit that the cross linking density of the wear layer can be increased. The increased cross linking density of the wear layer is beneficial for the hardness and the scratch resistance of the wear layer. Furthermore, it has been observed that the presence of reactive diluents increases the adhesion of the first formulation.

[0025] Preferred reactive diluents for use in the invention are ethoxylated reactive diluents or propoxylated reactive diluents; more preferably ethoxylated acrylate reactive diluents or propoxylated acrylate reactive diluents. An example of an ethoxylated acrylate reactive diluent that can be used in the invention is dipentaerythritol hexaacrylate. Other examples include ethoxylated trimethylolpropane triacrylate or PETA or PETIA.

[0026] Other hydrophilic reactive diluents could be used, such as hydroxy ethyl acrylate (HEA), hydroxypropyl acrylate (HP A).

[0027] Reactive diluents are components that comprise at least one reactive group - e.g. at least one (and preferably a plurality of) reactive acrylate group - and preferably have a molar mass less than 800 gram / mol, and more preferably less than 500 gram / mol.

[0028] The first composition preferably comprises less than 25 wt%, and more preferably less than 20 wt%, reactive diluents, and more preferably less than 15 wt% reactive diluents.

[0029] The first composition preferably comprises a reactive diluent, more preferably an acrylate reactive diluent, more preferably an ethoxylated acrylate reactive diluents. The first composition preferably comprises between 5 and 25 wt% reactive diluent, more preferably between 5 and 15 wt% more preferably between 10 and 15 wt% reactive diluent.

[0030] The presence of the reactive diluents has the benefit that the cross linking density of the wear layer can be increased. The increased cross linking density of the wear layer is beneficial for the hardness and the scratch resistance of the wear layer. Furthermore, it has been observed that the presence of reactive diluents increases the adhesion of the first formulation.

[0031] Preferred reactive diluents for use in the invention are ethoxylated reactive diluents or propoxylated reactive diluents, more preferably ethoxylated acrylate reactive diluents or propoxylated acrylate reactive diluents. An example of an ethoxylated acrylate reactive diluent that can be used in the invention is dipentaerythritol hexaacrylate. Other examples of ethoxylated reactive diluents include ethoxylated trimethylolpropane triacrylate or PETA or PETIA. It is a benefit of such reactive diluents that they can be dispersed in a water-based first formulation. Other hydrophilic reactive diluents could be used in the invention, such as hydroxyethyl acrylate (HEA), hydroxypropyl acrylate (HP A). and others. . .

[0032] A preferred method is characterized in that the first composition comprises a watermiscable multifunctional oligomer. The first composition preferably comprises less than 25 wt% watermiscable multifunctional oligomer, more preferably less than 20 wt% watermiscable multifunctional oligomer.

[0033] The presence of the watermiscable multifunctional oligomer has the benefit that the cross linking density of the wear layer is increased, resulting in increased hardness and increased scratch resistance of the wear layer.

[0034] A preferred method is characterized in that the first composition comprises a release agent. Such embodiments have the benefit that in a pressing operation the wear layer is less prone to sticking to the press equipment being used.

[0035] A preferred method is characterized in that the first composition comprises an antiblocking agent, such as wax or silica additives.

[0036] A preferred method is characterized in that the first composition comprises an antiblocking binder, such as casein or an acrylic resin.

[0037] Preferably, said first composition further comprises one or more thermo-initiators. The thermo-initiator may become active in said step of applying said sheet on said substrate, for example to initiate the final curing of said radiation curable lacquer in a heated press operation. Preferably the adherence to the substrate and at least the final curing of said first composition takes place in one and the same heated press operation. At the same time a structure can be provided in the surface of the panel, more particularly at least in that portion of the transparent or translucent wear layer that is formed by said first composition, by means of a structured press element applied in said heated press operation. It has been found that the first composition excellently takes over the structural details of the texture of a structured press element, including surface structures that define varying gloss or matte levels. In summary, such sheet can be applied on the substrate using techniques identical or very similar to DPL techniques (Direct Pressure Laminate) that are used in forming the decorative panels of the prior art.

[0038] It is clear that said first composition may comprise one or more photo-initiators, i.e. in the case of a water-based radiation curable lacquer. Such photo-initiator may be applied for initiating the partial or complete radiation curing, for example UV curing, of said UV curable lacquer. Instead of opting for a photo-initiator, the aqueous radiation curable lacquer may be curable through cationic radiation curing. Herein, the aqueous radiation curable lacquer may comprises one or more cationic catalysts for initiating the curing after radiation.

[0039] A preferred method is characterized in that the first composition comprises an encapsulated thermo-initiator. It is a benefit of such embodiments that the thermoinitiator is only released during a pressing operation, e.g. in which the wear layer is provided with a texture and is thermally cured. This way, the thermo-initiator will not be activated in the drying step performed after the application of the water-based radiation curable lacquer, the water-based acrylic or water-based polyurethane dispersion.

[0040] Preferably, said sheet comprises at least 5 grams per square meter of said first composition, or at least 10 grams or at least 20 grams per square meter, preferably wherein between 10 to 40 grams per square meter, more preferably between 25 and 40 grams per square meter - and more preferably 25 grams per square meter - is a practical value. Herein only the weight of the dry content of said lacquer is taken into account. Preferably said sheet comprises less than 300 grams per square meter of said first composition, for example 250 grams per square meter or less. Where the lower weights are applied, i.e. 80 grams per square meter or less, this preferably concerns a first composition for forming a first portion of said transparent or translucent wear layer in conjunction with a second portion formed by a different composition, for example by a second composition as further explained below. In such case, said second portion may form the majority of the thickness, for example 65% or more, of the transparent or translucent wear layer. With the higher weights, i.e. 100 grams per square meter or more, this preferably concerns a first portion that forms the majority of said transparent or translucent wear layer, for example 65% or more of the thickness of said transparent or translucent wear layer.

[0041] Preferably, said first composition forms a topmost surface of said sheet. In such case an optimal absence of tackiness may be obtained after drying and potentially partially curing of said radiation curable lacquer.

[0042] Preferably, said sheet further at least comprises a second composition for forming a second portion of said transparent or translucent wear layer, wherein said second composition has one or a combination of two or more of the following properties:

[0043] - the property that the main constituents of said second composition are different from the main constituents of said first composition;

[0044] - the property that said second composition is solvent-based;

[0045] - the property that said second composition is solvent-based and comprises a mixture of acrylate oligomers and monomers of reactive diluent;

[0046] - the property that said second composition comprises reactive diluent;

[0047] - the property that said second composition comprises a photo-initiator and a thermo-initiator;

[0048] - the property that said second composition is 100% solid content acrylate and / or unsaturated polyester resin;

[0049] - the property that said second composition is 100% solid mixture of acrylate oligomers and / or unsaturated polyester resin, and monomers of reactive diluent;

[0050] - the property that said second composition is a dual cure lacquer and / or a mixture of a hydroxy functional compound with an isocyanate functional compound.

[0051] For example, for said second composition, a composition disclosed in WO 2020 / 095196 and / or WO 2021 / 224843 and / or US 63 / 565,040 and / or US 63 / 654,113, both incorporated herein in their entirety by reference, may be applied.

[0052] The invention hence provides for the possibility of creating a non-tacky surface of a dried and / or partially cured aqueous radiation curable lacquer over an otherwise tacky second composition. Herein the second composition is preferably at least available between a surface of said raw sheet, for example raw paper sheet, and said first composition, wherein said first composition than preferably forms the topmost surface of the sheet. In such case an optimally functioning transparent or translucent wear layer can be obtained, while securing a good handling of thus treated sheets and a limited VOC emission in the production environment. The second composition may provide for a minimized sound generation in use and a good deeper scratch resistance and abrasion resistance, for example as measured with the taber test in accordance with ISO 4586-2: 1997. Preferably said second composition is at least partially cured before application of said first composition on said sheet and / or before applying said sheet on said substrate.

[0053] Preferably, the majority of the thickness of said transparent or translucent wear layer is formed by said second portion, i.e. by means of said second composition, for example at least 65%, or at least 85%, of the thickness of the transparent or translucent wear layer is formed by means of said second composition, while, preferably, the remainder is formed by means of said first composition.

[0054] Preferably, 35% or less of the thickness of said transparent or translucent wear layer is formed by said first portion, i.e. by means of said first composition, for example 15% or less of the thickness of the transparent or translucent wear layer is formed by means of said first composition, while, preferably, the remainder is formed by means of a further composition, for example said second composition, preferably available below said first portion. Preferably, at least 0.5% or at least 1.5% of the thickness of said transparent or translucent wear layer is formed by said first portion.

[0055] Here below some particular examples of a second composition are listed without desiring to be exhaustive.

[0056] According to a first particular example of said second composition, it comprises one or more oligomers selected from the group consisting of polyester acrylates and polyester methacrylates, or mixtures thereof; one or more acrylate reactive diluents having a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol; one or more photo- initiators; and one or more thermo-initiators. Preferably, the oligomers have a molar mass equal to or higher than 800 g / mol and lower than 7000 g / mol, more preferably lower than 4500 g / mol. Preferably, the one or more oligomers comprise polyester acrylates and polyester methacrylates. More preferably, the percentage by weight of the polyester methacrylate oligomers in the combination of the one or more polyester acrylate oligomers and polyester methacrylate oligomers is at least 30%, more preferably at least 40%, even more preferably at least 50%. The use of polyester methacrylate oligomers is preferred as it results in a coating that is more resistant to yellowing and staining. For example the compositions disclosed in US 63 / 565,040 may be applied.

[0057] According to a second particular example of said second composition, it is a composition comprising at least an acrylate oligomer and at least one isocyanate group, for example as disclosed in US 63 / 654,113. It is a benefit of such coating composition that it can be partly cured using increasing temperature in which the isocyanate groups reacts with hydroxyl groups present in the acrylate coating composition or with hydroxyl groups present in the substrate or sheet onto which the acrylate coating composition is applied. The reaction of isocyanate groups with hydroxyl groups leads to the formation of a urethane bond. The formation of the urethane bonds can result in the formation of a relatively tack free coating layer, that has a good shelf life and that can be cured in future processes by means of an addition reaction of the acrylate double bonds of the acrylate coating layer. The composition may comprise a hydroxy functional component, preferably wherein the hydroxy functional component is selected from one or more of

[0058] - hydroxy functional acrylate resins;

[0059] - hydroxy functional acrylate oligomers, preferably having a molar mass of at least 800 g / mol;

[0060] - hydroxy functional polyester resins, preferably unsaturated hydroxy functional polyester resins;

[0061] - hydroxy functional polyether resins (e.g. a trifunctional polyester acrylate);

[0062] - hydroxy functional urethane acrylates, preferably hydroxy functional acrylate oligomers;

[0063] - aliphatic polyols;

[0064] - hydroxy functional unsaturated polyester acrylic resins; - hydroxy functional unsaturated polyester resin;

[0065] - one or more hydroxy functional mono, di, tri, tetra or penta acrylate functional reactive diluents preferably having a molar mass lower than 1000 g / mol, and more preferably lower than 600 g / mol; or combinations thereof. The curing by addition reaction of the acrylate double bonds of the acrylate in said composition layer can be performed by a thermal pressing operation, in which the acrylate composition is not only cured but may also be provided with a texture by copying the texture of the structured press element, even though said first composition may be on top of said second composition, and in between said structured press element and said second composition.

[0066] According to a third particular example of said second composition, it comprises a thermally cured acrylate resin, for example as disclosed in WO 2020 / 095196. The acrylate resin can for example have the following composition:

[0067] - 5 to 80 percent by weight of monomers, or more preferably 5 to 60 percent by weight, which can be monofunctional, difunctional or multifunctional, preferably selected from the list of cyclic monofunctional monomers (CTFA (cyclic trimethylolpropane formal acrylate), TMCHA (trimethylcyclohexyl acrylate), TBCHA (4-tert-butylcyclohexyl acrylate), IBOA (isobomyl acrylate), THFA (tetrahydrofurfuryl acrylate), etc.), alkoxylated monofunctional monomers (PE4A, etc.), alkane monofunctional monomers (EOEOEA (2-(2- ethoxyethoxy)ethyl acrylate)), alkoxylated difunctional monomers, alkyl difunctional monomers, multifunctional monomers (TMPTA (trimethylolpropane triacrylate), GPTA (propoxylated glyceryl triacrylate), PET(T)A (pentaerythritol tri-(tetra)acrylate), etc.), acid-based adhesion promotor monomers;

[0068] - 0.1 to 10 percent by weight of additives such as defoaming agents, leveling agents;

[0069] - 0.1 to 30 percent by weight of nanosilica or corundum (A12O3);

[0070] - 5 to 80 percent by weight of oligomers of polyester acrylate, urethane acrylate, polyether acrylate, melamine acrylate, polycarbonate acrylate, epoxy acrylate, amine modified acrylate or urethane (meth)acrylate, preferably a urethane acrylate with the formula A-I-P-I-A, wherein

[0071] • A: acrylic or methacrylic, mono or polyfunctional

[0072] • I: isocyanate (aliphatic monomeric or oligomeric di- or multifunctional)

[0073] • P: polyol-long or short-chain polyester, poly ether, polycarbonate, di- or multifunctional;

[0074] - optionally, fillers, pigments and / or reinforcing agents;

[0075] - 0.05 (and preferably at least 0.1) to 5 percent by weight of a thermo-initiator, preferably organic peroxide or an azo polymerization initiator.

[0076] In accordance with a practical example, thermally curing acrylate resin is composed of the following components:

[0077] - 53.7 parts by weight of an aliphatic urethane acrylate;

[0078] - 0.3 parts by weight of benzoyl peroxide;

[0079] - 46 parts by weight of dipropylene glycol diacrylate;

[0080] - optionally defoaming agents, leveling agents, nanosilica and / or corundum (AI2O3).

[0081] According to a fourth particular example of said second composition, it comprises

[0082] - oligomers, preferably one or more of acrylates - preferably urethane acrylates, more preferably aliphatic urethane acrylates -, methacrylates and unsaturated polyester,

[0083] - one or more than one photo-initiator in a combined amount of photo-initiator between 0.05 and 3 percent by weight of the coating, more preferably less than 2 percent by weight, more preferably less than 1 percent by weight, more preferably less than 0.5 percent by weight, even more preferably less than 0.2 percent by weight,

[0084] - one or more than one thermo-initiator, preferably in an amount of 0.1 - 3 percent by weight, more preferably in an amount of 0.5 - 3 percent by weight;

[0085] - optionally a plasticizer;

[0086] - optionally acrylate monomer;

[0087] - optionally a hindered amine light stabilizer and / or a UV-absorber; - optionally particles that provide scratch resistance and / or taber resistance, e.g. Fe Al oxide;

[0088] - optionally a diluent, preferably functional diluents, more preferably wherein the diluents comprise diluents with functionality higher than 2 or even higher than 3.

[0089] More particularly the composition disclosed in WO 2021 / 224843 may be applied.

[0090] Preferably, said first composition further comprises particles of aluminum oxide, nanosilica, diamond, silicon carbide or other hard particles, wherein said particles preferably have a particle size as expressed by the d50 value of the particle size distribution that is 50 micrometer or smaller. Said particle size distribution preferably being measured as defined by laser light granulometry performed in accordance with ISO 13320. Such particle size distribution in said first composition may provide for a good resistance against microscratches at the surface of the transparent or translucent wear layer.

[0091] The second composition, when available, may also comprise particles of aluminum oxide, silicon carbide or other hard particles, for example 5 to 50 grams per square meter of hard particles, or 10 to 40 grams per square meter, though preferably having a particle size ass expressed by the d50 value that is 60 micrometer or more, or even 70 micrometer or mre. Such particle size distribution in said second composition may provide for a good resistance against deeper scratches or abrasion at the surface of the transparent or translucent wear layer. Alternatively or in combination therewith, said sheet, for example a paper sheet, comprises hard particles having preferably the herein mentioned particle size distribution, and / or preferably in the same amount, i.e. 5 to 50 gram per square meter or 10 to 40 grams per square meter. The hard particles may be added to a paper sheet in the paper production, i.e. in the paper pulp.

[0092] Preferably, said first composition further comprises a matting agent, silica, silicic acid, or a wax of polyethylene, polypropylene, carnauba, polytetrafluoroethylene or amide. In such case extra mat surfaces can be obtained. Alternatively said matting agent may be an organic material or a filler. These agents may form a micro-structure on the surface of said first composition. Such micro-structure or micro-roughness may further minimize the risk of blocking or adhering when a plurality of sheets comprising such first composition are stacked or when an virtually endless web of such sheet is provided in a roll.

[0093] Preferably, said first composition further comprises anti-static agents, preferably a salt, for example a quaternary ammonium salt.

[0094] Preferably, said first composition comprises an agent enhancing the easiness to clean the obtained transparent or translucent wear layer. For example said agent may comprise a silicone based additive or another hydrophobic polymer.

[0095] Preferably, said first composition comprises an additional crosslinking agent enhancing the adhesion between the various lacquers and the substrate, for example between a first and a second composition or between a first composition and an impregnation available in or on the sheet or between the first or second composition and the substrate. For example, said first composition may comprise a carbodiimide, aziridine and / or an isocyanate functional compound.

[0096] It is clear that said method may, in the case of a radiation curable lacquer, further comprises the step of curing or drying, preferably with radiation, said first composition to a B-stage, preferably before applying said sheet on said substrate. In such case an optimal absence of tackiness can be obtained prior to applying said sheet on said substrate.

[0097] The substrate can be a wood-based board, e.g. a wood fiber board (e.g. a medium density fiberboard, MDF or a high density fiberboard, HDF), a wood chip board, a plywood board or a combination thereof,

[0098] The substrate can be a mineral board, e.g. a cement board, a Portland cement board, a magnesium oxide board or a gypsum board; whether or not comprising fillers, e.g. wood particles or wood fibers. The substrate can be a board comprising a magnesium oxide based binder and fillers, such as wood particles or wood fibers, and optionally a polymer binder.

[0099] The substrate can comprise or consist of impregnated kraft paper, e.g. to create a so called HPL (High Pressure Laminate) or CPL (Continuous Pressure Laminate).

[0100] Preferably, said sheet is provided in a stack of sheets all comprising said first composition, or in a roll. Preferably said sheets in said stack of sheets, or in a roll, have been dried and potentially optionally semi-cured. In such case, the non-tackiness may be optimally used to prevent sticking of the sheets to the stack or in the roll.

[0101] Preferably, said step of applying said sheet on said substrate comprises a heated press operation. Herein preferably a structured press element is applied for embossing at least said first composition. Said second composition, when available, may provide for a deeper embossing with a minimized risk of pressing defects occurring. Preferably, with said embossing one or more impressions are realized that extend deeper than the depth of that portion of the transparent or wear layer that has been obtained through said first composition and / or one or more impressions having a depth of 10 micrometer or more, or even having a depth of 100 micrometer or more, or even preferably a depth of 250 micrometer or more. Preferably even the deepest portions, i.e. the bottoms, of such impressions are formed on the basis of said first impressions. In such case the gloss level and other qualities of the surface can be kept identical in such impressions as well as at the global upper surface of the eventually obtained decorative panel.

[0102] Said sheet comprising said first composition may further comprise one or more adhesion layers, such as an adhesion layer immediately below said first composition, for example adjacent to a printed pattern available on such paper sheet and / or an adhesion layer at the side of the paper opposite the first composition. For example the paper sheet may comprise from top to bottom an optional adhesion layer, the paper sheet with a core impregnation, potentially a printed pattern, an adhesion layer, said first composition. An adhesion layer may per se comprise a paper sheet having a raw paper surface weight of 10 to 30 grams per square meter and / or 4 to 30 grams per square meter of an aminoplast resin, such as melamine formaldehyde or urea formaldehyde, an acrylate resin, a polyurethane resin or a melamine acrylate. In case a paper sheet is available in the adhesion layer, this paper sheet is preferably also impregnated for example with one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof.

[0103] It is clear that there are several options for said first composition.

[0104] In accordance with a first option, said first composition is a water-based radiation curable lacquer, more particularly an aqueous UV curable polyurethane dispersion and / or an aqueous UV curable dispersion or a radiation curable compound with acrylate functionalities.

[0105] A first practical example of a first composition in accordance with said first option is the following:

[0106] • 90 wt% waterbased UV curable polyurethane dispersion

[0107] • 3 wt% aluminum oxide (average particle size d50 20 micrometer)

[0108] • 0.1 wt% antifoam agent

[0109] • 0.1 wt% photo-initiator

[0110] • 0.3 wt% wetting agent

[0111] • 2.5 wt% matting agent

[0112] • 4% water;

[0113] • and optionally in addition 0.1 parts by weight of thermo-initiator and / or 0.3 parts by weight of release agent.

[0114] This first composition is applied at a rate of 20 grams per square meter, wet weight, on a paper sheet having a Gurley value of 15 seconds. This corresponds to about 10 grams per square meter dry weight. The first composition is dried at 130°C during 1 minute. Optionally an excimer curing can be applied. A non-tacky surface is obtained on the sheet, which is subsequently heat pressed to an HDF substrate.

[0115] A second practical example of a first composition in accordance with said first option is the following: • 80 wt% waterbased UV curable polyurethane dispersion

[0116] • 0.1 wt% antifoam agent

[0117] • 0.05 wt% photo-initiator

[0118] • 0.3 wt% wetting agent

[0119] • 15 wt% nanosilica

[0120] • 2.5 wt% matting agent

[0121] • 2% water;

[0122] • and optionally in addition 0.1 parts by weight of thermo-initiator.

[0123] This first composition is applied at a rate of 20 grams per square meter, wet weight, on a paper sheet having a Gurley value of 15 seconds. This corresponds to about 10 grams per square meter dry weight. The first composition is dried at 130°C during 1 minute. Optionally an excimer curing can be applied. A non-tacky surface is obtained on the sheet, which is subsequently heat pressed to an HDF substrate.

[0124] In accordance with a second option, said first composition is a water-based lacquer, more particularly a polyurethane and / or acrylic water-based dispersion. A water-based lacquer that is not radiation curable or free of photo-initiators, may be a more economic alternative. The bound with potentially underlying layers may be less good due to the lesser amount or lack of free acrylates in such water-based lacquers. However, this lesser bound may be acceptable in the production environment, and may, after final curing, for example in a heated press, become insignificant.

[0125] A first practical example of a first composition in accordance with said second option is the following:

[0126] • 90 wt% waterbased polyurethane dispersion, for example an anionic dispersion of an aliphatic polyester - polyurethane

[0127] • 3 wt% aluminum oxide (average particle size d50 20 micrometer)

[0128] • 0.1 wt% antifoam agent

[0129] • 0.3 wt% wetting agent

[0130] • 2.6 wt% matting agent

[0131] • 4 wt% water. This first composition is applied at a rate of 20 grams per square meter, wet weight, on a paper sheet having a Gurley value of 15 seconds. This corresponds to about 10 grams per square meter dry weight. The first composition is dried at 120°C during 1 minute. A non- tacky surface is obtained on the sheet, which is subsequently heat pressed to an HDF substrate.

[0132] A second practical example of a first composition in accordance with said second option is the following:

[0133] • 90 wt% waterbased acrylic dispersion , for example a self-crosslinking, multiphase acrylic dispersion

[0134] • 3 wt% aluminum oxide (average particle size d50 20 micrometer)

[0135] • 0.1 wt% antifoam agent

[0136] • 0.3 wt% wetting agent

[0137] • 2.6 wt% matting agent

[0138] • 4 wt% water.

[0139] This first composition is applied at a rate of 20 grams per square meter, wet weight, on a paper sheet having a Gurley value of 15 seconds. This corresponds to about 10 grams per square meter dry weight. The first composition is dried at 120°C during 1 minute. A non- tacky surface is obtained on the sheet, which is subsequently heat pressed to an HDF substrate.

[0140] In accordance with a third option, said first composition is a mixture of a radiation curable water-based lacquer and a water-based lacquer, more particularly a mixture of a water-based UV curable lacquer and a water-based dispersion of polyurethane and / or acrylic. This third option may create an optimum of cost and bound with potentially underlying layers.

[0141] A first practical example of a first composition in accordance with said third option is the following:

[0142] • 71.5 wt% waterbased UV curable polyurethane dispersion

[0143] • 3 wt% aluminum oxide (average particle size d50 20 micrometer)

[0144] • 0.1 wt% antifoam agent • 25 wt% waterbased acrylic resin

[0145] • 0.1 wt% photo-initiator

[0146] • 0.3 wt% wetting agent and optionally in addition 0.1 parts by weight of a thermo-initiator.

[0147] This first composition is applied at a rate of 20 grams per square meter, wet weight, on a paper sheet having a Gurley value of 15 seconds. This corresponds to about 10 grams per square meter dry weight. The first composition is dried at 130°C during 1 minute. Optionally a curing using a UV-C mercury lamp and / or a radiation at a wavelength of 245-265 nanometer can be applied. A non-tacky surface is obtained on the sheet, which is subsequently heat pressed to an HDF substrate.

[0148] Here below three practical embodiments of decorative panels are described that may be obtained through the method of the invention. It is clear that such decorative panels form per se an independent inventive aspect of the invention.

[0149] According to a first practical embodiment, a decorative panel comprises a substrate, wherein the substrate may be wood based, mineral based, plastic based, or paper-based, for example kraft paper based. In particular the substrate may be a wood fiber board, such as an MDF or HDF board (medium or high density fiberboard) or a wood particle board. An impregnated paper sheet comprising a printed pattern and a transparent or translucent wear layer is applied to the top surface of said core. The paper sheet has a raw paper surface weight of between 60 and 85 grams per square meter and is provided with an amount of impregnation that is at least the same, i.e. at least 30 (and preferably at least 60)to at least 80 grams per square meter dry matter . The impregnation fluid is one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. The paper sheet has a Gurley value of 30 seconds or below; or more preferably 20 seconds or below. Said transparent or translucent wear layer is available at the side of said paper sheet that is provided with said printed pattern and is for the majority, i.e. at least for 65% of the thickness of the transparent or translucent wear layer, obtained from a first composition being an aqueous UV curable polyurethane dispersion. Alternatively, any first composition in accordance with said first, second or third option can be applied. Preferably said first composition is available at a rate of 10 to 60 grams per square meter dry weight. Said first portion forms the surface of the decorative panel and comprises hard particles, for example 10 to 40 grams per square meter of aluminum oxide having a particle size distribution with a d50 value of 50 micrometer or below, for example a d50 value of about 20 micrometer. Said surface of the decorative panel may be provided with impressions, for example impressions in register with said printed pattern. Optionally an adhesion layer may be provided between said paper sheet and the surface of said substrate and / or between said printed pattern and said first portion. The adhesion layer may comprise one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. Such adhesion layer may per se comprise a paper sheet, for example a paper sheet having a raw paper surface weight of 10 to 30 grams per square meter. In such case the paper sheet of the adhesion layer preferably is impregnated with one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof.

[0150] According to a second practical embodiment, a decorative panel comprises a substrate, wherein the substrate may be wood based, mineral based, plastic based, or paper-based, for example kraft paper based. In particular the substrate may be a wood fiber board, such as an MDF or HDF board (medium or high density fiberboard) or a wood particle board. An impregnated first paper sheet comprising a printed pattern is applied to the top surface of said core. The first paper sheet has a raw paper surface weight of between 60 and 85 grams per square meter and is provided with an amount of impregnation that is, i.e. preferably at least 30, more preferably at least 50, more preferably at least 60 to at least 80 grams per square meter. The impregnation fluid is one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. The first paper sheet has a Gurley value of 20 seconds or below. The first paper sheet and / or said impregnation fluid may comprise 10 to 40 grams per square meter of aluminum oxide having a particle size distribution with a d50 value of 70 micrometer or more. A transparent or translucent wear layer is available at the side of said first paper sheet that is provided with said printed pattern. The wear layer comprises an impregnated second paper sheet. The second paper sheet has a Gurley value of 25 seconds or below, and has a raw paper surface weight of between 10 and 30 grams per square meter, for example about 25 grams per square meter, and is provided with an amount of impregnation which is at least the same. The impregnation fluid is one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. The second paper sheet and / or said impregnation fluid may comprise 5 (and preferably at least 10) to 40 grams per square meter of aluminum oxide having a particle size distribution with a d50 value of 70 micrometer or more Said transparent or translucent wear layer is for the majority, i.e. at least for 65% of the thickness of the transparent or translucent wear layer, obtained from a first composition being an aqueous UV curable polyurethane dispersion, or alternatively any first composition in accordance with said first, second or third option. Preferably said first composition is available at a rate of 10 to 60 grams per square meter. Said first portion forms the surface of the decorative panel and comprises hard particles, for example 10 to 40 grams per square meter of aluminum oxide having a particle size distribution with a d50 value of 50 micrometer or below, for example a d50 value of about 20 micrometer. Said surface of the decorative panel may be provided with impressions, for example impressions in register with said printed pattern. Optionally an adhesion layer may be provided between said first paper sheet and the surface of said substrate and / or between said printed pattern and said second paper sheet and / or between said second paper sheet and said first portion. The adhesion layer may comprise one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. One or more of the adhesion layers may per se comprise a paper sheet, for example a paper sheet having a raw paper surface weight of 10 to 30 grams per square meter. In such case the paper sheet of the adhesion layer preferably is impregnated with one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof.

[0151] According to a third practical embodiment, a decorative panel comprises a substrate, wherein the substrate may be wood based, mineral based, plastic based, or paper-based, for example kraft paper based. In particular the substrate may be a wood fiber board, such as an MDF or HDF board (medium or high density fiberboard) or a wood particle board. An impregnated paper sheet comprising a printed pattern and a transparent or translucent wear layer is applied to the top surface of said core. The paper sheet has a raw paper surface weight of between 60 and 85 grams per square meter and is provided with an amount of impregnation that is, at at least 30, and preferably at least 60 to at least 80 grams per square meter. The impregnation fluid is one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. The paper sheet has a Gurley value of 30 seconds or below, more preferably a Gurley value of 20 seconds or lower. Said transparent or translucent wear layer is available at the side of said paper sheet that is provided with said printed pattern and is for the majority, i.e. at least for 65% of the thickness of the transparent or translucent wear layer, formed by a second portion obtained from a second composition in accordance with the first particular example mentioned above. Said transparent or translucent wear layer is for the remainder formed by a first portion obtained from a first composition being an aqueous UV curable polyurethane dispersion, or a first composition in accordance with any of the first, second and third option. Preferably said first composition is available at a rate of 10 to 60 grams per square meter dry weight. Said first portion forms the surface of the decorative panel and comprises hard particles, for example 5 to 20 grams per square meter of aluminum oxide having a particle size distribution with a d50 value of 50 micrometer or below, for example a d50 value of about 20 micrometer. Said surface of the decorative panel may be provided with impressions, for example impressions in register with said printed pattern. Optionally an adhesion layer may be provided between said paper sheet and the surface of said substrate and / or between said printed pattern and said first portion. The adhesion layer may comprise one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. Such adhesion layer may per se comprise a paper sheet, for example a paper sheet having a raw paper surface weight of 10 to 30 grams per square meter. In such case the paper sheet of the adhesion layer preferably is impregnated with one of melamine formaldehyde, urea formaldehyde, melamine urea formaldehyde, an acrylate dispersion, a polyurethane dispersion, a melamine acrylate, or a mixture thereof. As used in this document, the molar mass of a compound is the calculated molar mass. The calculated molar mass is obtained by adding the atomic masses of all atoms present in the structural formula of a compound. When the exact structural formula of a compound is not known, the molar mass of the compound is the number average molecular weight determined using Triple Detection Size Exclusion Chromatography using tetra hydrofuran THF as eluent.

[0152] Where particle sizes, such as DIO, D50, D90 value, and particle size distributions are discussed in the present disclosure, this preferably concerns particle sizes and distributions as defined by laser light granulometry performed in accordance with ISO 13320:2020, namely by a dynamic light scattering technique using a laser having an emission wavelength of 632.8 nm and measured under a scattering angle of 90 degrees. Such granulometry may e.g. be performed with a Malvern® Mastersizer 2000 or with a Malvern® Mastersizer 3000. For executing the measurement of the particle size distribution, the respective particles may be dispersed in a liquid, such as water.

[0153] The invention - according to a second aspect - also relates to a method for manufacturing a decorative laminate. The method for manufacturing a decorative laminate is a method according to any of the embodiments of the method for manufacturing decorative panels, but wherein the substrate comprises or consists of at least one or a plurality of resin impregnated sheet(s) of paper, preferably Kraft paper.

[0154] The resin impregnated sheet(s) of paper can be impregnated with a partially cured thermosetting resin, e.g. with a phenol formaldehyde resin.

[0155] In the method for manufacturing a decorative laminate, a so-called High Pressure Laminate (HPL) can be manufactured. When the decorative laminate is manufactured in a continuous pressing process (e.g. when the pressing is performed in a double-belt press), a so-called Continuous Pressure Laminate (CPL) can be manufactured. Such High Pressure Laminate (HPL) or such Continuous Pressure Laminate (CPL) can be glued onto a board, e.g. onto a wood-based board (e.g. a wood particle board), for manufacturing a decorative panel. Such approach can be used e.g. in the production of decorative panels for producing furniture, or in the production of floor panels.

[0156] The third aspect of the invention relates to a method for producing a sheet for use in a method as in any embodiment of the first aspect or as in any embodiment of the second aspect of the invention. The method of the third aspect comprises the steps of

[0157] - providing a sheet selected from a paper sheet or a thermoplastic foil;

[0158] - coating the sheet with a first composition; wherein the first composition comprises a water-based radiation curable lacquer, a water-based acrylic or water-based polyurethane dispersion, or a mixture of a water-based radiation curable lacquer and one or more of a water-based acrylic and water-based polyurethane dispersion;

[0159] - performing a drying step for evaporating water out of the first composition; preferably wherein the drying step dries the first composition to non-tacky state.

[0160] The first composition for coating onto the sheet may comprise a thermo-initiator. The thermo-initiator is preferably present in the first composition after drying the first composition, such that the thermo-initiator is provided for being activated in a thermal pressing operation wherein the first composition (e.g. comprising or consisting of a water-based polyurethane acrylate dispersion) is thermally cured and preferably provided with a texture by copying the texture of a textured press element.

[0161] It is a benefit of such embodiments that excellent anti-finger print properties can be obtained in a decorative laminate or decorative panel obtained with a sheet made this way. The use of the first composition provides in itself better anti -finger print properties than traditional melamine formaldehyde wear layers. Furthermore, textured press elements can be used, the texture of which is copied during the pressing operation, such that even better anti-finger print is obtained. Instead of textured press plates, flat press plates can be used within the scope of the invention.

[0162] The thermo-initiator may be an encapsulated thermo-initiator. After the drying step, the first composition preferably comprises acrylate groups. It is a benefit that the acrylate groups can be cured in a thermal pressing operation.

[0163] The first composition can comprise a water-based polyurethane acrylate dispersion, which, after the drying step, comprises acrylate groups.

[0164] The first composition coated on the sheet may comprise one or more of:

[0165] - a wetting agent, e.g. a silicone surfactant;

[0166] - acrylate reactive diluents or no acrylate reactive diluents;

[0167] - a hydrophobic agent;

[0168] - beads, e.g. glass beads, thermoplastic beads, or poly (methyl methacrylate) (PMMA) beads;

[0169] - wax;

[0170] - silica;

[0171] - casein;

[0172] - a silane oligomer;

[0173] - a matting agent;

[0174] - aluminum oxide particles or no aluminum oxide particles;

[0175] - a photo-initiator;

[0176] - a crosslinking agent, such as carbodiimide, isocyanate, or aziridine.

[0177] A wetting agent, e.g. a silicone surfactant, can be added to improved the wetting of the sheet onto which the first composition is coated. The addition of a wetting agent is of particular interest when the first composition comprises a thermo-initiator, as the inventors have noticed that the addition of a thermo-initiator can negatively affect the wetting.

[0178] The first composition can comprise acrylate reactive diluents or can be substantially free from acylate reactive diluents. With substantially free from acrylate reactive diluents is meant that no acrylate reactive diluents are added in the formulation of the first composition, or that the first composition comprises less than 1 wt% acrylate reactive diluents relative to the dry mass of the first composition.

[0179] Addition of acrylate reactive diluents can lead to increased crosslinking density in the final product, beneficial for the wear and scratch resistance.

[0180] A preferred embodiment of the third aspect of the invention is characterized in that the first composition comprises a reactive diluent, more preferably an acrylate reactive diluent, more preferably an ethoxylated acrylate reactive diluent or a propoxylated acrylate reactive diluent.

[0181] The first composition preferably comprises between 5 and 25 wt% reactive diluent, more preferably between 5 and 15 wt%, more preferably between 10 and 15 wt% reactive diluent.

[0182] The presence of the reactive diluents has the benefit that the cross linking density of the wear layer can be increased. The increased cross linking density of the wear layer is beneficial for the hardness and the scratch resistance of the wear layer. Furthermore, it has been observed that the presence of reactive diluents increases the adhesion of the first formulation.

[0183] Preferred reactive diluents for use in the invention are ethoxylated reactive diluents, more preferably ethoxylated acrylate reactive diluents. An example of an ethoxylated acrylate reactive diluent that can be used in the invention is dipentaerythritol hexaacrylate. It is a benefit of ethoxylated acrylate reactive diluents that they are soluble in a water-based first formulation.

[0184] Preferred reactive diluents for use in the invention are ethoxylated reactive diluents or propoxylated reactive diluents, more preferably ethoxylated acrylate reactive diluents or propoxylated acrylate reactive diluents. An example of an ethoxylated acrylate reactive diluent that can be used in the invention is dipentaerythritol hexaacrylate. Other examples include ethoxylated trimethylolpropane triacrylate or PETA or PETIA. Other hydrophilic reactive diluents could be used, such as e.g. hydroxyethyl acrylate (HEA), hydroxypropyl acrylate (HP A).... It is a benefit of such reactive diluents that they can be dispersed in a water-based first formulation.

[0185] It can be beneficial not to have acrylate reactive diluents in the first composition, as the presence of acrylate reactive diluents can result in tackiness after drying of the first composition.

[0186] The first composition can comprise a hydrophobic agent. It is a benefit that the hydrophobic agent improves the anti-fingerprint properties of the final product.

[0187] The first composition can comprise beads, e.g. glass beads, thermoplastic beads, or poly (methyl methacrylate) (PMMA) beads. Such embodiments have the benefit that the final surface obtained is less prone to micro-scratches without increasing the risk of tackiness after the drying step.

[0188] The first composition can comprise wax. Such embodiments have the benefit of improving the scratch resistance of the final surface without increasing the risk of tackiness after the drying step.

[0189] The first composition can comprise silica. Such embodiments have the benefit of improving the scratch resistance of the final surface without increasing the risk of tackiness after the drying step.

[0190] The first composition can comprise casein. Such embodiments have the benefit that after the drying step the surface of the first composition is less prone to tackiness.

[0191] The first composition can comprise a silane oligomer. Such embodiments have the benefit of improving the scratch resistance of the final surface without increasing the risk of tackiness after the drying step. The first composition can comprise a matting agent. It is a benefit of such embodiments that after the drying step a less tacky surface is obtained.

[0192] The first composition can comprise a crosslinking agent (e.g. isocyanate, carbodiimide, or aziridine). It is a benefit of such embodiments that after the curing step a more scratch resistant surface is obtained.

[0193] The first composition can comprise aluminum oxide particles. Such embodiments will provided a final product with improved wear and scratch resistance.

[0194] The first composition can be free from aluminum oxide particles or free from abrasion resistant particles. Such embodiments can be beneficial as the presence of the abrasion resistant particles - such as aluminum oxide - can be negative, e.g. causing excessive tool wear when machining the decorative panels.

[0195] The first composition may comprise a photo-initiator. Preferably in embodiments wherein the first composition comprises a photo-initiator, a UV-curing step is performed after drying the applied first composition for partially curing the first composition.

[0196] The first composition that is applied preferably comprises at least a water-based polyurethane dispersion, wherein the water-based polyurethane dispersion comprises or consists of a water-based polyurethane acrylate dispersion, preferably an aliphatic polyurethane acrylate dispersion.

[0197] Such embodiments have shown to provide in the final product a combination of good wear and scratch resistance, as well as good anti-fingerprint properties and an excellent copying of a textured press plate in the pressing operation in which the first composition is cured.

[0198] A preferred water-based polyurethane acrylate dispersion for use in the invention comprises a polyurethane acrylate dispersion as well as a polyurethane dispersion not comprising acrylate groups. Preferably, the water-based polyurethane acrylate dispersion comprises a blend of a polyurethane acrylate dispersion (thus, a polyurethane having acrylate groups) and a polyurethane dispersion not comprising acrylate groups.

[0199] It is a benefit of such embodiments that after application of such first composition and its drying, excellent blocking resistance is obtained, and that after a thermal pressing operation in which the first coating composition is thermally cured and embossed excellent transparency of the cured and embossed first coating composition is obtained.

[0200] More preferably, the polyurethane acrylate dispersion comprises at least 10 (and more preferably at least 15, more preferably at least 20, more preferably at least 30; and preferably less than 40, more preferably less than 35) parts by weight of solids of the polyurethane not comprising acrylate groups per 100 parts by weight of solids of the polyurethane acrylate. Such embodiments have shown to provide excellent blocking resistance and excellent transparency of the thermally cured and embossed first coating composition.

[0201] Preferably, the glass transition temperature of the polyurethane dispersion not comprising acrylate groups is higher - and preferably at least 10°C higher, more preferably at least 25 °C higher, and preferably less than 50 °C higher - than the glass transition temperature of the glass transition temperature of the polyurethane acrylate dispersion. Such embodiments have shown to provide excellent blocking resistance and excellent transparency of the thermally cured and embossed first coating composition.

[0202] The sheet used in the method of the third aspect of the invention can be a paper sheet, preferably a decorative paper sheet, e.g. a printed paper sheet or a colored paper sheet.

[0203] The paper sheet can be a resin impregnated paper sheet, preferably wherein the paper sheet is impregnated with 50 - 75 wt% (and preferably less than 65 wt%) of dry weight of resin relative to the weight of the paper sheet before impregnation. Meant is that after drying the water based resin, the paper sheet is impregnated with 50 - 75 wt% (and preferably less than 65 wt%) of dry weight of resin relative to the weight of the paper sheet before impregnation. Such embodiments provide the benefit that the paper sheet is not fully loaded with resin. As a consequence, the first composition can at least partially penetrate in the paper sheet which can improve the adhesion of the first composition to the paper sheet, even if no or limited bonding is obtained between the first composition and the resin with which the paper sheet is impregnated.

[0204] The paper sheet can be impregnated with a resin selected from a melamine formaldehyde resin, a polyurethane resin - whether or not having reactive acrylate groups -, an acrylate resin, or combinations thereof.

[0205] The paper sheet is preferably impregnated with a partially cured thermosetting resin. The partially cured thermosetting resin can be cured in a thermal pressing operation also curing the first composition and optionally providing a texture to the first composition.

[0206] The paper sheet impregnated with a partially cured thermosetting resin preferably comprises wear resistance increasing particles - e.g. aluminum oxide particles. It is a benefit that the wear resistance of the final product is improved.

[0207] In a preferred embodiment, wear resistance increasing particles - e.g. aluminum oxide particles - can be dispersed in the bath comprising the thermosetting resin with which the paper sheet is impregnated. It is a benefit that such embodiment provides impregnation of the paper sheet with thermosetting resin and at the same time wear resistance particles are added to the paper sheet.

[0208] In a preferred embodiment, wear resistance increasing particles - e.g. aluminum oxide particles - can be scattered on the paper sheet after impregnating the paper sheet with the thermosetting resin and before coating the paper sheet with the first composition. It is a benefit that such embodiment provides excellent positioning the wear resistance increasing particles on the paper sheet, such that excellent increase of wear resistance of the final product is obtained. The wear resistance increasing particles are preferably scattered on the paper sheet after impregnating the paper sheet with the thermosetting resin and before drying the resin with which the paper sheet is impregnated.

[0209] Wear resistance increasing particles - e.g. aluminum oxide particles - for use in such embodiments preferably have average particle size d50 between 40 and 100 micrometer.

[0210] In the step of coating the sheet with the first composition preferably between 10 and 40, more preferably between 20 and 40, more preferably between 20 and 30, more preferably between 20 and 25, grams per square meter dry weight of the first composition is applied.

[0211] Such embodiments have the benefit that an excellent sheet is obtained for use in the manufacture of decorative panels (e.g. floor panels or furniture panels) or of decorative laminates for the furniture industry. Sufficient wear and scratch resistance can be obtained, nice textures can be made, sufficient vapor density and good anti-fingerprint properties can be obtained at affordable cost.

[0212] The method of the third aspect may comprise the step of coating an adhesion layer at the side of the sheet opposite to the side coated or to be coated with the first composition. Such adhesion layer can be helpful to improve or provide adhesion in the step of adhering the sheet to a substrate.

[0213] The method of the third aspect may comprise a partial UV-curing step of the first composition after the drying step. Such embodiment can efficiently prevent blocking of the coated sheet. Preferably, the first composition for use in such embodiments comprises a photo-initiator. The photo-initiator can be activated in the partial UV-curing step for activating the partial UV-curing of the first composition.

[0214] The method of the third aspect of the invention preferably is free from a UV-curing step. Such embodiment simplifies the production process especially when the first composition is not tacky after the drying step. The first composition for use in the third aspect of the invention can have features as described in embodiments of the first aspect of the invention.

[0215] The fourth aspect of the invention is a sheet for use in a method according to any embodiment of the first aspect or of the second aspect of the invention. The sheet of the fourth aspect of the invention is obtained in a method according any embodiment of the third aspect of the invention.

[0216] The first composition can - in any of the aspects - comprise a matting agent. The matting agent can e.g. be a wax dispersion, e.g. a wax dispersion based on modified polyethylene.

[0217] The first composition can - in any of the aspects - comprise a wetting agent. The wetting agent can be a silicone surfactant. The wetting agent can e.g. be a polyether-modified polydimethylsiloxane or a modified ester of sulfocarboxylic acid.

[0218] The first composition can - in any of the aspects - comprise an emulsion of an amino functional poly siloxane. Such additive can improve the anti-fingerprint properties of the final product.

[0219] The first composition can comprise- in any of the aspects - a precipitated amorphous (preferably crystalline-free) silica, preferably with spherical particle shape. Such additives can improve the anti-fingerprint properties of the final product.

[0220] The first composition can comprise - in any of the aspects - wax, glass beads, thermoplastic beads, PMMA beads, a paraffin wax emulsion, or combinations thereof. Such embodiments have the benefit that the final product is more resistant to microscratches.

[0221] The first composition may comprise - in any of the aspects - casein, a silane oligomer, colloidal silica, micronized modified polyethylene wax, silane coupled glass beads, or combinations thereof. Such embodiments have the benefit of providing improved anti- blocking of the first composition after drying or partially curing it and before performing a thermal pressing operation to fully cure the first composition.

[0222] Water can be added to water-based first compositions for reducing the viscosity of the first composition, e.g. to ensure easy and even application.

[0223] For use in the invention, the glass transition temperature (Tg) can be measured according to ISO 11357-2:2020.

[0224] For use in the invention, the amount of solids in a water-based resin dispersion can be measured according to ISO 3251 :2019, drying at 140 °C during 2 hours.

[0225] In order to better demonstrate the features of the invention, some preferred embodiments are described below, by way of example and without any limiting character, with reference to the accompanying drawings, wherein: figure 1 schematically illustrates some steps in a method in accordance with the invention; figure 2 and 3 at a larger scale show a cross-sections in accordance with the line II-II, respectively III-III in figure 1 ; figure 4 and 5, in a same view as figure 3 represent variants; figure 6 shows a view on the area indicated with F6 in figure 1, though for a variant; and figure 7 shows an embodiment of a method according to the third aspect of the invention.

[0226] Figure 1 shows a method for manufacturing decorative panels 1. The panels 1 comprise a substrate 2 and a decorative top layer 3. The decorative top layer 3 comprises a decoration 4 and a translucent or transparent wear layer 5 applied over said decoration 4. In this case the decoration 4 is a printed pattern applied on a paper sheet 6.

[0227] The method comprises at least the step SI of providing said paper sheet 6, wherein the paper sheet 6 comprises at least a first composition 7 for forming a portion of said translucent or transparent wear layer 5. The method further comprises at least the step S2 of applying said sheet 6 on said substrate 2. The first composition 7 can be any of those mentioned in the introduction, for example a first composition 7 in accordance with said first option. In this case the first composition 7 is applied by means of a gravure roller 8. The illustrated method further comprises the optional step S3 of drying said first composition 7 and the step S4 of partially curing said first composition by means of radiation, preferably with a wavelength between 80 and 450 ( and more preferably less than 400) nanometer. It is clear that in case the first composition 7 is a water-based lacquer, i.e. not a radiation curable water-based lacquer, the optional step S3 can be omitted.

[0228] In the step S2 of applying said sheet 6 on said substrate 2, a heated press operation with a structured press element 9 is applied for embossing at least said first composition 7 applied to said sheet 6. At the bottom, though optionally, a similar paper sheet 6A, preferably also comprising a similar first composition 7, may be applied.

[0229] The decorative panels 1 that are eventually obtained by means of the method of figure 1 are in this case floor panels. One or more finishing steps, such as sawing and milling operations may be necessary to obtained the eventual floor panel 1, for example in order to form profiled edges with coupling parts 10 at one or more pairs of opposite edges enabling a glueless locking between two such floor panels 1 at the respective edges.

[0230] Figure 2 shows that the paper sheet 6 has been impregnated with an impregnation fluid 12 prior to providing said first composition 7. The impregnation fluid preferably fills at least the core of the paper sheet 6, and may form a surface layer at one or more sides of the raw paper sheet.

[0231] Figure 3 shows that the first composition 7 is applied at the side of the paper sheet having the printed pattern 4.

[0232] Figure 4 shows that one or more adhesion layers 13 may be comprised in said provided paper sheet 6. A first adhesion layer 13 may be present at the interface between the impregnation and the first composition 7. A second adhesion layer 13 may be present at the opposite side of the paper sheet 6, for example to create an enhanced bonding with the substrate 2.

[0233] Figure 5 shows an embodiment where the paper sheet 6 further comprises a second composition 14 in accordance with one of the particular examples mentioned thereof in the introduction. The second composition 14 is configured to form the majority, i.e. more than 65% of the thickness of the transparent or translucent wear layer 5, while the first composition 7 is configured to form the remainder of the thickness of the transparent or translucent wear layer 5 and forms the topmost surface of said paper sheet 6.

[0234] Figure 6 shows an embodiment where an overlay paper sheet 6A, i.e. a paper sheet that is made from alpha cellulose and has a weight of about 25 grams per square meter, is provided with said first composition 7. The paper sheet 6 A has been impregnated with an impregnation fluid 12 and an adhesion layer 13 is provided between the top side of the paper sheet 6A and the first composition 7. A separate decor layer 16 comprising a paper sheet 6 with a printed pattern 4 and impregnation fluid 12 is available between the overlay paper sheet 6A and the substrate 2. An adhesion layer 13 is provided between the decor layer 16 and the overlay paper sheet 6A, as well as between the decor layer and the substrate 2. It is illustrated here that a first one of these adhesion layers is available on the paper sheet 6 at the side that is provided with the printed pattern 4. Alternatively, this adhesion layer 13 may be provided at the bottom of the overlay paper sheet 6A. It is further illustrated that a second one of these adhesion layers is available on the paper sheet 6 at the side opposite said printed pattern 4. Alternatively, this adhesion layer 13 may be provided on the top surface of the substrate 2.

[0235] Figure 7 shows an embodiment of a method according to the third aspect of the invention. The resulting sheet can be used in a method according to the first aspect or according to the second aspect of the invention.

[0236] A paper sheet 6 is provided. The paper sheet 6 can be a decorative paper sheet, e.g. a paper sheet printed with a decor or a colored paper sheet. In process step S5, the paper sheet 6 is impregnated with a resin 20, excess resin is removed in squeezing unit 21. This way, the amount of resin can be set with which the paper sheet 6 is impregnated.

[0237] Optionally, in process step S9, wear resistance increasing particles can be scattered onto the paper sheet 6 impregnated with the resin 20.

[0238] The impregnated paper sheet can be dried in a drying step S6, e.g. by passing the impregnated paper sheet through an oven. This, way the impregnated paper sheet can be dried and the resin 20 can be partially cured.

[0239] The paper sheet 6 can e.g. have a weight of 75 gram per square meter and be impregnated with between 50 - 75 wt% (and preferably less than 65 wt%) of dry weight of resin (after the drying step S6) relative to the weight of the paper sheet before impregnation.

[0240] The resin can e.g. be a melamine formaldehyde resin.

[0241] The paper sheet is than coated - in the example shown using a gravure roller 8 - with a first composition 7 (which in the example shown is water-based) followed by a thermal drying step S7 to dry the first composition to non-tacky state.

[0242] The first composition 7 can be a water-based polyurethane acrylate dispersion, which, after the drying step S7, comprises acrylate groups.

[0243] In the example shown, the first composition 7 comprises a thermo-initiator , which is present after the drying step S7, and which can be activated in a thermal pressing operation such as indicated with S2 in figure 1.

[0244] Figure 7 shows the optional drying step S6 after impregnation of the paper sheet 6.

[0245] However, this step is optional, as the first composition 7 can be coated wet-on-wet. Optionally, a partial UV-curing step S8 can be performed after drying the first composition 7 for partially curing it. To this end, the first composition 7 can comprise a photo-initiator.

[0246] An example of a first composition that can be used in a method shown in figure 7 comprises:

[0247] 100 parts by weight of a water-based polyurethane acrylate dispersion having 40 wt% of solids, and which after the drying step S7 comprises reactive acrylate groups.

[0248] 0.2 parts by weight of a thermo-initiator (e.g. tert-butyl 3,5,5- trimethylperoxyhexanoate), which is still present in the first composition coated on the paper sheet after the drying step S7;

[0249] 2 parts by weight of a wetting agent, e.g. a silicone surfactant; optionally an ethoxylated acrylate reactive diluent, e.g. 10 - 15 parts by weight of dipentaerythritol hexaacrylate; and optionally one or more of a photo-initiator, glass beads, silica, wax, casein, a silane oligomer or a matting agent.

[0250] As an example, between 20 and 40 gram per square meter (dry weight) of first composition 7 can be applied.

[0251] The example shown in figure 7, with the exemplary first composition listed, has shown to be very well suited for use in manufacturing decorative panels for the furniture industry, and can be used also for floor panels.

[0252] The resulting sheet from the process shown in figure 7 can be used in a method according to the first aspect of the invention or in a method according to the second aspect of the invention. The sheet can be used in a process indicated with S2 in figure 1 for producing a decorative panel or a decorative laminate.

[0253] A second example of a first composition 7 that can be used in a method shown in figure 7 comprises: 100 parts by weight of a water-based polyurethane acrylate dispersion having 40 wt% of solids (thus providing in the first composition 40 parts by weight of solids of polyurethane acrylate), and which after the drying step S7 comprises reactive acrylate groups, this water-based polyurethane acrylate dispersion has glass transition temperature 104 °C;

[0254] 30 parts by weight of a water-based polyurethane dispersion not having acrylate groups and having 33 wt% solids and having a glass transition temperature of 129 °C (thus providing in the first composition 10 parts by weight of solids of polyurethane not comprising acrylate groups);

[0255] 0.2 - 0.8 parts by weight of a thermo-initiator (e.g. tert-butyl 3,5,5- trimethylperoxyhexanoate), which is still present in the first composition coated on the paper sheet after the drying step S7; optionally 1 - 2 parts by weight of ethylene bis stearamide (30 wt% solids) for improving the scratch resistance.

[0256] Optionally, a release agent can be added.

[0257] Water can be added to reduce the viscosity, if required for proper application of the first composition.

[0258] As an example, and referring to figure 7, between 20 and 40 gram per square meter (dry weight) of the second example of the first composition 7 can be applied using the gravure roller 8 (other coating applicators can be applied) after drying the impregnated paper sheet 6 in step S6. After applying this second example of the first composition 7 using the gravure roller 8, drying step S7 is performed. In this example, no partial UV-curing step S8 is performed. The resulting impregnated and coated sheet of paper has excellent anti-blocking properties.

[0259] The example shown in figure 7, with this exemplary first composition, has shown to be very well suited for use in manufacturing decorative panels for the furniture industry, and can be used also for floor panels. The resulting sheet from the process shown in figure 7 can be used in a method according to the first aspect of the invention or in a method according to the second aspect of the invention. The second example of the first composition has shown to result in high transparency of the wear layer obtained by thermal curing in a thermal pressing operation using a textured press element.

[0260] The present invention is by no means limited to the embodiments described above, however a decorative panel may be manufactured according to various variants without departing from the scope of the present invention.

Claims

Claims1 Method for manufacturing decorative panels, wherein said panels (1) at least comprise a substrate (2) and a decorative top layer (3) comprising a decoration and a transparent or translucent wear layer (5) applied over said decoration, wherein said method at least comprises- the step of providing a sheet (6-6A) comprising at least a first composition (7) for forming a portion of said transparent or translucent wear layer (5); and- the step of applying said sheet (6-6A) on said substrate (2); characterized in that said first composition (7) comprises a water-based radiation curable lacquer, a water-based acrylic or water-based polyurethane dispersion, or a mixture of a water-based radiation curable lacquer and one or more of a water-based acrylic and water-based polyurethane dispersion.2.- Method according to claim 1, characterized in that said sheet (6) is one of a paper sheet and a thermoplastic foil.3.- Method according to claim 1 or 2, characterized in that said decoration comprises a printed pattern (4) or a uniformly colored pattern.4.- Method according to claim 3, characterized in that said sheet (6) comprises said printed pattern (4).5.- Method according to any of the preceding claims 1 - 4, characterized in that said first composition (7) is free or essentially free from reactive diluent.6.- Method according to any of the preceding claims 1 - 4, characterized in that said first composition (7) comprises reactive diluents, preferably less than 25 wt% reactive diluents, more preferably less than 20 wt% reactive diluents.7.- Method according to any of the preceding claims, characterized in that said first composition (7) comprises a watermiscable multifunctional oligomer; preferably wherein the first composition comprises less than 25 wt% watermiscable multifunctional oligomer, more preferably less than 20 wt% watermiscable multifunctional oligomer.8.- Method according to any of the preceding claims, characterized in that said first composition (7) comprises a release agent.9.- Method according to any of the preceding claims, characterized in that said first composition (7) comprises an anti-blocking agent, such as wax or silica additives; and / or in that said first composition comprises an anti-blocking binder, such as casein or an acrylic resin.10.- Method according to any of the preceding claims, characterized in that said first composition (7) further comprises a photo-initiator and / or a thermo-initiator.11.- Method according to any of the preceding claims, characterized in that said first composition (7) comprises an encapsulated thermo-initiator.12.- Method according to any of the preceding claims, characterized in that said sheet (6) comprises at least 5 grams per square meter of said first composition, dry weight.13.- Method according to any of the preceding claims, characterized in that said first composition (7) forms a topmost surface (15) of said sheet (6-6A).14.- Method according to any of the preceding claims, characterized in that said sheet (6) further at least comprises a second composition (14) for forming a portion of said transparent or translucent wear layer (5), wherein said second composition (14) has one or a combination of two or more of the following properties:- the property that the main constituents of said second composition (14) are different from the main constituents of said first composition (7);- the property that said second composition (14) is solvent-based;- the property that said second composition (14) is solvent-based and comprises a mixture of acrylate oligomers and monomers of reactive diluent;- the property that said second composition (14) comprises reactive diluent;- the property that said second composition (14) comprises a photo-initiator and a thermo-initiator;- the property that said second composition (14) is 100% solid content acrylate and / or unsaturated polyester resin;- the property that said second composition (14) is 100% solid mixture of acrylate oligomers and / or unsaturated polyester resin, and monomers of reactive diluent;- the property that said second composition (14) is a dual cure lacquer and / or a mixture of a hydroxy functional compound with an isocyanate functional compound.15.- Method according to any of the preceding claims, characterized in that said first composition (7) further comprises particles of aluminum oxide, silicon carbide or other hard particles, wherein said particles preferably have a particle size as expressed by the d50 value of the particle size distribution that is 50 micrometer or smaller.16.- Method according to any of the preceding claims, characterized in that said first composition (7) further comprises a matting agent, silica, silicic acid, or a wax of polyethylene, polypropylene, carnauba, polytetrafluoroethylene or amide.17.- Method according to any of the preceding claims, characterized in that said method further comprises the step of drying or curing, preferably with radiation, said first composition (7) to a B-stage, preferably before applying said sheet on said substrate.18.- Method according to any of the preceding claims, characterized in that said sheet (6- 6A) is provided in a stack of sheets all comprising said first composition, or in a roll.19.- Method according to any of the preceding claims, characterized in that said step of applying said sheet (6-6A) on said substrate (2) comprises a heated press operation,preferably applying a structured press element (9) for embossing at least said first composition (7).20.- Method according to any of the preceding claims, characterized in that said first composition (7) comprises at least a water-based radiation curable lacquer, wherein said water-based radiation curable lacquer is an aqueous UV curable polyurethane dispersion and / or a aqueous UV curable dispersion of a compound with acrylate functionalities.21.- Method according to any of the preceding claims, characterized in that said first composition (7) comprises at least a water-based acrylic or water-based polyurethane dispersion.22.- Method according to any of the preceding claims, characterized in that said first composition (7) comprises at least a water-based polyurethane dispersion, wherein the water-based polyurethane dispersion comprises or consists of a water-based polyurethane acrylate dispersion, preferably an aliphatic polyurethane acrylate dispersion.23.- Method according to claim 22, characterized in that the water-based polyurethane acrylate dispersion comprises one or more of:- a thermo-initiator, preferably a thermo-initiator present in the first composition (7) after drying the first composition, such that the thermo-initiator is provided for being activated in a thermal pressing operation wherein the water-based polyurethane acrylate dispersion is thermally cured and preferably provided with a texture by copying the texture of a textured press element;- a wetting agent, e.g. a silicone surfactant;- acrylate reactive diluents or no acrylate reactive diluents;- a hydrophobic agent;- beads, e.g. glass beads, thermoplastic beads, or poly (methyl methacrylate) (PMMA) beads;- wax;- silica;- casein;- a silane oligomer;- aluminum oxide particles or no aluminum oxide particles;- a photo-initiator;- a crosslinking agent, such as isocyanate, carbodiimide or aziridine.24.- Method according to claims 22 or 23, characterized in that the first composition comprises a reactive diluent, preferably an acrylate reactive diluent, more preferably an ethoxylated or propoxylated acrylate reactive diluents; preferably the first composition comprises between 5 and 25 wt% reactive diluent, more preferably between 5 and 15 wt%, more preferably between 10 and 15 wt%.25.- Method according to claims 22 - 24, characterized in that the water-based polyurethane acrylate dispersion comprises a polyurethane acrylate dispersion as well as a polyurethane dispersion not comprising acrylate groups; preferably wherein per 100 parts by weight of solids of polyurethane acrylate the polyurethane acrylate dispersion comprises at least 10 parts by weight of solids of the polyurethane not comprising acrylate groups.26.- Method according to claim 25, characterized in that the glass transition temperature of the polyurethane dispersion not comprising acrylate groups is higher - and preferably at least 10°C higher - than the glass transition temperature of the glass transition temperature of the polyurethane acrylate dispersion.27.- Method according to any of the preceding claims, characterized in that the method is a method for manufacturing a decorative laminate instead of a method for manufacturing decorative panels; wherein the substrate comprises or consists of at least one or a plurality of resin impregnated sheet(s) of paper, preferably Kraft paper.28.- Method for producing a sheet for use in a method as in any of the preceding claimed 1 - 27, wherein the method comprises the steps of- providing a sheet (6) selected from a paper sheet or a thermoplastic foil;- coating the sheet (6) with a first composition (7); wherein the first composition (7) comprises a water-based radiation curable lacquer, a water-based acrylic or water-based polyurethane dispersion, or a mixture of a water-based radiation curable lacquer and one or more of a water-based acrylic and water-based polyurethane dispersion;- performing a drying step for evaporating water out of the first composition (7); preferably wherein the drying step dries the first composition to non-tacky state.29.- Method according to claim 28, characterized in that the first composition (7) comprises one or more of:- a thermo-initiator, preferably wherein the thermo-initiator present is present in the first composition (7) after drying the first composition, such that the thermo-initiator is provided for being activated in a thermal pressing operation wherein the water-based polyurethane acrylate dispersion is thermally cured and preferably provided with a texture by copying the texture of a textured press element;- a wetting agent, e.g. a silicone surfactant;- acrylate reactive diluents or no acrylate reactive diluents;- a hydrophobic agent;- beads, e.g. glass beads, thermoplastic beads, or poly (methyl methacrylate) (PMMA) beads;- wax;- silica;- casein;- a silane oligomer;- a matting agent;- aluminum oxide particles or no aluminum oxide particles;- a photo-initiator;- a crosslinking agent, such as isocyanate, carbodiimide or aziridine.30.- Method according to any of the preceding claims 28 - 29, characterized in that the first composition comprises a reactive diluent, preferably an acrylate reactive diluent, more preferably an ethoxylated acrylate reactive diluent or a propoxylated acrylatereactive diluent; preferably the first composition comprises between 5 and 25 wt% reactive diluent, more preferably between 5 and 15 wt%, more preferably between 10 and 15 wt%.31.- Method according to any of the preceding claims 28 - 30, characterized in that said first composition (7) comprises at least a water-based polyurethane dispersion, wherein the water-based polyurethane dispersion comprises or consists of a water-based polyurethane acrylate dispersion, preferably an aliphatic polyurethane acrylate dispersion.32.- Method according to claim 31, characterized in that the water-based polyurethane acrylate dispersion comprises a polyurethane acrylate dispersion as well as a polyurethane dispersion not comprising acrylate groups; preferably wherein per 100 parts by weight of solids of polyurethane acrylate the polyurethane acrylate dispersion comprises at least 10 parts by weight of solids of the polyurethane not comprising acrylate groups.33.- Method according to claim 32, characterized in that the glass transition temperature of the polyurethane dispersion not comprising acrylate groups is higher - and preferably at least 10°C higher - than the glass transition temperature of the glass transition temperature of the polyurethane acrylate dispersion.34.- Method according to any of the preceding claims 28 - 34, characterized in that the sheet is a paper sheet, preferably a decorative paper sheet, e.g. a printed paper sheet or a colored paper sheet.35.- Method according to any of the preceding claims 31 - 33, characterized in that the paper sheet is a resin impregnated paper sheet, preferably wherein the paper sheet is impregnated with 50 - 80 wt% )- and preferably with 50 - 65 wt% - of dry weight of resin relative to the weight of the paper sheet before impregnation.36.- Method as in claim 35, characterized in that the paper sheet is impregnated with a resin selected from a melamine formaldehyde resin, a polyurethane resin - whether or not having reactive acrylate groups -, an acrylate resin, or combinations thereof.37.- Method as in any of the preceding claims 35 - 36, characterized in that the paper sheet is impregnated with a partially cured thermosetting resin.38.- Method as in any of the preceding claims 37, characterized in that the paper sheet comprises wear resistance increasing particles - e.g. aluminum oxide particles; preferably wherein the wear resistance increasing particles have been dispersed in the bath comprising the thermosetting resin with which the paper sheet is impregnated; or preferably wherein wear resistance increasing particles have been scattered on the paper sheet after impregnating it with the thermosetting resin and before coating the paper sheet with the first composition (7).39.- Method according to any of the preceding claims 28 - 38, characterized in that in the step of coating the sheet (6) with the first composition (7) between 10 and 40, preferably between 20 and 40, preferably between 20 and 30, more preferably between 20 and 25, grams per square meter dry weight of the first composition (7) is applied.40.- Method according to any of the preceding claims 28 - 39, characterized in that the method comprises the step of coating an adhesion layer at the side of the sheet opposite to the side coated or to be coated with the first composition.41.- Method according to any of the preceding claims 28 - 40, characterized in that the method comprises after the drying step a partial UV-curing step of the first composition; or in that the method is free from UV-curing step.42.- Sheet for use in a method according to any of the preceding claims 1 - 27, characterized in that the sheet is obtained in a method according to any of the preceding claims 28 - 41.

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