Decorative panel

Abstract

The present invention relates to a decorative panel, comprising a core layer provided with a decor layer, the décor layer comprising a substrate layer provided with at least one coating, wherein within the decorative panel at least one light source is located. The present invention furthermore relates to the use of such a decorative panel in furniture, in exterior walls and facades and in interior decoration.

Claims

1. A decorative panel, comprising a core layer provided with a decor layer, said décor layer comprising a substrate layer provided with at least one coating, wherein within said decorative panel at least one light source is located, said décor layer being transparent to light emitted by said at least one light source; wherein said decorative panel further comprises at least one intermediate layer positioned adjacent to said at least one light source; and wherein said at least one intermediate layer comprises a resin impregnated paper having an inhomogeneous resin distribution, wherein a resin concentration in said resin impregnated paper at an area corresponding to the position of said at least one light source is higher than another area of said resin impregnated paper.

2. The decorative panel according to claim 1, wherein said at least one light source is a Light Emitting Diode (LED) chosen from the group of organic and inorganic LEDs.

3. The decorative panel according to claim 1, wherein said at least one light source is located within the core layer.

4. The decorative panel according to claim 1, wherein said at least one light source is cast into a protective matrix, said protective matrix being transparent to light emitted by said at least one light source.

5. The decorative panel according to claim 1, wherein said decorative panel further comprises at least one power source connected to said at least one light source.

6. The decorative panel according to claim 1, wherein said decorative panel comprises at least two light sources, said at least two light sources being connected in series or in parallel by wires connectable to at least one power source.

7. The decorative panel according to claim 6, wherein said at least one power source is not incorporated in said decorative panel.

8. The decorative panel according to claim 1, wherein said at least one intermediate layer is positioned between said at least one light source and said décor layer, said at least one intermediate layer being transparent to light emitted by said at least one light source.

9. The decorative panel according to claim 1, wherein said at least one intermediate layer comprises thermally conductive materials.

10. The decorative panel according to claim 1, wherein said at least one intermediate layer comprises a resin impregnated kraft paper, wherein the resin is selected from the group consisting of phenol resin, melamine resin, urea resin, epoxy resin, polyester resin, polyisocyanate resin, melamine acrylate, polyurethane acrylate and combinations thereof.

11. The decorative panel according to claim 1, wherein said core layer is chosen from the group of resin impregnated papers, prepregs, non-wovens and wovens of wood fibres, glass fibres, textile fibres, synthetic fibres, metallic fibres, ceramic fibres and carbon fibres, or a mixture thereof, wherein said core layer comprises a thermo pressed stack of resin impregnated papers.

12. The decorative panel according to claim 11, wherein said at least one light source is located in said thermo pressed stack of resin impregnated papers.

13. The decorative panel according to claim 11, wherein said stack of resin impregnated papers is provided with one or more recesses in which said at least one light source is disposed.

14. The decorative panel according to claim 13, wherein said one or more recesses provided with said at least one light source are covered with at least one thermo pressed resin impregnated paper transparent to light emitted by said at least one light source.

15. The decorative panel according to claim 13, wherein said one or more recesses are provided with light reflecting means.

16. The decorative panel according to claim 1, wherein said core comprises at least one thermo formable sheet.

17. The decorative panel according to claim 16, wherein said core further comprises a stack of resin impregnated papers, wherein said at least one thermo formable sheet is positioned between said décor layer and said stack of resin impregnated papers.

18. The decorative panel according to claim 17, wherein a thermo curable layer of resin impregnated paper is positioned between said décor layer and said thermo formable sheet.

19. The decorative panel according to claim 16, wherein said at least one thermo formable sheet is provided with one or more recesses in which said at least one light source is placed.

20. The decorative panel according to claim 1, wherein said core layer further comprises at least one prepreg.

21. The decorative panel according to claim 20, wherein said at least one prepreg is provided with one or more recesses in which said at least one light source is placed.

22. The decorative panel according to claim 1, wherein said substrate layer of said décor layer is chosen from the group of resin impregnated papers, non-wovens and wovens of any one or more of wood fibres, glass fibres, textile fibres, synthetic fibres, metallic fibres, ceramic fibres and carbon fibres, foils of any one or more of polymers, metals and ceramics, or a combination of anyone of these, wherein the structure of said substrate layer is such that said décor layer including said substrate layer is transparent to light emitted by said at least one light source.

23. The decorative panel according to claim 1, wherein said at least one light source is provided as a rigid light source or a flexible light source, or a combination thereof, said flexible light source chosen from the group consisting of a light source deposited on a flexible carrier made of paper, plastic foil, metal, ceramic, glass or textile.

24. The decorative panel according to claim 1, wherein said at least one light source cannot be removed without destructing said decorative panel.

25. The decorative panel according to claim 1, wherein said at least one light source is invisible as viewed from outside of the décor layer.

26. The decorative panel according to claim 1 used in at least one of indoor furniture, outdoor furniture, table tops, laboratory tables, kitchen countertops, dining tables, nightstands, picnic tables, hot plates, countertops, indoor decorations, outdoor decorations, interior walls, exterior walls, ceilings, and facades.

27. A decorative panel, comprising: a core layer provided with a décor layer, said décor layer comprising a substrate layer provided with at least one coating, wherein within said decorative panel at least one light source is located, said décor layer being transparent to light emitted by said at least one light source; wherein said core layer comprises a thermo pressed stack of resin impregnated papers; and wherein said at least one light source is located in said thermo pressed stack of resin impregnated papers.

28. A decorative panel, comprising a core layer provided with a décor layer, said décor layer comprising a substrate layer provided with at least one coating, wherein within said decorative panel at least one light source is located, said décor layer being transparent to light emitted by said at least one light source; wherein said core layer comprises a thermo pressed stack of resin impregnated papers; and wherein said thermo pressed stack of resin impregnated papers is provided with one or more recesses in which said at least one light source is disposed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages of the invention will become apparent by reference to the detailed description of preferred embodiments. Although the figures shown here only mention one light source the present invention is not restricted to a specific number of light sources. On basis of legibility and clarity all electrical (internal and external) connections and power sources have been omitted in the figures.

(2) FIG. 1A shows a decorative panel according to the present invention.

(3) FIG. 1B shows another embodiment of a decorative panel according to the present invention.

(4) FIG. 1C shows another embodiment of a decorative panel according to the present invention.

(5) FIG. 1D shows another embodiment of a decorative panel according to the present invention.

(6) FIG. 1E shows another embodiment of a decorative panel according to the present invention.

(7) FIG. 2A shows a decorative panel according to the present invention.

(8) FIG. 2B shows a decorative panel according to the present invention.

(9) FIG. 2C shows a decorative panel according to the present invention.

(10) FIG. 2D shows another embodiment of a decorative panel according to the present invention.

(11) FIG. 2E shows another embodiment of a decorative panel according to the present invention.

(12) FIG. 2F shows another embodiment of a decorative panel according to the present invention.

(13) FIG. 2G shows another embodiment of a decorative panel according to the present invention.

(14) FIG. 2H shows another embodiment of a decorative panel according to the present invention.

(15) FIG. 2I shows another embodiment of a decorative panel according to the present invention.

(16) FIG. 2J shows another embodiment of a decorative panel according to the present invention.

(17) FIG. 2K shows another embodiment of a decorative panel according to the present invention.

(18) FIGS. 3A-3E show different stages of a thermoforming process according to the present invention.

DETAILED DESCRIPTION

(19) In the Figures the same reference numbers are used for the same components.

(20) FIG. 1A shows a panel 10 comprising a décor layer 1, an intermediate layer 6, a light source 2 and a core layer 3, wherein the light source 2 is positioned between core layer 3 and intermediate layer 6.

(21) FIG. 1B shows a panel 20 comprising a décor layer 1, intermediate layer 6, a light source 2 and a core layer 3. Light source 2 is positioned in core layer 3. Intermediate layer 6 is positioned between core layer provided with light source 2 and décor layer 1.

(22) FIG. 1C shows a panel 30 comprising a décor layer 1, a light source 2 and a core layer 3, wherein the light source 2 is positioned in recess 5 provided in core layer 3. The presence of such a recess will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(23) FIG. 1D shows a panel 40 comprising a décor layer 1, an intermediate layer 6, a light source 2 and a core layer 3, wherein the light source 2 is positioned in recess 5 provided in core layer 3. The intermediate layer 6 is positioned between décor layer 1 and light source 2. The presence of such a recess will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer. And the presence of the intermediate layer 6 will further help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(24) FIG. 1E shows a panel 50 comprising a décor layer 1, intermediate layer 6, a light source 2 and a core layer 3. Light source 2 is positioned in recess 5 provided in core layer 3. Intermediate layer 6 is positioned between décor layer 1 and light source 2. The presence of such a recess will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer. And the presence of the intermediate layer 6 will further help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(25) In the embodiments shown here the resin concentration of the intermediate layer(s) at an area corresponding to the position of the light source may be higher than another area of the intermediate layer(s). In the embodiments shown here the resin composition of the intermediate layer(s) may be chemically different from the resin composition of the core layer. In the embodiments shown here the intermediate layer(s) may comprise heat conductivity enhancing materials. The presence of intermediate layer will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer. In addition, the presence of intermediate layer will have a positive influence on the mechanical properties of the final decorative panel. Although intermediate layer is depicted here as a single layer, such an intermediate layer may comprise one or more sub layers. In addition, core layer is depicted here as a number of layers, but core layer may comprise one single layer, for example a prepreg, or a combination of layers, for example several prepregs, or individual layers and one or more prepregs.

(26) FIG. 2A shows a panel 60 comprising a décor layer 1, a light source 2 and a core layer, comprising a thermoformable sheet or prepreg 4. Light source 2 is positioned between the core layer and décor layer. During the pressing step for manufacturing the panel the light source 2 will be somewhat pressed into the thermoformable sheet or prepreg 4. The panel thus obtained may experience some relief at the outer surface thereof, i.e. at the décor layer.

(27) FIG. 2B shows a panel 70 comprising a décor layer 1, a light source 2 and a core layer, comprising a thermoformable sheet or prepreg 4 and a number of resin impregnated paper layers 3. Light source 2 is positioned between the core layer and décor layer. A disadvantage of such a construction is the lack of flatness of the panel. During the pressing step for manufacturing the panel the light source 2 will be somewhat pressed into the thermoformable sheet or prepreg 4. The panel thus obtained may experience some relief at the outer surface thereof, i.e. at the décor layer.

(28) FIG. 2C shows a panel 80 comprising a décor layer 1, a light source 2, an intermediate layer 6 and a core layer 3, comprising a thermoformable sheet or prepreg 4 and a number of resin impregnated paper layers 3. The intermediate layer 6 is positioned between core layer and décor layer. During the pressing step for manufacturing the panel the light source 2 will be somewhat pressed into the thermoformable sheet or prepreg 4. The presence of the intermediate layer 6 will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(29) FIG. 2D shows a panel 90 comprising a décor layer 1, a light source 2 and a core layer, comprising of a thermoformable sheet 4 or prepreg 4 and a number of resin impregnated paper layers 3. Light source 2 is positioned in the core layer, namely between thermoformable sheet or prepreg 4 and a number of resin impregnated paper layers 3. During the pressing step for manufacturing the panel the light source 2 will be somewhat pressed into the thermoformable sheet or prepreg 4.

(30) FIG. 2E shows a panel 100 comprising a décor layer 1, a light source 2, an intermediate layer 6 and a core layer, comprising of a thermoformable sheet 4 or prepreg 4 and a number of resin impregnated paper layers 3. Light source 2 is positioned in the core layer, namely between thermoformable sheet or prepreg 4 and a number of resin impregnated paper layers 3. During the pressing step for manufacturing the panel the light source 2 will be somewhat pressed into the thermoformable sheet or prepreg 4. The presence of the intermediate layer 6 will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(31) FIG. 2F shows a panel 110 comprising a décor layer 1, a core layer comprising a thermoformable sheet 4 or prepreg 4 provided with a recess 5. In recess 5 a light source 2 is positioned. The presence of such a recess will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(32) FIG. 2G shows a panel 120 comprising a décor layer 1, a core layer comprising a thermoformable sheet 4 or prepreg 4 provided with a recess 5. In recess 5 a light source 2 is positioned. Panel 120 is further provided with a number of resin impregnated papers 3. The presence of such a recess will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(33) FIG. 2H shows a panel 130 comprising a décor layer 1, an intermediate layer 6, a core layer comprising a thermoformable sheet 4 or prepreg 4 and a number of resin impregnated papers 3. Thermoformable sheet 4 or prepreg 4 is provided with a recess 5, in which recess 5 a light source 2 is positioned. Recess 5 is located at the upper surface of thermoformable sheet 4 or prepreg 4. The presence of the intermediate layer 6 will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(34) FIG. 2I shows a panel 140 comprising a décor layer 1, a core layer comprising a thermoformable sheet 4 or prepreg 4 and resin impregnated paper 3. Thermoformable sheet 4 or prepreg 4 is provided with a recess 5 at its bottom surface, in which recess 5 a light source 2 is positioned.

(35) FIG. 2J shows a panel 150 comprising a décor layer 1, a core layer comprising a thermoformable sheet 4 or prepreg 4 and resin impregnated paper 3 provided with a recess 5. Thermoformable sheet 4 or prepreg 4 is provided with a recess 5 at its bottom surface, in which recess 5 a light source 2 is positioned.

(36) FIG. 2K shows a panel 160 comprising a décor layer 1, an intermediate layer 6, a core layer comprising a thermoformable sheet 4 or prepreg 4 and a number of resin impregnated papers 3. Thermoformable sheet 4 or prepreg 4 is provided with a recess 5, in which recess 5 a light source 2 is positioned. Recess 5 is located at the bottom surface of thermoformable sheet 4 or prepreg 4. The presence of the intermediate layer 6 will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer.

(37) In the embodiments shown the resin concentration of the intermediate layer(s) at an area corresponding to the position of the light source may be higher than another area of the intermediate layer(s). In the embodiments shown the resin composition of the intermediate layer(s) may be chemically different from the resin composition of the core layer. In the embodiments shown the intermediate layer(s) may comprise heat conductivity enhancing materials. The presence of intermediate layer will help to prevent the occurrence of relief at the outer surface thereof, i.e. at the décor layer. In addition, the presence of intermediate layer will have a positive influence on the mechanical properties of the final decorative panel.

(38) FIGS. 3A-E show different stages of a thermoforming process according to the present invention, wherein in step 3A a hot press 200 with structure 210 is brought into contact with a thermoformable sheet 4 or prepreg 4. In step 3B the structure 210 creates a thermo deformation in thermoformable sheet 4 or prepreg 4. In step 3C the contact between hot press 200 and thermoformable sheet 4 or prepreg 4 is interrupted resulting in the formation of a recess 5 in thermoformable sheet 4 or prepreg 4. In step 3D a light source 2 is positioned in recess 5, resulting in a thermoformable sheet 4 or prepreg 4 provided with a light source 2.

Example 1

(39) A prepreg manufactured according to U.S. Pat. No. 6,387,489 was provided with a recess. A LED strip was placed in the recess and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 160° C. and 20 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The LED lights functioned well and its colour was changed on demand.

Example 2

(40) A prepreg manufactured according to U.S. Pat. No. 6,387,489 was provided with a recess. A LED strip was placed in the recess and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 130° C. and 20 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The monochromic LED lights functioned well and emitted light on demand.

Example 3

(41) A prepreg manufactured according to U.S. Pat. No. 6,387,489 was provided with a recess. A LED strip was placed in the recess and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 160° C. and 70 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The monochromic LED lights functioned well and emitted light on demand.

Example 4

(42) A prepreg manufactured according to U.S. Pat. No. 6,387,489 was provided with a recess. A LED strip was placed in the recess and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 130° C. and 70 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The monochromic LED lights functioned well and emitted light on demand.

Example 5

(43) A stack of resin impregnated papers was provided and the outer most layers were cut such that a recess was obtained. A LED strip was placed in the recess of resin impregnated papers, and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 160° C. and 20 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The LED lights functioned well and its colour was changed on demand.

Example 6

(44) A stack of resin impregnated papers was provided and the outer most layers were cut such that a recess was obtained. A LED strip was placed in the recess of resin impregnated papers, and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 160° C. and 70 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The LED lights functioned well and its colour was changed on demand.

Example 7

(45) A stack of resin impregnated papers was provided and the outer most layers were cut such that a recess was obtained. A LED strip was placed in the recess of resin impregnated papers, and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 130° C. and 20 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The LED lights functioned well and its colour was changed on demand.

Example 8

(46) A stack of resin impregnated papers was provided and the outer most layers were cut such that a recess was obtained. A LED strip was placed in the recess of resin impregnated papers, and a décor layer was positioned on top of the recess as the outer surface. The composite thus obtained was pressed at 130° C. and 70 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The LED lights functioned well and its colour was changed on demand.

Example 9

(47) A prepreg manufactured according to U.S. Pat. No. 6,387,489 was provided with a recess. A LED strip was placed in the recess and a thermo formable sheet was positioned directly on top of the recess. The thermo formable sheet thus positioned was covered with a décor layer as the outer surface. The composite thus obtained was pressed at 160° C. and 20 bars until curing of the thermoset resin was achieved. The LED strip was connected with a cable to a transformer. The LED lights functioned well and its colour was changed on demand. The specific position of the thermo formable sheet equalized the surface, and acted as light guide for the LED light. The light from the LED shines through the décor and is transported to the side edges of the panel. The effect is a decorative panel with glowing edges.