Panel, in Particular a Floor Panel, Ceiling Panel or Wall Panel, and Use of an Additional Layer in a Laminated Multi-Layer Structure of a Panel

Abstract

Provided is a panel, in particular a floor panel, ceiling panel, or wall panel, having a laminated multi-layer structure which includes a core layer, a decorative layer above the core layer, a transparent top layer above the decorative layer, and an intermediate layer situated between the decorative layer and the top layer. The intermediate layer is transparent, and made from a protective material which includes a polyurethane composition which is the reaction product of a polyester polyol, a polyether polyol, and an isocyanate. The polyurethane composition is a thermoset polymer material. Also provided is a use of an additional layer in a laminated multi-layer structure of a panel in particular a floor panel, ceiling panel, or wall panel. The additional layer is transparent, and is made from a protective material which includes a polyurethane composition which is the reaction product of a polyester polyol, a polyether polyol, and an isocyanate. The polyurethane composition is a thermoset polymer material.

Claims

1. A panel, in particular a floor panel, ceiling panel, or wall panel, having a laminated multi-layer structure which comprises: a core layer, a decorative layer above the core layer, a transparent top layer above the decorative layer, and an intermediate layer situated between the decorative layer and the top layer, which intermediate layer is transparent, and made from a protective material which comprises a polyurethane composition which is the reaction product of a polyester polyol, a polyether polyol, and an isocyanate, and wherein the polyurethane composition is a thermoset polymer material.

2. The panel according to claim 1, wherein the respective layers of the laminated multi-layer structure are directly or indirectly attached onto each other.

3. The panel according to claim 1, wherein the polyurethane composition is a cross-linked polymer.

4. The panel according to claim 1, wherein the polyester polyol has a weight average molar mass Mw in the range of 500 to 20,000, and comprises preferably a polyester polyol having linear monomers of 5 to 8 carbon atoms.

5. The panel according to claim 1, wherein the polyether polyol has a weight average molar mass Mw in the range of 400 to 10,000, and comprises preferably a polyether polyol having branched monomers of 2 to 5 carbon atoms.

6. The panel according to claim 1, wherein the isocyanate is a di-isocyanate and/or tri-isocyanate, preferably methylene diphenyl di-isocyanate.

7. The panel according to claim 1, wherein the protective material contains 5-50 wt. % reacted polyester polyol.

8. The panel according to claim 1, wherein the protective material contains 10-40 wt. % reacted polyether polyol.

9. The panel according to claim 1, wherein the protective material contains 5-20 wt. % reacted isocyanate.

10. The panel according to claim 1, wherein the protective material comprises a filler material as an additive, such as microfibers and/or alumina, preferably in a range of 0.2-5 wt. % with respect to the protective material.

11. The panel according to claim 1, wherein the intermediate layer is directly attached onto the decorative layer and/or onto the top layer.

12. The panel according to claim 1, wherein the top side of the top layer is embossed with a relief, which relief preferably corresponds to the decorative image of the decorative layer.

13. The panel according to claim 1, wherein the intermediate layer has a grammage of 20 up to 80 g/m2.

14. The panel according to claim 1, wherein the intermediate layer is colorless.

15. The panel according to claim 1, wherein the intermediate layer has a relatively low reflectance of 4%, 3%, 2% or lower.

16. The panel according to claim 1, comprising a first panel edge which comprises a first coupling profile, and a second panel edge, preferably opposite to the first panel edge, comprising a second coupling profile being designed to engage by interlocking with said first coupling profile of an adjacent panel, both in horizontal direction and in vertical direction, wherein the first coupling profile and the second coupling profile are preferably configured such that two of such panels can be coupled to each other by means of a lowering movement.

17. The panel according to claim 1, comprising at least one third coupling profile and at least one fourth coupling profile located respectively at a third panel edge and a fourth panel edge, wherein the third coupling profile comprises: a sideward tongue extending in a direction substantially parallel to the upper side of the core, at least one second downward flank lying at a distance from the sideward tongue, and a second downward groove formed between the sideward tongue and the second downward flank, wherein the fourth coupling profile comprises: a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile of an adjacent panel, said third groove being defined by an upper lip and a lower lip, wherein said lower lip is provided with an upward locking element, wherein the third coupling profile and the fourth coupling profile are configured such that two of such panels can be coupled to each other by means of a turning movement, wherein, in coupled condition: at least a part of the sideward tongue of a first panel is inserted into the third groove of an adjacent, second panel, and wherein at least a part of the upward locking element of said second panel is inserted into the second downward groove of said first panel.

18. An additional layer in a laminated multi-layer structure of a panel in particular a floor panel, ceiling panel, or wall panel, wherein the additional layer is transparent, and is made from a protective material which comprises a polyurethane composition which is the reaction product of a polyester polyol, a polyether polyol, and an isocyanate, and wherein the polyurethane composition is a thermoset polymer material.

19. Additional layer according to claim 18, wherein the polyurethane composition is a cross-linked polymer.

20. Additional layer according to claim 18, wherein the laminated multi-layer structure of the panel comprises: a core layer, a decorative layer above the core layer, a transparent top layer above the decorative layer, and the additional layer is applied as an intermediate layer situated between the decorative layer and the top layer.

21. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0069] The invention will be further elucidated by specific preferred embodiments which are shown in the appended figures, wherein:

[0070] FIG. 1 shows a cross-section of a laminated multi-layer structure of the panel according to the invention;

[0071] FIGS. 2 and 3 show in cross-section two types of engaging coupling profiles suitable for a panel according to the invention.

DESCRIPTION OF THE INVENTION

[0072] FIG. 1 shows schematically a cross-section of a laminated multi-layer structure of a panel 100, which is constituted from multiple layers which are directly connected to each other. These layers include a backing layer 101, a core layer 102, a decorative layer 103 provided with a decorative image, an intermediate layer 104 and an embossed top layer 105. The embossed top layer contains depressions 106 and elevations 107, so that a relief is formed on the top surface of the top layer which corresponds to the pattern of the decorative image that is facing upwards from the decorative layer 105. The intermediate layer 104 is formed from a protective material in accordance with the invention, and is transparent and colorless.

[0073] FIGS. 2 and 3 show two types of engaging coupling profiles 401A, 401B resp. 402A, 402B, of two interconnecting panels 400A, 400B according to the present invention. The panels 400A and 400B comprise an embossed top layer 410. As a whole, each panel has a laminated multi-layer structure in accordance with FIG. 1 (which is however not further shown in detail in FIGS. 2 and 3).

[0074] FIG. 2 shows panels 400A and 400B, which respectively comprise a first panel edge 440A comprising a first coupling profile 401A, and a second panel edge 440B opposite to the first panel edge 440A, comprising a second coupling profile 401B being designed to engage by interlocking with said first coupling profile 401A of an adjacent panel, both in horizontal direction and in vertical direction, wherein the first coupling profile 401A and the second coupling profile 401B are configured such that two of such panels can be coupled to each other by means of a lowering movement.

[0075] FIG. 3 shows panels 400A and 400B, which respectively comprise a third coupling profile 402A and a fourth coupling profile 402B located respectively at a third panel edge 441A and a fourth panel edge 441B. The third coupling profile 402A and the fourth coupling profile 402B are configured such that the two panels 440A, 440B can be coupled to each other by means of a turning movement, wherein, in coupled condition at least a part of a sideward tongue 404B of a first panel is inserted into a groove 404A of an adjacent, second panel, and wherein at least a part of an upward locking element 406A of said second panel is inserted into a second downward groove 406B of said first panel.

[0076] It is noted that the invention is not limited to the examples shown and described above, but that numerous variants are possible within the scope of the attached claims that will be clear to a person skilled in the art.

[0077] The verb “comprise” and conjugations thereof used in the description are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof.