Method for producing decorative laminates and decorative laminates

Abstract

The present invention relates to a method for producing decorative laminates (1-1') comprising at least a plate-shaped board (2) and a decorative top layer (9). The plate-shaped board (2) comprises a first major surface (3), a second major surface (4), and one 5 or more side edges (5-6-7-8) connecting the first major surface (3) and second major surface (4). The decorative top layer (9) comprises a resin. The plate-shaped board (2) is provided with one or more steam release channels (14) at the first major surface (3) and / or second major surface (4), wherein each steam release channel (14) extends to at least one said side edge (5-6-7-8). A further object of the invention is a decorative 10 laminate (1-1') which may be obtained through said method.

Description

[0001] METHOD FOR PRODUCING DECORATIVE LAMINATES AND DECORATIVE LAMINATES.

[0002] The present invention relates to a method for producing decorative laminates as well as decorative laminates, wherein said decorative laminates can be obtained by the method of the present invention.

[0003] In particular, this invention relates to decorative laminates comprising at least a decorative top layer placed upon a plate-shaped board, preferably with a balance layer attached to the plate-shaped board at the side opposite to the decorative top layer. The decorative top layer comprises at least a decor layer and possibly a wear layer, said decor layer being for example a resin-impregnated printed paper comprising a decor, and said wear layer being for example a transparent or translucent resin layer possibly comprising a resin-impregnated paper. Instead of a resin-impregnated printed paper, it is possible to apply a decor directly on the substrate. The plate-shaped board is preferably an MDF or an HDF board (Medium Density Fiberboard or High Density Fiberboard), or a particle board. The balance layer is for example a resin-impregnated paper, such as a resin- impregnated kraft paper, or comprises resin and is free of sheets. In the case where the decorative laminate is a furniture element, for example a furniture panel, the decorative laminate often comprises two decorative layers on opposite sides of the plate-shaped board. Resins used for decorative laminates are often thermosetting resins, such as a melamine resins or phenol resins. Said decorative laminate is obtained by placing the wear layer, the decor layer, the plate-shaped board, and the balance layer on top of each other, as such forming a stack, and pressing the stack. In one and the same pressing treatment, the resin is then cured and binds the several layers, including the plate-shaped board, together. The pressing treatment can take place at a temperature between 170 and 220 °C. Said decorative laminates can be floor panels, furniture panels and wall panels or can be half-products from which said panels can be obtained. The inventors found that, during production of decorative laminates, some plate-shaped boards explode when the pressure is released. The results of the plate-shaped board exploding can be substantial. Of course, an exploded plate-shaped board interrupts the production process, and may even require the production line to be halted for clean-up or repairs. This further also hinders subsequent steps in the production process, leading to a reduced production volume and economical losses. Furthermore, since an explosion is a violent event, surrounding personnel or machinery could be severely injured or damaged by the projected debris. There is thus a clear desire for a production method that has a lower risk of explosion of the plate-shaped board.

[0004] It is therefore an object of the present invention to, in a first place, provide an alternative method for producing decorative laminates. According to some embodiments, problems with the methods of the state of the art are solved. A further object of the invention are alternative decorative laminates to the decorative laminates of the present invention. According to some embodiments, problems with the decorative laminates of the state of the art are solved.

[0005] Therefore, the invention, according to its first independent aspect, relates to a method for producing decorative laminates, wherein the method comprises the steps of: providing a plate-shaped board comprising a first major surface, a second major surface opposite said first major surface and one or more side edges connecting said first major surface and second major surface; a lamination step wherein at least a decorative top layer is provided upon said first major surface, wherein said decorative top layer comprises at least a resin, preferably at least a resin-impregnated sheet, and wherein said resin is cured to laminate the decorative top layer to the first major surface; optionally performing further processing steps for obtaining said decorative laminates; wherein the first major surface and / or the second major surface of the plate-shaped board comprises one or more steam release channels which each extends to at least one of said one or more side edges.

[0006] The plate-shaped board may be a board comprising plant particles glued together with a glue, such as for example an MDF or HDF board, or a board comprising mineral particles such as an magnesiumoxide (MgO) board. The plate-shaped board can also be particle board. The first and second major surface typically relate to the upper and lower surfaces of the plate-shaped board, wherein the first and second major surface each have a surface area which is larger than the surface area of each of the one or more side edges. The first major surface extends substantially in a first plane and the second major surface extends substantially in a second plane, wherein the first plane and the second plane are preferably parallel to each other. Such plate-shaped boards thus have a height, wherein the height is seen in a direction perpendicular to the first major surface. Preferably, the side edges extend substantially perpendicular to the first major surface and / or to the second major surface. The decorative top layer can comprise a decor layer and optionally a wear layer. Said wear layer preferably comprises a resin, possibly a resin-impregnated paper. The decor layer preferably relates to a resin-impregnated printed paper or a resin- impregnated uniformly colored paper or a resin-impregnated printed textile.

[0007] During the lamination step, water can be transformed into steam. Said water may originate from several sources, such as for example from residual moisture of the plateshaped board and / or from the glue of the plate-shaped board and / or from the resin and / or from the air humidity at the production site. Said water can for example be produced during curing of the resin. Upon releasing the pressure at the end of the lamination, the steam may cause the plate-shaped board to explode. In methods of the state of the art, the risk of explosion can be reduced by releasing pressure in an intermediate pressurerelease step during the lamination, which results in the production process requiring a longer time. Further, the interruption in the lamination, which is typically designed to take place at a predefined pressure and temperature, may cause disturbances in the curing process of the resin, leading to an inferior quality of the obtained decorative laminates. The steam release channels of the present invention are channels that allow said steam to be released during the lamination step. The steam can diffuse to the nearest steam release channel, such that it can be released at the side edge to which the steam release channel extends. As such, the method of the first aspect provides a number of advantages over the methods for producing decorative laminates of the prior art. Because the steam can be released during the lamination step, the risk of the plate-shaped board exploding is significantly reduced. Further, there is thus no need for an intermediate pressure-release step, such that the lamination step may take place uninterruptedly. Of course intermediate pressure-release is not excluded. Further this method allows the pressure and / or temperature to build up rapidly during the lamination step. The method of the invention may thus provide a faster, less complex, and more efficient method for producing decorative laminates. Of course, by reducing the risk of the plate-shaped board exploding and possibly injuring an operator, the method is much safer than the methods of the state of the art. Furthermore, because there is less likelihood of the plate-shaped board exploding, the production process will run with less incidents and standstill time, providing a higher production volume and increased profits. This method further requires less quality of the used plate-shaped board, thus allows to make use of a plate-shaped board having less glue and / or having a lesser density and / or having a less qualitative glue. Throughout the lamination step, the desired temperature and pressure may be applied continuously, providing a better control of the curing process of the resin. The inventive method may thus provide a better cured resin, as well as a superior quality of the obtained decorative laminate in comparison to the decorative laminates of the state of the art. Furthermore, it now is no longer needed to take the formation of steam into account for the building up of the pressure and / or the temperature in the lamination step. It is noted that the steam release channels could further also be beneficial for other operations, such as for the alignment of the decorative laminate for a further processing step such as for example dividing. In a preferred embodiment, the further processing steps can comprise dividing . The decorative laminates can thus be smaller decorative panels. Preferably, said decorative panels are then free of said steam release channels. For example, steam release channels may be removed because they substantially coincide with lines along which the dividing takes place. The further processing steps may also comprise providing coupling parts, such that the decorative panels comprise coupling parts to couple said decorative panels to each other. During the providing of the coupling parts, steam release channels may be removed.

[0008] In a preferred embodiment, providing said plate-shaped board comprises the following steps: providing a basic plate-shaped board comprising a first large surface and a second large surface opposite said first large surface; providing the first large surface and / or second large surface of the basic plateshaped board with one or more steam release channels by cutting and / or milling and / or pressing.

[0009] A steam release channel preferably is a groove which may be milled or cutted into the first or second major surface. A steam release channel is preferably gutter-shaped, such that it allows certain fluids, in this case predominantly steam, to be released. In the context of the present invention, cutting may also be interpreted as sawing, for example by a rotating saw blade. Most preferably, the basic plate-shaped board is provided with the one or more steam release channels by cutting and / or milling. This is beneficial since cutting and milling operations can be controlled very accurately. Further, cutting and milling tools can be incorporated into a production facility, requiring only a limited amount of modifications of an already existing production line. Specifically, the one or more steam release channels may be provided by cutting and pressing, or by milling and pressing. Possibly, steam release channels are provided into the basic plate-shaped board by pressing, after which more steam release channels are provided by cutting and / or milling, possibly in other directions than the former steam release channels. The order of these operations may be reversed. This may allow for an efficient production of steam release channels in multiple directions, and may be adapted based on an existing production line. Pressing of steam release channels into the basic plate-shaped board may be done by a pressing device such as a roll press or a continuous belt press, wherein the pressing device comprises portions to introduce said steam release channels.

[0010] In a special embodiment, wherein the basic plate-shaped board is moved along a feeding direction, for example the feeding direction of a machine such as for example a continuous pressing device, steam release channels are provided by a combination of pressing and cutting or milling. In this special embodiment, it is preferred that steam release channels are pressed into the basic-plate shaped board in a direction perpendicular to the feeding direction. Steam release channels may then also be provided in the direction along the feeding direction by cutting, for example by a cutting blade, or by milling, for example by a rotating milling tool. Herein, it is of course also possible that a part of the steam release channels in the direction along the feeding direction are provided by cutting, and the remaining part by milling. This may allow for a very efficient production of steam release channels in multiple directions, and may be incorporated into an existing production line.

[0011] Alternatively, providing said plate-shaped board may comprise the step of consolidating a cake by a pressing device, preferably a continuous pressing device such as a double belt press, wherein the pressing device comprises one or more press elements having portions to press the one or more steam release channels into the cake, such that a plateshaped board comprising said one or more steam release channels is manufactured. The benefit is that in such a way, the plate-shaped board is provided directly with the one or more steam release channels, reducing the required machinery and the number of steps. It is noted that additional steam release channels may be provided. Preferably by any of the ways described earlier for the basic plate-shaped board. Said cake may comprise plant particles such as wood fibers or wood chips, wherein the plant particles are provided with a glue, for example a ureaformaldehyde glue or a melamine ureaformaldehyde glue or a bio-based glue.

[0012] Preferably, the plate-shaped board has a length, a width, and a height, wherein the height is the distance between the first major surface and the second major surface. Said first and second major surface preferably extend parallel to each other, and wherein the height is preferably the dimension according to a direction perpendicular to said first major surface. In a preferred embodiment, the plate-shaped board is rectangular, preferably oblong, wherein the length of the plate-shaped board is at least as long as the width of the plate-shaped board.

[0013] Preferably, a steam release channel has a length, a width, and a height, wherein the height of the steam release channel is seen in the height direction of the plate-shaped board. The width of a steam release channel is seen in the plane perpendicular to the length direction of a steam release channel and in a direction perpendicular to the height direction of the plate-shaped board.

[0014] In a very preferred embodiment, at least one steam release channel extends in its longitudinal direction up until the said at least one side edge of the plate-shaped board. This beneficially provides steam release from regions located internally in the plateshaped board, seen in the plane of the plate-shaped board.

[0015] Preferably, the plate-shaped board has a length, a width and a height, wherein at least one steam release channel extends substantially in the length direction of the plate-shaped board. More preferably said plate-shaped board comprises two or more steam release channels, wherein at least half of said two or more steam release channels extend substantially in the length direction of the plate-shaped board. This facilitates the providing of the steam release channel, as it is oriented along a main direction of the plate-shaped board, possibly the direction wherein the plate-shaped board is moved during a production process. Preferably, at least one steam release channel extends substantially in the width direction of the plate-shaped board. Most preferably, at least one steam release channel extends in the length direction of the plate-shaped board and at least one steam release channel extends in the width direction of the plate-shaped board. This improves the efficiency of the steam release by providing more directions wherein the steam can be released. It is possible that all steam release channels extend substantially in the length direction of the plate-shaped board, or alternatively, in the width direction of the plate shaped board. This reduces the complexity of the providing of the steam release channels. Said further processing steps can comprise dividing to form decorative panels, said decorative panels preferably being rectangular, oblong or square.

[0016] Preferably, the plate-shaped board comprises at least two of said side edges, being a first side edge and a second side edge, wherein at least one steam release channel extends, in its longitudinal direction, uninterruptedly from said first side edge to said second side edge, wherein the first side edge and the second side edge are preferably opposite side edges of the plate-shaped board. This improves the efficiency of the steam release, since the steam can be released at two side edges of the plate-shaped board, which thus further reduces the risk of explosion of the plate-shaped board.

[0017] In a very preferred embodiment, the lamination step comprises pressing, preferably heat pressing with for example a discontinuous pressing device, wherein said resin is at least partially cured during said pressing. Said pressing preferably at least comprises applying pressure at the side of the decorative top layer and at the opposite side. The pressure preferably is applied by press elements such as press plates or press rollers or press belts or the like. For example use can be made of a discontinuous pressing device comprising press plates, such as a single daylight press or a multi daylight press. Use can also be made of a continuous pressing device comprising rollers or of a continuous double belt press. In the case that a continuous pressing device is used, it is preferred that at least one steam release channel is oriented perpendicular to the feeding direction. Since continuous pressing devices can be longer than they are wide, this allows for steam to be released without issues. It may also be beneficial that at least one steam release channel is provided in the feeding direction of the continuous pressing device. The pressing, more particularly heat pressing, has the benefit that a strong connection can be obtained between the decorative top layer and the plate-shaped board. Said resin may partially impregnate into the plate-shaped board, providing a local increase in strength and / or a strong connection. During the pressing, a relief can be provided, wherein the decorative top layer, and possibly also the plate-shaped board, comprises said relief. Said relief may be provided by a structured press element at the side of the decorative top layer. Preferably, said resin is at least partially cured during said pressing. Said discontinuous pressing device can be a single daylight or a multidaylight press. In preferred embodiments, water is released during the curing of said resin. For example, said resin may be a resin that undergoes polycondensation reactions during curing. For resins that release water upon curing, the invention provides significant benefits. Since this released water only comes into existence during the curing, it cannot be removed before the curing. The method of the invention provides an effective solution to this problem by providing a way of releasing steam, even when it is produced during the pressing.

[0018] In a preferred embodiment, the resin is a thermosetting resin, preferably wherein water is released during the curing of the thermosetting resin. This released water may be a result of polycondensation reactions. The thermosetting resin may comprise formaldehyde and is preferably selected from the list of: melamine-formaldehyde resin (MF), urea-formaldehyde resin (UF), melamine-urea-formaldehyde resin (MUF), phenol-formaldehyde resin (PF), melamine-urea-phenol-formaldehyde resin (MUPF) or combinations thereof; and / or the thermosetting resin may be a bio-based resin comprising for example reducing sugars and amine groups. In the case of a bio-based resin, the released water can be the result of Maillard reactions between reducing sugars and amine groups. Alternatively, the thermosetting resin may be a methylene diphenyl diisocyanate (MDI) resin or a polymeric methylene diphenyl diisocyanate (pMDI) resin or an acrylate resin.

[0019] Said decorative top layer can comprise two or more resins, for example at least a thermosetting resin which releases water upon curing -such as a melamine formaldehyde resin- and a thermosetting resin which does not release or hardly releases water upon curing- such as an acrylate resin or an unsaturated polyester resin-. For example said decorative top layer can comprise a decorative resin-impregnated paper, preferably comprising a printed paper or a uniformly coloured paper, with said resin being a melamine formaldehyde resin, and further can comprise a lacquer layer, said lacquer layer preferably comprising an acrylate lacquer, e.g. an acrylate resin.

[0020] In a very preferred embodiment, the lamination step comprises pressing the decorative top layer and the plate-shaped board together at a temperature higher than 20 °C, preferably higher than 50 °C, wherein a first press element, for example a first press plate, applies pressure at the side of the decorative top layer and a second press element, for example a second press plate, applies pressure at a side opposite said decorative top layer, wherein during the lamination step, spaces between the contour of said one or more steam release channels and the respective press element are present. Said spaces ensure that the steam release channels remain open during pressing, and thus allow to release the steam that is produced during the lamination step, e.g. during the curing of the resin, and thus reduce the risk of the explosion of the decorative laminates upon releasing the pressure. Preferably, said space is substantially continuous along the entire length of said one or more steam release channels. As such, the steam can efficiently be released. Said lamination step can take place at a temperature of more than 120 °C, preferably more than 150 °C, more preferably more than 170 °C. Preferably, said lamination step takes place at a temperature of less than 250 °C, more preferably less than 220 °C, most preferably less than 210 °C. A good value can be 195 °C. The pressing can take place at a maximum pressure of at most 60 bar, for example at a maximum pressure of approximately 45 bar. The pressing may last for a pressing time of between 5 and 60 seconds, preferably between 12 and 35 seconds.

[0021] In a preferred embodiment, the plate-shaped board has a height, wherein the minimum height of a said steam release channel, seen in the height direction of the plate-shaped board, is more than 0.5 mm, preferably more than 1 mm, more preferably more than 2 mm. This ensures that the steam release channel does not become filled during the lamination step, for example filled with resin, and / or that the steam release channel disappears due to pressing. Further, it is preferred that the maximum height of a said steam release channel is less than 7 mm, preferably less than 5 mm, more preferably less than 4 mm. This ensures that the plate-shaped board, at the location of said steam release channel, retains sufficient strength and does not break, for example during the lamination step or during further processing steps. The minimum height and maximum height of a steam release channel refer to the smallest, respectively largest, value of the height of the steam release channel along the length of the steam release channel.

[0022] Further preferably, the plate-shaped board is a wood-based board having an average density in a range of 500 and 1200 kg / m3. The plate-shaped board can for example be a wood fiberboard having a density an average density in a range of 650 to 1200 kg / m3. Said plate-shaped board preferably has a centrally located area, said area being remote from said first major surface and said second major surface, and having a density lower than said average density. Preferably a said steam release channel, and all said steam release channels extend into said centrally located area. For example if the plate-shaped board is a particle board, then the particle board can be a three-layered particle board having a central area located between two outer areas, said central area comprising more coarse wood chips than said outer areas, and said central area being less dense and thus being said centrally located area. Because a said steam release channel extends into the centrally located area, which is less dense, steam can be very well released during pressing. In a preferred embodiment, the plate-shaped board has a height, wherein the minimum width of a said steam release channel is more than 0.5 mm, preferably more than 1 mm, even more preferably more than 1.5 mm, most preferably more than 2 mm, wherein the minimum width is seen in the plane perpendicular to the longitudinal direction of the corresponding steam release channel and in a direction perpendicular to the height direction of the plate-shaped board, preferably at the height of the major surface comprising said steam release channel. This ensures that the steam release channel does not become filled during the lamination step, for example filled with resin, and allows a large amount of steam to pass through the steam release channel. Preferably, the width of a said steam release channel at the major surface comprising said steam release channel is the maximum width of the steam release channel. This is preferably the case for any cross-section along the length of a said steam release channel. This improves the efficiency of the steam release and reduces the complexity of providing the steam release channel. It is preferred that the maximum width of a said steam release channel is less than 15 mm, preferably less than 10 mm, more preferably less than 5 mm. This reduces the risk of introducing pressing defects during the lamination step. Pressing defects may relate to zones where there is a poor connection between the decorative top layer and the plate-shaped board and / or to wrinkling of the decorative top layer and / or to bubbles in the decorative top layer. If such pressing defects would be formed, they would be very small, and it could be made so that the pressing defects are insignificant by positioning the steam release channel at a non-critical portion of the plate-shaped board. Such non- critical portions may correspond to parts of the plate-shaped board that are to be removed in a further processing step, for example dividing and / or providing of coupling parts, such that the obtained decorative laminates do not comprise said steam release channels. Preferably, the maximum width of a said steam release channel is less than the height of the plate-shaped board. The minimum width and maximum width of a steam release channel refer to the smallest, respectively largest, value of the width of the steam release channel along the length of the steam release channel. In a very preferred embodiment, the plate-shaped board has a height, wherein the plateshaped board has a remaining height at the location of a said steam release channel, wherein the minimum remaining height of the plate-shaped board is at least 0.5 mm, preferably at least 1 mm, more preferably at least 1.5 mm, most preferably at least 2 mm. The remaining height refers to the height of the material of the plate-shaped board at the location of a steam release channel. In other words, the remaining height corresponds to the height of the plate-shaped board minus the height of the steam release channel. This provides a good balance between the remaining strength of the plate-shaped board and the efficiency of the steam release.

[0023] Preferably, the plate-shaped board has a height and a said steam release channel has a height, seen in the height direction of the plate-shaped board, wherein the ratio of the maximum height of the steam release channel to the height of the plate-shaped board is less than 70%, preferably less than 50%, more preferably less than 40%, most preferably less than 25%. This ensures that the plate-shaped board has sufficient strength at the height of a steam release channel. It is preferred that the ratio of the maximum height of a said steam release channel to the height of the plate-shaped board is more than 5%, preferably more than 10%, more preferably more than 20%, most preferably more than 30%. This ensures that the steam release channel will have sufficient height so that the steam can be released efficiently, and that the steam release channel does not disappear during pressing.

[0024] Preferably, at least one steam release channel has a substantially constant cross-section along its length. This reduces the complexity of providing such a steam release channel. Preferably, the substantially constant cross-section refers to a substantially constant cross-sectional area as well as a substantially constant cross-sectional shape. Generally, the cross-section of a steam release channel is seen perpendicular to the direction in which the steam release channel extends, or in other words, perpendicular to the length direction of the steam release channel. In a preferred embodiment, at least one steam release channel has a varying cross- sectional area along its length, preferably wherein the varying cross-sectional area increases with an increasing distance from the geometric center of the plate-shaped board. The geometric center of the plate-shaped board is meant to be understood as the center point of the plate-shaped board, as seen in the plane of the plate-shaped board. Preferably, the varying cross-sectional area increases with a reducing distance between the cross-section and the closest side edge to which the steam release channel extends. In either scenario, the increasing cross-sectional area beneficially allows a larger amount of steam to pass through the steam release channel. This is beneficial since portions of a steam release channel that are closer to the corresponding side edge receive not only the steam from its own surrounding material, but also steam that is already present in the steam release channel, coming from more internal material.

[0025] In a preferred embodiment, the plate-shaped board comprises a glue. Preferably, the glue is a thermosetting glue, preferably curable by polycondensation. Preferably, the thermosetting glue is substantially fully cured. The thermosetting glue may be selected from the list comprising melamine-formaldehyde resin (MF), urea-formaldehyde resin (UF), melamine-urea-formaldehyde resin (MUF), phenol-formaldehyde resin (PF), melamine-urea-phenol-formaldehyde resin (MUPF), diphenylmethane diisocyanate resin (MDI), or combinations thereof. Alternatively, or in combination therewith, the thermosetting glue may be a bio-based glue comprising for example reducing sugars and amine groups. Possibly, the cured thermosetting glue comprises Maillard reaction products. As a further alternative, the thermosetting glue may be a methylene diphenyl diisocyanate (MDI) glue or a polymeric methylene diphenyl diisocyanate (pMDI) glue. Preferably, the plate-shaped board comprises thermosetting glue in an amount of less than 20 wt%, preferably less than 15 wt%, more preferably less than 10 wt%, even more preferably less than 8 wt%, most preferably less than 6 wt%, and this preferably based on dry matter weight plant particles. Beneficially, since the presence of the one or more steam release channels reduces the risk of explosion of the plate-shaped board, the plate- shaped board may be provided with a reduced amount of thermosetting glue. Preferably, the plate-shaped board comprises plant particles glued together with said thermosetting glue of the plate-shaped board, wherein said plant particles preferably comprise wood fibers and / or wood chips. Said plant particles can comprise recycled plant particles, for example recycled wood fibers or recycled wood chips. The reduced risk of explosion of the plate-shaped board because of the presence of the one or more steam release channels, allows materials of lower quality to be used in the plate-shaped board, reducing the material and production costs. The plate-shaped board can comprise mineral particles, such as chalk or calcium carbonate (CaCCh). The plate-shaped board can comprise mineral particles and plant particles. In a preferred embodiment, the plate-shaped board is a wood fiber board or a particle board. Alternatively, the plate-shaped board can comprise a plurality of paper layers, wherein each paper layer of said plurality of paper layers is impregnated with a thermosetting glue, preferably wherein the thermosetting glue is the same thermosetting glue for each paper layer of said plurality of paper layers.

[0026] The plate-shaped board preferably has a height of less than 8 mm, preferably less than 6 mm, more preferably less than 5 mm, even more preferably less than 4 mm. Possibly, the plate-shaped board may have a height of less than 3 mm or less than 2 mm. Such small height may be produced since the risk of the explosion of the plate-shaped board no longer needs to be taken into account for the dimensioning of the plate-shaped board.

[0027] In a specific embodiment, the decorative top layer comprises a decor directly printed upon the first major surface. Directly printed is meant to be understood that the decor is printed onto the plate-shaped board without the use of an intermediate sheet, however, the use of a primer or an ink receiver layer is not excluded. Preferably, direct printing makes use of digital printing, more particularly digital inkjet printing. Digital printing advantageously provides almost complete freedom in the decor, wherein it is possible to provide a decor without repeats. In such a case, the lamination step can first comprise applying a decor by direct printing, followed by applying a transparent or translucent wear layer comprising resin, after which the plate-shaped board and wear layer are laminated together by pressing at a temperature above 20 °C, or by other curing methods.

[0028] In a preferred embodiment the decorative top layer comprises a printed sheet comprising a decor and / or a uniformly colored sheet. Said sheet is preferably a paper sheet, impregnated with said resin. According to a first possibility, the paper sheet may already be impregnated before the lamination step. According to a second possibility, the paper sheet is provided with said resin at the upper and / or lower surface of the paper sheet, for example by spraying the resin, such that the resin impregnates into the paper sheet during the step of lamination. In this case, the lamination step can comprise providing a stack comprising at least said plate-shaped board, a printed sheet such as a printed paper sheet and optionally a translucent or transparent wear layer, wherein said wear layer preferably comprises a resin-impregnated paper sheet. Said wear layer may comprise hard particles such as corundum or aluminumoxide particles. It is noted that a uniformly colored sheet, preferably a uniformly colored paper sheet, may be used in the stack instead of a printed sheet.

[0029] Preferably, the lamination step comprises providing a balance layer on the second major surface of the plate-shaped board, wherein the balance layer comprises at least a second resin, and curing said second resin to laminate the balance layer to the second major surface. The balance layer may comprise a sheet, preferably impregnated with said second resin. Said sheet is preferably a kraft paper. According to a first possibility, the balance layer may already be impregnated before pressing. According to a second possibility, the balance layer is provided with said second resin at the upper and / or lower surface of the balance layer, for example by spraying the second resin, such that the second resin impregnates into the balance layer during pressing. The second resin may be the same as a said resin of the decorative top layer. According to a preferred example, instead of a balance layer, the lamination step comprises providing a second decorative layer on the second major surface of the plateshaped board, wherein the second decorative layer comprises a second sheet which may be a printed sheet comprising a decor or a uniformly colored sheet. Said second sheet is preferably a second paper sheet, impregnated with a further resin. According to a first possibility, the second paper sheet may already be impregnated before the lamination step. According to a second possibility, the second paper sheet is provided with said further resin at the upper and / or lower surface of the second paper sheet, for example by spraying the further resin, such that the further resin impregnates into the second paper sheet during pressing. The further resin may be the same as a said resin of the decorative top layer. This embodiment may be beneficial in the case that the decorative laminate is intended for a use in furniture, for example as a furniture panel where it is desired that both sides of the furniture panel have an aesthetically pleasing appearance.

[0030] It is noted that, when there is a layer of resin at the first major surface as well as at the second major surface, it is preferred that steam release channels are provided at the first major surface and at the second major surface. This provides additional ways for the steam to be released, ensuring that the plate-shaped board will not explode. The steam release channels at opposite major surfaces are preferably placed at an offset from each other, i.e. they are not above / below each other. This ensures that the plate-shaped board has a sufficiently high remaining height and remaining strength at the location of the steam release channels. On the other hand, if only the decorative top layer comprises a resin layer at the first major surface, it can be that the majority, or possibly all, of the one or more steam release channels are provided at the second major surface. This reduces the risk of pressing defects at the decorative side of the decorative laminate.

[0031] The decorative top layer may comprise a protective lacquer layer as the uppermost layer. Said protective lacquer layer may provide additional features to the decorative laminate such as a low or high reflectivity and / or low tackiness. Preferably, said protective lacquer layer is a UV-curable or electron beam curable lacquer layer. In some embodiments, said protective lacquer layer is a polyurethane-based lacquer layer or an acrylic-based lacquer layer. In some embodiments, said protective lacquer layer is placed directly above the decor layer, wherein the decor layer preferably comprises a resin-impregnated printed paper sheet.

[0032] In a preferred embodiment, the outer surface of the decorative top layer is provided with a relief. In the case that the decorative top layer comprises a decor, the relief is preferably in register with said decor. This may provide very realistic imitations of elements of nature such as wood and / or stone. Alternatively, where the decorative top layer comprises a uniformly colored sheet, the relief may be used to provide aesthetic features to the decorative laminate. Providing the relief may be during the lamination step, or may take place as an additional step, preferably after the lamination step.

[0033] In a preferred embodiment, the lamination step provides a decorative laminate halfproduct; wherein the decorative laminate half-product comprises, seen in the plane of the decorative laminate half-product, a plurality of panel-shaped zones separated by technical zones, wherein the further processing steps comprise at least dividing the decorative laminate half-product at one or more of said technical zones for obtaining said decorative laminates. Preferably, the plate-shaped board comprises at least two of said side edges, being a first side edge and a second side edge, wherein the first side edge and the second side edge are preferably opposite side edges of the plate-shaped board; and said technical zones preferably extend uninterruptedly between the first side edge of the plate-shaped board and the second side edge of the plate-shaped board. The obtained decorative laminates are preferably obtained from said panel-shaped zones. As such, multiple decorative laminates can be obtained from one decorative laminate half-product. Decorative laminates obtained after dividing and before other further processing steps, such as profiling to form coupling parts, have been performed, may also be referred to as basic decorative panels throughout the disclosure. Technical zones are zones that are intended to be removed by a technical operation, such as dividing with for example a sawing blade and / or profiling to form coupling parts, and / or sanding and / or cutting and / or milling to provide lowered edges, such as chamfers or bevels. Obtaining multiple decorative laminates from one decorative laminate half-product is much more efficient than making only one decorative laminate with said lamination step.

[0034] Preferably, at least one steam release channel extends along a said technical zone, wherein the steam release channel preferably extends uninterruptedly along the entire said technical zone. This is advantageous since the steam release channel will normally not be present in the decorative laminate, since it is removed for example during said further processing steps such as dividing and profiling. A further benefit is that less material needs to be removed during the further processing steps, such that the wear of the sawing or milling tools is reduced. The presence of the steam release channel contributes to the production process and is no longer present in the obtained decorative laminates. As such, possible pressing defects due to the steam release channel are not present in the obtained decorative laminates. This further also ensures that a steam release channel will not reduce the quality of the lamination in the panel-shaped zones. Also, the obtained decorative laminates do not suffer from loss of strength as the reduced height of the plate-shaped board associated with a steam released channel does not overlap with a panel-shaped zone. Coupling parts can also be provided without problems since there is no risk that the coupling parts extend at the height of the steam release channel.

[0035] Preferably, the maximum width of the steam release channel extending along a technical zone is less than the width of the corresponding technical zone. As such, the steam release channel, or possibly two steam release channels on the same or on opposite major surfaces, is completely removed. In a preferred embodiment, a technical zone comprises two steam release channels, wherein each of the first major surface and second major surface comprises one of said two steam release channels, wherein there is an offset between the two steam release channels. This improves the steam release while still maintaining sufficient strength of the plate-shaped board, especially in the case where there is a resin layer at the first and at the second major surface. In another preferred embodiment, at least two adjacent technical zones each comprise a steam release channel, wherein the steam release channels of said two adjacent technical zones are located on opposite major surfaces. This provides a good overall steam release performance, especially in the case where there is a resin layer at the first and at the second major surface.

[0036] Possibly, at least one steam release channel extends through one or more panel-shaped zones, wherein said second major surface preferably comprises said steam release channel. This may facilitate the incorporation of certain elements in the obtained decorative laminates, for example wires in the length direction.

[0037] Preferably, said further processing steps comprise forming coupling parts such that the decorative laminates comprise profiles edges with coupling parts that allow two of such decorative laminates to be coupled to each other. It is possible that there is no dividing and that the profiled edges with coupling parts are edges of the decorative laminate half- product. Preferably, there is a further processing step of dividing such that the profiled edges with coupling parts are edges of the decorative laminate obtained after dividing. The decorative laminates obtained after dividing and forming coupling parts may be referred to as decorative panels in the disclosure. Said decorative panels can be floor panels. The forming of coupling parts may be done by a double-end tenoner. Preferably, the coupling parts comprise locking parts that prevent that two such decorative laminates, in the coupled state, may come apart. Preferably, said locking parts provide for a locking in the vertical direction perpendicular to the plane of the decorative laminates, and / or for a locking in the horizontal direction in the plane of the decorative laminates and perpendicular to the profiled edges. Preferably, said coupling parts are made substantially as a tongue and a groove. Said coupling parts may comprise one or more of the features of WO 2018 / 172955 A2, WO 2020 / 109961 Al, WO 2021 / 105798 Al, WO 2021 / 070022 Al, WO 2021 / 111210 Al, and / or WO 2023 / 100029 Al, wherein the coupling parts described in said patent publications are hereby incorporated by reference. Further, if said coupling parts comprise a groove, in a preferred embodiment, said groove is bordered by a lower lip and an upper lip, wherein the lower lip preferably extends, in a direction perpendicular to the corresponding profiled edge, beyond the most distal point of the upper lip. In such a case, it is possible that the lower lip comprises a (part of a) steam release channel. Preferably, a steam release channel in the lower lip is located beyond, or at least partly beyond, the most distal point of the upper lip. Such a steam release channel may provide additional bendability of the lower lip, which may facilitate the coupling of two such decorative laminates. This may be obtained by providing a said panel-shaped zone with a steam release channel at the height where the lower lip will be located.

[0038] Preferably, the decorative laminates are floor panels, furniture panels, wall panels, or ceiling panels. Preferably, the decorative laminates are rectangular, preferably oblong.

[0039] According to a special variant of the first aspect of the invention, the decorative top layer does not comprise a decor. The decorative top layer comprises a layer of said resin, preferably a sheet impregnated with said resin, preferably a paper sheet, wherein the resin-impregnated sheet then does not relate to a printed sheet or a uniformly colored sheet. This may be the case when the laminate is not intended to serve a decorative purpose, for example when it is to be used as a construction panels, for example for concrete formwork. Preferred embodiments of the first independent aspect apply similarly to the special variant.

[0040] It is noted that a decorative laminate obtainable with the method of the first independent aspect forms an independent aspect of the present invention. Also said decorative laminate half-product obtained during the method of the first independent aspect forms an independent aspect of the present invention. Therefore, the invention, in accordance with a second independent aspect, relates to a decorative laminate, wherein the decorative laminate comprises a plate-shaped board and a decorative top layer, wherein the plate- shaped board comprises a first major surface, a second major surface opposite said first major surface and one or more side edges connecting the first major surface and the second major surface, wherein the decorative top layer comprises at least a resin, preferably a resin-impregnated sheet, wherein the decorative top layer is attached to the first major surface of the plate-shaped board, wherein the first major surface and / or the second major surface of the plate-shaped board comprises one or more steam release channels which each extends to at least one said side edge. The plate-shaped board may be a board comprising plant particles glued together with a glue, such as for example an MDF or HDF board, or a board comprising mineral particles such as an MgO board. The decorative top layer comprises at least a decor layer and optionally a wear layer, wherein the wear layer preferably comprises a resin, possibly a resin-impregnated paper. The decor layer preferably is a resin-impregnated printed paper or resin-impregnated uniformly colored paper. A decorative laminate of the second independent aspect can be efficiently produced using the method of the first independent aspect of the invention. The benefits of the first independent aspect and the specific and preferred embodiments of the first independent aspect apply mutatis mutandis to the second independent aspect, and the benefits of the second independent aspect and the specific and preferred embodiments of the second independent aspect apply mutatis mutandis to the first independent aspect.

[0041] It is noted that the decorative laminates of the second independent aspect may either be a half-product or an end product. For example, a decorative laminate could be divided into several basic decorative panels and is then a decorative laminate half-product. Herein, it is possible that the steam release channels provide indications on the locations where the decorative laminate should be divided. As such, it may be that the steam release channels, or at least some of them, are removed by the dividing. In the case where the decorative laminate is an end product, the steam release channels may be used as cable ducts, for example for electrical wiring. This can be very advantageous for decorative laminates used as a wall, floor, ceiling or furniture element, since it is still possible to install additional wires, e.g. for lighting, without the need for drilling or cutting in already existing structures. Further, it is possible that the steam release channels facilitate alignment during further use of the decorative laminates, especially when the steam release channels are provided at equal distances between consecutive steam release channels.

[0042] In a very preferred embodiment, at least one steam release channel extends in its longitudinal direction up until the said at least one side edge of the plate-shaped board.

[0043] Preferably, the plate-shaped board has a length, a width and a height, wherein at least one steam release channel extends substantially in the length direction of the plate-shaped board. More preferably, said plate-shaped board comprises two or more steam release channels, wherein at least half of said two or more steam release channels extend substantially in the length direction of the plate-shaped board. Preferably, at least one steam release channel extends substantially in the width direction of the plate-shaped board. Most preferably, at least one steam release channel extends in the length direction of the plate-shaped board and at least one steam release channel extends in the width direction of the plate-shaped board. It is possible that all steam release channels extend substantially in the length direction of the plate-shaped board, or alternatively, in the width direction of the plate shaped board. The presence of steam release channels reduces the weight of the decorative laminate, making it easier to handle and install. Further, having steam release channels in multiple directions provides a higher degree of freedom when used as cable ducts.

[0044] Preferably, the plate-shaped board comprises at least two of said side edges, being a first side edge and a second side edge, wherein at least one steam release channel extends, in its longitudinal direction, uninterruptedly from said first side edge to said second side edge, wherein the first side edge and the second side edge are preferably opposite side edges of the plate-shaped board. This may provide for one or more continuous steam release channels if several decorative laminates are placed adjacent to each other, which may facilitate the alignment of adjacent decorative laminates. It is even conceivable that the steam release channels are oriented in such a manner that it becomes possible to reach certain locations with wires, for example electrical wires, without the need of cutting or drilling in the substructure whereon the decorative laminate may be placed. This could save a significant amount of time and effort, for example when remodeling the floor or walls of a building or room.

[0045] In a preferred embodiment, the resin is a cured resin, obtained by curing a resin, preferably a thermosetting resin, that releases water during curing. This released water may be a result of polycondensation reactions. The cured thermosetting resin may comprise formaldehyde and may be selected from the list of: melamine-formaldehyde resin (MF), urea-formaldehyde resin (UF), melamine-urea-formaldehyde resin (MUF), phenol-formaldehyde resin (PF), melamine-urea-phenol-formaldehyde resin (MUPF) or combinations thereof. The cured thermosetting resin can also comprise Maillard reaction products that are the result of Maillard reactions between reducing sugars and amine groups. Alternatively, the cured thermosetting resin may be a methylene diphenyl diisocyanate (MDI) resin or a polymeric methylene diphenyl diisocyanate (pMDI) resin.

[0046] The preferred embodiments with regards to the shape and size, i.e. relating to the height and width, of a steam release channel of the first independent aspect apply vice versa to the steam release channels of the second independent aspect.

[0047] Preferably, at least one steam release channel has a substantially constant cross-section along its length. This ensures that, in case wires are passed through the steam release channel, the wires will not become stuck inside the steam release channel. Preferably, the substantially constant cross-section refers to a substantially constant cross-sectional area as well as a substantially constant cross-sectional shape. Generally, the cross-section of a steam release channel is seen perpendicular to the direction in which the steam release channel extends, or in other words, perpendicular to the length direction of the steam release channel. Preferably, at least one steam release channel has a varying cross-sectional area along its length.

[0048] In a preferred embodiment, the plate-shaped board comprises a glue. Preferably, the glue is a thermosetting glue, preferably cured by polycondensation. The thermosetting glue may be selected from the list comprising melamine-formaldehyde resin (MF), ureaformaldehyde resin (UF), melamine-urea-formaldehyde resin (MUF), phenolformaldehyde resin (PF), melamine-urea-phenol-formaldehyde resin (MUPF), diphenylmethane diisocyanate resin (MDI), or combinations thereof. Alternatively, or in combination therewith, the cured thermosetting glue may comprise Maillard reaction products that are the result of Maillard reactions between reducing sugars and amine groups. As a further alternative, the thermosetting glue may be a methylene diphenyl diisocyanate (MDI) glue or a polymeric methylene diphenyl diisocyanate (pMDI) glue. Preferably, the plate-shaped board comprises thermosetting glue in an amount of less than 20 wt%, preferably less than 15 wt%, more preferably less than 10 wt%, even more preferably less than 8 wt%, most preferably less than 6 wt%, and this preferably based on dry matter weight plant particles. Preferably, the plate-shaped board comprises plant particles glued together with said thermosetting glue of the plate-shaped board, wherein said plant particles preferably comprise wood fibers and / or wood chips. Said plant particles can comprise recycled plant particles, for example recycled wood fibers or recycled wood chips. The presence of lower quality material such as recycled plant particles may reduce the material and production costs. The plate-shaped board can comprise mineral particles, such as chalk or calcium carbonate (CaCCh). The plateshaped board can comprise mineral particles and plant particles. In a preferred embodiment, the plate-shaped board is a wood fiber board or a particle board. Alternatively, the plate-shaped board can comprise a plurality of paper layers, wherein each paper layer of said plurality of paper layers is impregnated with a thermosetting glue, preferably wherein the thermosetting glue is the same thermosetting glue for each paper layer of said plurality of paper layers. The plate-shaped board preferably has a height of less than 8 mm, preferably less than 6 mm, more preferably less than 5 mm, even more preferably less than 4 mm. Possibly, the plate-shaped board has a height of less than 3 mm, or even less than 2 mm. Such small heights have the benefit that the decorative laminates are relatively lightweight and are easier to install and handle.

[0049] In a specific embodiment, the decorative top layer comprises a decor directly printed upon the first major surface. Directly printed is meant to be understood that the decor is printed onto the plate-shaped board without the use of an intermediate sheet, however, the use of a primer or an ink receiver layer is not excluded. Preferably, direct printing makes use of digital printing, more particularly digital inkjet printing. Digital printing advantageously provides almost complete freedom in the decor, wherein it is possible to provide a decor without repeats. The decorative top layer preferably comprises a transparent or translucent wear layer comprising resin above the directly printed decor.

[0050] In a preferred embodiment the decorative top layer comprises a printed sheet comprising a decor or a uniformly colored sheet. Said sheet preferably relates to a paper sheet, impregnated with resin. Preferably, said decorative top layer comprises a translucent or transparent wear layer above the printed sheet, wherein said wear layer preferably comprises a resin-impregnated paper sheet. Said wear layer may comprise hard particles such as corundum or aluminum oxide particles.

[0051] In a preferred embodiment, the decorative laminate comprises a balance layer on the second major surface of the plate-shaped board, wherein the balance layer comprises at least a second resin. The balance layer may comprise a sheet, preferably impregnated with said second resin. Said sheet preferably is a kraft paper. The second resin may be the same as the resin of the decorative top layer. According to a preferred example, the decorative laminate comprises a second decorative layer on the second major surface of the plate-shaped board, wherein the second decorative layer comprises a second sheet which may be a printed sheet comprising a decor or a uniformly colored sheet. Said second sheet is preferably a second paper sheet, impregnated with a further resin. The further resin may be the same as the resin of the decorative top layer. This embodiment may be beneficial in the case that the decorative laminate is intended for a use in furniture, for example as a furniture panel where it is desired that both sides of the furniture panel have an aesthetically pleasing appearance.

[0052] The decorative top layer may comprise a protective lacquer layer as the uppermost layer. Said protective lacquer layer may provide additional features to the decorative laminate such as a low or high reflectivity and / or low tackiness. Preferably, said protective lacquer layer is a UV-curable or electron beam curable lacquer layer. In some embodiments, said protective lacquer layer is a polyurethane-based lacquer layer or an acrylic-based lacquer layer. In some embodiments, said protective lacquer layer is placed directly above the decor layer, wherein the decor layer preferably comprises a resin-impregnated printed paper sheet.

[0053] In a preferred embodiment, the outer surface of the decorative top layer comprises a relief. In the case that the decorative top layer comprises a decor, the relief is preferably in register with said decor. This may provide very realistic imitations of elements of nature such as wood and / or stone. Alternatively, where the decorative top layer comprises a uniformly colored sheet, the relief may be used to provide aesthetic features to the decorative laminate.

[0054] In a preferred embodiment, the decorative laminate is a decorative laminate half-product, wherein the decorative laminate half-product comprises, seen in the plane of the decorative laminate half-product, a plurality of panel-shaped zones separated by technical zones. Preferably, the plate-shaped board comprises at least two of said side edges, being a first side edge and a second side edge, wherein the first side edge and the second side edge are preferably opposite side edges of the plate-shaped board. Said technical zones preferably extend uninterruptedly between the first side edge of the plateshaped board and the second side edge of the plate-shaped board. The panel-shaped zones are preferably rectangular, preferably oblong. It is thus clear that in this case, the decorative laminate half-product may be divided at the technical zones, such that the panel-shaped zones become basic decorative panels.

[0055] Further preferably, at least one steam release channel extends along a said technical zone, wherein the steam release channel preferably extends uninterruptedly along the entire technical zone. This is advantageous since the steam release channel will be removed when dividing the decorative laminate at the technical zones, such that this steam release channel will no longer exist after the dividing. As such, possible pressing defects due to the steam release channel may not be present in the obtained basic decorative panels. This further also ensures that a steam release channel will not reduce the quality of the lamination at the location of the panel-shaped zones. Also, the obtained basic decorative panels do not suffer from loss of strength as the reduced height of the plate-shaped board associated with a steam released channel does not overlap with a panel-shaped zone. Preferably, the maximum width of the steam release channel extending along a technical zone is less than the width of the corresponding technical zone. As such, the steam release channel, or two steam release channels on opposite major surfaces, is completely removed.

[0056] In a preferred embodiment, at least one steam release channel extends through one or more panel-shaped zones, wherein said second major surface preferably comprises said steam release channel. This may provide the benefit, as already explained before, that the steam release channel may be used as cable duct or for alignment purposes. It is noted that the wording “length direction” and “longitudinal direction” are used interchangeably throughout the disclosure, both meaning the direction of the length.

[0057] With the intention of better showing the characteristics of the invention, some preferred embodiments are described below, as examples without any limiting character, with reference to the corresponding drawings, wherein:

[0058] Figure 1 shows a perspective view of a decorative laminate in accordance with the second independent aspect of the invention;

[0059] Figures 2 and 3 show, on a larger scale, the cross-section according to lines II-II and III-III of Figure 1, respectively;

[0060] Figures 4, 5 and 6 show some steps in a method in accordance with the first independent aspect of the invention for producing decorative laminates.

[0061] Figure 1 shows a perspective view of a decorative laminate (F) in accordance with the second independent aspect of the invention. In the displayed embodiment, the decorative laminate (F) comprises a plate-shaped board (2) with a first major surface (3), a second major surface (4) opposite the first major surface (3) and four side edges (S-6-7-8). The plate-shaped board (2) has a length (L), a width (W), and a height (H). The first major surface (3) and second major surface (4) are substantially parallel to each other, and lay in planes defined by the length (L) and width (W) direction of the plate-shaped board (2). The plate-shaped board (2) comprises plant particles such as wood fibers or wood chips glued together by a thermosetting glue, for example a ureaformaldehyde glue, a melamine ureaformaldehyde glue or a melamine-formaldehyde glue. The plant particles may comprise recycled plant particles such as recycled wood fibers or recycled wood chips. Preferably, the plate-shaped board (2) is an MDF or HDF board or a particle board. The plate-shaped board (2) can have a height of 6 mm or 8 mm, and comprises thermosetting glue in an amount of for example 6 wt%, 8 wt% or 10 wt% based on dry matter weight plant particles. The decorative laminate (F) further comprises a decorative top layer (9) attached to the first major surface (3) of the plate-shaped board (2). In this embodiment, the decorative top layer (9) comprises a printed paper sheet (10) comprising a decor and a transparent or translucent wear layer (12) above the printed paper sheet (10). Both the printed paper sheet (10) and the wear layer (12) are impregnated with thermosetting resin such as melamine-formaldehyde resin. The wear layer (12) preferably comprises corundum and / or aluminumoxide particles for improved wear resistance. The decorative top layer (9) is provided with a relief. The decorative laminate (F) further comprises a balance layer (13) at the second major surface (4) of the plateshaped board (2), wherein the balance layer (13) preferably is a kraft paper impregnated with for example a melamine-formaldehyde resin. The balance layer (13) does not comprise a decor, however, depending on the intended application of the decorative laminate (F), instead of a balance layer (13), a second decorative layer may be used. The latter is for example beneficial for furniture panels with two visible sides.

[0062] The plate-shaped board (2) is provided with steam release channels (14) at the first major surface (3) and / or at the second major surface (4). It is remarked that the steam release channels (14) are not drawn for the perspective view of the entire decorative laminate (F) shown in figure 1 in order to keep the figure understandable. In this embodiment, the steam release channels (14) extend substantially in the length (L) direction of the plate-shaped board (2), wherein the steam release channels (14) extend uninterruptedly from a first side edge (5) to a second side edge (6), wherein the first side edge (5) and the second side edge (6) are opposite side edges. Each of the steam release channels (14) has a height (Hl) of at least 2 mm, a width (Wl) of at least 1.5 mm, and a substantially constant cross-section along their length. It is noted that it is also possible that the steam release channels (14) are provided in the width (W) direction of the plate-shaped board (2), or that the plate-shaped board (2) is provided with steam release channels (14) in both the length (L) and the width (W) direction. In the shown embodiment of Figure 1, the decorative laminate (F) is a decorative laminate half-product (1), wherein the decorative laminate half-product (F) comprises, seen in the plane of the decorative laminate half-product (F), a plurality of panel-shaped zones (15) separated by technical zones (16). Said technical zones (16) are intended to be removed in further processing steps, such as for example dividing, such that the panelshaped zones (15) may become decorative panels (1). Said technical zones (16) extend uninterruptedly between the first and second side edge (5-6) or between the third and fourth side edge (7-8) of the plate-shaped board (2). The steam release channels (14) extend along technical zones (16) that separate panel-shaped zones (15). The panelshaped zones (15) are rectangular and oblong, and have a length direction that is substantially parallel to the length (L) direction of the plate-shaped board (2).

[0063] The zoom of Figure 1 provides an enlarged view of a corner of the decorative laminate (F). In the zoom, it can be seen that a technical zone (16) along the length (L) direction of the plate-shaped board (2) is provided with a steam release channel (14).

[0064] Figures 2A and 2B show two possible configurations of a cross-section along the line Illi of Figure 1, which corresponds to a technical zone (16) in the length (L) direction of the plate-shaped board (2). The panel-shaped zones (15) are separated by technical zones (16). As already mentioned, the decorative laminate half-product (F) of Figure 1 may be intended to be divided at technical zones (16), such that basic decorative panels are obtained, wherein said basic decorative panels are preferably provided with coupling parts (17-18), for example in the form of a tongue (17) and a groove (18), such as those indicated in dotted lines such that decorative panels (1) are obtained. Figure 2Aillustrates a preferred embodiment, wherein the steam release channel (14) extends along the entire length of the corresponding steam release channel (14). The steam release channel (14) has a constant cross-section along the length of the steam release channel (14). The maximum value of the height (Hl) of the steam release channel (14) is for example 2 mm; the height (H) of the plate-shaped board (2) is for example 6 mm. In this example, the ratio of the maximum value of the height (Hl) of the steam release channel (14) to the height (H) of the plate-shaped board (2) is about 33%, and the remaining height of the plate-shaped board (2) at the location of the steam release channel (14) is 4 mm. These values provide a good balance between efficiency of the steam release channel (14) and strength of the plate-shaped board (2).

[0065] Figure 2B illustrates an alternative, wherein the steam release channel (14) does not extend along the entire length of the corresponding technical zone (16). Instead, two steam release channels (14) extend along the same technical zone (16). In this example, the two steam release channels (14) have the same cross-section, however, it is remarked that this is not necessary according to the invention. This may provide a reduced reduction in the wear of a possible cutting or milling device that provides the steam release channel (14). A further benefit is that less material is lost, and that a better lamination between the decorative top layer (9) and the plate-shaped board (2) is obtained.

[0066] Figures 3 A-3E show several possible configurations of a cross-section along the line III- III of Figure 1, which corresponds to a technical zone (16) in the width (W) direction of the plate-shaped board (2). Figure 3 A displays a first possible arrangement of the steam release channels (14) that extend in the length (L) direction of the plate-shaped board (2), wherein all steam release channels (14) are located at the first major surface (3), wherein all steam release channels (14) are located in a technical zone (16). Here, all steam release channels (14) have the same cross-section, which reduces the complexity of providing the steam release channels (14). In Figure 3B, a second possible arrangement is shown, wherein the steam release channels (14) have different shapes and cross-sections. Figure 3C shows a third possible arrangement wherein the steam release channels (14) are provided alternatingly at the first major surface (3) and at the second major surface (4), however, still every time extending along a technical zone (16). A fourth possible arrangement is shown in Figure 3D, wherein the plate-shaped board (2), at its first major surface (3), is provided with a steam release channel (14) at every second technical zone (16). Figure 3E shows a fifth possible arrangement, wherein steam release channels (14) are provided at the first major surface (3) as well as at the second major surface (4), and are located both in technical zones (16) and in panel-shaped zones (15). As depicted, it is preferred that the steam release channels (14) extending through panel-shaped zones (15) are located at the second major surface (4), however, this is not required according to the invention. It is further noted that the five possible arrangements here provided are not exhaustive, that is, there are many more possible arrangements that have not been taken up here. It is clear that combinations of features of the provided five possible arrangements are also possible, as well as steam release channels (14) extending through panel-shaped zones (15) that are located at the first major surface (3).

[0067] Figure 4 schematically represents some steps in a method for manufacturing decorative laminates (1), in this case decorative panels (1), having a lowered edge region (19). Herein, this relates to a method comprising at least the following steps: the step SI of providing a basic plate-shaped board (2’) comprising a first large surface (3’) and a second large surface (4’) opposite said first large surface (3’); the step S2 of structuring the first large surface (3’) of the basic plate-shaped board (2’), wherein this structure consists at least of a recess (20) in the first large surface (3’) of the basic plate-shaped board (2’) at the location of said lowered edge region (19). The recesses (20) may be provided, for example, by a sawing and / or milling device, for example, a sawing device with a plurality of parallel positioned rotating saws, wherein each saw preferably forms one of the aforementioned recesses (20). Such a device is not represented here. This can be in-line with the pressing device (21) of the following step S4, or possibly off-line; the step S3 of providing one or more steam release channels (14). The steam release channels (14) are provided along the length of the technical zones (16), and are preferably positioned at the location of said recesses (20). It is remarked that the recesses (20) in the first large surface (3’) are considered a structure of the first large surface (3’) and are intended for forming said lowered edge regions (19), and should thus not be confused with steam release channels (14). Said steam release channels (14) may be provided, for example, by a cutting and / or milling device. The result of step S3 is a plateshaped board (2) with one or more steam release channels (14) the step S4 of composing and laminating a stack (22) which comprises at least said plate-shaped board (2) and one or more layers (10-12-13). In this case, the stack (22) at the top comprises two paper sheets (10-12) impregnated with melamine-formaldehyde resin, namely, a printed paper sheet (10) and a wear layer (12). At the bottom, the stack (22) also comprises a balance layer (13) which comprises a resin-impregnated paper layer. In the example, both the printed paper sheet (10) and the wear layer (12) comprise a plurality of adjacently situated paper strips. However, it is not excluded that one paper strip for the printed paper sheet (10) and / or one paper sheet of the wear layer (12) may be applied. The lamination comprises pressing which is performed in a heated pressing device (21). The heated pressing device (21) may be a single-daylight press operating at a temperature of for example 195 °C, comprising a first press plate (23) and a second press plate (24). During lamination, the melamine-formaldehyde resin cures, and the resin, together with the printed paper sheet (10) and the wear layer (12), forms a decorative top layer (9) adhered directly onto the plate-shaped board (2). During pressing, a relief may be provided to the decorative top layer (9), and possibly to the plate-shaped board (2) by using a structured first press plate (23). The second press plate (24) may be structured in order to provide a relief at the balance layer (13). It is noted that, during pressing, a space is maintained between the contour of the steam release channels (14) and the corresponding press element, in this case the first press plate (23). In this example, the lamination step provides a decorative laminate half-product (1’), for example the decorative laminate half-product (F) of Figure 1; the step S5 of dividing the decorative laminate half-product (F) into basic decorative panels. In this case, this dividing takes place at the location of the technical zones (16), such that steam release channels (14) are removed during the dividing. It can be advantageous to saw as little as possible through the pressed decorative top layer (9) in order to limit the wear of the dividing device. Preferably, there will be no sawing through the pressed decorative top layer (9); the step S6 of providing the basic decorative panels with coupling parts (17-18), to form decorative laminates (1) which are decorative panels (1) that can be coupled to each other.

[0068] It is clear that the method illustrated by Figure 4 in steps SI up until S4 can be applied for realizing the decorative laminate half-product (1’) of Figure 1, or more in general the method illustrated by Figure 4 can be used for realizing the decorative laminates (1-1’) of the second aspect of the invention. For clarity’s sake, in Figure 4 the shape of the final coupling parts (17-18) is indicated in dashed line. Further, it is clear that the view represented in Figure 4 relates to a cross-section across the plate-shaped board (2), namely in a direction perpendicular to the length (L) of the plate-shaped board (2).

[0069] Figure 5 represents another example of some steps in a method for manufacturing decorative laminates (1), in this case decorative panels (1), having a lowered edge region (19). This method is similar to the method as disclosed in Figure 4 with the difference that the printed paper sheet (10) and the wear layer (12) extend in the stack (22) uninterruptedly over the technical zone (16) between two adjacent panel-shaped zones

[0070] (15), and with the difference that a local protrusion (25) is provided in a said technical zone (16) at the first large surface (3’) such that a controlled tearing of the printed paper sheet (10) and the wear layer (12) may be obtained during the lamination step. Further, in this situation, it is preferred that the steam release channel (14) at said technical zone

[0071] (16) then is provided at the opposite large surface, namely at the second large surface (4’). Besides this, the method illustrated by Figure 5 is identical to that of Figure 4.

[0072] Figure 6 represents yet another example of some steps in a method for manufacturing decorative laminates (1), in this case decorative panels (1). In this example no lowered edge regions (19) are present. There is thus no step S2. As there are no lowered edge regions (19), it is preferred that the printed paper sheet (10) and the wear layer (12) are uninterrupted. In this example a said steam release channel (14) is present at a said technical zone (16) and at the first large surface (3’). Besides this, the method illustrated by Figure 6 is identical to that of Figure 4.

[0073] The present invention is in no way limited to the herein above-described embodiments, on the contrary may such decorative laminates (1-1’) and methods be realized without leaving the scope of the present invention as defined by the claims.

Claims

CLAIMS.1.- A method for producing decorative laminates (1-1 ’), wherein the method comprises the steps of: providing a plate-shaped board (2) comprising a first major surface (3), a second major surface (4) opposite said first major surface (3) and one or more side edges (S-6-7-8) connecting said first major surface (3) and second major surface (4); a lamination step wherein at least a decorative top layer (9) is provided upon said first major surface (3), wherein said decorative top layer (9) comprises at least a resin, preferably at least a resin-impregnated sheet, and wherein said resin is cured to laminate the decorative top layer (9) to the first major surface (3); optionally performing further processing steps for obtaining said decorative laminates (1-1 ’); characterized in that the first major surface (3) and / or the second major surface (4) of the plate-shaped board (2) comprises one or more steam release channels (14) which each extends to at least one of said one or more side edges (S-6-7-8).2.- The method in accordance with claim 1, wherein providing said plate-shaped board (2) comprises the following steps: providing a basic plate-shaped board (2’) comprising a first large surface (3’) and a second large surface (4’) opposite said first large surface (3’); providing the first large surface (3’) and / or second large surface (4’) of the basic plate-shaped board (2’) with one or more steam release channels (14) by cutting and / or milling and / or pressing.3.- The method in accordance with any one of the preceding claims, wherein at least one steam release channel (14) extends in its longitudinal direction up until the said at least one side edge (5-6-7-8) of the plate-shaped board (2).4.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) has a length (L), a width (W) and a height (H), wherein at least one steam release channel (14) extends substantially in the length (L) direction of the plateshaped board (2).5.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) comprises at least two of said side edges (5-6-7-8), being a first side edge (5) and a second side edge (6), wherein at least one steam release channel (14) extends, in its longitudinal direction, uninterruptedly from said first side edge (5) to said second side edge (6), wherein the first side edge (5) and the second side edge (6) are preferably opposite side edges of the plate-shaped board (2).6.- The method in accordance with any one of the preceding claims, wherein the lamination step comprises pressing, preferably heat pressing with for example a discontinuous pressing device (21), wherein said resin is at least partially cured during said pressing.7.- The method in accordance with any of the preceding claims, wherein the resin is a thermosetting resin, preferably wherein water is released during the curing of the thermosetting resin.8.- The method in accordance with claim 7, wherein the thermosetting resin comprises formaldehyde and is preferably selected from the list of: melamine-formaldehyde resin(MF), urea-formaldehyde resin (UF), melamine-urea-formaldehyde resin (MUF), phenol-formaldehyde resin (PF), melamine-urea-phenol-formaldehyde resin (MUPF) or combinations thereof; and / or wherein the thermosetting resin is a bio-based resin comprising for example reducing sugars and amine groups.9.- The method in accordance with any one of the preceding claims, wherein the lamination step comprises pressing the decorative top layer (9) and the plate-shaped board (2) together at a temperature higher than 20 °C, preferably higher than 50 °C, wherein a first press element (23), for example a first press plate, applies pressure at the side of the decorative top layer (9) and a second press element (24), for example a second press plate, applies pressure at a side opposite said decorative top layer (9), wherein during the lamination step, spaces between the contour of said one or more steam release channels (14) and the respective press element (23-24) are present.10.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) has a height (H), wherein the minimum height (Hl) of a said steam release channel (14), seen in the height direction of the plate-shaped board (2), is more than 0.5 mm, preferably more than 1 mm, more preferably more than 2 mm.11.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) has a height (H), wherein the minimum width (Wl) of a said steam release channel (14) is more than 0.5 mm, preferably more than 1 mm, even more preferably more than 1.5 mm, most preferably more than 2 mm, wherein the minimum width (Wl) is seen in the plane perpendicular to the longitudinal direction of the corresponding steam release channel (14) and in a direction perpendicular to the height (H) direction of the plate-shaped board (2), preferably at the height of the major surface (3-4) comprising said steam release channel (14).12.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) has a height (H), wherein the plate-shaped board (2) has a remaining height at the location of a said steam release channel (14), wherein the minimum remaining height of the plate-shaped board (2) is at least 0.5 mm, preferably at least 1 mm, more preferably at least 1.5 mm, most preferably at least 2 mm.13.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) has a height (H) and a said steam release channel (14) has a height (Hl), seen in the height direction of the plate-shaped board (2), wherein the ratio of the maximum height (Hl) of the steam release channel (14) to the height (H) of the plateshaped board (2) is less than 70%, preferably less than 50%, more preferably less than 40%, most preferably less than 25%.14.- The method in accordance with any one of the preceding claims, wherein at least one steam release channel (14) has a substantially constant cross-section along its length.15.- The method in accordance with any one of the preceding claims, wherein at least one steam release channel (14) has a varying cross-sectional area along its length, preferably wherein the varying cross-sectional area increases with an increasing distance from the geometric center of the plate-shaped board (2).16.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) comprises a glue, wherein the glue is a thermosetting glue, and wherein the plate-shaped board (2) is preferably a wood fiber board or a particle board.17.- The method in accordance with any one of the preceding claims, wherein the plateshaped board (2) has a height (H) of less than 8 mm, preferably less than 6 mm, more preferably less than 5 mm, even more preferably less than 4 mm.18.- The method in accordance with any one of the preceding claims, wherein the decorative top layer (9) comprises a decor directly printed upon the first major surface (3) or the decorative top layer (9) comprises a printed sheet (10) or a uniformly colored sheet.19.- The method in accordance with any one of the preceding claims, wherein the lamination step comprises providing a balance layer (13) on the second major surface (4) of the plate-shaped board (2), wherein the balance layer (13) comprises at least a second resin, and curing said second resin to laminate the balance layer (13) to the second major surface (4) .20.- The method in accordance with any one of the preceding claims, wherein the outer surface of the decorative top layer (9) is provided with a relief.21.- The method in accordance with any one of the preceding claims, wherein the lamination step provides a decorative laminate half-product (T); wherein the decorative laminate half-product (T) comprises, seen in the plane of the decorative laminate half-product (T), a plurality of panel-shaped zones (15) separated by technical zones (16), wherein the further processing steps comprise at least dividing the decorative laminate half-product (1’) at one or more of said technical zones (16) for obtaining said decorative laminates (1).22.- The method in accordance with claim 21 , wherein at least one steam release channel (14) extends along a said technical zone (16), wherein the steam release channel (14) preferably extends uninterruptedly along the entire said technical zone (16).23.- The method in accordance with claim 22, wherein the maximum width (Wl) of the steam release channel (14) extending along a technical zone (16) is less than the width of the corresponding technical zone (16).24.- The method in accordance with any one of claims 21 to 23, wherein at least one steam release channel (14) extends through one or more panel-shaped zones (15), wherein said second major surface (4) preferably comprises said steam release channel (14).25.- The method in accordance with any one of claims 21 to 24, wherein said further processing steps comprise forming coupling parts (17-18) such that the decorative laminates (1) comprise profiled edges with coupling parts (17-18) that allow two of such decorative laminates (1) to be coupled to each other.26.- A decorative laminate (1-1’), wherein the decorative laminate (1-1 ’) comprises a plate-shaped board (2) and a decorative top layer (9), wherein the plate-shaped board (2) comprises a first major surface (3), a second major surface (4) opposite said first major surface (3) and one or more side edges (S-6-7-8) connecting the first major surface (3) and the second major surface (4), wherein the decorative top layer (9) comprises at least a resin, preferably a resin-impregnated sheet, wherein the decorative top layer (9) is attached to the first major surface (3) of the plate-shaped board (2), characterized in that the first major surface (3) and / or the second major surface (4) of the plate-shaped board (2) comprises one or more steam release channels (14) which each extends to at least one said side edge (S-6-7-8).27.- The decorative laminate (1-1’) in accordance with claim 26, wherein at least one steam release channel (14) extends in its longitudinal direction up until the said at least one side edge (5-6-7-8) of the plate-shaped board (2).28.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 27, wherein the plate-shaped board (2) has a length (L), a width (W) and a height (H), wherein at least one steam release channel (14) extends substantially in the length direction of the plate-shaped board (2).29.- The decorative laminate(l-l ’) in accordance with any one of claims 26 to 28, wherein the plate-shaped board (2) comprises at least two of said side edges (5-6-7-8), being a first side edge (5) and a second side edge (6), wherein at least one steam release channel (14) extends, in its longitudinal direction, uninterruptedly from the first side edge(5) to the second side edge (6), wherein the first side edge (5) and the second side edge(6) are preferably opposite side edges of the plate-shaped board (2).30.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 29, wherein the resin is a cured resin, obtained by curing a resin, preferably a thermosetting resin, that releases water during curing.31.- The decorative laminate (1-1’) in accordance with claim 30, wherein the cured thermosetting resin comprises formaldehyde and is preferably selected from the list of: melamine-formaldehyde resin (MF), urea-formaldehyde resin (UF), melamine-urea- formaldehyde resin (MUF), phenol-formaldehyde resin (PF), melamine-urea-phenol- formaldehyde resin (MUPF), or combinations thereof; and / or wherein the curedthermosetting resin comprises Maillard reaction products that are the result of Maillard reactions between amines and reducing sugars.32.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 31, wherein the plate-shaped board (2) has a height (H), wherein the minimum height (Hl) of a said steam release channel (14), seen in the height (H) direction of the plate-shaped board (2), is more than 0.5 mm, preferably more than 1 mm, more preferably more than 2 mm, most preferably more than 3 mm.33.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 32, wherein the plate-shaped board (2) has a height (H), and that the minimum width (Wl) of a said steam release channel (14) is more than 0.5 mm, preferably more than 1 mm, even more preferably more than 1.5 mm, most preferably more than 2 mm, wherein the minimum width (Wl) is seen in the plane perpendicular to the longitudinal direction of the corresponding steam release channel (14) and in a direction perpendicular to the height (H) direction of the plate-shaped board (2), preferably at the height of the major surface (3-4) comprising said steam release channel (14).34.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 33, wherein the plate-shaped board (2) has a height (H), wherein the plate-shaped board (2) has a remaining height at the location of a said steam release channel (14), wherein the minimum remaining height of the plate-shaped board (2) is at least 0.5 mm, preferably at least 1 mm, more preferably at least 1.5 mm, most preferably at least 2 mm.35.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 34, wherein the plate-shaped board (2) has a height (H) and a said steam release channel (14) has a height (H), wherein the ratio of the maximum height (Hl) of a said steam releasechannel (14) to the height (H) of the plate-shaped board (2) is less than 70%, preferably less than 50%, more preferably less than 40%, most preferably less than 25%.36.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 35, wherein at least one said steam release channel (14) has a substantially constant crosssection along its length.37.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 36, wherein at least one said steam release channel (14) has a varying cross-sectional area along its length, wherein the varying cross-sectional area preferably increases with an increasing distance from the geometric center of the plate-shaped board (2).38.- The decorative laminate (1-1’) in accordance with any one of claims 26 to 37, wherein the plate-shaped board (2) comprises a glue, wherein the glue is a thermosetting glue.39.- The decorative laminate (1-1’) in accordance with any one of the claims 26 to 38, wherein the plate-shaped board (2) has a height (H) of less than 8 mm, preferably less than 6 mm, more preferably less than 5 mm, even more preferably less than 4 mm.40.- The decorative laminate (1-1’) in accordance with any one of the claims 26 to 39, wherein the decorative top layer (9) comprises a decor directly printed upon the first major surface (3) or the decorative top layer (9) comprises a printed sheet (10) or a uniformly colored sheet.41.- The decorative laminate (1-1’) in accordance with any one of the claims 26 to 40, wherein decorative laminate (1-1’) comprises a balance layer (13) attached to the second major surface (4) of the plate-shaped board (2), wherein the balance layer (13) comprises at least a second resin.42.- The decorative laminate (1-1’) in accordance with any one of the claims 26 to 41, wherein the outer surface of the decorative top layer (9) comprises a relief.43.- The decorative laminate (1-1’) in accordance with any one of the claims 26 to 42, wherein the decorative laminate (1-1’) is a decorative laminate half-product (1’), wherein the decorative laminate half-product (1’) comprises, seen in the plane of the decorative laminate half-product (1’), a plurality of panel-shaped zones (15) separated by technical zones (16).44.- The decorative laminate (1 ’) in accordance with claim 43, wherein at least one steam release channel (14) extends along a technical zone (16), preferably wherein the steam release channel (14) extends uninterruptedly along the entire technical zone (16).45.- The decorative laminate (1’) in accordance with claim 44, wherein the maximum width (Wl) of the steam release channel (14) extending along a technical zone (16) is less than the width of the corresponding technical zone (16).46.- The decorative laminate (1’) in accordance with any one of claims 43 to 45, wherein at least one steam release channel (14) extends through one or more panel-shaped zones (15), wherein said second major surface (4) preferably comprises said steam release channel (14).

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