A method for manufacturing decorative panels and a decorative panel.

Abstract

A method for manufacturing a decorative panel comprising the steps of: - pouring a slurry into a mold, wherein said slurry is formed by a mixture that comprises a resin package and a mineral filler; - curing the mixture into the mold; wherein said mineral filler comprises a waste engineered stone material and / or waste of ceramic material.

Description

[0001] A method for manufacturing decorative panels and a decorative panel.

[0002] The present invention relates to a method for manufacturing decorative panels and a decorative panel. In particular the decorative panel of the invention are of the type used for wall covering. More in particular, the decorative panel of the invention are of the so called “cast marble” type. Cast marble is an expression used on the market to refer to thin decorative panel made of a mixture comprising a resin with embedded mineral fillers obtained by casting of the mixture in a mold.

[0003] Cast marble panels are made starting from a mixture comprising a mineral filler. Said mineral fillers are often of a natural origin. The invention has the scope of providing an alternative method for manufacturing decorative panels, possibly by limiting the environmental impact thereof.

[0004] Thereto according to its independent aspect, the invention relates to a method for manufacturing a decorative panel comprising the steps of: pouring a slurry into a mold, wherein said slurry is formed by a mixture comprising a resin package and a mineral filler; curing the mixture into the mold; wherein said mineral filler comprises a waste engineered stone material and / or waste of ceramic material. In this way the environmental impact of the method can be reduced by making use of recycled waste.

[0005] Said waste of engineered stone material can comprise waste deriving from manufacturing of engineered stone, preferably from polishing, calibration and / or squaring process. Within the context of the present invention with engineered stone it preferably referred to a material also known on the market as “quartz” formed by silica based minerals, in particular silica sand or cristobalite, and polyester resin, and having a water absorption rate near to 0, preferably below 0,1%, and having a proportion between minerals and resin higher than 8:2, preferably 9: 1. Engineered stone in the context of the invention is preferably obtained in the so called Breton process, involving vibro-vacuum compression as described for example in US 11,628,593 which is herein incorporated by reference in its entirety. Preferably, said waste of engineered stone material comprises silica sand, cristobalite, feldspar, feldspathoid, titanium oxide and / or calcium carbonate. Preferably the, waste of engineered stone can comprise a residual binder composition, wherein said residual binder preferably comprises unsaturated polyester resin, possibly crosslinked with styrene.

[0006] Preferably the waste of engineered stone material has an average particle size equal to or lower than 20 microns. Said dimension has been found to be optimal to distribute in the mixture to provide a desired coloration to the decorative panel. It is noted that engineered stone is often white and colored with titanium oxide pigment and also the silica-based minerals are selected to show the whitest possible color. To achieve the desired dimension the method can comprise grinding said waste of engineered stone.

[0007] The waste of engineered stone can be provided in a form, for example a form of filter- pressed cake, having a residual humidity of 25%. Thereto the method can comprise the step of drying the waste of engineered stone, preferably to a residual humidity below 1%.

[0008] Said waste of ceramic material can comprise porcelain stoneware waste. Other ceramic material can be used, although porcelain is preferred for its whiteness and capacity of neing colored by means of specific pigments. The waste of ceramic material can comprise waste deriving from manufacturing of ceramic material, preferably from polishing, calibration and / or squaring process. Example of ceramic process is disclosed for example in US 11,298,971 which is herein incorporated by reference in its entirety.

[0009] Preferably, the waste of ceramic material can have an average particle size higher than 1 mm and / or lower than 4 mm. In this way the ceramic material can provide to the decorative panel the desired mechanical properties. It is noted that the ceramic waste is harder to mill and bring it to lower particle dimension compared to engineered stone waste, therefore this solution leads to a reduced energy consumption in the manufacturing of the decorative panel.

[0010] In some embodiments, the mineral filler comprises waste engineered stone material and waste of ceramic material in a ratio between 1 : 1 and 2:1, preferably 1,5: 1. Inventors have found that these ratios, in particular the preferred one, may be possible to maximize the mechanical properties of the decorative panel. In particular with this proportion between the components of the mineral filler the waste of ceramic material can form the “skeleton” of the decorative panel forming the frame providing the main mechanical strength, whereas the waste of engineered stone material can fill the interstices between the particles of ceramic waste to contribute to the mechanical resistance.

[0011] In some embodiments, the mineral filler represents at least 70% of the weight of the mixture, preferably between 70% and 80% of the weight of the mixture. The resin package can represent maximum 30% of the weight of the mixture, preferably between 20 and 30% weight of the mixture. In this way it is possible to provide a slurry with a good flowability for casting the mixture in the mold.

[0012] Preferably the resin package comprises unsaturated polyester resin.

[0013] In some embodiments, the resin package comprises: coupling agent, preferably silane coupling agent; and / or catalyst, preferably cobalt based; and / or crosslinker, preferably MEKP (methyl ethyl ketone peroxide); and / or viscosity modifier; and / or pigments, preferably titanium oxide. In particular, it is noted that MEKP preferred above other peroxides, like styrene peroxides, as they allow curing at lower temperatures, for example at room temperature. In deviant embodiments styrene peroxides can be used.

[0014] Preferably curing can be performed at a temperature below 60°C, more preferably below 30 °C, even more preferably at room temperature. In this way the method can be performed with a reduced waste of energy.

[0015] In some embodiments the method can comprise one or more finishing steps after curing, said finishing steps comprising sanding, polishing and / or cutting.

[0016] Preferably the method can comprise applying a decorative pattern on a surface of the decorative pattern after curing, preferably said decorative pattern involving inkjet printing, possibly with UV inks. The method can also comprise applying a primer and / or a base coat before applying said decorative pattern, and / or applying a protective coat after applying said decorative pattern. Printing and coatings are described for example in WO 2019 / 070621, WO 2024 / 003735 and WO 2024 / 121738 which are herein incorporated by reference in their entirety.

[0017] In the preferred embodiment, the method comprises applying a gel coat on one or more internal surfaces of the mold before casting the mixture. The gel coat can comprise, preferably consists of, a thermosetting resin. In particular the gel coat can be formed, by the resin package also used in the mixture, and possibly one or more pigments. The gel coat can have the effect of sealing the top surface of the decorative panel.

[0018] The method can also comprise placing a fiberglass mat, or a fiberglass web in the mold before curing.

[0019] The obtained decorative panel can comprise a thickness below 10 mm, preferably below 8 mm, and / or a thickness above 3 mm, preferably above 5 mm. In this way it is provided a thin decorative panel for covering of wall or shower boxes. The obtained decorative panel can show a water absorption rate above 0.1% and / or lower than 1%.

[0020] The invention in accordance with its second independent aspect can further relate to a decorative panel, preferably obtained in the method of the first independent aspect, comprising a resin binder and a mineral filler, wherein said mineral filler comprises a waste engineered stone material and / or waste of ceramic material. The decorative panel of the second aspect can comprise one or more of the features described in relation to the first aspect.

[0021] The present invention is in no way limited to the hereinabove described embodiments, but such method and decorative panel may be realized according to different variants without leaving the scope of the present invention.

[0022] With the intention of better showing the characteristics of the invention, in the following, as an example without any limitative character, several preferred forms of embodiments are described with reference to the accompanying drawings, wherein: Figure 1 shows in a perspective view a decorative panel according to the invention;

[0023] Figure 2 shows schematically some steps in a method for manufacturing the decorative panel of figure 1.

[0024] Figure 1 shows a decorative panel 1 according to the invention that comprises a substrate 2 and a top layer 4. The decorative panel 1 is preferably used for panels.

[0025] The support layer 2 comprises a binder and a mineral filler. The binder comprises polyester resin. The mineral filler comprises a mixture of waste of engineered stone material and waste of waste of ceramic material. Said engineered stone comprises silica sand, cristobalite, feldspar, feldspathoid, titanium oxide and / or calcium carbonate. Said ceramic material comprises particles of porcelain stoneware.

[0026] The top layer 4 comprises polyester resin mixed with pigment to form a decorative layer of the decorative panel. In the embodiment the pigments are distributed in order to form a predetermined decor 6, in particular a decor simulating a marble veining.

[0027] The decorative panel 1 further comprises a fiberglass mat 8 embedded in the support layer 2.

[0028] The decorative panel 1 comprises a thickness of 6 mm.

[0029] Figure 2 shows some steps in a method for manufacturing the decorative panel 1. The method comprises a step SI of preparing waste of engineered stone 10.

[0030] Waste of engineered stone 10 comprises particles of silica sand, cristobalite, feldspar, feldspathoid, titanium oxide and / or calcium carbonate, at least partially embedded in crosslinked polyester resin. The particles of waste of engineered stone have an average particle size equal to or lower than 20 microns. Said dimension has been found to be optimal to distribute in the mixture to provide a desired coloration to the decorative panel. The waste of engineered stone 10 can be provided in a form of filter-pressed cake 11, having a residual humidity of 25% and the method comprises sub-steps of: crushing S2 the filter-cake, grinding S3 the waste of ceramic material 12 to obtain the desired average dimension, and drying S3 the waste of engineered stone 12 to a residual humidity below 1%.

[0031] The method comprises the step of mixing S4 the prepared waste of engineered stone 10 with waste of ceramic material 12.

[0032] The waste of ceramic material 12 comprises porcelain stoneware waste deriving from squaring process, having an average particle size higher of 2 mm.

[0033] In mixing step S4 it is obtained a mineral filler 14 that comprises waste engineered stone material 10 and waste of ceramic material 12 in a ratio between of 1,5: 1.

[0034] The method then comprises a step of mixing S5 the mineral filler 14 with resin package 16 provided in liquid form, to obtain a slurry 17. The resin package 16 comprises unsaturated polyester resin. In addition the resin package 16comprises: silane coupling agent; and cobalt based catalyst; and crosslinker in the form od MEKP (methyl ethyl ketone peroxide); and and viscosity modifier;

[0035] The mixture obtained in mixing step S5 comprises mineral filler 14 in an amount between 70% and 80% of the weight of the mixture, and resin package 16 in an amount between 20 and 30% weight of the mixture.

[0036] The method comprises a step S6 of preparing a mold 18. In said step S8 the mold 18 is spray coated with gel coat resin 16 and pigments 20 are distributed on the surface of resin package according to a pattern for forming the desired decor 6. In the embodiment, the pigment 20 is printed by inkjet printing by means of piezoelectric printheads. The method comprises the step S7 of pouring the mixture of mineral filler 14 and resin package 16 into the mold 18.

[0037] After pouring the mixture into the mold 18, the method comprises a step S8 of providing a fiberglass mat 8.

[0038] The method then continues with a curing step S9 performed at room temperature for obtaining the decorative panel 1.

[0039] Further, as is clear from the content of the description, the present invention relates to one or more of the items listed below:

[0040] 1. A method for manufacturing a decorative panel comprising the steps of:

[0041] - pouring a slurry into a mold, wherein said slurry is formed by a mixture that comprises a resin package and a mineral filler;

[0042] - curing the mixture into the mold; wherein said mineral filler comprises a waste engineered stone material and / or waste of ceramic material.

[0043] 2. The method according to item 1, wherein said waste of engineered stone material comprises silica sand, cristobalite, feldspar, feldspathoid, titanium oxide and / or calcium carbonate.

[0044] 3. The method according to item 1 or 2, wherein said waste of engineered stone material comprises waste deriving from manufacturing of engineered stone, preferably from polishing, calibration and / or squaring process.

[0045] 4. The method according to any of the preceding items, wherein the waste of engineered stone material has an average particle size equal or lower than 20 microns.

[0046] 5. The method according to any of the preceding items, wherein said waste of ceramic material comprises porcelain stoneware waste. 6. The method according to any of the preceding items, wherein said waste of ceramic material comprises waste deriving from manufacturing of ceramic material, preferably from polishing, calibration and / or squaring process.

[0047] 7. The method according to any of the preceding items, wherein the waste of ceramic material has an average particle higher than 1 mm and / or lower than 4 mm.

[0048] 8. The method according to any of the preceding items, wherein the mineral filler comprises waste engineered stone material and waste of ceramic material in a ratio between 1 : 1 and 2: 1, preferably 1,5:1.

[0049] 9. The method according to any of the preceding items, wherein the mineral filler represents at least 70% of the weight of the mixture, preferably between 70% and 80% of the weight of the mixture.

[0050] 10. The method according to any of the preceding items, wherein the resin package represents maximum 30% of the weight of the mixture, preferably between 20 and 30% weight of the mixture.

[0051] 11. The method according to any of the preceding items, wherein the resin package comprises unsaturated polyester resin.

[0052] 12. The method according to any of the preceding items, wherein the resin package comprises: coupling agent, preferably silane coupling agent; and / or catalyst, preferably cobalt based; and / or crosslinker, preferably MEKP (methyl ethyl ketone peroxide); and / or

[0053] - viscosity modifier; and / or pigments, preferably titanium oxide.

[0054] 13. The method according to any of the preceding items, wherein curing is performed at a temperature below 60°C, more preferably below 30 °C, even more preferably at room temperature. 14. The method according to any of the preceding items, comprising one or more finishing steps after curing, said finishing steps comprising sanding, polishing and / or cutting.

[0055] 15. The method according to any of the preceding items, comprising applying a decorative pattern on a surface of the decorative pattern after curing, preferably said decorative pattern involving inkjet printing, possibly with UV inks.

[0056] 16. The method according to item 15, comprising applying a primer and / or a base coat before applying said decorative pattern, and / or applying a protective coat after applying said decorative pattern.

[0057] 17. The method according to any of the preceding items, comprising applying a gel coat on one or more internal surfaces of the mold before casting the mixture.

[0058] 18. The method according to item 17, wherein the gel coat comprises, preferably consists of, a thermosetting resin.

[0059] 19. The method according to item 17 or 18, wherein the gel coat comprises the resin package, and possibly one or more pigments.

[0060] 20. The method according to any of the preceding items, comprising the step of drying the mineral filler, preferably at least the waste of engineered stone, before preparing the mixture, preferably to a residual humidity below 1% weight.

[0061] 21. The method according to any of the preceding items, wherein the obtained decorative panel comprises a thickness below 10 mm, preferably below 8 mm, and / or a thickness above 3 mm, preferably above 5 mm.

[0062] 22. The method according to any of the preceding items, wherein the obtained decorative panel comprises a thickness below 10 mm, preferably below 8 mm, and / or a thickness above 3 mm, preferably above 5 mm.

[0063] 23. The method according to any of the preceding items, wherein the obtained decorative panel shows a water absorption rate above 0.1% and / or lower than 1%. 24. A decorative panel comprising a resin binder and a mineral filler, wherein said mineral filler comprises a waste engineered stone material and / or waste of ceramic material.

[0064] 25. The panel according to item 24, wherein said waste of engineered stone material comprises silica sand, cristobalite, feldspar, feldspathoid, titanium oxide and / or calcium carbonate.

[0065] 26. The panel according to item 24 or 25, wherein said waste of engineered stone material comprises waste deriving from manufacturing of engineered stone, preferably from polishing, calibration and / or squaring process.

[0066] 27. The panel according to any of items 24 to 26, wherein the waste of engineered stone material has an average particle size equal or lower than 20 microns.

[0067] 28. The panel according to any of items 24 to 27, wherein said waste of engineered stone material comprises porcelain stoneware waste.

[0068] 29. The panel according to any of items 24 to 28, wherein said waste of ceramic material comprises waste deriving from manufacturing of ceramic material, preferably from polishing, calibration and / or squaring process.

[0069] 30. The panel according to any of items 24 to 29, wherein the waste of ceramic material has an average particle higher than 1 mm and / or lower than 4 mm.

[0070] 31. The panel according to any of items 24 to 30, wherein the mineral filler comprises waste engineered stone material and waste of ceramic material in a ratio between 1 : 1 and 2: 1, preferably 1,5: 1.

[0071] 32. The panel according to any of items 24 to 31, wherein the mineral filler represents at least 70% of the weight of the mixture, preferably between 70% and 80% of the weight of the mixture. 33. The panel according to any of items 24 to 32, wherein the resin package represents maximum 30% of the weight of the mixture, preferably between 20 and 30% weight of the mixture. 34. The panel according to any of items 25 to 33, wherein the resin binder comprises polyester resin.

[0072] 35. The panel according to any of items 25 to 34, comprising a top layer consisting of said binder.

Claims

Claims1. A method for manufacturing a decorative panel (1) comprising the steps of:- pouring a slurry (17) into a mold (18), wherein said slurry (17) is formed by a mixture that comprises a resin package (16) and a mineral filler (14);- curing the mixture (17) into the mold (18); wherein said mineral filler (14) comprises a waste engineered stone material (10) and / or waste of ceramic material (12).

2. The method according to claim 1 , wherein said waste of engineered stone material (10) comprises silica sand, cristobalite, feldspar, feldspathoid, titanium oxide and / or calcium carbonate.

3. The method according to any of the preceding claims, wherein said waste of engineered stone material (10) comprises waste deriving from manufacturing of engineered stone, preferably from polishing, calibration and / or squaring process.

4. The method according to any of the preceding claims, wherein the waste of engineered stone material (10) has an average particle size equal or lower than 20 microns.

5. The method according to any of the preceding claims, wherein said waste of ceramic material (12) comprises porcelain stoneware waste.

6. The method according to any of the preceding claims, wherein said waste of ceramic material (12) comprises waste deriving from manufacturing of ceramic material, preferably from polishing, calibration and / or squaring process.

7. The method according to any of the preceding claims, wherein the waste of ceramic material (12) has an average particle higher than 1 mm and / or lower than 4 mm.

8. The method according to any of the preceding claims, wherein the mineral filler (14) comprises waste engineered stone material (10) and waste of ceramic material (12) in a ratio between 1 : 1 and 2: 1, preferably 1,5: 1.

9. The method according to any of the preceding claims, wherein the mineral filler (14) represents at least 70% of the weight of the mixture, preferably between 70% and 80% of the weight of the mixture.

10. The method according to any of the preceding claims, wherein the resin package (16) represents up to 30% of the weight of the mixture, preferably between 20 and 30% weight of the mixture.

11. The method according to any of the preceding claims, wherein the resin package (16) comprises unsaturated polyester resin.

12. The method according to any of the preceding claims, wherein the resin package (16) comprises: coupling agent, preferably silane coupling agent; and / or catalyst, preferably cobalt based; and / or crosslinker, preferably MEKP (methyl ethyl ketone peroxide); and / or- viscosity modifier; and / or pigments, preferably titanium oxide.

13. The method according to any of the preceding claims, wherein curing is performed at a temperature below 60°C, more preferably below 30 °C, even more preferably at room temperature.

14. The method according to any of the preceding claims, comprising one or more finishing steps after curing, said finishing steps comprising sanding, polishing and / or cutting.

15. The method according to any of the preceding claims, comprising applying a decorative pattern on a surface of the decorative pattern after curing, preferably said decorative pattern involving inkjet printing, possibly with UV inks.

16. The method according to claim 15, comprising applying a primer and / or a base coat before applying said decorative pattern, and / or applying a protective coat after applying said decorative pattern.

17. The method according any of the preceding claims, comprising applying a gel coat on one or more internal surfaces of the mold before casting the mixture.

18. The method according to claim 17, wherein the gel coat comprises is formed by the resin package (16).

19. The method according to claim 17 or 18, wherein the gel coat comprises one or more pigments for forming a decor..

20. The method according to any of the preceding claims, comprising the step of drying the mineral filler, preferably at least the waste of engineered stone, before preparing the mixture, preferably to a residual humidity below 1% weight.

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