Method for manufacturing a decorative panel

Abstract

A method for manufacturing a decorative panel comprises the steps of - providing a substrate;5- applying a first coating composition on the substrate, thereby obtaining a first coating layer; - at least partially drying, or at least partially solidifying or at least partially curing the first coating layer; - applying a second coating composition on the first coating layer, thereby obtaining a second coating layer; - at least partially drying, or at least partially solidifying or at least partially curing the second coating layer; - optionally applying a third coating composition on the second coating layer, thereby obtaining a third coating layer; and at least partially drying, or at least partially solidifying or at least partially curing the optional third coating layer.

Description

[0001] Method for manufacturing a decorative panel

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

[0003] W02020 / 095196A1 discloses a coated panel with at least a substrate and a top layer. The top layer comprises at least a decor layer and a translucent or transparent wear layer. The wear layer comprises a thermally cured acrylate resin or a thermally cured unsaturated polyester resin. The thermal curing preferably cures the resin partially or completely. The acrylate resin or the unsaturated polyester resin can at least be partially cured by means of a thermally initiated radical crosslinking reaction. W02020 / 095196A1 also relates to a method for the production of such coated panels, in particular of such floor panels.

[0004] It is an object of the invention to provide methods for manufacturing decorative panels with improved properties of the wear layer.

[0005] The first aspect of the invention is a method for manufacturing a decorative panel. The method comprises the steps of

[0006] - providing a substrate;

[0007] - applying a first coating composition on the substrate, thereby obtaining a first coating layer;

[0008] - at least partially drying, or at least partially solidifying or at least partially curing the first coating layer;

[0009] - applying a second coating composition on the first coating layer, thereby obtaining a second coating layer;

[0010] - at least partially drying, or at least partially solidifying or at least partially curing the second coating layer.

[0011] The first coating layer can provide a primer layer and the second coating layer can provide a topcoat. The first coating composition and the second coating composition can be tuned for optimum performance. The first coating composition can be tuned for adhesion to the substrate, whereas the second coating composition can be tuned for optimum wear resistance of the decorative panel, including for optimal scratch resistance.

[0012] The method optionally comprises the step of applying a third coating composition on the second coating layer, thereby obtaining a third coating layer; and at least partially drying, or at least partially solidifying or at least partially curing the optional third coating layer.

[0013] It is meant that the method of the first aspect of the invention can be performed with or without application of the third coating layer.

[0014] The third coating composition - if applied - can be tuned for optimum wear resistance of the decorative panel, including for optimal scratch resistance of the decorative panel that will be made. If a third coating composition is used, the second coating composition can be selected for adhesion with the first coating composition and with the third coating composition, and can be selected for being cheap.

[0015] The first coating layer, the second coating layer and the optional third coating layer are preferably transparent or translucent after being fully cured.

[0016] The first coating composition, the second coating composition, and the optional third coating composition can be applied by any method for applying a coating composition. The different coating compositions can be applied each using the same techniques, or using different techniques. The first coating composition, the second coating composition and the optional third coating composition can e.g. be applied using a roller coater, using a curtain coater, using a screen coater, or using a knife coater.

[0017] Embodiments wherein a first coating layer, a second coating layer and a third coating layer are applied allow optimization of the properties of the coated substrate after the combined coating layer comprising the first coating layer, the second coating layer and the third coating layer are fully cured. The first coating composition can be selected for optimum adhesion to the substrate. The second coating composition can be a cheaper composition than the first coating composition and than the third coating composition. Applying a combined coating layer via application of a first coating composition, a second coating composition and a third coating composition is beneficial as the application of the multiple coating layer allows better control of the combined coating layer, e.g. better control of the combined amount of coating applied on the substrate. Such approach results in a decorative panel of better and more consistent quality after fully curing the combined coating layer, e.g. in a thermal pressing operation in which the curing of the combined coating layer is combined with pressing a texture in the combined coating layer.

[0018] The third coating composition can be tailored for optimum wear resistance of the decorative panel, including for optimal scratch resistance.

[0019] The second coating layer can be thicker than the first coating layer and than the third coating layer.

[0020] The steps of at least partially drying the first coating layer, and / or the second coating layer and / or the optional third coating layer can be performed using heat, e.g. in an oven, using infrared radiation or using microwaves; and / or using radiation energy (such as UV- radiation, electron beam radiation or LEDs, e.g. UV-radiation emitting LEDs).

[0021] Optionally, additional coating layers can be applied between the first coating layer and the second coating layer, e.g. a fourth coating layer and optionally even a fifth coating layer. Such approach improves the optimization of the combined coating layer, and / or improves the consistency and quality of the combined coating layer. The coating composition for applying the fourth coating layer and / or the coating composition for applying the fifth coating layer can be the same or different from the second coating composition. It is preferred however that the first coating composition is different from the fourth coating composition and the fifth coating composition, if used. It is a benefit that the first coating composition can be optimized for excellent adhesion to the substrate onto which the first coating composition is applied. If used, the fourth coating composition and the fifth coating composition can have the same chemical nature as the second coating composition and preferably also of the third coating composition. This has the benefit of excellent adhesion in final curing between the different coating layers in the combined coating layer. The fourth coating composition and the fifth coating composition can e.g. comprise (meth)acrylate oligomers and (meth)acrylate reactive diluents.

[0022] A preferred method is characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the first coating layer, formation takes place of one or more of urethane bonds, allophonate bonds, urea bonds, amide groups, isocyanurate groups or oxazolidone in the first coating layer.

[0023] Such embodiments are favorable as the crosslinking in the final cured coating layer is increased, resulting in increased wear resistance of the coated substrate. Furthermore, such embodiments are beneficial as the ease of applying the second coating composition is facilitated.

[0024] The formation of the bonds mentioned can be made possible via the integration of components with appropriate reactive groups in the first coating layer.

[0025] A preferred method is characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the first coating layer, a partial UV- curing or a partial electron beam curing is performed on the first coating layer.

[0026] To this end, the first coating composition preferably comprises a photo-initiator.

[0027] To this end, the first coating composition preferably comprises components comprising at least one (meth)acrylate group, e.g. (meth)acrylate oligomers and / or (meth)acrylate reactive diluents and / or polyurethane resin comprising reactive (meth)acrylate groups.

[0028] The use of UV-curing or electron beam curing results in a fast curing and does not require a lot of space in the production line. The step of partial UV-curing or partial electron beam curing of the first coating layer can e.g. involve an addition reaction of unsaturated carbon - carbon bonds (e.g. provided by (meth)acrylate groups or by unsaturated polyester resin) in the first coating layer; and / or using radiation energy (such as UV-radiation, electron beam radiation or LEDs, e.g. UV-radiation emitting LEDs)..

[0029] A preferred method is characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer, formation takes place of one or more of urethane bonds, allophonate bonds, urea bonds, amide groups, isocyanurate groups or oxazolidone in the second coating layer.

[0030] Such embodiments are favorable as the crosslinking in the final cured coating layer is increased, resulting in increased wear resistance of the decorative panel. Furthermore, such embodiments are beneficial as the ease of applying the optional third coating composition is facilitated.

[0031] The formation of the bonds mentioned can be made possible via the integration of components with appropriate reactive groups in the second coating layer.

[0032] A preferred method is characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer, a partial UV-curing or a partial electron beam curing is performed on the second coating layer.

[0033] To this end, the second coating composition preferably comprises a photo-initiator.

[0034] To this end, the second coating composition preferably comprises components comprising at least one (meth)acrylate group, e.g. (meth)acrylate oligomers and / or (meth)acrylate reactive diluents and / or polyurethane resin comprising reactive (meth)acrylate groups.

[0035] The use of UV-curing or electron beam curing results in a fast curing and does not require a lot of space in the production line. The step of partial UV-curing or partial electron beam curing of the second coating layer can e.g. involve an addition reaction of unsaturated carbon - carbon bonds (e.g. provided by (meth)acrylate groups or by unsaturated polyester resin) in the second coating layer.

[0036] A preferred method is characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer, formation takes place of one or more of urethane bonds, allophonate bonds, urea bonds, amide groups, isocyanurate groups or oxazolidone in the third coating layer.

[0037] Such embodiments are favorable as the crosslinking in the final cured coating layer is increased, resulting in increased wear resistance of the coated substrate. Furthermore, it facilitates handling of the coated substrate - e.g. when stored during some time - before being processed in a thermal pressing operation for creating a texture and for further thermal curing the coating layers.

[0038] The formation of the bonds mentioned can be made possible via the integration in the third coating layer of components with appropriate reactive groups.

[0039] A preferred method is characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer, a partial UV- curing or a partial electron beam curing is performed on the third coating layer.

[0040] To this end, the third coating composition preferably comprises a photo-initiator.

[0041] To this end, the second coating composition preferably comprises components comprising at least one (meth)acrylate group, e.g. (meth)acrylate oligomers and / or (meth)acrylate reactive diluents and / or polyurethane resin comprising reactive (meth)acrylate groups.

[0042] The use of UV-curing or electron beam curing results in a fast curing and does not require a lot of space in the production line. The step of partial UV-curing or partial electron beam curing of the third coating layer can e.g. involve an addition reaction of unsaturated carbon - carbon bonds (e.g. provided by (meth)acrylate groups or provided by unsaturated polyester resin) in the third coating layer.

[0043] The viscosity of the first coating composition is preferably lower than the viscosity of the second coating composition. Such embodiments are beneficial as the lower viscosity of the first coating composition than the viscosity of the second coating composition improves the adhesion of the combined coating layer to the substrate.

[0044] The first coating composition preferably has a viscosity between 10 and 2000 mPa.s.

[0045] The second coating composition preferably has a viscosity between 100 and 5000 mPa.s.

[0046] The viscosity of the coating compositions can be measured using a rotational viscosity measurement technique. The viscosity is measured at room temperature.

[0047] The first coating composition may comprises a wetting agent. The second coating composition may comprise no wetting agent, or the second coating composition may comprise a lower mass percentage of wetting agent than the first coating composition.

[0048] Such embodiment is beneficial as the performance of the combined coating layer in the final coating product is improved. The wetting agent in the first coating composition improves the wetting of the substrate; and therewith the adhesion to the substrate. The lower amount of wetting agent in the second coating composition - or even the absence of wetting agent in the second coating composition - is beneficial as the wetting agent is a component which does not contribute or contributes less to the wear resistance of the coating layer.

[0049] A glue layer can be applied to the substrate before - and preferably in line with - the step of applying the first coating composition on the substrate. The application of the glue layer is beneficial for improving the adhesion of the first coating layer to the substrate. The glue layer can be a polyurethane glue layer (and preferably a water-based polyurethane glue layer, even more preferably a water-based polyurethane dispersion), more preferably a polyurethane layer comprising reactive (meth)acrylate groups.

[0050] The second coating composition may comprise first abrasion resistant particles; or first abrasion resistant particles may be scattered into the first coating layer or into the second coating layer. Such embodiments are beneficial as they allow to increase the wear resistance of the coating layer of the coated substrate.

[0051] The third coating composition - if applied - may comprise second abrasion resistant particles; or second abrasion resistant particles may be scattered into the second coating layer or into the third coating layer. Such embodiments are beneficial as it allows to increase the wear resistance and the scratch resistance of the coating layer of the coated substrate.

[0052] Preferably, the D50 particle size of the second abrasion resistant particles is at least 10 micrometer smaller than the D50 particle size of the first abrasion resistant particles.

[0053] Such embodiments are beneficial as a combination is obtained in the decorative panel of excellent wear resistance and of excellent scratch resistance. The second abrasion resistant particles are provided closer to the surface - and preferably even in the uppermost coating layer - of the decorative panel. Therefore, and thanks to their smaller size, they are beneficial for establishing excellent scratch resistance. The first abrasion resistant particles are bigger and situated deeper in the combined coating layers of the decorative panel and provide wear resistance.

[0054] The D50 particle size of the abrasion resistant particles is the size at which 50% by volume of the particles is smaller than this size. The D50 particle size can be determined from the distribution curve according to volume as measured using laser diffraction according to ISO 13320:2020. The D50 particle size of the second abrasion resistant particles can e.g. be 50 micrometer or smaller. The D50 particle size of the first abrasion resistant particles can e.g. be at least 60 micrometer, or at least 70 micrometer.

[0055] Abrasion resistant particles - e.g. for the first abrasion resistant particles and / or for the second abrasion resistant particles - can be selected from aluminum oxide particles, diamond particles, silicon carbide particles, boron nitride particles, or combinations thereof.

[0056] The third coating composition preferably differs in composition from the first coating composition.

[0057] The third coating layer is preferably applied for providing the surface of the decorative panel.

[0058] The third coating composition is preferably configured such that when fully cured it has a higher crosslinking density than the first coating layer and / or second coating layer when fully cured.

[0059] Such embodiments provide decorative panels with improved scratch resistance, as the higher cross linking density of the third coating layer improves the scratch resistance of the decorative panel. The improved scratch resistance is combined with sound dampening when walking on the panel, thanks to the lower crosslinking density of the first coating layer and / or the second coating layer.

[0060] The third coating composition preferably has a higher amount of (meth)acrylate groups per unit of dry mass than the second coating layer and / or than the first coating layer. Such embodiment can result in higher crosslinking density and higher hardness of the third coating layer compared to the second coating layer and preferably also of the first coating layer. The third coating composition is preferably configured such that when fully cured it has a higher hardness than the first coating layer and / or than the second coating layer when fully cured.

[0061] Such embodiments provide decorative panels with improved scratch resistance, as the higher hardness of the third coating layer improves the scratch resistance of the decorative panel. The improved scratch resistance is combined with sound dampening when walking on the panel, thanks to the lower hardness of the first coating layer and / or of the second coating layer.

[0062] The hardness of coating layers can be measured using a sclerometer.

[0063] The second coating composition preferably differs in composition from the first coating composition and / or from the - if used - third coating composition.

[0064] Such embodiments allow optimizing the properties of the decorative panel and facilitating the production of the decorative panel.

[0065] The second coating composition can have the same composition as the first coating composition and / or of the - if used - third coating composition.

[0066] Such embodiments reduce the complexity in coating compositions - and of raw materials required for them - that are needed. It facilitates the production of the decorative panel to a large extent.

[0067] The first coating composition may comprise a thermo-initiator. More preferably, the first coating layer comprises at least part of the thermo-initiator after the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer; and - if a third coating composition is applied - after the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer. The thermo-initiator of the first coating composition is useful for being activated in a thermal pressing operation. The thermo-initiator can initiate thermal curing by addition reactions in a thermal pressing operation on the substrate comprising the combined coating layers. In the thermal pressing operation, the combined coating layers can be embossed and thermally cured.

[0068] The second coating composition preferably comprises a thermo-initiator. More preferably, the second coating layer comprises at least part of the thermo-initiator after the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer; and - if a third coating composition is applied - after the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer.

[0069] The thermo-initiator of the second coating composition is useful for being activated in a thermal pressing operation. The thermo-initiator can initiate thermal curing by addition reactions in a thermal pressing operation on the substrate comprising the combined coating layers. In the thermal pressing operation, the combined coating layers can be embossed and thermally cured.

[0070] If used, the third coating composition preferably comprises a thermo-initiator. More preferably, the third coating layer comprises at least part of the thermo-initiator after the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer.

[0071] The thermo-initiator of the third coating composition is useful for being activated in a thermal pressing operation. The thermo-initiator can initiate thermal curing by addition reactions in a thermal pressing operation on the substrate comprising the combined coating layers. In the thermal pressing operation, the combined coating layers can be embossed and thermally cured. Either one, both or all three of the first coating composition, the second coating composition and the third coating composition can comprise a plurality of thermoinitiators having different dissociation temperatures.

[0072] It is a benefit of such embodiments that thermal curing during a thermal pressing operation in which the combined coating layers are embossed is more gradual, facilitating pressing the texture in the combined coating layers.

[0073] A preferred method is characterized in that only one of the first coating composition, the second coating composition or the third coating composition comprises at least one thermo-initiator. More preferably, only the second coating composition comprises at least one thermo-initiator.

[0074] It is a benefit of such embodiments that the thermo-initiator can migrate into the different coating layers. As a result, when activating the thermo-initiator in a thermal pressing operation, thermally induced curing will be initiated in each of the coating layers by the dissociation of the thermo-initiator. Coating compositions not comprising a thermoinitiator have a higher stability, including a longer pot life; and can therefore be preferred.

[0075] A preferred method is characterized in that only two of the first coating composition, the second coating composition and the third coating composition comprise at least one thermo-initiator.

[0076] The thermo-initiators can migrate into the different coating layers. As a result, when activating the thermo-initiators in a thermal pressing operation, thermally induced curing will be initiated in each of the coating layers by the dissociation of the thermo-initiator. Coating compositions not comprising a thermo-initiator have a higher stability, including a longer pot life; and can therefore be preferred.

[0077] A preferred method is characterized that in all three of the first coating composition, the second coating composition and the third coating composition comprise at least one thermo-initiator. Such embodiments are preferred as it guarantees that each of the coating layers is properly cured in a thermal pressing operation, as in each of the coating layers it is ensured that dissociation of thermo-initiators will result in proper initiation of curing reactions.

[0078] A preferred method is characterized in that the first coating composition comprises a first thermo-initiator. The second coating composition comprises a second thermo-initiator and the third coating composition comprises a third thermo-initiator. The dissociation temperature of the third thermo-initiator is higher than the dissociation temperature of the second thermo-initiator and / or of the dissociation temperature of the first thermoinitiator; and / or the dissociation temperature of the second thermo-initiator is higher than the dissociation temperature of the first thermo-initiator.

[0079] The first thermo-initiator, the second thermo-initiator and the third thermo-initiator will be at least partially present respectively in the first coating layer, the second coating layer and the third coating layer at the moment a thermal pressing operation is performed in the manufacturing process of a decorative panel. It is beneficial when thermo-initiators in coating layers located closer to the surface of the combined coating layer have a higher dissociation temperature than thermo-initiators in coating layers located closer to the substrate, as the formation of a texture in the combined coating layers by copying the structure of a structured press surface in the thermal pressing operation is facilitated. In the thermal pressing operation, coating layers closer to the surface are heating up faster than coating layers closer to the substrate. In order to allow sufficient flow of the coating layers for creating the texture, it is beneficial that the thermal curing in the coating layers closer to the surface of the combined coating layers is somewhat delayed. This can be achieved by the mentioned difference in the dissociation temperatures of the thermoinitiators.

[0080] The combination of the first coating layer, the second coating layer and the third coating layer preferably has a dry weight between 50 and 300 gram per square meter. The first coating composition may comprise

[0081] - one or more (meth)acrylate oligomers, preferably wherein the oligomers have a molar mass equal to or higher than 800 g / mol;

[0082] - one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluents; wherein the reactive diluents have a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol;

[0083] - optionally at least one photo-initiator;

[0084] - optionally at least one thermo-initiator, or no thermo-initiator;

[0085] - optionally at least one isocyanate functional component;

[0086] - optionally at least one hydroxyl functional component (e.g. a - preferably primary - alcohol; or a polyol, preferably comprising a primary hydroxyl group); optionally wherein the one or more (meth)acrylate oligomers comprises at least a urethane (meth)acrylate oligomer.

[0087] Such first coating compositions are beneficial, as they can be cured in a thermal pressing operation by means of addition reaction of the (meth)acrylate groups of the first coating composition.

[0088] Such first coating compositions are beneficial, as they can be first partially cured by means of addition reactions of the (meth)acrylate groups of the first coating composition.

[0089] The optional presence of at least a photo-initiator is beneficial as it allows partial curing of the first coating layer by means of a UV-curing step.

[0090] The presence of at least one isocyanate functional component and the presence of at least one hydroxyl functional component is preferred as these components can react and contribute and / or result in (partial) curing.

[0091] The second coating composition may comprise

[0092] - one or more (meth)acrylate oligomers, preferably wherein the oligomers have a molar mass equal to or higher than 800 g / mol; - one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluents; wherein the reactive diluents have a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol;

[0093] - optionally at least one photo-initiator;

[0094] - optionally at least one thermo-initiator, or no thermo-initiator;

[0095] - optionally at least one isocyanate functional component;

[0096] - optionally at least one hydroxyl functional component (e.g. a - preferably primary - alcohol; or a polyol, preferably comprising a primary hydroxyl group); optionally wherein the one or more (meth)acrylate oligomers comprises at least a urethane (meth)acrylate oligomer.

[0097] Such second coating compositions are beneficial, as they can be cured in a thermal pressing operation by means of addition reactions of the (meth)acrylate groups of the second coating composition.

[0098] Such second coating compositions are beneficial, as they can be first partially cured by means of addition reactions of the (meth)acrylate groups of the second coating composition.

[0099] The presence of at least one isocyanate functional component and the presence of at least one hydroxyl functional component is preferred as these components can react and contribute and / or result in (partial) curing.

[0100] The third coating composition may comprise

[0101] - one or more (meth)acrylate oligomers, preferably wherein the oligomers have a molar mass equal to or higher than 800 g / mol;

[0102] - one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluents; wherein the reactive diluents have a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol;

[0103] - optionally at least one photo-initiator;

[0104] - optionally at least one thermo-initiator, or no thermo-initiator;

[0105] - optionally at least one isocyanate functional component; - optionally at least one hydroxyl functional component (e.g. a - preferably primary - alcohol; or a polyol, preferably comprising a primary hydroxyl group); optionally wherein the one or more (meth)acrylate oligomers comprises at least a urethane (meth)acrylate oligomer.

[0106] Such third coating compositions are beneficial, as they can be cured in a thermal pressing operation by means of addition reactions of the (meth)acrylate groups of the third coating composition.

[0107] Such third coating compositions are beneficial, as they can be first partially cured by means of addition reactions of the (meth)acrylate groups of the third coating composition.

[0108] The presence of at least one isocyanate functional component and the presence of at least one hydroxyl functional component is preferred as these components can react and contribute and / or result in (partial) curing.

[0109] It is preferred that the first coating composition, the second coating composition and the third coating composition each have a composition as described in the preceding paragraphs. Such embodiments are beneficial, as the (meth)acrylate groups in the different coating layers allow reaction between the (meth)acrylate groups of the different coating layers resulting in excellent adhesion between the different coating layers.

[0110] This adhesion between the coating layers can even be enhanced if the coating compositions each comprise at least one isocyanate functional component and at least one hydroxyl functional component as their presence will lead to chemical reactions in the partial curing step or in the final curing using a thermal pressing operation resulting in additional chemical bonds between the different coating layers.

[0111] The first coating composition preferably comprises a higher mass percentage of the combination of one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluents, having a molar mass lower than 800 g / mol - and preferably lower than 500 g / mol-, than the third coating composition.

[0112] Such embodiments are beneficial for the performance of the decorative panel as the adhesion of the combined coating layers with the substrate is improved.

[0113] The third coating composition preferably comprises a higher mass percentage than the first coating composition and than the second coating composition of molecules having (meth)acrylate functionality at least three. The third coating composition preferably comprises a higher mass percentage of molecules having (meth)acrylate functionality at least four than the first coating composition and than the second coating composition.

[0114] Such embodiments are beneficial as they result in a higher scratch resistance of the surface after the coating layers have been fully cured, e.g. after having been fully cured in a thermal pressing operation.

[0115] The third coating composition may comprise or may consist of a water-based polyurethane resin, whether with or without reactive (meth)acrylate groups; or the third coating composition may comprises or may consist of a water-based (meth)acrylate resin, whether with or without reactive (meth)acrylate groups.

[0116] The third coating composition is preferably provided to provide the top layer of the decorative panel. Such third coating composition allows more easily obtaining a tack free surface of the combined coating layers after the step of at least partially drying, or at least partially solidifying or at least partially curing the optional third coating layer. The product obtained can then be stacked and stored during some time; and a thermal pressing operation for obtaining the decorative panel can be performed later.

[0117] The first coating composition may comprise a water-based polyurethane dispersion having (meth)acrylate functionality. Such first coating composition may optionally comprise at least one photo-initiator. Such first coating composition may optionally comprise at least one thermo-initiator. The second coating composition may comprise a water-based polyurethane dispersion having (meth)acrylate functionality. The second coating composition may comprise at least one photo-initiator. The second coating composition may comprise at least one thermo-initiator.

[0118] The third coating composition may comprise a water-based polyurethane dispersion having (meth)acrylate functionality. The third coating composition may comprise at least one photo-initiator. The third coating composition may comprise at least one thermoinitiator.

[0119] The use of water-based polyurethane dispersions having (meth)acrylate functionality is beneficial. They have low viscosity and can be easily applied. They can be easily partially cured; and can be easily cured in a subsequent thermal pressing operation.

[0120] As an alternative to water-based polyurethane dispersions, solvent based polyurethane resins having (meth)acrylate functionality can be used for the first coating composition, and / or for the second coating composition and / or for the third coating composition.

[0121] The substrate can comprise a sheet material, e.g. a whether or not printed sheet of paper; or a whether or not printed thermoplastic film. The whether or not printed sheet of paper can be impregnated with a thermosetting resin.

[0122] The substrate can comprise a board and a - preferably printed - decor. The decor can also be a decor of uniform color.

[0123] A printed decor may be printed on the board, preferably on a primer layer applied on the board.

[0124] The substrate may comprise a sheet of paper providing the - preferably printed - decor, wherein the sheet of paper is laminated onto the board or provided for being laminated on the board. The sheet of paper may be laminated onto - or is provided for being laminated onto - the board using an aminoplast resin or using a polyurethane resin or using a polyvinyl acetate resin or using a hotmelt adhesive. The sheet of paper can be laminated onto the board in a thermal pressing operation.

[0125] The sheet of paper may be impregnated with a resin; preferably with a partially cured thermoset resin. The partially cured resin may be an aminoplast resin (e.g. a melamine resin, a melamine urea resin, a melamine urea formaldehyde resin), an (meth)acrylate resin, a urethane (meth)acrylate resin, a polyurethane resin or combinations thereof.

[0126] The sheet of paper may not be impregnated with resin.

[0127] As an alternative to a sheet of paper, a - preferably printed - thermoplastic film can be provided, e.g. a polyvinyl chloride film, a polyester film, a polyethylene film or a polypropylene film.

[0128] The board may be selected from a wood-based board (e.g. a wood fiber board, a wood particle board, or a plywood board), a mineral based board (e.g. a Portland cement based board, a magnesium oxide based board or a gypsum based board), or a whether or not filled thermoplastic board (e.g. a polyvinyl chloride based board, a polyester based board, or a polypropylene based board).

[0129] Thermoplastic boards may be filled with fillers comprising wood fibers, wood dust or mineral fillers such as calcium carbonate.

[0130] The second aspect of the invention is a method as in any embodiment of the first aspect of the invention; wherein the method comprises the step of performing a thermal pressing operation on the substrate comprising a combined coating layer, wherein the combined coating layer comprises the first coating layer, the second coating layer and optionally the third coating layer. In the thermal pressing operation a texture is pressed in the combined coating layer and a thermally activated curing of the combined coating layer is performed. In the method of the second aspect of the invention, a balancing layer can be laminated in the thermal pressing operation at the side of the substrate opposite to the side comprising the combined coating layer. The balancing layer can compensate for tensions created in the thermal pressing operation. The balancing layer can comprise or consist of a resin impregnated sheet of paper.

[0131] The thermal pressing operation can be performed in a single daylight press, in a multiple daylight press or in a continuous press.

[0132] The texture pressed in the thermal pressing operation is preferably in register with a printed decor of the substrate.

[0133] The texture is preferably pressed in the combined coating layer by copying the texture of a structured press element, e.g. a structured press plate, a structured press roller or a structured film introduced between the press element and the substrate comprising the combined coating layer.

[0134] The step of performing the thermal pressing operation can be performed in line with the step of applying the third coating composition on the second coating layer; and preferably also in line with the step of applying the second coating composition on the first coating layer; and preferably also in line with the step of applying the first coating composition on the substrate.

[0135] The third aspect of the invention is a coated substrate obtained in a method as in any embodiment of the first aspect of the invention. The coated substrate comprises a combined coating layer, wherein the combined coating layer comprises the first coating layer, the second coating layer and optionally a third coating layer. The first coating layer, the second coating layer - and optionally the third coating layer - are partially cured.

[0136] The coated substrate of the third aspect of the invention can be used in the production of a decorative panel by performing a thermal pressing operation as in the second aspect of the invention. The first coating layer and the second coating layer - and optionally also the third coating layer - may comprise a thermo-initiator.

[0137] The fourth aspect of the invention is a method for producing a decorative panel. The method comprises the step of providing a coated substrate as in any embodiment of the third aspect of the invention. The method comprises the step of performing a thermal pressing operation on the coated substrate. In the thermal pressing operation a texture is pressed in the combined coating layer and a thermally activated curing of the combined coating layer is performed.

[0138] The thermal pressing operation can be performed in the same way and / or can have the same characteristics as described for the method of the second aspect of the invention.

[0139] The fifth aspect of the invention is a decorative panel obtained in a method according to any embodiment of the second aspect of the invention, or obtained in a method according to any embodiment of the fourth aspect of the invention.

[0140] The sixth aspect of the invention is a decorative panel - optionally obtained via a method as in any embodiment of the second aspect of the invention, or obtained in any embodiment of the fourth aspect of the invention. The decorative panel comprises

[0141] - a substrate comprising a board and a - preferably printed - decor; and

[0142] - a combined coating layer comprising a first coating layer, a second coating layer and optionally a third coating layer.

[0143] The combined coating layer comprises a texture. The first coating layer, the second coating layer and - if present - the third coating layer are (meth)acrylate and / or polyurethane coating layers, preferably urethane (meth)acrylate coating layers. The composition of the second coating layer differs from the composition of the first coating layer; and optionally from the composition of the third coating layer.

[0144] The second coating layer preferably comprises first abrasion resistant particles. The third coating later preferably comprises second abrasion resistant particles.

[0145] The D50 particle size of the second abrasion resistant particles is preferably at least 10 micrometer smaller than the D50 particle size of the first abrasion resistant particles. The D50 particle size of the abrasion resistant particles is the size at which 50% by volume of the particles is smaller than this size. The D50 particle size can be determined from the distribution curve according to volume as measured using laser diffraction according to ISO 13320:2020.

[0146] The D50 particle size of the second abrasion resistant particles can e.g. be 50 micrometer or smaller. The D50 particle size of the first abrasion resistant particles can e.g. be at least 60 micrometer, or at least 70 micrometer. It is a benefit that the first abrasion resistant particles can provide improved wear resistance to the decorative panel. It is a benefit that the second abrasion resistant particles can provide improved scratch resistance to the decorative panel.

[0147] When a UV-curing step is performed, the UV-curing can be performed using UV-lamps, using excimer lamps or using UV-radiation emitting LEDs (Light Emitting Diodes); or using combinations thereof.

[0148] A printed decor can be used in the invention.

[0149] It is also possible that the decor is a uni-decor, e.g. obtained by coloring or dyeing a - whether or not resin impregnated - sheet of paper.

[0150] With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0151] Figure 1 shows an example of a method according to the invention. Figure 1 shows a non-limiting example of a method according to the invention, illustrating different steps that can be included in the method according to the invention. A board 10 is provided. The board 10 can be a wood-based board, e.g. a wood fiber board such as a medium density fiberboard (MDF) or a high density fiberboard (HDF). However, the invention is not limited to wood-based boards. Other boards can be used in the invention.

[0152] A glue layer 12 can optionally be applied to the board 10, e.g. polyurethane glue layer.

[0153] In the example shown, a printed sheet of paper 14 is applied on the substrate. Figure 1 shows an embodiment in which prior to application of the printed sheet of paper 14, a glue layer 12 has been applied to the board 10.

[0154] However, the application of such glue layer is not necessary for the invention. It is possible that the printed sheet of paper 14 is impregnated with a partially cured thermosetting resin, which will be cured in the thermal pressing operation and as such will provide the adhesion between the printed sheet of paper 14 and the board 10.

[0155] As an alternative to the application of a printed sheet of paper, the board can have been printed (e.g. by means of digital printing technique, e.g. via inkjet printing), preferably after application of a primer on the board. The glue layer applied in the example shown in figure 1 can be applied for obtaining excellent adhesion between the printed board and the first coating composition that will be applied subsequently. However, it is also possible to apply the first coating composition on the printed board without first applying a glue layer onto the printed board.

[0156] A first coating composition 21 is applied by a first coating applicator 22 (in the example shown by means of a roller coater), thereby obtaining a first coating layer 23.

[0157] The first coating layer 23 is then partially dried, or partially solidified or partially cured in a first treatment unit 27. If the first coating composition comprises (meth)acrylate groups, the first coating layer can be partially cured in a UV-curing step in which radiation induced addition reactions between (meth)acrylate groups occur. To this end, the first coating composition preferably comprises a photo-initiator.

[0158] If the first coating composition comprises isocyanate groups and hydroxyl groups, the first coating layer can be partially cured in a thermal treatment step - e.g. in an oven - by reactions between the isocyanate groups and the hydroxyl groups.

[0159] A second coating composition 31 is applied by a second coating applicator 32 (in the example shown by means of a roller coater), thereby obtaining a second coating layer 33.

[0160] The viscosity of first coating composition is preferably lower than the viscosity of the second coating composition in order to improve the adhesion of the first coating layer to the substrate onto which the first coating composition is applied.

[0161] The second coating composition 31 can comprise first abrasion resistant particles. It is also possible, as an alternative, - as shown in figure 1 - to scatter first abrasion resistant particles 35 into the second coating layer 33 using a first scatter unit 34. The first abrasion resistant particles can e.g. be aluminum oxide particles. The first abrasion resistant particles are useful for increasing the wear resistance of the fully cured decorative panel that is manufactured in the embodiment shown in figure 1 of the method according to the invention.

[0162] The second coating layer 33 is partially dried, or partially solidified or partially cured in a second treatment unit 37. If the second coating composition comprises (meth)acrylate groups, the second coating layer can be partially cured in a UV-curing step in which radiation induced addition reaction between (meth)acrylate groups occurs. To this end, the second coating composition 31 preferably comprises a photo-initiator.

[0163] If the second coating composition comprises isocyanate groups and hydroxyl groups, the second coating layer can be partially cured in a thermal treatment step - e.g. in an oven - by reactions between the isocyanate groups and the hydroxyl groups. A third coating composition 41 is applied by a third coating applicator 42 (in the example shown by means of a roller coater), thereby obtaining a third coating layer 43.

[0164] The third coating composition 41 can comprise second abrasion resistant particles. It is also possible, as an alternative, - as shown in figure 1 - to scatter second abrasion resistant particles 45 into the third coating layer 43 using a second scatter unit 44. The second abrasion resistant particles can e.g. be aluminum oxide particles.

[0165] For optimized wear and scratch resistance of the decorative panel, the D50 particle size of the second abrasion resistant particles 45 is preferably at least 10 micrometer smaller than the D50 particle size of the first abrasion resistant particles 35.

[0166] The third coating layer 43 is partially dried, or partially solidified or partially cured in a third treatment unit 47. If the third coating composition 41 comprises (meth)acrylate groups, the third coating layer can be partially cured in a UV-curing step in which radiation induced addition reaction between (meth)acrylate groups occurs. To this end, the third coating composition preferably comprises a photo-initiator.

[0167] If the third coating composition comprises isocyanate groups and hydroxyl groups, the third coating layer can be partially cured in a thermal treatment step - e.g. in an oven - by reactions between the isocyanate groups and the hydroxyl groups.

[0168] The third coating composition 41 is preferably selected such that when fully cured it has a higher crosslinking density and / or a higher hardness than the first coating layer and than the second coating layer when fully cured.

[0169] In the example shown, the first coating composition 21, the second coating composition 31 and the third coating composition 41 each comprise at least a thermo-initiator which is at least partially still present after the step of partially drying, partially solidifying or partially curing the third coating layer 43. Alternatively, it can be sufficient that only one of the first coating composition 21, the second coating composition 31 or the third coating composition 41 comprises a thermoinitiator which is at least still partially present after the step of partially drying, partially solidifying or partially curing the third coating layer 43.

[0170] The embodiment of the inventive method shown in figure 1 comprises the step of performing in a single daylight press 51 a thermal pressing operation on the board 10, with the printed sheet of paper 12 and the combined coating layers - comprising the first coating layer 23, the second coating layer 33 and the third coating layer 43 on it. Underneath the board, a resin impregnated sheet of paper 53 can be added.

[0171] A textured press plate 55 is used in the thermal pressing operation shown in figure 1. Its use results in a texture being pressed in the combined coating layers comprising the first coating layer 23, the second coating layer 33 and the third coating layer 43. In the thermal pressing operation, the coating layers 23, 33, 43 are thermally cured. This curing can comprise addition reactions between (meth)acrylate groups in the coating layers, initiated by decomposition of thermo-initiators present in the coating layers thanks to the increase of temperature in the thermal pressing operation. Via an appropriate textured press plate and correct relative positioning in the press, the texture 61 can be provided in register with the printed decor of the printed sheet of paper 14, e.g. for a realistic imitation of a wooden plank.

[0172] In the thermal pressing operation of the exemplary embodiment shown in figure 1 of the method according to the invention, the printed sheet of paper 14 is laminated onto the board 10 and the resin impregnated sheet of paper 53 positioned underneath the board is laminated to the board. This resin impregnated sheet of paper 53 laminated at the bottom of the board can act as a balancing layer 63, balancing the stresses applied to the board 10 by laminating onto the board 10 the printed sheet of paper 14 with its coating layers 23, 33, 43. In the embodiment of the method according to the invention shown in figure 1, all steps shown can be performed in line with each other. However, this is not necessary the case for the invention. The result of the method shown in figure 1 is a decorative panel 60 comprising a balancing layer 63, a board 10, a printed sheet of paper 14 providing a printed decor, and a combined coating layer comprising the first coating layer 23, the second coating layer 33 and the third coating layer 43. The combined coating layer comprising the first coating layer 23, the second coating layer 33 and the third coating layer 43 comprises a texture 61.

[0173] The present invention is in no way limited to the embodiments described as examples and represented in the figures, on the contrary the invention can be realized in various forms and dimensions, without leaving the scope of the invention.

Claims

Claims1 Method for manufacturing a decorative panel, wherein the method comprises the steps of- providing a substrate;- applying a first coating composition on the substrate, thereby obtaining a first coating layer;- at least partially drying, or at least partially solidifying or at least partially curing the first coating layer;- applying a second coating composition on the first coating layer, thereby obtaining a second coating layer;- at least partially drying, or at least partially solidifying or at least partially curing the second coating layer;- optionally applying a third coating composition on the second coating layer, thereby obtaining a third coating layer; and at least partially drying, or at least partially solidifying or at least partially curing the optional third coating layer.2.- Method as in claim 1, characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the first coating layer, formation takes place of one or more of urethane bonds, allophonate bonds, urea bonds, amide groups, isocyanurate groups or oxazolidone in the first coating layer.3.- Method as in any of the preceding claims, characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the first coating layer, a partial UV-curing or a partial electron beam curing is performed on the first coating layer; preferably wherein the first coating composition comprises a photoinitiator.4.- Method as in any of the preceding claims, characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer, formation takes place of one or more of urethane bonds, allophonate bonds,urea bonds, amide groups, isocyanurate groups or oxazolidone in the second coating layer.5.- Method as in any of the preceding claims, characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer, a partial UV-curing or a partial electron beam curing is performed on the second coating layer; preferably wherein the second coating composition comprises a photo-initiator.6.- Method as in any of the preceding claims, characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer, formation takes place of one or more of urethane bonds, allophonate bonds, urea bonds, amide groups, isocyanurate groups or oxazolidone in the third coating layer.7.- Method as in any of the preceding claims, characterized in that in the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer, a partial UV-curing or a partial electron beam curing is performed on the third coating layer; preferably wherein the third coating composition comprises a photoinitiator.8.- Method as in any of the preceding claims, characterized in that the viscosity of the first coating composition is lower than the viscosity of the second coating composition.9.- Method as in any of the preceding claims, characterized in that the first coating composition comprises a wetting agent; and that the second coating composition comprises no wetting agent or that the second coating composition comprises a lower mass percentage of wetting agent than the first coating composition.10.- Method as in any of the preceding claims, characterized in that a glue layer is applied to the substrate before - and preferably in line with - the step of applying the first coating composition on the substrate; preferably wherein the glue layer is apolyurethane glue layer, more preferably a polyurethane layer comprising reactive (meth)acrylate groups.11.- Method as in any of the preceding claims, characterized in that the second coating composition comprises first abrasion resistant particles or in that first abrasion resistant particles are scattered into the first coating layer or into the second coating layer.12.- Method as in any of the preceding claims, characterized in that the third coating composition comprises second abrasion resistant particles; or in that second abrasion resistant particles are scattered into the second coating layer or into the third coating layer.13.- Method as in claims 11 and 12, characterized in that the D50 particle size of the second abrasion resistant particles is at least 10 micrometer smaller than the D50 particle size of the first abrasion resistant particles.14.- Method as in any of the preceding claims, characterized in that the third coating composition differs in composition from the first coating composition.15.- Method as in any of the preceding claims, characterized in that the third coating composition is configured such that when fully cured it has a higher crosslinking density and / or higher hardness than the first coating layer and / or than the second coating layer when fully cured.16.- Method as in any of the preceding claims 1 - 15, characterized in that the second coating composition differs in composition from the first coating composition and / or from the third coating composition.17.- Method as in any of the preceding claims 1 - 15, characterized in that the second coating composition has the same composition as the first coating composition and / or as the third coating composition.18.- Method as in any of the preceding claims, characterized in that the first coating composition comprises a thermo-initiator; preferably wherein the first coating layer comprises at least part of said thermo-initiator after the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer; and - if a third coating composition is applied - after the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer.19.- Method as in any of the preceding claims, characterized in that the second coating composition comprises a thermo-initiator; preferably wherein the second coating layer comprises at least part of said thermo-initiator after the step of at least partially drying, or at least partially solidifying or at least partially curing the second coating layer; and - if a third coating composition is applied - after the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer20.- Method as in any of the preceding claims, characterized in that the third coating composition comprises a thermo-initiator; preferably wherein the third coating layer comprises at least part of said thermo-initiator after the step of at least partially drying, or at least partially solidifying or at least partially curing the third coating layer.21.- Method as in any of the preceding claims, characterized in that only one of the first coating composition, the second coating composition or the third coating composition comprises at least one thermo-initiator; or characterized in that only two of the first coating composition, the second coating composition or the third coating composition comprise at least one thermo-initiator; or characterized in that all three of the first coating composition, the second coating composition and the third coating composition comprise at least one thermo-initiator.22.- Method as in any of the preceding claims, characterized in that the first coating composition comprises a first thermo-initiator, in that the second coating composition comprises a second thermo-initiator, and in that the third coating composition comprises a third thermo-initiator; wherein the dissociation temperature of the third thermo-initiator is higher than the dissociation temperature of the second thermo-initiator and / or than thedissociation temperature of the first thermo-initiator; and / or wherein the dissociation temperature of the second thermo-initiator is higher than the dissociation temperature of the first thermo-initiator.23.- Method as in any of the preceding claims, characterized in that the combination of the first coating layer, the second coating layer and the third coating layer has a dry weight between 50 and 300 gram per square meter.24.- Method as in any of the preceding claims, characterized in that the first coating composition comprises- one or more (meth)acrylate oligomers, preferably wherein said oligomers have a molar mass equal to or higher than 800 g / mol;- one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluent; wherein said reactive diluents have a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol;- optionally at least one photo-initiator;- optionally at least one thermo-initiator, or no thermo-initiator;- optionally at least one isocyanate functional component;- optionally at least one hydroxyl functional component; optionally wherein the one or more (meth)acrylate oligomers comprises at least a urethane (meth)acrylate oligomer.25.- Method as in any of the preceding claims, characterized in that the second coating composition comprises- one or more (meth)acrylate oligomers, preferably wherein said oligomers have a molar mass equal to or higher than 800 g / mol;- one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluent; wherein said reactive diluents have a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol;- optionally at least one photo-initiator;- optionally at least one thermo-initiator, or no thermo-initiator;- optionally at least one isocyanate functional component;- optionally at least one hydroxyl functional component; optionally wherein the one or more (meth)acrylate oligomers comprises at least a urethane (meth)acrylate oligomer.26.- Method as in any of the preceding claims, characterized in that the third coating composition comprises- one or more (meth)acrylate oligomers, preferably wherein said oligomers have a molar mass equal to or higher than 800 g / mol;- one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluent; wherein said reactive diluents have a molar mass lower than 800 g / mol, and preferably lower than 500 g / mol;- optionally at least one photo-initiator;- optionally at least one thermo-initiator, or no thermo-initiator;- optionally at least one isocyanate functional component;- optionally at least one hydroxyl functional component; optionally wherein the one or more (meth)acrylate oligomers comprises at least a urethane (meth)acrylate oligomer.27.- Method as in claim 24 and as in claim 26, characterized in that the first coating composition comprises a higher mass percentage of the combination of one or more (meth)acrylate reactive diluent and / or (meth)acrylamide reactive diluents, having a molar mass lower than 800 g / mol - and preferably lower than 500 g / mol-, than the third coating composition.28.- Method as in any of the preceding claims, characterized in that the third coating composition comprises or consists of a water-based polyurethane resin, whether with or without reactive (meth)acrylate groups; or in that the third coating composition comprises or consists of a water-based (meth)acrylate resin, whether with or without reactive (meth)acrylate groups.29.- Method as in any of the preceding claims, characterized in that the first coating composition comprises a water-based polyurethane dispersion having (meth)acrylatefunctionality, optionally wherein the first coating composition comprises at least one photo-initiator, optionally wherein the first coating composition comprises at least one thermo-initiator.30.- Method as in any of the preceding claims, characterized in that the second coating composition comprises a water-based polyurethane dispersion having (meth)acrylate functionality, optionally wherein the second coating composition comprises at least one photo-initiator, optionally wherein the second coating composition comprises at least one thermo-initiator.31.- Method as in any of the preceding claims, characterized in that the third coating composition comprises a water-based polyurethane dispersion having (meth)acrylate functionality, optionally wherein the third coating composition comprises at least one photo-initiator, optionally wherein the third coating composition comprises at least one thermo-initiator.32.- Method as in any of the preceding claims, characterized in that the substrate comprises or consists of a sheet material, e.g. a whether or not printed sheet of paper; or a whether or not printed thermoplastic film.33.- Method as in any of the preceding claims, characterized in that the substrate comprises a board and a - preferably printed - decor.34.- Method as in claim 33, characterized in that the decor is a printed decor, wherein the printed decor is printed on the board, preferably on a primer layer applied on the board.35.- Method as in claim 33, characterized in that the substrate comprises a sheet of paper providing the - preferably printed - decor, wherein the sheet of paper is laminated onto the board or provided for being laminated onto the board; preferably wherein the sheet of paper is laminated or is provided for being laminated onto the board using anaminoplast resin or using a polyurethane resin or using a polyvinyl acetate resin or using a hotmelt adhesive.36.- Method as in claim 35, characterized in that the sheet of paper is impregnated with a resin - preferably with a partially cured thermoset resin or in that the sheet of paper is not impregnated with resin.37.- Method as in any of the preceding claims 33 - 36, characterized in that the board is selected from a wood-based board (e.g. a wood fiber board, a wood particle board, or a plywood board), a mineral based board (e.g. a Portland cement based board, a magnesium oxide based board or a gypsum based board), or a whether or not filled thermoplastic board (e.g. a polyvinyl chloride based board, a polyester based board, or a polypropylene based board).38.- Method as in any of the preceding claims, characterized in that the method comprises the step of performing a thermal pressing operation on the substrate comprising a combined coating layer, wherein the combined coating layer comprises the first coating layer, the second coating layer and optionally the third coating layer; wherein in the thermal pressing operation a texture is pressed in the combined coating layer and a thermally activated curing of the combined coating layer is performed.39.- Method as in claim 38, characterized in that the step of performing a thermal pressing operation is performed in line with the step of applying the third coating composition on the second coating layer; and preferably also in line with the step of applying the second coating composition on the first coating layer; and preferably also in line with the step of applying the first coating composition on the substrate.40.- Coated substrate, wherein the coated substrate is obtained in a method as in any of the preceding claims 1 - 37, characterized in that the coated substrate comprises a combined coating layer, wherein the combined coating layer comprises the first coatinglayer, the second coating layer and optionally a third coating layer; wherein the first coating layer, the second coating layer - and optionally the third coating layer - are partially cured.41.- Coated substrate as in claim 40, characterized in that the first coating layer and the second coating layer - and optionally also the third coating layer - comprise a thermoinitiator.42.- Method for producing a decorative panel, characterized in that the method comprises the step of providing a coated substrate as in claims 40 or 41; and that the method comprises the step of performing a thermal pressing operation on the coated substrate; wherein in the thermal pressing operation a texture is pressed in the combined coating layer and a thermally activated curing is performed of the combined coating layer.43.- Decorative panel, wherein the decorative panel is obtained in a method according to claims 38 - 39, or according to claim 42.44.- Decorative panel - optionally obtained via a method as in claims 38 - 39 or as in claim 42, characterized in that the decorative panel comprises- a substrate comprising a board and a - preferably printed - decor;- a combined coating layer comprising a first coating layer, a second coating layer and optionally a third coating layer; wherein the combined coating layer comprises a texture; wherein the first coating layer, the second coating layer and - if present - the third coating layer are (meth)acrylate and / or polyurethane coating layers, preferably urethane (meth)acrylate coating layers ; wherein the composition of the second coating layer differs from the composition of the first coating layer; and optionally from the composition of the third coating layer.45.- Decorative panel as in claim 44, characterized in that the second coating layer comprises first abrasion resistant particles.46.- Decorative panel as in any of the preceding claims 44 - 45, characterized in that the third coating later comprises second abrasion resistant particles. 47.- Decorative panel as in claim 45 and as in claim 46, characterized in that the D50 particle size of the second abrasion resistant particles is at least 10 micrometer smaller than the D50 particle size of the first abrasion resistant particles.

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