Abstract
The invention relates to decorative panel and a method for producing such panel. The panel according to the present invention comprises a core layer, and a decorative top layer attached to the upper core surface of said core layer. The panel further comprises at least one chamfer provided at at least one of said side edges, wherein the chamfer extends through at least part of the decorative top layer and/or through at least part of the core layer, and the panel comprises at least one coating layer.
Claims
1. A decorative building panel comprising: at least one core layer, the core layer comprising an upper core surface and a bottom core surface and at least one pair of opposite side edges, at least one decorative top layer attached to the upper core surface of said core layer, the decorative top layer comprising an upper surface, wherein the panel comprises at least one chamfer provided at at least one of said side edges, wherein the chamfer extends through at least part of the decorative top layer and/or through at least part of the core layer, and wherein the panel comprises at least one coating layer which covers at least part of the upper surface of the decorative top layer and at least part of the surface of said chamfer.
2. The decorative building panel according to claim 1, wherein the coating layer is a substantially transparent coating layer.
3. The decorative building panel according to claim 1, wherein the decorative top layer comprises at least one décor layer and at least one transparent wear layer.
4. The decorative building panel according to claim 1, wherein the decorative top layer comprises at least one décor layer and at least one base coating layer.
5. The decorative building panel according to claim 1, wherein the coating forming the coating layer is applied with a weight of at least 1-50 g/m2 per layer, 4-40 g/m2 per layer, or 5-15 g/m2 per layer.
6. The decorative building panel according to claim 1, wherein the viscosity of the coating layer is smaller than 5000 Pa.Math.s at 25 degrees Celsius, between 500 and 3000 Pa.Math.s at 25 degrees Celsius or between 800 and 1500 Pa.Math.s at 25 degrees Celsius, in an uncured condition.
7. The decorative building panel according to claim 1, wherein the angle of at least one chamfer ranges from 2 to 30 degrees, from 4 to 15 degrees, or from 6 to 9 degrees.
8. The decorative building panel according to claim 1, wherein the decorative top layer includes at least one décor layer selected from the group comprising: a PVC decorative film, a PP decorative film, a PET decorative film, a stone veneer and/or a wood veneer.
9. The decorative building panel according to claim 1, wherein the décor layer is formed by a decorative print which is printed directly on the upper core surface of the core layer.
10. The decorative building panel according to claim 1, wherein the decorative top layer includes a tactile texture of at least 0.1 mm depth.
11. The decorative building panel according to claim 1, wherein at least one coating layer is a polyurethane coating, an acrylic coating, and/or an epoxy polyol coating.
12. The decorative building panel according to claim 1, wherein at least one coating layer comprises a thermoset resin and a photoinitiator cross-linked by a UV or electron beam curing process.
13. The decorative building panel according to claim 1, wherein at least one coating layer covers at least 1%, at least 25%, at least 50%, or at least 95% of the surface of the top layer.
14. The decorative building panel according to claim 1, wherein the depth of at least one chamfer is smaller than the thickness of the decorative top layer.
15. The decorative building panel according to claim 1, wherein at least one chamfer fully extends through the decorative top layer.
16. The decorative building panel according to claim 1, wherein the gloss level of the upper surface of the decorative top layer substantially equals the gloss level of the surface of the chamfer.
17. The decorative building panel according to claim 1, wherein the gloss level of at least one coating layer ranges from 3% to 100%, from 40% to 60%, from 3% to 12%, or from 4% to 8%.
18. (canceled)
19. The decorative building panel according to claim 1, wherein at least one chamfer has a substantially linear shape and/or a substantially convex shape.
20. (canceled)
21. The decorative building panel according to claim 1, wherein the core layer comprises at least one mineral material and at least one binder.
22. The decorative building panel according to claim 1, wherein at least one pair of opposite side edges is provided with complementary coupling parts.
23-25. (canceled)
Description
[0037] The invention will be further elucidates based upon the following non-limitative figures. Herein shows:
[0038] FIG. 1 a first possible embodiment of a panel according to the present invention;
[0039] FIG. 2 a second possible embodiment of a panel according to the present invention;
[0040] FIG. 3 a third possible embodiment of a panel according to the present invention;
[0041] FIG. 4 a fourth possible embodiment of a panel according to the present invention;
[0042] FIG. 5 a fifth possible embodiment of a panel according to the present invention;
[0043] FIG. 6 a sixth possible embodiment of a panel according to the present invention; and
[0044] FIG. 7 a seventh possible embodiment of a panel according to the present invention.
[0045] Each figure shows a cross section two adjacent decorative panels which are mutually connected, coupled, attached to or neighbouring another.
[0046] FIG. 1 show a cross section of a first possible embodiment two decorative panels 100 according to the present invention. The figure shows in particular a cross section of the panels 100 which are adjacently positioned thereby forming a (floor, wall or ceiling) covering. Each panel 100 comprises a core layer 101, which core layer 101 comprising an upper core surface 101a and a bottom core surface 101b and at least one pair of opposite side edges 101c, 101d. The panels 100 are provided with interlocking coupling means to provide easy coupling between adjacent panels 100. The panels 100 further comprise a decorative top layer 102 disposed on the upper core surface 101a of said core layer 101. Each panel 100 further comprises a chamfer 103 provided a side edge 101c, 101d. In the shown embodiment, the chamfers 103 extend through part of the decorative top layer 102. The core layer 101 is in the shown embodiment not provided with part of the chamfer 103. The panel 100 also comprises a coating layer 104 which covers at least part of the upper surface 102a of the decorative top layer 102 and at least part of the surface of said chamfer 103. The decorative top layer 103 comprises a plurality of layers. In particular, the decorative top layer 103 comprises a décor layer 105, a transparent wear layer 106 and a base coating layer 107. In the shown embodiment, the chamfers 103 extends though both the base coating layer 107 and the transparent wear layer 106.
[0047] FIG. 2 shows a second possible embodiment of panels 200 according to the present invention. Each panel 200 comprises a core layer 201, which core layer 201 comprises an upper core surface 201a and a bottom core surface 201b and at least one pair of opposite side edges 201c, 201d. Each panel 200 also comprises a decorative top layer 202 attached to the upper core surface 201a of the core layer 201, the decorative top layer comprising an upper surface 202a. Each panel 200 comprises a chamfer 203 provided at at least one of said side edges 201c, 201d, wherein the chamfer 203 extends through part of the decorative top layer 202. The panels 200 further comprise a plurality of coating layers 204a, 204b wherein each layer 204a, 204b covers at least part of the upper surface 202a of the decorative top layer 202 and at least part of the surface of the chamfer 203. The decorative top layer 203 comprises a plurality of layers. In particular, the decorative top layer 203 comprises a décor layer 205, a first transparent wear layer 206, a second transparent wear layer 208, a base coating layer 207, and a further base coating layer 209. The panels 200 are connected via a tongue and groove coupling system. In the shown embodiment, the chamfers 203 extends though the base coating layers 207, 209 and the transparent wear layers 206, 208.
[0048] FIG. 3 shows a third possible embodiment of panels 300 according to the present invention. Each panel 300 comprises a core layer 301, which core layer 301 comprises an upper core surface 301a and a bottom core surface 301b and at least one pair of opposite side edges 301c, 301d. Each panel 300 also comprises a decorative top layer 302 attached to the upper core surface 301a of the core layer 301, the decorative top layer comprising an upper surface 302a. Each panel 300 comprises a chamfer 303 provided at at least one of said side edges 301c, 301d, wherein the chamfer 303 extends through part of the decorative top layer 302.
[0049] The panels 300 further comprise a plurality of coating layers 304a, 304b wherein each layer 304a, 304b covers at least part of the upper surface 302a of the decorative top layer 302 and at least part of the surface of the chamfer 303. The decorative top layer 302 substantially equals the decorative top layer as shown in FIG. 2. The decorative top layer 302 comprises a plurality of layers. In particular, the decorative top layer 302 comprises a décor layer 305, a first transparent wear layer 306, a second transparent wear layer 308, a base coating layer 307, and a further base coating layer 309. The panels 300 of the shown embodiment are not provided with interconnecting coupling means. The panel further comprises a backing layer 310 which is attached to the bottom core surface 301b of the core layer 301. In the shown embodiment, the chamfers 303 extends though the base coating layers 307, 309 and the transparent wear layers 306, 308. The shown embodiment differs from the embodiment of FIG. 2 in that the thickness of the coating layers 304a, 304b is different at the surface of the chamfer. This may result in a different gloss level. Another difference can be found in the angle of the chamfers when comparing the embodiments. FIG. 4 shows a fourth possible embodiment of panels 400 according to the present invention. Each panel 400 comprises a core layer 401 and a decorative top layer 402. The decorative top layer 402 substantially equals the decorative top layer as shown in FIGS. 2 and 3. The decorative top layer 402 comprises a plurality of layers. In particular, the decorative top layer 402 comprises a décor layer 405, a first transparent wear layer 406, a second transparent wear layer 408, a base coating layer 407, and a further base coating layer 409. Each panel 400 comprises a chamfer 403 provided at at least one of the side edges 401c, 401d, wherein the chamfer 403 extends through the decorative top layer 402 and through part of the core layer 401. It can be seen that the depth D of the chamfer 403 is larger than the thickness T of the decorative top layer 402. The panels 400 are provided with interlocking coupling means to provide easy coupling between adjacent panels 400.
[0050] FIG. 5 shows a fifth possible embodiment of panels 500 according to the present invention. Each panel 500 comprises a core layer 501 and is provided with interlocking coupling means to provide easy coupling between adjacent panels 500. The panels 500 further comprise a decorative top layer 502 disposed on the upper core surface 501a of said core layer 501. Each panel 500 further comprises a chamfer 503 provided a side edge 501c, 501d. In the shown embodiment, the chamfers 503 extend through part of the decorative top layer 502. The core layer 501 is in the shown embodiment not provided with part of the chamfer 503. Each panel 500 also comprises a coating layer 504 which covers at least part of the upper surface 502a of the decorative top layer 502 and at least part of the surface of said chamfer 503. The decorative top layer 502 comprises a plurality of layers. In particular, the decorative top layer 502 comprises a décor layer 505, a transparent wear layer 506 and a base coating layer 507. In the shown embodiment, the chamfers 503 extends though both the base coating layer 507 and the transparent wear layer 506. In the embodiments of FIGS. 1-4, the chamfers 103, 203, 303, 403 have a substantially linear shape, defining a V-shape in an interconnected state. In the shown embodiment, the chamfers 503 have a substantially convex shape. It can be seen that the chamfers 503 of the two adjacent panels 500 define a substantially U-shaped cut-out portion.
[0051] FIG. 6 shows a sixth possible embodiment of panels 600 according to the present invention. Each panel 600 comprises a core layer 601 and a decorative top layer 602. The panels 600 are not provided with any coupling means. Each panel 600 further comprises a chamfer 603. In the shown embodiment, the chamfers 603 extend through part of the decorative top layer 602 and through the core layer 601. Each panel 600 also comprises a first coating layer 604a, and a second coating layer 604b which covers at least part of the upper surface of the decorative top layer 602 and at least part of the surface of said chamfer 603. The decorative top layer 602 comprises a plurality of layers. In particular, the decorative top layer 602 comprises a décor layer 605 and a transparent wear layer 606. In the shown embodiment, the chamfers 603 of the panels 600 have a substantially convex shape, such that the two adjacent panels 600 define a substantially U-shaped cut-out portion.
[0052] FIG. 7 shows a seventh possible embodiment of panels 700 according to the present invention. Each panel 700 comprises a core layer 701 and a decorative top layer 702. The panels 700 of the shown embodiment are not provided with any coupling means. Each panel 700 further comprises a chamfer 703. In the shown embodiment, the chamfers 703 extend through part of the decorative top layer 702. Each panel 700 also comprises a first coating layer 704a, and a second coating layer 704b which covers at least part of the upper surface of the decorative top layer 702 and at least part of the surface of said chamfer 703. The decorative top layer 702 comprises a plurality of layers. In particular, the decorative top layer 702 comprises a décor layer 705 and a base coating layer 707. In the shown embodiment, the chamfers 703 of the panels 700 extent up to the décor layer 705, such that the décor of the décor layer 705 is directly visible through the (transparent) coating layers 704a, 704b.
[0053] The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.
[0054] The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof. When it is referred to reinforcing layer also a reinforcing element can be meant, or vice versa.
