Abstract
Floor panel with a substrate (8) and a provided thereon decorative layer (6) of wood veneer (7) with a thickness (T1) of 1 millimeter or less, wherein a lacquer layer (23) including transparent or translucent surface material is provided on the wood veneer (7), wherein the lacquer layer (23) preferably comprises hard particles and extends from the upper surface of the wood veneer (7) at least up to a side edge (28) of the wood veneer (7), such that the side edge (28) is at least partially covered by the lacquer (23).
Claims
1. A floor panel with a substrate and a provided thereon decorative layer of wood veneer with a thickness of 1 millimeter or less, wherein a lacquer layer, comprising transparent or translucent surface material, is provided on the wood veneer, wherein the lacquer layer comprises hard particles and extends from an upper surface of the wood veneer at least up to a side edge of the wood veneer, such that the side edge is at least partially covered by the lacquer layer.
2. The floor panel of claim 1, wherein the lacquer layer comprises at least two sublayers, wherein at least an uppermost sublayer of the at least two sublayers at least partially covers the side edge.
3. The floor panel of claim 2, wherein the uppermost sublayer comprises the hard particles, while another sublayer of the two sublayers is free from hard particles.
4. The floor panel of claim 2, wherein the hard particles comprise first hard particles in the uppermost sublayer, and second hard particles in another of the two sublayers.
5. The floor panel of claim 4, wherein the second hard particles have an average particle size that is larger than an average particle size of the first hard particles, wherein the average particle size of the second hard particles is at least 2 times larger than the average particle size or the first hard particles.
6. The floor panel of claim 4, wherein the first hard particles have an average particle size of 30 micron or below, or of 15 micron or below, and wherein the second hard particles have an average particle size of 120 micron or below, or of 85 micron or below, or above 30 micron.
7. The floor panel of claim 1, wherein the decorative layer is provided on the substrate by a glue layer which is between the substrate and the decorative layer, wherein the glue layer comprises third hard particles.
8. The floor panel of claim 7, wherein the third hard particles have an average particle size that is larger than an average particle size of the first hard particles, wherein the average particle size of the third hard particles is at least 3 times larger than the average particle size or the first hard particles.
9. The floor panel of claim 7, wherein the third hard particles have an average particle size which is at least one third of the thickness of the wood veneer, or less than two thirds of the thickness of the wood veneer.
10. The floor panel of claim 7, wherein the third hard particles have an average particle size above 120 micron, or above 180 micron.
11. The floor panel of claim 7, wherein the third particles have an average particle size above 200 micron.
12. (canceled)
13. The floor panel of claim 7, wherein the wood veneer is at least partially impregnated by the thermosetting resin.
14. The floor panel of claim 7, wherein the third hard particles at an underside of the decorative layer penetrate into the wood veneer.
15. (canceled)
16. The floor panel of claim 7, wherein the third hard particles comprise particles penetrating into the wood veneer at an underside over a distance of at least 20% of the thickness of the wood veneer.
17. The floor panel of claim 16, wherein the third hard particles penetrate for 30% by weight or more of the third hard particles at the underside into the wood veneer over a distance of at least 20% of the thickness of the wood veneer.
18. The floor panel of claim 1, wherein the substrate is a wood fiberboard, or an HDF wood fiberboard.
19. The floor panel of claim 1, wherein the wood veneer has a thickness between 0.3 and 1 millimeter, or between 0.45 and 0.7 millimeters, or approximately 0.6 millimeters.
20. (canceled)
21. The floor panel of claim 1, wherein the substrate, at the surface where the decorative layer is situated, has a density of more than 900 kilograms per cubic meter.
22. (canceled)
23. A method for manufacturing floor panels, wherein the floor panels comprise at least a substrate and a provided thereon decorative layer of wood veneer, wherein the method comprises: providing a basic board; composing a stack which comprises at least the basic board, a glue layer, third hard particles and one or more wood veneers; pressing the stack, wherein the veneers are adhered to the basic board; and wherein the third hard particles have an average particle size which is at least one third of the thickness of the wood veneer, and wherein the third hard particles are provided by scattering the particles in or on the glue layer.
24. A method for manufacturing floor panels, wherein the floor panels comprise at least a substrate and a provided thereon decorative layer of wood veneer, wherein the method comprises: providing a basic board; composing a stack which comprises at least the basic board, a glue layer and one or more wood veneers; pressing the stack, wherein the wood veneers are adhered to the basic board; dividing the pressed stack into a plurality of panels, and potentially profiling edges of panels obtained, wherein the veneers are cross cut; and wherein, subsequent to dividing and potentially subsequent to profiling, a lacquer layer, comprising transparent or translucent surface material, is provided on the wood veneer, wherein the lacquer layer comprises first hard particles, and extends from an upper surface of the wood veneer at least up to a side edge of the wood veneer.
25. (canceled)
26. The method of claim 18, wherein the method is applied for manufacturing a floor panel of claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0083] With the intention of better showing the characteristics of the invention, herein below, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:
[0084] FIG. 1 in perspective represents a floor panel with the characteristics of the invention;
[0085] FIGS. 2 and 3, at a larger scale, represent a cross-section according to the lines II-II and III-Ill, respectively, represented in FIG. 1;
[0086] FIG. 4, in a view similar to that of FIG. 2, represents a variant;
[0087] FIG. 5, at a larger scale, represents the floor panel of FIG. 4 in coupled condition;
[0088] FIG. 6, at a larger scale, shows a view onto the region indicated by F6 in FIG. 2;
[0089] FIG. 7, in a view similar to that of FIG. 6, represents a variant;
[0090] FIGS. 8 and 9 illustrate a step in a method with the characteristics of the invention;
[0091] FIG. 10 represents a variant in a view onto the region indicated by F10 in FIG. 8; and
[0092] FIG. 11 on a larger scale represents another variant of a floor panel in a view similar in accordance with the are indicated as F11 on FIG. 7.
DETAILED DESCRIPTION OF THE DRAWINGS
[0093] FIG. 1 represents a decorative panel, more particularly a floor panel 1, in accordance with the invention. The panel 1 is rectangular and oblong and comprises a pair of opposite short edges 2-3 and a pair of opposite long edges 4-5. The decorative top layer 6 is formed by a wood veneer 7 with a thickness of 1 millimeter or less, in this case the veneer has a thickness T1 of approximately 0.6 millimeters.
[0094] FIG. 2 clearly shows that the decorative panel 1 comprises a substrate material 8 on which the wood veneer 7 is provided by a layer on the basis of thermosetting resin 9, situated between the substrate and the decorative layer. In the example, the substrate 8 has an average density of more than 750 kilograms per cubic meter. In this case, this relates to an HDF board material with an average density of 900 kilograms per square meter and a surface density of more than 1000 kilograms per square meter. At the edges 2-3 and 4-5, mechanical coupling structure(s) 10 are formed in the substrate material by milling cutters. At the underside of the substrate material 8, a backing layer 11 is provided, for example, glued or otherwise attached to the substrate material 8. According to a preferred embodiment of the invention, such backing layer 11 is also attached to the substrate material 8 by a layer of thermosetting resin. Such backing layer 11 preferably is made of a wooden veneer layer with a thickness T2 of at least 50 percent of the decorative top layer. Still better, the decorative top layer of the wood veneer 7 and the backing layer 11 differ from each other at least in that the wood veneer of the backing layer 11 is thicker than the wood veneer 7 of the top layer. The backing layer 11 may consist, for example, of a rotary peeled veneer with a thickness T2 of 1.5 millimeters or thicker, whereas the wood veneer 7 of the top layer is a veneer with a thickness T1 of less than 1 millimeter.
[0095] FIGS. 2 and 3 represent that both pairs of opposite edges 2-3-4-5 are provided with mechanical coupling structure(s) 10 which substantially are realized as a tongue 12 and a groove 13 bordered by an upper lip 14 and a lower lip 15, wherein the tongue 12 and the groove 12 substantially are responsible for the locking in a vertical direction V, and wherein the tongue 12 and the groove 13 are provided with additional locking parts 16-17, which substantially are responsible for the locking in a horizontal direction H. Preferably, the locking parts comprise a protrusion 16 at the underside of the tongue 12 and a recess 17 in the lower groove lip 15. The coupling structure(s) represented in FIGS. 2 and 3 allow at least a coupling by an angling or rotational movement W around the respective edges 2-3-4-5 and/or a coupling by a shifting movement S in a substantially horizontal manner of the edges 2-3-4-5 to be coupled towards each other.
[0096] FIGS. 4 and 5 represent a variant with a pair of short edges 2-3, which allow obtaining a coupling at least by a downward movement D. An edge 2 is provided with a male coupling part 18, whereas the other edge 3 is provided with a female coupling part 19. By the downward movement D the male coupling part 18 is pressed into the female coupling part 19 in order to be locked there in the vertical direction V, as a result of a pair of cooperating protrusions 20 and recesses 21. In this case, the recess 21 is partially formed by a resilient element 22 present in the female coupling part 19.
[0097] FIG. 6 represents a detail of the upper edge of the floor panel from FIG. 2. It is shown clearly that the layer of thermosetting resin 9 can penetrate partially into the substrate material 8 and partially into the wood veneer 7 of the top layer.
[0098] FIG. 6 further clearly shows that the decorative layer 6 at the surface comprises a lacquer layer 23 of a transparent or translucent surface material. In this case, this relates to a material with a matte structure, namely with a gloss degree of 10 or less, as measured according to DIN 67530.
[0099] The floor panel from the FIGS. 1 to 6 is provided with lower edge regions 24 on one or more edges 2-3-4-5, wherein the wood veneer 7 extends in one piece from on the surface 25 of the substrate 8 over these lower edge regions 24. In the example, the lower edge regions 24 are realized as bevel or chamfer. The wood veneer 7 extends over the lower edge region 24 at least up to a point 26, wherein the veneer surface is situated at a level L in a horizontal plane which intersects the aforementioned substrate 8. At the location of the lower edge regions 24, the wood veneer 7, seen on average, has a thickness TB which is smaller than the global thickness T1 of the wood veneer 7. At these edges, the wood veneer 7 is compressed or impressed. In the present case, also the substrate material 8 is impressed at the location of these edges. This compression of the wood veneer 7 leads to an increased resistance against moisture penetration. Preferably, the average thickness TB of the wood veneer on the lower edge regions is less than 85% of the global thickness T1 of the wood veneer. Instead of working with a compressed wood veneer 7, in accordance with a not represented embodiment, a lower edge region may be created by removing an amount of material from the veneer 7 at the respective edge. Such is preferably executed before application of the lacquer 23.
[0100] FIG. 7 represents a variant of the floor panel of the FIGS. 1 to 6, where such lowered edge regions are absent, or where, in other words, the wood veneer 7 extends to one or more or all of the edges 2-3-4-5 of the floor panel 1 in a substantially horizontal manner.
[0101] In the examples, the thermosetting resin 9 extends uninterruptedly underneath the entire wood veneer 7, inclusively the lower edge regions 24.
[0102] The surface material 23 follows the relief of the wood veneer 7 at least over the lowered edges 24 or chamfers.
[0103] FIG. 6 schematically represents that the thermosetting resin 9 or the glue layer comprises third hard particles 27. In this example, the third hard particles 17 show an average particle size which is at least one third of the thickness T1 of the wood veneer 7. These particles penetrate at the underside into the wood veneer 7 and there provide for a barrier against the final wearing through of the veneer 7. Due to the choice of the average particle size, the particles 27 penetrate from on the underside into the veneer 7 over a distance which is larger than the distance D, wherein the distance D is 20% of the thickness T1 of the wood veneer 7.
[0104] In accordance with the first aspect of the invention, also in the surface material of the lacquer 23 there are wear-resistant particles, however, with a smaller average particle size, for example, of 10 micrometers or smaller.
[0105] FIGS. 6 and 7 represent that, in accordance with the first aspect of the invention, the lacquer 23 at least partially covers a side edge 28 of the wood veneer 7. In this case it concerns the side edge 28 of the wood veneer 7 formed at a short edge 3 of the panel 1. The wood veneer 7, as illustrated on FIG. 1, has been cross cut, and may have open wood vessels, which are sealed by the lacquer 23.
[0106] FIG. 9 represents a pressing step in a method for manufacturing, e.g. the panels of FIGS. 1 to 6. A stack 29, comprising the wood veneer 7 and a basic board 8A, is pressed. For the press treatment in this case a structured press element 30 is applied. The stack 29 comprises a basic board 8A with an average density of more than 750 kilograms per cubic meter, a layer of thermosetting resin 9 and a wood veneer 7 for forming the decorative top layer 6. Further, the stack 29 also comprises a wood veneer for forming the backing layer 11 and a layer of thermosetting resin 9 for attaching this backing layer 11 to the underside of the basic board 8A. In the figure, the layers with thermosetting resin 9 are shown in exploded view, but are in reality applied to the surface 25 of the basic board 8A, for example by a roller application. The wood veneer 7 comprises a sewing connection 31, which is positioned above a portion 32 of the basic board 8A, which has to be removed in subsequent treatments for subdividing and profiling or forming of coupling structure(s) 10, which here already are represented in dashed line. In the example, the basic board 8A comprises a flat upper surface 25. However, it is not excluded that the upper surface may be pre-formed, entirely or partially, corresponding to the applied press element 30.
[0107] FIG. 10 represents the obtained pressed whole 33. Herein, the decorative top layer 6 and the backing layer 11 is represented only schematically each time as one layer, namely without representing the layers with resin 9. From this, it is clear that the veneer 7 and the backing layer 11 are adhered to the basic board 8A by the hardened resin 9. Moreover, the basic board 8A is deformed such that the upper surface 25 shows a structure. The wood veneer 7 follows the contour of the structured upper surface 25. Hereby, in this case, it is obtained that the wood veneer 7 comprises a relief of scraped parquet with lowered edges 24.
[0108] FIG. 10 represents that at least the third hard particles 27 can remain absent at the location of the portion 32. In this manner it is achieved that the cutting tools, which have to remove the portion 32 in order to form the coupling structure(s), are less subjected to wear. In this case, an embodiment is represented wherein the resin 9 and the hard particles 27 are areawise applied to the stack 29, ie in areas with an intermediate space 34. Herein, the space 34 is situated above the portion 32 and in this case extends at least over this entire portion. According to the variant represented in dashed line it is also possible that the resin 9 extends continuously over the portion 32, however, that the third hard particles 27 remain absent there or anyhow at least are present to a much more limited extent.
[0109] FIG. 10 further represents that, whether or not in combination with the above, a plurality of wood veneers 7 situated next to each other can be applied instead of veneers which are composed, via a sewing connection, to a continuous sheet. Preferably, between the wood veneers 7 a space is maintained at the location of the portion 32. The dashed line 36 represents a continuous sheet which may or may not have a seam for example due to a sewing connection 31.
[0110] FIG. 10 further also represents that there are similar options for the glue layer at the underside and for the backing layer 11.
[0111] Referring to FIGS. 9 to 10, it is clear that the press treatment preferably is performed on a larger basic board 8A, which finally shall be subdivided into a plurality of floor panels 1. In transverse direction as well as in longitudinal direction, a plurality of floor panels 1 lying next to each other can be formed from the larger basic board 8A. The portions 32 of the basic board 8A can be present between adjacent long edges 4-5 as well as between adjacent short edges 2-3 of the final floor panels 1.
[0112] Preferably subsequent to the dividing operation the lacquer layer 23 is applied to the surface of the wood veneer 7 and to the side edge 28 of the wood veneer 7.
[0113] FIG. 11 shows an embodiment where the lacquer layer 23 comprises at least two sublayers 23a-23b. In the example, only the uppermost sublayer 23a covers a part of the side edge 28 of the wood veneer 7. The other of the two sublayers 23b extends up until the upper edge of the wood veneer 7. Preferably, both the uppermost sublayer 23a and the other sublayer 23b comprise hard particles, not shown here. Preferably the hard particles of the uppermost sublayer 23a are of a smaller average particle size than the hard particles of the other sublayer 23b. Preferably the uppermost sublayer 23a has a thickness Ta which is smaller, preferably at least 30% smaller, than the thickness Tb of the other sublayer 23b.
[0114] FIG. 11 further illustrates by the dashed lines 37 that a lowered edge 24 can be realized by removing an amount of material from the wood veneer 7 at the respective edge 3. Preferably the lacquer layer 23 is available on the surface of the lowered edge 24, and preferably at least the uppermost layer 23ain this case only the uppermost layer 23aextends over the upper edge to cover at least a part of the side edge 28 of the wood veneer 7.
[0115] The present invention is in no way limited to the herein above-described embodiments, on the contrary can such methods and decorative panels be realized according to various variants, without leaving the scope of the present invention. Amongst others, it is clear that the characteristics of the invention of any aspect also are interesting with other decorative panels, such as furniture panels, wall panels or ceiling panels. So, for example, does the invention offer the possibility for more wear-resistant counter tops for kitchens, office furniture, tables and the like, which comprise only a thin veneer layer as a decorative layer.
[0116] Although in the above practically exclusively wood veneer is mentioned, it is evident that the above independent aspects and preferred embodiments thereof also are applied in decorative panels with a thin top layer of another material. So, for example, it can be applied in decorative top layers of leather, bamboo, textile, aluminum, metal, stone veneer, plastic foils or the like.
