DECORATIVE PANEL HAVING ANTIMICROBIAL PROPERTIES

Abstract

A decorative panel includes a substrate, a decor layer and a cover layer. The cover layer has a lacquer or is composed of a lacquer. The lacquer includes antimicrobial additives; and has an acrylate matrix and/or a methacrylate matrix.

Claims

1-99. (canceled)

100. A decorative panel, wherein the decorative panel comprises a substrate, a decor layer and a cover layer, wherein the substrate comprises one or more polyvinyl chloride layers or is composed thereof, optionally wherein one or more of these layers comprises a filler and/or other additives, optionally wherein one or more of the polyvinyl chloride layers is foamed; wherein the decor layer comprises a printed polyvinyl chloride film; wherein a transparent polyvinyl chloride film is applied to the printed polyvinyl chloride film; wherein the cover layer comprises a transparent polyvinyl chloride film either with or without a relief; wherein the cover layer comprises a lacquer or is composed thereof, wherein the lacquer comprises antimicrobial additives; wherein the lacquer comprises an acrylate matrix and/or a methacrylate matrix.

101. The decorative panel in accordance with claim 100, wherein the matrix of the lacquer is at least partially cured by means of UV irradiation and/or by means of electron beam.

102. The decorative panel as in claim 100, wherein the antimicrobial additives in the lacquer are selected from one or more of particles comprising silver components, particles comprising silver phosphate, silver phosphate glass particles, quaternary ammonium salts, quaternary ammonium groups built into the matrix of the lacquer, particles or additives that comprise quaternary ammonium groups, metallic silver particles, silver salts, silver complexes, silver chelates, copper salts, copper and alloys thereof, zinc oxide, essential oils, oleoresins, polybiguanides, chitosan, isothiazolinone, antibiotics, or trichloromethylsulfenyl-containing fungicides, silver adsorbed to silicon oxide, silver chloride adsorbed to titanium dioxide, silver nitrate, silver sodium hydrogen zirconium phosphate, silver zinc zeolite, silver copper zeolite, silver phosphate glass, and silver borosilicate glass.

103. The decorative panel as in claim 100, wherein the surface of the lacquer has a gloss value lower than 20.

104. The decorative panel as in claim 100, wherein the lacquer comprises less than 5% by weight of a matting agent.

105. The decorative panel as in claim 100, wherein the lacquer comprises particles that increase the wear resistance of the decorative panel, selected from one or more of nanosilicate, aluminum oxide and diamond.

106. The decorative panel as in claim 100, wherein the transparent polyvinyl chloride film comprises a biocide.

107. The decorative panel as in claim 100, wherein the antimicrobial additives have virus-killing activity.

108. A decorative panel, wherein the decorative panel comprises a substrate and a top layer, wherein the top layer comprises a decor layer and a wear layer, wherein the decor layer comprises a printed paper layer impregnated with melamine resin or with acrylate resin, wherein the wear layer comprises a paper layer impregnated with melamine resin, wherein the wear layer comprises antimicrobial additives.

109. The decorative panel as in claim 108, wherein the antimicrobial additives in the wear layer are selected from one or more of particles comprising silver components, particles comprising silver phosphate, silver phosphate glass particles, quaternary ammonium salts, quaternary ammonium groups built into the melamine resin of the wear layer, particles or additives that comprise quaternary ammonium groups, metallic silver particles, silver salts, silver complexes, silver chelates, copper salts, copper and alloys thereof, zinc oxide, essential oils, oleoresins, polybiguanides, chitosan, isothiazolinone, antibiotics, or trichloromethylsulfenyl-containing fungicides, silver adsorbed to silicon oxide, silver chloride adsorbed to titanium dioxide, silver nitrate, silver sodium hydrogen zirconium phosphate, silver zinc zeolite, silver copper zeolite, silver phosphate glass, and silver borosilicate glass.

110. The decorative panel as in claim 108, wherein the wear layer comprises antimicrobial additives both above and below its paper layer, wherein the concentration of antimicrobial additives in the wear layer is substantially the same above and below the paper layer of the wear layer.

111. The decorative panel, as in claim 108 wherein the decor layer comprises antimicrobial additives.

112. The decorative panel in accordance with claim 111, wherein the antimicrobial additives in the decor layer are selected from one or more of particles comprising silver components, particles comprising silver phosphate, silver phosphate glass particles, quaternary ammonium salts, quaternary ammonium groups built into the matrix of the melamine resin of the decor layer, particles or additives that comprise quaternary ammonium groups, metallic silver particles, silver salts, silver complexes, silver chelates, copper salts, copper and alloys thereof, zinc oxide, essential oils, oleoresins, polybiguanides, chitosan, isothiazolinone, antibiotics, or trichloromethylsulfenyl-containing fungicides, silver adsorbed to silicon oxide, silver chloride adsorbed to titanium dioxide, silver nitrate, silver sodium hydrogen zirconium phosphate, silver zinc zeolite, silver copper zeolite, silver phosphate glass, and silver borosilicate glass.

113. The decorative panel in accordance with claim 108, wherein the wear layer comprises particles that increase the wear resistance, selected from one or more of nanosilicate, aluminum oxide, corundum, diamond and synthetic diamond.

114. The decorative panel as in claim 108, wherein the wear layer comprises, both between its paper layer and the side facing the decor layer and between its paper layer and the side facing away from the paper layer, particles that increase the wear resistance.

115. The decorative panel as in claim 108, wherein the substrate is selected from a wood fiberboard, an MDF (medium density fiberboard) panel, an HDF (high density fiberboard) panel, a chipboard, a thermoplastic panel, a polyvinyl chloride-based panel, a mineral panel, a magnesium oxide board, a fiber cement board, a fiber plaster board, a silicate board, and a mineral fiber board.

116. The decorative panel as in claim 108, wherein the surface of the panel comprises a texture embossed into the decorative surface of the panel, wherein the deepest depressions of this texture also comprise the decor layer and the wear layer, wherein the decor layer and/or the wear layer also comprise(s) antimicrobial additives in these deepest depressions of the texture.

117. A decorative panel, wherein the decorative panel is a parquet panel, a multiple-layer parquet panel, a composite parquet panel, or a so-called “engineered wood” panel; wherein the decorative panel comprises a wood-based decor layer to which at least one lacquer layer is applied, wherein the wood-based decor layer is a wood veneer layer or a wood layer thicker than a veneer layer; wherein the at least one lacquer layer comprises at least one lacquer layer that comprises antimicrobial additives.

118. The decorative panel as in claim 117, wherein the antimicrobial additives in the lacquer layer are selected from one or more of particles comprising silver components, particles comprising silver phosphate, silver phosphate glass particles, quaternary ammonium salts, quaternary ammonium groups built into the lacquer layer, particles or additives that comprise quaternary ammonium groups, metallic silver particles, silver salts, silver complexes, silver chelates, copper salts, copper and alloys thereof, zinc oxide, essential oils, oleoresins, polybiguanides, chitosan, isothiazolinone, antibiotics, or trichloromethylsulfenyl-containing fungicides, silver adsorbed to silicon oxide, silver chloride adsorbed to titanium dioxide, silver nitrate, silver sodium hydrogen zirconium phosphate, silver zinc zeolite, silver copper zeolite, silver phosphate glass, and silver borosilicate glass.

Description

[0145] In order to better illustrate the features of the invention, several preferred embodiments are described below, as examples that are by no means limitative, with reference to the attached drawings, wherein:

[0146] FIG. 1 shows a partially installed floor covering composed of decorative floor panels in accordance with an example of the invention,

[0147] FIG. 2 shows a top view of a decorative floor panel in accordance with an example of the invention such as used in the floor covering of FIG. 1,

[0148] FIG. 3 shows the section of the decorative floor panel along line III-III of FIG. 2,

[0149] FIG. 4 shows the section of the decorative floor panel along line IV-IV in FIG. 2,

[0150] FIG. 5 shows a larger-scale view of the structure of the upper part of the decorative panel of FIGS. 1-4,

[0151] FIG. 6 illustrates a decorative panel in accordance with aspects of the invention,

[0152] FIG. 7 shows a detail of the decorative panel of FIG. 6,

[0153] FIG. 8 shows a detail of the decorative panel of FIG. 6,

[0154] FIG. 9 shows an alternative embodiment of chamfered edges of a decorative panel in accordance with the invention, and

[0155] FIG. 10 illustrates a decorative panel in accordance with aspects of the invention.

[0156] A decorative panel in accordance with the invention can be produced in the following manner. A printed polyvinyl chloride film, and on top of this, a transparent polyvinyl chloride film are laminated onto a polyvinyl chloride substrate.

[0157] An example of a transparent polyvinyl chloride film that can be used has the following composition: polyvinyl chloride, a plasticizer, stabilizers, process auxiliaries, and optionally 0.1-2% by weight of a biocide. Reported examples of biocides used in the transparent polyvinyl chloride film may include trichloromethylsulfenyl-containing fungicides or thiabendazole.

[0158] Optionally, a relief can be embossed into the transparent polyvinyl chloride film, preferably during lamination.

[0159] In order to increase adhesion, an adhesive layer is applied to this laminate – and thus to the transparent polyvinyl chloride layer. Such an adhesive layer can for example be applied as a water-based acrylate, a solvent-based acrylate, or a 100% acrylate primer. For example, 5-20 g (expressed as solid matter) of adhesive layer per square meter is applied. More preferably, 6-12 g (expressed as solid matter) of adhesive layer per square meter is applied. Optionally, the adhesive layer comprises antimicrobial additives, for example silver phosphate water glass, preferably in an amount of 0.1-4% by weight based on the dry matter of the adhesive layer; and more preferably in an amount of 0.2-2% by weight based on the dry matter of the adhesive layer.

[0160] The adhesive layer is then gelled, for example by means of UV lamps, optionally preceded by thermal treatment.

[0161] After this, the lacquer is applied. An example of a lacquer that can be used comprises the following composition: [0162] 20-70% by weight of acrylate and/or methacrylate oligomer. This can be composed of one or more of an acrylate, a urethane acrylate, a polyester acrylate, or an epoxy acrylate; or similar methacrylates; [0163] 1-50% by weight of monomers (preferably acrylate and/or methacrylate monomers), for example one or more of trimethylol propane triacrylate, dipropylene glycol diacrylate, 1,6-hexane diol diacrylate, 3,3,5-trimethyl cyclohexyl acrylate, acryloyl morpholine, 3-vinyl-5-methyl-2-oxazolidinone; [0164] 0.1-4% by weight of silver phosphate glass; [0165] no matting agent, or optionally 0.1-5% by weight of a matting agent; [0166] 0.1-10% by weight of wear-resistant particles, such as for example corundum (this is a form of aluminum oxide), nanosilica or microdiamond; [0167] 0.1-5% by weight of a photoinitiator; [0168] optionally 0.1-5% by weight of a thermoinitiator; [0169] optionally 0.1-5% by weight of dual-cure crosslinking agents such as isocyanates or carbodiimide; [0170] optionally 0.1-5% by weight of silicone and/or fluorine-based polymers.

[0171] For example, 5-20 g per square meter of lacquer can be applied in one or in two steps. After this, the lacquer is cured. This can take place in various ways, for example via options A, B, and C. However, option A is preferred.

[0172] In option A, the lacquer is irradiated under an inert atmosphere with an excimer light source having a wavelength of 172 nm, which cures the lacquer on the surface. This produces crimping stresses at the surface of the lacquer which provide a microtexture (and a low gloss value). The excimer light source is immediately followed by a UV curing step, wherein the lacquer is cured in further depth. The process in accordance with option A makes it possible, even with few or no matting agents in the lacquer, to achieve a low gloss value of the lacquer layer.

[0173] In option B, the lacquer is cured with standard UV lamps. In order to obtain a low gloss value, for example a silk matt gloss with a gloss value lower than 20; or a matt lacquer layer with a gloss value lower than 10, such lacquer must contain a sufficient amount of a matting agent, more than 7% by weight or even more than 10% by weight.

[0174] In option C, the gloss value of the lacquer is determined by polymerizing the lacquer by means of a pressing treatment with a structured press, optionally also followed by thermal or UV curing in order to completely cure the lacquer layer.

[0175] FIG. 1 shows a partially installed floor covering composed of decorative floor panels in accordance with an example of the invention. These decorative floor panels 1 comprise coupling components on the first pair of opposite edges 2, 3 - these are the long edges of the rectangular and oblong floor panels. The coupling components are substantially configured in the form of male coupling components and female coupling components for coupling two such panels to each other at their first pair of opposite edges. The coupling components of the first pair of opposite edges 2, 3 are configured such that two such panels can be coupled to each other at their first pair of opposite edges by means of an angling movement.

[0176] The second pair of opposite edges 4, 5 – which in this case are the short edges – are also provided with coupling components in the form of male coupling components and female coupling components in order to couple two such panels 1 to each other at their second pair of opposite edges 4, 5. The coupling components at the second pair of opposite edges 4, 5 are configured such that two such panels 1 can be coupled to each other at their second pair of opposite edges 4, 5 by means of a substantially downward movement in the direction perpendicular to the plane of the floor covering. Such a downward movement is possible with coupling components of the so-called “push-down,” “push-lock,” or “drop” types.

[0177] Thanks to the specific configurations of the coupling components, the decorative panel 1, starting from an inclined position, can be coupled in a single movement F at its long edge 2 and also at its short edge 5 to already-installed floor panels 1. This installation method of floor panels is known as “fold-down” installation. The “fold-down” movement F makes it possible to install decorative floor panels in accordance with the invention in a rapid and efficient manner.

[0178] FIG. 2 shows a top view of a decorative floor panel in accordance with an example of the invention such as used in the floor covering of FIG. 1. The decorative panel 1 is rectangular and oblong and comprises a first pair of opposite edges 2, 3 that form the long edges of the panel and a second pair of opposite edges 4, 5 that form the short edges of the panel. The panel of the example comprises a printed decorative pattern, and said decorative pattern is not shown in FIGS. 1 and 2.

[0179] FIG. 3 shows the section of the decorative floor panel along line III-III of FIG. 2. The floor panel 1 comprises a multilayer substrate 6, a decor layer – in the form of a printed polyvinyl chloride film 41 – and a cover layer. The cover layer comprises a transparent polyvinyl chloride film 43, an adhesive layer 45, and a lacquer 47 that comprises antimicrobial additives. These can be configured as in the example described above. FIG. 5 shows a larger-scale view of the structure of the upper part of the decorative panel, wherein the second layer 6B of the substrate, the printed polyvinyl chloride film 41, the transparent polyvinyl chloride film 43, the adhesive layer 45, and the lacquer 47 that comprises antimicrobial additives are shown. The irregular surface of the lacquer 47 provides a low gloss value of the decorative panel. This can be achieved via option A of the above-mentioned ways of curing the lacquer.

[0180] In this example, the substrate is multi-layered. However, the substrate can also consist of only one polyvinyl chloride layer that may or may not be foamed and may or may not comprise fillers.

[0181] In the example, the substrate 6 comprises two layers. A first layer 6A and a second layer 6B. The first layer 6A can be produced based on polyvinyl chloride that comprises no plasticizers or comprises less than 20 phr of a plasticizer. The polyvinyl chloride of the first layer can be foamed and can comprise fillers, such as mineral fillers or wood-based fillers. This first layer 6A is a stiff layer. Such a described layer can also be the only layer of the substrate.

[0182] The multilayer substrate 6 of the example comprises a more flexible second layer 6B above the first layer 6A. This more flexible layer 6B is a polyvinyl chloride layer that comprises more than 20 phr of a plasticizer. This second layer 6B can comprise fillers such as mineral fillers or wood-based fillers.

[0183] Preferably, the first layer 6A forms at least half of the thickness of the decorative panel 1.

[0184] The first pair of opposite edges 2, 3 is provided with coupling components 8, 9 that allow two such panels at their first pair of opposite edges 2, 3 to be coupled to each other by means of an angling movement R around an axis parallel to the floor panel and parallel to the first pair of opposite edges 2, 3. The coupling components 8, 9 are substantially produced from material of the substrate 6, and in particular in the example from material of the first, stiffer layer 6A.

[0185] The coupling components 8, 9 of the first pair of opposite edges are substantially produced as a tongue 10 and a groove 11 that are provided with interlocking components 12, 13 which, in a coupled state of two such panels, prevent the panels from being slid away from each other in the plane of the panels in the direction perpendicular to the first pair of opposite edges 2, 3.

[0186] The groove 11 is delimited by an upper lip 14 and by a lower lip 15. The lower lip 15 extends in a distal direction farther than the distal end 16 of the upper lip 14. The lower lip 15 comprises an interlocking component 13 in the form of an upward facing interlocking component 13.

[0187] FIG. 4 shows the section of the decorative floor panel along line IV-IV in FIG. 2. The reference numbers in FIG. 4 have the same meaning as those in FIG. 3.

[0188] The second pair of opposite edges 4, 5 is provided with coupling components 17, 18 that allow two such panels 1 at their second pair of opposite edges to be coupled by means of a substantially vertical movement M in the direction perpendicular to the plane of the floor covering. The coupling components 17, 18 are configured as hook-shaped components 19, 20 that form an interlocking system that allows interlocking to occur in the plane of the floor panel and perpendicular to the second pair of coupled edges 4, 5. These coupling components 17, 18 comprise interlocking components 21, 22 and interlocking components 23, 24, each of which forms an interlocking system that allows interlocking to occur in the direction perpendicular to the plane of the coupled panels.

[0189] The coupling components 8, 9 on the first pair of opposite edges 2, 3; and the coupling components 17, 18 on the second pair of opposite edges 4, 5, allow such decorative panels to be installed in a floor covering by means of the “fold-down” installation technique F, as illustrated in FIG. 1.

[0190] FIG. 6 illustrates a decorative panel 1 in accordance with aspects of the invention in the same section as in FIG. 3. FIG. 7 shows a detail F7 of the panel of FIG. 6. The panel 1 of FIG. 6 is rectangular and oblong. As does the panel of FIG. 3, the panel of FIG. 6 comprises coupling components, and in the example these are configured as in the panel of FIG. 3.

[0191] The panel comprises a substrate 51 – for example a high density fiberboard (HDF) – and a top layer 52. The top layer 52 comprises a decor layer 53 and a wear layer 54. The decor layer 53 comprises a printed paper layer 56 impregnated with melamine resin. The wear layer comprises a paper layer 57 impregnated with melamine resin. Both the wear layer and the decor layer comprise antimicrobial additives 59, wherein the antimicrobial additives are comprised in the respective melamine resins. Both the decor layer 53 and the wear layer 54 comprise antimicrobial additives 59 above and below their respective papier layer, substantially in the same concentration above and below their respective paper layer.

[0192] The wear layer 54 comprises particles 60, 61 that increase the wear resistance. In the example, the wear layer 54 comprises such particles both above and below its paper layer 57. The particles 60 above the paper layer 57 are on average finer than the particles 61 below the paper layer 57.

[0193] The panel 1 comprises a balance layer 62 on the underside of the panel. The balance layer 62 comprises a paper layer impregnated with melamine resin. The balance layer 62 comprises antimicrobial additives 63.

[0194] In the example, the antimicrobial additives 59, 63 are the same in the decor layer, the wear layer, and the balance layer. This does not necessarily have to be the case in the invention. Moreover, these three layers do not all have to comprise antimicrobial additives.

[0195] The surface of the panel 1 comprises a texture embossed into the decorative surface of the panel. At least a part of the texture is embossed into the substrate 51. The deepest depressions 64 of this texture also comprise the decor layer 53 and the wear layer 54. The decor layer 53 and the wear layer 54 also comprise the antimicrobial additives 59 in these deepest depressions of the texture.

[0196] The panel 1 of the example of FIG. 6 comprises side edges with lower edge areas, more specifically pressed-in chamfered edges 66. FIG. 8 shows in detail these pressed-in chamfered edges 66 in accordance with F8 of FIG. 6. These pressed-in chamfered edges 66 comprise the decor layer 53 and the wear layer 54, so that antimicrobial additives 59 are also present on these pressed-in chamfered edges via the decor layer 53 and the wear layer 54.

[0197] The side edges of the panel 1 of FIG. 6 are impregnated with an impregnating agent 68 that makes the side edges water-repellent. In the example, this impregnating agent also comprises antimicrobial additives.

[0198] FIG. 9 shows – in the same view as in FIG. 8 – an alternative embodiment of chamfered edges of a decorative panel in accordance with the invention. In the example of FIG. 9, the chamfered edges 70 are chamfered edges milled on the side edges. These chamfered edges only partially comprise the decor layer and the wear layer. The chamfered edges 70 comprise a colored lacquer layer 71 that comprises antimicrobial additives 72.

[0199] The same reference numbers as in FIGS. 6-8 have the same meaning.

[0200] FIGS. 6-9 illustrate multiple aspects of the invention. However, the combination of these aspects is not essential in the framework of the invention; each of these aspects can occur separately.

[0201] FIG. 10 illustrates a decorative panel 1 in accordance with aspects of the invention. The panel 1 is a multiple-layer parquet panel. The panel comprises a decorative wood layer 80 on two other wood layers 81, 82. The decorative wood layer comprises lacquer layers 83, 84. In practice, a plurality of lacquer layers can be applied to the panel.

[0202] The upper lacquer layer 83 comprises antimicrobial additives. The underlying lacquer layer 84 comprises particles 60 that increase the wear resistance of the panel. In the example, both the upper lacquer layer 83 and the underlying lacquer layer 84 comprise antimicrobial additives 60. This is not necessary for the invention; in accordance with the invention, one or more lacquer layers may comprise antimicrobial additives. The other reference numbers have the same meaning as in FIGS. 3 and 6-9.