Abstract
A fluoroacrylate polymer is used to create a covering or treatment of the edges of decorative panels. A method for manufacturing decorative panels involves using fluoroacrylate polymer as a covering or treatment.
Claims
1.-13. (canceled)
14. Use of a fluoroacrylate polymer to achieve a covering or treatment at the side edges of decorative panels.
15. The use according to claim 14, wherein the aforementioned fluoroacrylate polymer has the following formula: ##STR00003## wherein one or more of the R groups are fluorine atoms, and the other R groups are hydrogen atoms.
16. The use according to claim 14, wherein the aforementioned fluoroacrylate has the following formula: ##STR00004## wherein, the R′ group is free of hydrogen atoms, and chosen from the list consisting of Sodium, Potassium, CF3.
17. The use according to claim 14, wherein the aforementioned fluoroacrylate polymer is part of a solvent-based mixture, or, alternatively, of a water-based mixture.
18. The use according to claim 17, wherein the aforementioned solvent-based mixture has a flash point of 35° C. or more.
19. The use according to claim 17, wherein the aforementioned solvent-based mixture includes alkanes, isoalkanes, as solvents.
20. The use according to claim 17, wherein the solvents and additives in the aforementioned solvent-based mixture are exclusively of the aliphatic type, or, that the proportion of solvent and additive of the aromatic type in the mixture is less than 1000 ppm.
21. The use according to claim 14, wherein the aforementioned fluoroacrylate polymer is part of a mixture containing at least glycol ether or another wetting agent, or surface tension reducing agent.
22. The use according to claim 14, wherein the aforementioned fluoroacrylate polymer is part of a mixture containing at least alkyd resin, wherein the aforementioned alkyd resin is modified urethane or isocyanate.
23. The use according to claim 14, wherein the aforementioned fluoroacrylate polymer is part of a mixture containing at least a liquid colorant, or at least a colorant free from solid pigments.
24. A method for manufacturing decorative panels, wherein the method includes the step of applying a covering or treatment on at least part of one side edge of the aforementioned panels, wherein the aforementioned covering or treatment includes fluoroacrylate polymer, as defined by claim 15.
25. The method according to claim 24, wherein this method is used for the production of panels with at least two opposite side edges comprising coupling means, which allow two such panels to be coupled at the relevant side edges, wherein, in the coupled condition, an interlocking comes into existence in a direction normal to the plane of the coupled panels and/or an interlocking in a direction in the plane of the panels and normal to the coupled side edges.
26. The method according to claim 24, wherein the aforementioned decorative panels are floor panels chosen from the list consisting of: floor panels with a porous or moisture-absorbing substrate, including MDF, HDF, MgO, cement fiberboard, or foamed substrates including thermoplastic foamed substrates; floor panels with a decorative top layer, including a print, wherein the decorative top layer is directly or indirectly fixed to an underlying substrate; floor panels with a decorative top layer comprising a wood veneer (thickness <2.5 mm) or a layer of wood (thickness from 2.5 mm), with any wood veneer having a thickness of 0.4 to 0.8 mm; and floor panels for composing a floating floor covering, with an MDF or HDF substrate, or with a thermoplastic substrate.
Description
[0034] With a view to better demonstrating the characteristics of the invention, the following, as an example without any restrictive character, describes some preferred embodiments, with reference to the accompanying drawings, wherein: [0035] FIG. 1 a floor panel obtained according to the use and method of the invention; [0036] FIG. 2 shows this floor panel in a cross-section according to line II-II shown in FIG. 1; [0037] FIG. 3 for a variant on a larger scale shows the area indicated by F3 in FIG. 2; and FIG. 4 shows a variant in a similar view.
[0038] FIG. 1 shows an oblong rectangular floor panel 1 which at two pairs of opposite side edges, 2-3 and 4-5, is provided with profiled edge areas 6 which include mechanical coupling parts 7.
[0039] FIG. 2 shows that the used coupling parts 7 allow an interlocking of two such floor panels 1 both in a horizontal direction H as well as in a vertical direction V. For the interlocking in vertical direction V, which is in a direction perpendicular to the top side 8 of the floor panel 1, the coupling parts 7 shown here are mainly in the form of a tongue 9 and a groove 10. Interlocking in the horizontal direction H, i.e. in a direction perpendicular to the vertical direction V referred to above and in the plane of FIG. 2, is obtained, in this case, by means of locking elements in the form of a protrusion 11 on the underside of the tongue 9 and a recess 12 in the lower lip of the groove 10. Upon coupling two such floor panels 1, the locking elements 11-12 cooperate and prevent the floor panels 1 from moving apart. This is shown by the floor panel 1 shown in dashed line 13, where it is clearly visible that there may be an overlap 14 between the not coupled contours of the groove 10 and the tongue 9, more specifically between the contours of the respective locking elements 11-12. By means of such an overlap 14, a so-called pre-tensioning can be achieved when two floor panels are coupled. The concept of pre-tensioning is in itself known from WO 97/47834. Preferably, the used mechanical coupling parts 7 will result in an interlocking free from play of two such floor panels in the aforementioned horizontal direction H and vertical direction V and better still, the coupling parts 7 will result in an interlocking free from play in all directions in the plane determined by the aforementioned directions V and H.
[0040] It is clear that the floor panels 1 obtained in the context of the invention may have any shape, such as a rectangular, square, hexagonal or similar shape, as well as may be provided with any coupling parts 7.
[0041] The floor panel 1 shown in FIGS. 1 and 2 is a laminate floor panel 1 containing a substrate 15, wherein this substrate 15 consists entirely of a wood-based material such as MDF or HDF. In addition, the aforementioned coupling parts 7 are executed in one-piece with this substrate 15. The floor panel 1 also contains a decorative top layer 16 based on synthetic material. In this case, the decorative top layer 16 is a so-called “DPL” layer which, in this example, consists of a decorative layer 17 with a printed motif 18 and a wear-resistant layer 19 applied to it, such as a so-called overlay. Both the decorative layer 17 and the overlay 19 contain a paper layer soaked in resin. Herein, the overlay also contains wear-resistant particles such as corundum. On its underside 20, the floor panel 1 has a counter layer 21 which also contains a layer of paper soaked in resin.
[0042] At least part of the surface 22 of the profiled edge areas 6 is provided with a covering 23 in which fluoroacrylate polymer is used according to the invention.
[0043] FIG. 2 shows that the covering 23 or treatment here forms a layer or film with a certain thickness T. In this figure as well as in FIGS. 3 and 4 discussed below, this layer is schematically shown as a layer lying on top of surface 22 of the profiled edge areas 6. It is clear that in reality this layer may have penetrated to a greater or lesser extent, or even completely, into the surface area 22 of the relevant edge area 6. It is clear that it is preferably taken care off that the thickness T of the layer on top of the surface 22 is limited to a minimum thickness T, e.g. by applying a suitable dilution to better absorb the covering 23 or treatment into substrate 15. In this way, it does not constitute a major obstacle when connecting the relevant edges 2-3 to a similar floor panel 1. It is noted that the thickness T of the film is shown in an exaggerated manner. In reality, the thickness T may be in the micron range or be non-existent.
[0044] FIG. 3 shows a variant wherein the covering 23 covers the transition between substrate 15 and the decorative top layer 16 as well as a limited band below the top edge of the floor panel 1. The use of fluoroacrylate polymer, according to the current invention, in a band-shaped covering 23 is very useful for classic laminate floor panels or other floor panels that are not specifically intended for use in damp rooms. After all, with classic laminate flooring panels there is the disadvantage that when cleaning with a damp cloth, moisture is absorbed into the substrate, causing it to swell and the laminate top layer to be pressed up permanently near the edges of the floor panels. Because a particularly efficient seal can now be achieved by means of the aforementioned active substances, it is no longer possible for moisture to penetrate directly underneath the laminate top layer into the substrate, by which the aforementioned effect is eliminated, if not minimized.
[0045] In dashed line S it is shown in FIG. 3 that the covering 23 can also extend to the top surface 8 of the floor panel 1. In general, the aim is for the covering 23 to cover at least the transition between substrate 15 and the top layer 16.
[0046] FIG. 4 shows a variant in which the profiled edge areas 6 include at least a surface 22A which is formed as a lower edge area 24 or chamfer, in this case as a bevelled edge. As shown, the covering 23 can also be provided on surface 22A of this lower edge area 24. In the example shown, the decorative top layer 16 extends continuously from the top surface 8 of the floor panel 1 over the surface 22A of the lower edge area 24.
[0047] It is clear that in the examples given in FIGS. 2 to 4, the undisplayed groove side 3-5 of the floor panel 1 has preferably undergone a similar treatment.
[0048] Generally speaking, it should also be noted that indicating means may be incorporated into the covering 23 to be able to check that it has been applied in a completely covering manner to the desired surface. Such indicating means may consist of a dye or a substance which, for example, lights up when irradiated with light or the like.
[0049] The current invention is by no means limited to the embodiments described above, but similar methods for manufacturing panels may be realized without exceeding the scope of the invention.
