PRESSED LAMINATE PANEL WITH A SINGLE LAYER ELASTOMERIC TREATED PAPER

Abstract

A laminated panel is provided which comprises, or consists of, a core panel to which an elastomeric resin impregnated single finishing printed paper layer has been applied. The paper for the single finishing printed paper layer is printed to provide a design feature on the laminated panel. Preferably, the design feature has been printed on a lower surface of the single finishing printed paper layer. As a result of the resin impregnation and heating and pressing operations, the single finishing printed paper layer becomes translucent or transparent, and thus allows the printed design feature to become visible. The design feature can be printed onto the single finishing printed paper prior to treatment with the elastomeric resin, or printed onto the previously treated elastomeric resin impregnated paper. The laminated panels can be used in the production of laminated flooring, wall panels or furniture panels.

Claims

1. A laminated panel consisting of a core panel and a treated layer on at least one side of the core panel, which treated layer is a single printed finishing paper layer which single printed finishing paper layer has been treated with, or impregnated with an elastomeric resin, before or after printing an image onto said paper layer, and prior to production of said laminated panel.

2. A laminated panel as claimed in claim 1, wherein said single finishing printed paper layer is printed, before or after treatment, or impregnation, of the paper with the elastomeric resin.

3. A laminated panel as claimed in claim 2 wherein said image on said paper layer is printed after treatment, or impregnation, of the single finishing printed paper with the elastomeric resin.

4. A laminated panel as claimed in claim 1 wherein said image printed onto said single finishing printed paper, is applied to the side of the single finishing printed paper which will be located next to the core panel.

5. A laminated panel as claimed in claim 1 wherein said single finishing printed paper includes abrasion resistant particles.

6. A laminated panel as claimed in claim 1 wherein said single finishing printed paper is, or becomes, translucent or transparent after application of the elastomeric resin, and/or after pressing to form the laminated panel.

7. A laminated panel as claimed in claim 1 wherein said elastomeric resin comprises natural and/or synthetic resins, or combinations thereof, having with elastomeric properties including any one or a combination of elastomeric thermosetting or thermoplastic resins including polyethylene (PE); Polyurethanes; Polypropylene; Ethylene vinyl acetates; Ethylene vinyl alcohol; Polyesters; Polyolefin; elastomeric-modified Melamine thermoset resins, Urea and Urea-modified thermoset resins; ESI (ethylene styrene interpolymer), or any of the styrene acrylic copolymers and Acrylic resins; rubber based materials, silicone, fluorocarbon, acrylamide, epichlorohydrin, and/or carboxylated natural and synthetic latexes; or combinations thereof.

8. A laminated panel as claimed in claim 7 wherein said polyethylene grade is LLDPE (Linear Low-density Polyethylene), LDPE (Low-density Polyethylene), MDPE (Medium-density Polyethylene) or HDPE (High-density Polyethylene), said Polyolefin is TPO (Thermoplastic polyolefin), or wherein said rubber based material is NBR (nitrile butadiene), SBR (styrene butadiene) or CR (chloroprene).

9. A laminated panel as claimed in claim 1 wherein said core panel is a natural wood core.

10. A laminated panel as claimed in claim 1 wherein said core panel is particleboard, MDF or HDF board, plywood, or a wood-based panel made from natural fibers.

11. A laminated panel as claimed in claim 1 wherein said core panel is a wood-plastic composite material, a plastic material, or a metallic material.

12. A laminated panel as claimed in claim 1 wherein said core panel is a base panel covered with a wood veneer.

13. A laminated panel as claimed in claim 1 wherein said core panel is covered on one side with a single finishing printed paper layer, in the absence of a backing layer on the opposite side of the core panel.

14. A laminated panel as claimed in claim 1 consisting of a core panel and a single finishing printed paper layer on both sides of said core panel, wherein each single finishing printed paper layer has been treated with, or impregnated with an elastomeric resin, before or after printing an image onto a paper layer, and prior to production of said laminated panel.

15. A laminated panel as claimed in claim 14 wherein the image printed onto the single finishing printed layer applied to the two sides of the core panel, differ one from the other, so that the laminated panel has a different appearance on, or has different properties on, each side of the panel.

16. A method for the manufacture of a laminated panel consisting of: (i) preparing a flexible, treated or impregnated single finishing printed paper layer by: (a) printing an image onto a paper layer, and treating the resultant printed paper layer with an elastomeric resin, and thus produce the flexible, treated or impregnated single finishing printed paper layer; or (b) treating a paper layer with an elastomeric resin to produce a treated or impregnated paper layer, and then printing an image onto said treated or impregnated paper layer to produce the flexible, treated or impregnated single finishing printed paper layer; (ii) placing the flexible, treated or impregnated single finishing printed paper layer adjacent to at least one side of a core panel, as a laminate structure, in a laminate panel press; (iii) pressing said laminate structure, with heating, in said press; and (iv) optionally embossing said laminate structure in said press, so as to produce a laminated panel.

17. A method as claimed in claim 16 wherein said image printed onto said paper is a colour or image which covers only a portion of the paper, and thus, allows at least part of the surface of the core panel to be visible, or wherein said image printed onto said paper is a solid printed image, or a printed background colour, which ensures that the final printed image will substantially block the visibility, or the colour, of the core panel.

18. A method as claimed in claim 16 wherein said elastomeric resin comprises natural and/or synthetic resins, or combinations thereof, having with elastomeric properties including any one or a combination of elastomeric thermosetting or thermoplastic resins including polyethylene (PE); Polyurethanes; Polypropylene; Ethylene vinyl acetates; Ethylene vinyl alcohol; Polyesters; Polyolefin; elastomeric-modified Melamine thermoset resins, Urea and Urea-modified thermoset resins; ESI (ethylene styrene interpolymer), or any of the styrene acrylic copolymers and Acrylic resins; rubber based materials, silicone, fluorocarbon, acrylamide, epichlorohydrin, and/or carboxylated natural and synthetic latexes; or combinations thereof.

19. A method as claimed in claim 18 wherein said polyethylene grade is LLDPE (Linear Low-density Polyethylene), LDPE (Low-density Polyethylene), MDPE (Medium-density Polyethylene) or HDPE (High-density Polyethylene), said Polyolefin is TPO (Thermoplastic polyolefin), or wherein said rubber based material is NBR (nitrile butadiene), SBR (styrene butadiene) or CR (chloroprene).

20. A method as claimed in claim 16 wherein said laminate structure is pressed with said single finishing paper on one side of the core panel, in the absence of a backing layer on the opposite side of the core panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Embodiments of this invention will now be described by way of example only in association with the accompanying drawings in which:

[0052] FIG. 1 is a perspective view of a printed paper layer, of use in the practise of the present invention;

[0053] FIG. 2 is a perspective view of the same paper layer, after impregnation with an elastomeric resin;

[0054] FIG. 3 is a perspective view of the impregnated paper layer of FIG. 2 positioned over a core panel;

[0055] FIG. 4 is a perspective view of the paper layer and core panel of FIG. 3, after pressing and embossing;

[0056] FIG. 5 is a perspective view of a core panel, with an impregnated paper layer on each side of the core panel;

[0057] FIG. 6 is a perspective view of the core panel and papers of FIG. 5, after pressing and embossing;

[0058] FIG. 7 is a perspective view of a further embodiment of the present invention, wherein the core comprises a wood veneer bonded to a core panel;

[0059] FIG. 8 is a perspective view of a printed paper layer after impregnation with an elastomeric resin, of use in the practise of the present invention; wherein the paper layer is an opaque, solid coloured paper with a printed image on the top surface; and

[0060] FIG. 9 is a perspective view of the core panel and printed paper of FIG. 8, after pressing and embossing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0061] The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example only. In the drawings, like reference numerals depict like elements.

[0062] It is expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. Also, unless otherwise specifically noted, all of the features described herein may be combined with any of the above aspects, in any combination.

[0063] Referring to FIG. 1, a perspective view of a paper 10, according to the present invention, is shown. Paper 10 is an opaque paper having a weight of 30 g/m.sup.2, prior to treatment, and has an upper surface 12, and a lower surface 14. A wood grain pattern 16 has been printed onto the lower surface 14 of paper 10.

[0064] In FIG. 2, paper 10 has been impregnated with an elastomeric resin, and as a result of this impregnation, paper 10 has become translucent. As such, the wood grain pattern 16 printed onto the lower surface 16 of paper 10, is now partially visible, as wood grain image 18, on the upper surface 12 of paper 10.

[0065] The thickness of paper 10 after impregnation by the elastomeric resin, is preferably between 0.1 to 3 mm, but thinner or thicker papers also be used. The overall weight of paper 10 after impregnation is preferably between 40 and 300 g/m.sup.2, and more preferably between 50 and 250, and still more preferably between 100 and 200 g/m.sup.2. Preferably, the elastomeric resin is in the form of a water-based dispersion, or a water-based or solvent-based solution polymer, and which has been applied to the paper by known impregnation devices.

[0066] In more detail, in the embodiment shown in FIG. 2, the 30 g/m.sup.2 paper, optionally containing aluminum oxide particles, is impregnated with a water-based polyurethane resin system, such as Flexcoat WB-400 or WB-420 (both available from Purchem Systems Inc.), to provide an impregnated single finishing printed paper having a final weight after drying, of 100 g/m.sup.2.

[0067] During production of a laminate panel, translucent finishing printed paper 10 is placed on one side of an MDF core panel 20, as shown in FIG. 3. The loose paper 10 and core panel 20, are assembled together as a laminate structure, and this structure is pressed together, with heating, to produce the laminated panel 22, shown in FIG. 4. As part of the pressing operation, the impregnated resin cures, and provides adhesion of the finishing printed paper to the core panel. As such, as a result of pressing, the finishing printed paper 10 is pressed onto core panel 20, and adheres to the core panel 20, without the need for any glue or other adhesives, or the like.

[0068] The pressing operation can be achieved using any one of a variety of pressing processes, but preferably pressing is done using existing short-cycle presses, and in particular, direct pressure laminate (DPL) processes. However, depending on the resin selected, the elastomeric treated, finishing printed paper can provide a wide processing window. Preferably though, the laminate structure is pressed at temperatures and pressures normally used in the production of prior art laminate panels. For example, the laminate structure could be heated to 120 degrees C. to 140 degrees C. for 3 minutes under a surface pressure of 20 to 70 kg force per cm.sup.2 of surface area. Other temperatures and pressure can be used, however.

[0069] Once the pressing operation is complete, single finishing printed paper 10 becomes transparent, so that the wood grain pattern 16 is now fully visible through paper 10. Also, because of this transparency, the surface of core panel 20 is at least partially visible through paper 10.

[0070] In other embodiments, the lower surface 14 of single finishing printed paper 10 can be printed to show a wood pattern, and/or a desired wood panel colour. When applied to the core panel 20, the wood panel pattern and colour would further hide appearance of the surface of core panel 20.

[0071] Additionally, simultaneously to pressing, laminated panel impressions can be preferably applied by the press, as the surface of the pressing part comes into contact with the upper surface of single finishing printed paper 10. In this option, the pressing plate includes the desired relief features which features are transferred to panel 22. After curing of the elastomeric resin, the resultant laminated panel 22 includes the embossed textured feature 24. Preferably, the embossed texture depth may range from essentially flat and smooth, with a glossy or matt finish, or a texture that is pressed 0.05 to 0.6 mm below the pressed panel surface providing for a realistic looking finished panel.

[0072] In FIG. 5, a second embodiment of the present invention is provided wherein an MDF core panel 20 has an elastomeric resin impregnated single finishing printed paper layer 10, as described in FIGS. 1 and 2, on each side of the core panel, and this laminate structure can be pressed, as previously described.

[0073] After pressing and embossing, laminated panel 26 is provided having a textured, wood grain finish on both its upper and lower surface. While the textured wood grain finish as shown in FIG. 6, can be essentially identical on both the upper and lower surfaces of panel 26, this is not required or preferred. In fact, in one preferred embodiment, the appearance of the two surfaces can vary, one from the other. This provides flexibility in the manufacturing of a wide variety of different panel designs and features.

[0074] In FIG. 7, a laminated panel similar to the panel in FIG. 3 is shown, wherein core panel 30 is a wood veneer comprising a particleboard base panel 32 to which a wood veneer 34 has been glued prior to laminating paper 40 to the top of veneer 34. Paper 40 is an elastomeric resin impregnated single finishing printed paper, similar to item 10. However, in this case, paper 40 has been printed to provide a transparent colour stain 42. This allows the wood grain appearance and grain of the veneer 34 to be seen, through paper 40, once paper 40 is laminated to core panel 30.

[0075] In FIG. 8, a further embodiment of a laminated panel 50, according to the present invention is shown wherein an HDF core panel 52 has an elastomeric resin impregnated single finishing printed paper layer 54, positioned above core panel 52. Paper layer 54 is an opaque, solid coloured paper with an printed image 56, on its top surface. This assembly is pressed and optionally embossed, as previously described.

[0076] After pressing and embossing, laminated panel 50, as shown in FIG. 9, is provided having a textured, finish on one surface, and the HDF core layer 52 is not visible through paper layer 54.

[0077] Thus, it is apparent that there has been provided, in accordance with the present invention, a laminated panel, and decorative printed paper, which fully satisfies the goals, objects, and advantages set forth hereinbefore. Therefore, having described specific embodiments of the present invention, it will be understood that alternatives, modifications and variations thereof may be suggested to those skilled in the art, and that it is intended that the present specification embrace all such alternatives, modifications and variations as fall within the scope of the appended claims.

[0078] Additionally, for clarity and unless otherwise stated, the word comprise and variations of the word such as comprising and comprises, when used in the description and claims of the present specification, is not intended to exclude other additives, components, integers or steps. Further, the invention illustratively disclosed herein suitably may be practised in the absence of any element which is not specifically disclosed herein.

[0079] Moreover, words such as substantially or essentially, when used with an adjective or adverb is intended to enhance the scope of the particular characteristic; e.g., substantially planar is intended to mean planar, nearly planar and/or exhibiting characteristics associated with a planar element.

[0080] Further, use of the terms he, him, or his, is not intended to be specifically directed to persons of the masculine gender, and could easily be read as she, her, or hers, respectively.

[0081] Also, while this discussion has addressed prior art known to the inventor, it is not an admission that all art discussed is citable against the present application.