Abstract
The present invention relates to a panel, in particular a floor panel or wall panel, comprising a core layer comprising a mineral filler, a polymeric binder, and optionally a plasticizer; and a coating layer located on a bottom surface of the core layer. The invention further relates to a composition for forming a coating layer. The invention further relates to a method of manufacturing a panel, comprising providing a core layer comprising at least one mineral filler and at least one polymeric binder, applying a composition to at least part of a bottom surface of the core layer, and at least partially crosslinking the composition to obtain a coating layer.
Claims
1. A floor panel or wall panel, comprising: at least one core layer comprising at least one mineral filler, at least one polymeric binder, and at least one plasticizer; at least one decorative top layer located on a top surface of the at least one core layer, said at least one decorative top layer comprising at least one printed layer, at least one wear layer and at least one top coating layer; and at least one bottom coating layer located on a bottom surface of the at least one core layer; wherein the at least one printed layer is at least partially digitally printed; wherein the at least one wear layer has a thickness in the range of 0.2 mm to 0.8 mm and comprises one or more transparent layers of a thermoplastic or thermosetting resin; wherein the at least one top coating layer comprises at least one viscoelastic coating layer, at least one thermoset coating, at least one acrylic coating layer, at least one excimer cured coating layer or any combination thereof, and comprises at least partially a tactile texture provided thereon by chemical or mechanical means; and wherein the at least one bottom coating layer comprises an at least partly crosslinked polymer impermeable to the at least one plasticizer.
2. The panel according to claim 1, wherein the at least one bottom coating layer has a shrinking rate A when tested according to ISO 23999 and wherein the at least one top coating layer and/or decorative top layer has a shrinking rate B when tested according to ISO 23999, wherein B<A and/or wherein A1.1.Math.B.
3. The panel according to claim 1, wherein a thickness of the at least one decorative top layer is in the range of 0.05 mm to 0.10 mm.
4. The panel according to claim 1, wherein the at least one decorative top layer forms integral part of the at least one core layer.
5. The panel according to claim 1, wherein a primer is provided on a top facing surface of the at least one core layer.
6. The panel according to claim 1, wherein a coating layer is provided on a top facing surface of the at least one core layer.
7. The panel according to claim 1, wherein the at least partially crosslinked polymer has a crosslinking density of at least 50%.
8. The panel according to claim 1, wherein the at least one bottom coating layer comprises 30-50 wt. % of at least one acrylate oligomer, 10-20 wt. % of at least one acrylate monomer, and 1-5 wt. % of at least one photoinitiator.
9. The panel according to claim 8, wherein the at least one acrylate oligomer is selected from urethane acrylate oligomers, polyester-based urethane acrylate oligomers, aliphatic urethane acrylate oligomers, aromatic urethane acrylate oligomers, polyether-based urethane acrylate oligomers, waterborne urethane acrylate oligomers, polyester acrylate oligomers, unsaturated polyester acrylates, polyester acrylates, adhesion-promoting polyester acrylates, low-molecular weight polyester acrylates, water-reducible polyester acrylates, epoxy acrylate oligomers, bisphenol A epoxy acrylates, aliphatic epoxy acrylates, cycloaliphatic epoxy acrylates, low-viscosity epoxy acrylates, novolac epoxy acrylates, silicone acrylate oligomers, hydrophilic silicone acrylates, silicone acrylates, silicone-modified acrylates, low-viscosity silicone acrylates, silicone-modified urethane acrylate, or any combination thereof.
10. The panel according to claim 8, wherein the at least one acrylate monomer is selected from tetrahydrofurfuryl acrylate, pentaerythritol triacrylate, 2-hydroxyethyl acrylate (HEA), ethoxylated bisphenol A diacrylate (EBDA), trimethylolpropane triacrylate (TMPTA), isobornyl acrylate (IBOA), cyclohexyl acrylate (CHA), or any combination thereof.
11. The panel according to claim 1, wherein the at least one core layer comprises 10-40 wt. % of the at least one polymeric binder, 20-60 wt. % of the at least one mineral filler, and at least 4 wt. %, of the at least one plasticizer, based on total weight of the at least one core layer.
12. The panel according to claim 1, wherein the at least one plasticizer is selected from diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), diethylhexyl phthalate (DEHP), dibutyl phthalate (DBP), butyl benzyl phthalate (BBP), di(2-ethylhexyl) adipate (DEHA), di(2-ethylhexyl) sebacate (DOS), di(2-ethylhexyl) terephthalate (DOTP), diisononyl cyclohexane-1,2-dicarboxylate (DINCH), triethyl citrate (TEC), di(2-ethylhexyl) phthalate (DEHP), di-n-octyl phthalate (DNOP), diisobutyl phthalate (DIBP), di-n-hexyl phthalate (DNHP), diethyl phthalate (DEP), dicyclohexyl phthalate (DCHP), diethylene glycol dibenzoate (DEDB), epoxidized soybean oil (ESBO), citrates, citrate esters, castor oil derivatives, epoxidized vegetable oils, succinic acid esters, tartaric acid, sorbitol, polyethylene glycol, starch, epoxidized soybean oil (ESBO), tributyl citrate (TBC), acetyl tributyl citrate (ATBC), triethyl citrate A (TEC-A), triclocarban (TCC), bis(2-ethylhexyl) maleate, bis(2-ethylhexyl) fumarate, DOML (linseed oil), DOP (castor oil based), DEHT (castor oil), GEFA, ELO, ESO, EVO, ELOV, ELOVAT, DOSA, DOA, DIDA, DES, DBS, PEG, Lactic Acid, Oleic acid, PPG, PES, Paraffinic oils, naphthenic oils, esters, or any combination thereof.
13. The panel according to claim 1, wherein the at least one polymeric binder is selected from polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC), chlorinated polyethylene (CPE), Polylactic Acid (PLA), Polyhydroxyalkanoates (PHA), Polybutylene Succinate (PBS), Polyhydroxyurethane (PHU), Cellulose Acetate (CA), Starch-based Bioplastics, Polyglycolic Acid (PGA), Polyhydroxyalkanoate-Co-Valerate (PHA-V), Polybutylene Adipate Terephthalate (PBAT), TPU, LDPE, LLDPE, HDPE, PS, HIPS, GPPS, PA, PETG, PPC, PC, ABS, PVDF, starch-based polymers, PHD, Bio-PE, LA, cellulose acetate, or any combination thereof.
14. The panel according to claim 1, wherein at least one mineral material comprises magnesium oxide, magnesium carbonate, magnesium oxysulphate, magnesium oxychloride cement (MOC), magnesium chloride (MgCl2), magnesium sulphate (MgSO4), Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite mineral, stone, chalk, clay, calcium silicate and/or talc.
15. A method of manufacturing a floor panel or wall panel, comprising the steps of: providing at least one core layer comprising at least one mineral filler, at least one polymeric binder, and at least one plasticizer; providing at least one decorative top layer to a top surface of the at least one core layer, said at least one decorative top layer comprising at least one printed layer, at least one wear layer and at least one top coating layer; and providing at least one bottom coating layer to a bottom surface of the at least one core layer; wherein the at least one wear layer has a thickness in the range of 0.2 mm to 0.8 mm and comprises one or more transparent layers of a thermoplastic or thermosetting resin; wherein the at least one top coating layer comprises at least one viscoelastic coating layer, at least one thermoset coating, at least one acrylic coating layer, at least one excimer cured coating layer or any combination thereof, and comprises at least partially a tactile texture provided thereon by chemical or mechanical means; and wherein the at least one bottom coating layer comprises an at least partly crosslinked polymer impermeable to the at least one plasticizer.
16. The method according to claim 15, wherein a mass of the composition is applied to the bottom surface of the core layer in a range between 10 and 90 g/m2.
17. The method according to claim 15, wherein the at least one core layer comprises 10-40 wt. % of the at least one polymeric binder, 20-60 wt. % of the at least one mineral filler, and at least 4 wt. %, of the at least one plasticizer, based on total weight of the at least one core layer.
18. The method according to claim 15, wherein the at least one bottom coating layer has a shrinking rate A when tested according to ISO 23999 and wherein the at least one top coating layer and/or decorative top layer has a shrinking rate B when tested according to ISO 23999, wherein B<A and/or wherein A1.1.Math.B.
19. The method according to claim 15, wherein a thickness of the at least one decorative top layer is in the range of 0.05 mm to 0.10 mm.
20. The method according to claim 15, wherein the printed layer is a digitally printed layer.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0139] The invention will now be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures. Herein shows:
[0140] FIG. 1 a perspective view of a prior art panel comprising plasticizer molecules;
[0141] FIG. 2 a cross sectional view of a panel according to the present invention;
[0142] FIG. 3 a cross sectional view of another panel according to the present invention;
[0143] FIG. 4 a cross sectional view of another panel according to the present invention;
[0144] FIG. 5 a cross sectional view of another panel with an acoustic backing according to the present invention;
[0145] FIG. 6 a cross sectional view of another panel according to the present invention including embossing on the top protective layer and multiple layers of the coating layer;
[0146] FIG. 7 a cross sectional view of another panel according to the present invention including an embossing layer;
[0147] FIG. 8 a cross sectional view of another panel according to the present invention including a pre-attached acoustic backing;
[0148] FIG. 9 a cross sectional view of a wall panel according to the present invention:
[0149] FIG. 10 an illustration of the crosslinking in the coating layer;
[0150] FIGS. 11a, 11b and 11c an illustration of the crosslinking in the coating layer at varying densities, i.e., 50%, 60%, and 70% and a reference thereof in FIG. 11d;
[0151] FIG. 12a an illustration of the relationship of the crosslinking density with void diameter and a reference illustration in FIG. 12b;
[0152] FIG. 13 an illustration of an alternative embodiment of a top layer according to the present invention;
[0153] FIG. 14 an illustration of an alternative embodiment of a top layer with a digitally printed layer according to the present invention;
[0154] FIG. 15 an illustration of an alternative embodiment of a top layer further comprising an embossing according to the present invention;
[0155] FIG. 16 an illustration of an alternative embodiment of a top layer without a wear layer according to the present invention;
[0156] FIG. 17 an illustration of an alternative embodiment of a top layer further comprising a gloss control layer according to the present invention;
[0157] FIG. 18 an illustration of an alternative embodiment of a top layer further comprising at least one acrylic layer according to the present invention;
[0158] FIG. 19 an illustration of an alternative embodiment of a top layer wherein embossing is applied up to at least part of the at least one acrylic layer according to the present invention;
[0159] FIG. 20 an illustration of an alternative embodiment of a top layer further comprising a gloss control layer wherein embossing is applied up to at least part of the at least one acrylic layer according to the present invention;
[0160] FIG. 21 an illustration of another aspect of the present invention;
[0161] FIG. 22 an illustration of another aspect of the present invention; and
[0162] FIG. 23 an illustration of another aspect of the present invention.
[0163] Within these figures, the same reference number refer to similar or equivalent technical features.
[0164] FIG. 1 shows a perspective view of a prior art panel 101 installed on a substrate 200. The panel 101 comprises a core layer 102 and a top coating layer 103. Due to curing of the top coating layer 103 during manufacturing of the panel 101, the panel 101 is curved or cupping. The side edges of the panel comprising the complementary coupling means 104, 105, are located at a relatively large distance from the substrate 200, as compared to the distance of the centre 106 of the panel 101 from the substrate 200.
[0165] The panel 101 is adhered to the substrate 200 via an adhesive layer 107. Plasticizer molecules 108 have migrated from the core layer 102 of the panel 101 into the adhesive layer 107. The adhesive layer 107 has liquified as a result.
[0166] FIG. 2 shows a cross section of a panel 101 according to the present invention, wherein the panel 101 is installed on a substrate 200, for example a floor surface. The panel 101 comprises complementary coupling means 104, 105. The panel comprises a coating layer 110 on the bottom side of the core layer 102. Plasticizer molecules 108 are distributed over the core layer 102. Due to the coating layer 110 being cured, it has shrunk during manufacturing of the panel. As such, the coating layer 110 has balanced the panel 101, resulting in the panel 101 being straight. The adhesive layer 107 has a uniform thickness due to the alignment of the lower bottom surface 111 of the coating layer 110 and the substrate 200. Due to the uniform thickness of the adhesive layer, adherence between the panel 101 and the substrate 200 is improved.
[0167] Curing of the coating layer 110 during manufacturing of the panel 101 has not only shrunk the coating layer 110 but has also crosslinked the oligomers and monomers within the coating to form a polymeric network. The polymeric network contains voids having a relatively small diameter, that prevent the plasticizer molecules 108 from migrating through the coating layer 110 into the adhesive layer 107. As a result, the adhesive layer 107 does not liquefy.
[0168] Referring now to FIG. 3, a panel 101 installed on a substrate 200 is shown. The panel 101 comprises complementary coupling means 104, 105. This panel 101 differs from the panel in FIG. 2 as it comprises an additional coating layer 110c located in between the top layer 103 and the core layer 102 comprising plasticizer molecules 108. The top layer 103 of the panel 101 of FIG. 3 is a decorative top layer, comprising a printed pattern. The coating layer 110c directly underneath the top layer 103 prevents plasticizer molecules 108 from migrating out of the core layer 102 into the printed pattern. In this way, the coating layer 110c directly underneath the top layer 103 prevents dissolving of the ink in the printed pattern. As such, the printed pattern is maintained for a long period of time. Further, the coating layer 110 provided between the core layer 102 and adhesive layer 107 allows for enhanced adhesion and compatibility with adhesives due to the presence of organosilanes, and improvement in balancing when subjected to temperature fluctuations.
[0169] FIG. 4 shows an embodiment of the panel 101 of the present invention, wherein the panel 101 is installed on a substrate 200 and comprises a top layer 103 comprising at least one visual design and at least one protective layer, the top layer 103 having a first shrinking rate, at least one coating layer 110a comprising at least one carboxyl functional group able to react with the at least one plasticizer and at least one coating layer 110b comprising at least one organosilane, allowing a strong bond with the adhesive layer 107, where coating layers 110a and 110b have a second shrinking rate being larger than the top layer's 103 first shrinking rate, preferably being around 10% larger than the top layer's first shrinking rate, thereby balancing the construction. The panel 101 has as a result a cupping rate of less than 1 mm, preferably less than 0.5 mm, when tested to ISO 23999. The panel 101 of the shown embodiment is free of coupling means.
[0170] As further exemplified in the panel 101 installed on a substrate 200 as shown in FIG. 5, a top layer 103 is arranged on the top surface of the core layer 102 comprising plasticizer molecules 108. This panel 101 comprises an acoustic backing 202 attached to the back side of the coating layer 110, which is adhered to the core layer 102 by means of an adhesive layer 107. The panel 101 comprises complementary coupling means 104, 105.
[0171] As shown in the panel 101 of FIG. 6, the top layer 103 is a top protective layer 103 comprising a top sealing layer 1031, a decorative print layer 1032, and a top protective layer with embossing 1033. The panel 101 as shown in FIG. 6 comprises multiple coating layers 110, 111 are included in the panel 101, such that a first bottom surface coating layer 110 and a second bottom surface coating layer 111 represent multiple coating layers provided onto the bottom surface of the core layer 102. The panel 101 is installed on a substrate 200 and the core layer 102 comprises plasticizer molecules 108.
[0172] The panel 101 as shown in FIG. 7 has a tactile embossing or texture layer 1034. This mechanically or chemically applied texture layer 1034 is present between a top coating layer 1035 and at least one protective layer 1033. The entirety of the top layer 103 construction, including the top sealing layer 1031, decorative print layer 1032, protective layer 1033, embossing layer 1034 and top coating layer 1035 combined having a first shrinking rate; and the entirety of the at least one bottom coating 110, 111 or sealing layer buildup having a second shrinking rate, such as the first coating layer 110 and second coating layer 111, with the second shrinking rate being larger than the top layer 103 construction's first shrinking rate, preferably being around 10% larger than the top layer's first shrinking rate, thereby balancing the construction. The panel 101 has as a result a cupping rate of less than 1 mm, preferably less than 0.5 mm, when tested to ISO 23999. It is conceivable that the at least one coating layer 110 comprises at least one carboxyl functional group able to react with the at least one plasticizer and/or has an average crosslink void diameter which is smaller than the average plasticizer diameter, and/or that the at least one second coating layer 111 comprises at least one organosilane, allowing a strong bond with the adhesive layer 107. The panel 101 as shown is installed on a substrate 200 and the core layer 102 comprises plasticizer molecules 108.
[0173] The panel 101 in FIG. 8 comprises a pre-attached acoustic backing 203 which is adhered to the panel 101 by means of an adhesive layer 107. The adhesive's integrity as well as the panel's stability and flatness are ensured by presence of a first bottom surface coating layer 110 and a second bottom surface coating layer 111. The panel 101 as shown is installed on a substrate 200 and the core layer 102 comprises plasticizer molecules 108. The top layer 103 comprises a top sealing layer 1031, a decorative print layer 1032, a protective layer 1033 and an embossing layer 1034.
[0174] FIG. 9 shows another exemplary embodiment of a panel 101 according to the present invention such that panel 101 is constructed as a wall panel and is attached to the wall substrate 200. Tongue and groove coupling means 104 and 105 are provided herein for a locking mechanism of the wall panel 101. The core layer 102 comprises plasticizer molecules 108 dispersed over the core layer 102. The panel 101 as shown comprises multiple coating layers 110, 111 are included in the panel 101, such that a first bottom surface coating layer 110 and a second bottom surface coating layer 111 represent multiple coating layers provided onto the bottom surface of the core layer 102. The top layer 103 comprises a top sealing layer 1031, a decorative print layer 1032 and a protective layer 1033.
[0175] FIG. 10 shows a part of a panel 101, wherein a part of the coating 110 (depicted by a square) is enlarged and schematically shown. The enlarged square in FIG. 10 shows the three-dimensional network, defined by the polymeric backbone 1101 and crosslinks 1102. FIG. 10 further shows the crosslinked properties of the polymer coat or the coating layer 110. The void diameter, Vdia, 1103 (the diameter of the dotted circle) is the measure of the average size of gaps/spaces within the three-dimensional network of the crosslinked polymer. The panel 101 further comprises a core layer 102 comprising plasticizer molecules 108 and a decorative top layer 103. The panel could optionally be provided with coupling means 104.
[0176] FIGS. 11a, 11b and 11c show schematic representations of the three-dimensional networks defined by the polymeric backbone 1101 and crosslinks 1102 for different crosslink densities. The crosslink density of the three-dimensional networks are 50%, 60% and 70%, respectively for FIGS. 11a, 11b and 11c. The number of crosslinks 1102 and the interconnectedness increases with increasing crosslinking densities. Now with reference to FIGS. 2-9, the increase in the densification of the crosslinking reduces the void diameter in the polymeric coating layer 110, which is smaller than the diameter of gyration of the plasticizer molecules 108. Thus, the adhesive layer 107 does not liquefy. The coating layer 110 then functions as a mechanical barrier to inhibit the migration of the plasticizer molecules 108 from the core layer 102 to the adhesive layer 107. FIG. 11d shows a reference figure of the crosslink densities as shown in FIGS. 11a-11c wherein the effect of the increased crosslinked density is shown.
[0177] FIG. 12a shows the relationship of the crosslinking density with the void diameter, such that the crosslinking density is inversely proportional with the void diameter of the polymeric network of the coating layer. The figure shows that a drastic decrease in the void diameter is due to the increase of the crosslinking density on the coating layer. In a densely crosslinked network, the formation of voids is less likely, and the void diameter tends to be smaller. As the crosslinking density decreases, the network becomes less connected, allowing the formation of larger voids.
[0178] Additionally, the size and distribution of voids can be influenced by the polymer's molecular weight, the degree of crosslinking, and the presence of any plasticizers or other additives. The network topology, such as the arrangement of crosslinks, also plays a role in determining the void structure.
[0179] FIG. 12b is a reference figure showing histograms of nanovoid volumes in poly(dicyclopentadiene) (pDCPD) and poly(5-ethylidene-2-norbornene) (pENB) undergoing uniaxial extension deep in the glassy state (150 K) at 0% (solid symbols) and 35% (open symbols) engineering strain. Inset shows the nanovoid volume percent, i.e., the percent of the simulation box volume occupied by nanovoids.
[0180] FIG. 13 shows a schematic, exploded view of another possible embodiment of a panel 101 according to the invention. It is conceivable that the top layer 103 of the panel comprises at least one top coating layer 1031, at least one tactile or texture layer 1033, and (optionally) at least one wear layer 1034. The top layer 103 is provided at least partially on a top surface of a core 102, and a coating layer 110 is provided on the bottom surface of a core layer 102. The thickness of the at least one wear layer is at least 0.2 mm, most preferably up to 0.5 mm. It is conceivable that at least two wear layers are provided, where it is conceivable that wear resistant particles are provided between two wear layers at a weight of 20-50 g/m2, preferably at around 30-35 g/m2.
[0181] FIG. 14 shows a schematic, exploded view of an alternative embodiment of a panel 101 according to the invention, and in particular a top layer 103 of the panel. The panel comprises a top layer 103 which comprises a coating layer 1031, at least one texture or embossing layer 1035, a gloss control layer 1036, an acrylic coating layer 1037 comprising wear resistant particles at a load of 5-15% by weight, a decorative print layer 1032, and a primer layer 1038. The at least one acrylic coating layer 1037 may also comprise scattered wear resistant particles. The embossing layer 1035 can be a viscoelastic coating layer. The decorative print layer 1032 is alternatively a digitally printed layer. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102.
[0182] FIG. 15 shows a schematic, exploded view of an alternative embodiment of panel 101 according to the invention, and in particular a possible embodiment of a top layer 103 according to the present invention. The panel 101 comprises a top layer 103 which alternatively comprises a top coating layer 1031, at least one embossing layer 1035, a gloss control layer 1036, at least one wear layer 1034, where it is conceivable that at least two wear layers are provided and/or that a ceramic bead load is provided between at least two wear layers at a weight of 20-50 g/m2, preferably at around 30-35 g/m, a decorative print layer 1032, and/or a primer layer 1038. Embossing is at least partially provided on the top layer 103 by mechanical, chemical or abrasive means, where the top coating layer 1031 covers at least part of the embossing layer 1035. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102.
[0183] FIG. 16 shows yet another schematic, exploded view of an alternative embodiment of a panel 101 according to the invention, and in particular a top layer 103 of the panel. The panel comprises a top layer 103 which alternatively comprises a top coating layer 1031, at least one embossing layer 1034, a gloss control layer 1036, a decorative print layer 1032, and/or a primer layer 1038. Embossing is at least partially provided on the top layer 103, specifically extending vertically in the embossing layer 1034, wherein the top coating layer 1031 covers at least part of the embossing layer 1034. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102.
[0184] FIG. 17 shows a schematic, exploded view of an alternative embodiment of panel 101 according to the invention, and in particular the top layer 103 of the panel 101. The panel 101 comprises a top layer 103 which preferably comprises a top coating layer 1031, at least one embossing layer 1035, a gloss control layer 1036, a wear layer 1034, a decorative print layer 1032 and/or a primer layer 1038. The thickness of the at least one wear layer 1034 is at least 0.2 mm, most preferably up to 0.5 mm. It is conceivable that at least part of the at least one embossing layer 1035 and/or the gloss control layer 1036 is covered with the top coating layer 1031. It is further conceived that the embossing layer 1035 is a viscoelastic coating layer and that the decorative print layer 1032 is a digitally printed layer. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102.
[0185] FIG. 18 shows a schematic, exploded view of an alternative embodiment of panel 101 according to the invention, and in particular the top layer 103 of the panel 101. The panel 101 comprises a top coating layer 103 which preferably comprises at least one acrylic coating layer 1037, a decorative print layer 1032 and/or at least one wear layer 1034. The thickness of the at least one wear layer is at least 0.2 mm, most preferably up to 0.5 mm. It is conceivable that embossing is applied to at least part of the acrylic coating layer 1037 to at least part of the decorative print layer 1032 and/or to at least part of the core layer 102. The core layer 102 comprises plasticizer molecules 108. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102. It is further conceived that the at least one acrylic coating layer 1037 contains wear-resistant particles in the range of 1% to 30%, preferably in the range of 1% to 10%.
[0186] FIG. 19 shows a schematic, exploded view of an alternative embodiment of panel 101 according to the invention, and in particular the top layer 103 of the panel 101. The panel 101 comprises a top layer 103 which preferably comprises a top coating layer 1031, at least one embossing layer 1035, a plurality of acrylic coating layers 1037 and/or a wear layer 1034. The thickness of the at least one wear layer 1034 is at least 0.2 mm, most preferably up to 0.5 mm. It is conceivable that embossing is applied to at least part of the embossing layer 1035, at least one acrylic coating layer 1037 and/or to at least part of the wear layer 1034. It is further conceived that at least part of the at least one embossing layer 1035, at least one acrylic coating layer 1037 and/or wear layer 1034 is covered with the top coating layer 1031. It is also conceived that the at least one acrylic coating layer 1037 contains wear-resistant particles in the range of 1% to 30%, preferably in the range of 1% to 10%. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102.
[0187] FIG. 20 shows a schematic, exploded view of an alternative embodiment of a panel 101 according to the invention, and in particular the top layer 103 of the panel 101. The panel 101 comprises a top layer 103 which preferably comprises a top coating layer 1031, at least one embossing layer 1035, a plurality of acrylic coating layers 1037, a gloss control layer 1036 and/or a wear layer 1034. The thickness of the at least one wear layer 1034 is at least 0.2 mm, most preferably up to 0.5 mm. It is conceivable that embossing is applied to at least part of the embossing layer 1035, and/or to at least part of the acrylic coating layer 1037. It is further conceived that at least part of the at least one embossing layer 1035 and/or the at least one acrylic coating layer 1037 is covered with the top coating layer 1031. It is also conceived that the at least one acrylic coating layer 1037 contains wear-resistant particles in the range of 1% to 30%, preferably in the range of 1% to 10%. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102.
[0188] FIG. 21 shows another schematic, exploded view of an alternative embodiment of a panel 101 according to the present invention. The panel 101 comprises top layer 103, further comprising a thin top coating 1031, at least one embossing layer 1050, at least one first wear layer 1034a, and/or at least one second wear layer 1034b. At least one scatting layer 1060, for example an aluminium oxide scattering layer can be provided below at least one first wear layer 1034a, and/or above at least one second wear layer 1034b. The wear resistant particles may be scattered, at least partially enclosed or embedded, preferably completely enclosed or embedded, by the at least one first wear layer 1034a and the at least one second wear layer 1034b after being adhered to each other. The top layer 103 is provided at least partially on a top surface of a core 102, and an optional coating layer 110 is provided on the bottom surface of a core layer 102.
[0189] FIG. 22 shows a schematic, exploded view of an alternative embodiment of a panel 101 according to the invention. The panel 101 comprises a top layer 103, a core layer 102, and at least one coating layer 110. The top layer 103 alternatively comprises a top coating layer 1031, at least one wear layer 1034, and a decorative print layer 1032. It is conceivable that the at least one wear layer 1034 has a thickness between 0.2 to 0.5 mm. It is further conceivable that decorative print layer 1032 is a digitally printed layer and/or an impregnated paper layer. If an impregnated paper layer is used, then an overlay layer 1039 is added in between the impregnated paper and the core layer 102, preferably adjacent to the impregnated paper.
[0190] FIG. 23 shows a schematic, exploded view of an alternative embodiment of a panel 101 according to the invention. The panel 101 comprises a top coating layer 103, a core layer 102, and at least one coating layer 110. The top layer 103 comprises a top coating layer 1031, a digital printed layer 1032, and a primer layer 1308.
[0191] It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.
[0192] The verb comprise and conjugations thereof used in this patent publication are understood to mean not only comprise, but are also understood to mean the phrases contain, substantially consist of, formed by and conjugations thereof.
