Abstract
Boards have a mineral content, including magnesiumoxychloride and/or magnesiumoxysulphate, and may be finished with a DPL laminate decorative layer.
Claims
1.-75. (canceled)
76. A board, wherein this board is a board comprising: 5Mg(OH2).MgSO4.7H2O.
77. The board according to claim 76, wherein the board comprises at least one layer based on MgO and MgSulphate.
78. The board according to claim 76, wherein this board comprises at least two layers having a mutually different composition, wherein a first layer of said at least two layers comprises or is obtained from at least MgO and MgChloride, while a second layer of said at least two layers comprises or is obtained from at least MgO and MgSulphate.
79. The board according to claim 76, wherein this board comprises at least two layers having a mutually different composition, wherein a first layer of said at least two layers is based on magnesiumoxychloride, while a second layer of said at least two layers is based on magnesiumoxysulphate.
80. The board according to claim 76, wherein said board comprises at least three layers, wherein a layer based on magnesiumoxychloride is adjacent to two layers based on magnesiumoxysulphate, namely one at the bottom and one at the top of the magnesiumoxychloride based layer.
81. The board according to claim 76, wherein said board comprises at least three layers, wherein a layer based on magnesiumoxysulphate is adjacent to two layers based on magnesiumoxychloride, namely one at the bottom and one at the top of the magnesiumoxysulphate based layer.
82. A coated panel comprising a board according to claim 76, wherein said panel comprises a decorative layer provided on said board, wherein said decorative layer comprises thermosetting resin, such as melamine, and a printed paper sheet and/or an overlay paper and/or an underlay paper and/or a wood veneer.
83. The coated panel as in claim 82, wherein said coated panel is obtained through a DPL press treatment.
84. The coated panel comprising a board as in claim 76, wherein said panel comprises a decorative layer provided thereon, wherein said decorative layer comprises a wood veneer, or a ceramic tile, or a stone veneer, or a thermoplastic top layer.
85. A panel, wherein the panel is a floor, wall or ceiling panel, wherein the panel comprises a coated panel as in claim 82; wherein the board is provided at at least two opposite edges with coupling means allowing to couple two such panels at the respective edges, wherein a vertical locking perpendicular to the plane of coupled panels and/or a horizontal locking perpendicular to the respective edges and in the plane of the coupled panels is obtained; wherein said coupling means are basically shaped as a tongue and a groove, wherein the groove is bordered by an upper lip and a lower lip.
86. The panel in accordance with claim 76, wherein said lower lip and/or said upper lip comprises a locking element taking part in said horizontal locking, wherein the respective lip is at least partially provided in a layer of the board that comprises cellulose fibers and/or magnesiumoxychloride.
87. A method of manufacturing board, wherein said method comprises: the step of providing a mixture of at least 35 to 50 wt % of MgO having a purity of 80-98% (wt %) 50 to 65 wt % of MgSO4 in a 20-40% (wt %) solution in water; the step of solidifying said mixture.
88. The method of manufacturing board according to claim 87, wherein said method comprises the step of providing one or more of citric acid, sodium citrate and phosphoric acid is provided in said mixture.
Description
[0175] With the intention of better showing the characteristics according to the invention, in the following, as an example without limitative character, some embodiments are described, with reference to the accompanying drawings, wherein:
[0176] FIG. 1, in perspective, shows a floor panel in accordance with the invention;
[0177] FIG. 2 at larger scale shows a cross-section according to the line II-II on FIG. 1;
[0178] FIG. 3 in a similar view shows a variant;
[0179] FIG. 4 schematically illustrates a method in accordance with the invention;
[0180] FIGS. 5 and 6 in a view similar to that of FIG. 4 illustrate variants;
[0181] FIG. 7 in a view similar to that of FIGS. 2 and 3 illustrate another floor panel;
[0182] FIG. 8 illustrates some steps in a method in accordance with the tenth independent aspect of the invention;
[0183] FIG. 9 illustrates a panel in accordance with the eleventh independent aspect of the invention;
[0184] FIG. 10 illustrates some steps in a method in accordance with the twelfth independent aspect of the invention;
[0185] FIG. 11 illustrates a panel obtained through such method;
[0186] FIG. 12 in a view on the area indicated with F12 in FIG. 10 illustrates a variant;
[0187] FIG. 13 in a view similar to that of FIGS. 2 and 3 illustrate a floor panel comprising a board with the characteristics of the thirteenth independent aspect of the invention;
[0188] FIG. 14 illustrates some steps in a method ideally suited for manufacturing a board having the characteristics of the thirteenth independent aspect of the invention;
[0189] FIG. 15 illustrates some steps in a method in accordance with the fifteenth aspect of the invention;
[0190] FIG. 16 on a larger scale shows a cross-section in accordance with the line XVI-XVI in FIG. 15; and
[0191] FIG. 17 illustrates some steps in a method in accordance with the sixteenth aspect of the invention.
[0192] FIG. 1 illustrates a panel 1 in accordance with amongst others the first aspect of the invention. In this case it is a floor panel 1 that is oblong and rectangular and comprises a long pair of opposite edges 2-3 and a short pair of opposite edges 4-5, both provided with coupling parts 6 allowing to couple two such panels at the respective edges 2-3; 4-5.
[0193] FIG. 2 shows that the coupling parts 6 at least on the long pair of opposite edges 2-3 are basically shaped as a tongue 7 and a groove 8 provided with locking elements 9-10 preventing the moving apart of the tongue and groove connection. These coupling parts 6 are realized in one piece with the core or board 11 of the floor panels 1. The cooperation of the coupling parts 6 results in two such panels 1 to become interlocked, wherein a vertical locking in a direction V1 perpendicular to the plane of coupled panels 1 and a horizontal locking in a direction H1 perpendicular to the respective edges 2-3 and in the plane of the coupled panels 1 is obtained.
[0194] FIG. 2 further shows that the floor panel 1 comprises a board 11 and a provided thereon decorative layer 12. At the bottom of the board 11 a counterbalancing layer 13 is provided.
[0195] The board comprises a plurality of layers 14-15-16 having a different composition. In the example, the board 11 is a three layered board, with a centrally located layer 14 and two more outwardly situated layers 15-16 at each side of the central layer 14.
[0196] In the example, the centrally located layer 14 is based on magnesiumoxychloride or MOC and is directly adjacent to the two more outwardly situated layers 15-16 based on magnesiumoxysulphate, namely the outwardly situated layer 16 at the bottom and the outwardly situated layer 14 at the top.
[0197] It is clear that the illustrated board fulfils the features of the seventh independent aspect of the invention. With the top outermost layer 15 being based on magnesiumoxysulphate an enhanced adhesion with the decorative layer 12 can be obtained, especially in the present case were said decorative layer 12 comprise melamine resin. Moreover the more outwardly situated layers 15-16 may prevent leaching of the centrally located layer 14, which in itself brings an enhance structural strength to the board 11.
[0198] Preferably, the more outwardly situated layers 15-16 each comprise a higher cellulose content than the central layer 14. The cellulose content of the outer layers 15-16 may be 15 wt % or higher, while the cellulose content of the centrally located layer 14 is between 0 and 6 wt %.
[0199] The decorative layer 12 comprises a printed paper sheet 17 being treated with a melamine formaldehyde resin, wherein the paper sheet 17 has a raw paper weight of 50 to 100 grams per square meter and has a resin content of 50 to 130 grams per square meter dry weight. The decorative layer 12 further comprises an overlay, in this case a paper sheet 18 that is transparent or translucent in the obtained panel and applied on top of said printed paper sheet 17. Said overlay is treated with melamine formaldehyde resin as well, has a raw paper weight of 8 to 30 grams per square meter and a resin content of 30 to 100 grams per square meter. The overlay comprises, at its side facing said printed paper sheet 17, particles of aluminum oxide in an amount of 8-20 grams per square meter. Said counterbalancing layer 13 also comprises a paper sheet 19 and melamine formaldehyde resin, for example a paper sheet 19 having a raw paper weight of 70 to 100 grams per square meter and a resin content of 80 to 200 grams per square meter dry weight.
[0200] It is clear that the illustrated floor panel is an example of a coated panel having the characteristics of the first independent aspect of the invention.
[0201] The higher cellulose content in the upper outer layer 15 is beneficial for creating a sufficient adherence with the melamine formaldehyde resin containing top decorative layer 12. The lower cellulose content in the centrally located layer 14 ensures an acceptable dimensional stability of the coated panel 1 as a whole in changing ambient relative humidity.
[0202] It is noted that, in the example of FIG. 2, the groove 8 at said long pair of opposite edges 2-3 is bordered by an upper lip 20 and a lower lip 21, and, in this case, it is the lower lip 21 that comprises a locking element 10 taking part in said horizontal locking. The lower lip 21 is provided at least partially in the outer layer 16 situated at the bottom of said central layer 14, namely in a layer of the board that comprises cellulose fibers. Preferably, as is the case here, at least half of the thickness TL of the lower lip 21 at its thinnest zone 22 is formed by said lower outer layer 16.
[0203] In the example tongue-and-groove locking system, the lower lip 21 of the groove 8 is required to or resiliently deform upon coupling. The lower lip 21 can therefore be regarded as a critical area of the coupling system. Because of it being at least partially provided in the cellulose containing lower outer layer 16 of the board 11, the risk of failure of the lower lip 21 upon coupling and afterwards can be limited.
[0204] In the engaged condition of two or more of such panels 1 the locking elements 9-10 exert a tension force upon each other which forces the panels 1 towards each other. In the example the lower lip 21 of the groove 8 has an elastically bendable portion 23 which, in the engaged condition, is at least partially bent and in this manner provides the aforementioned tension force. Said bendable portion 23 is provided with a contact surface 24 which inwardly slopes downward.
[0205] Preferably, the coupling parts 6 and the locking means 9-10 are realized in one piece with the core or board 11 of the panels 1, e.g. floor panels.
[0206] The floor panels 1 illustrated in FIG. 2 further show the characteristics that the coupling parts 6 have such a shape that two subsequent floor panels can at least be engaged into each other by a turning movement W, whereby each subsequent floor panel 1 can be inserted laterally into the previous; that the coupling parts 6 provide in an interlocking, free from play, according to all directions in the plane which is situated perpendicular to the aforementioned edges 2-3; that the possible difference E between the upper lip 20 and lower lip 21 of the groove 8, measured in the plane of the panel and perpendicular to the longitudinal direction of the groove 8, is smaller than one time the total thickness T of the panel 1; that the total thickness T of each related panel 1 is larger than or equal to 5 mm, or even larger than or equal to 7 mm.
[0207] The tongue 7, or at least that part of the tongue 7 that protrudes beyond the upper edge is entirely realized in the centrally located layer 14. The part of the groove 8 cooperating with said part of the tongue 7 may also be entirely realized in the centrally located layer 14, as is the case here. As this layer 14 is based on magnesiumoxychloride an enhanced strength is obtained of the locking in the vertical direction V1.
[0208] FIG. 3 shows a similar example floor panel 1 as that illustrated by means of FIGS. 1 and 2, with two main differences, as explained here below.
[0209] A first difference is in that the board 11 of the FIG. 3 embodiment essentially comprises five layers 14-15-16-25-26 instead of three. In the example, the centrally located layer 14 is based on magnesiumoxychloride or MOC and is adjacent to the two intermediate layers 25-26 based on magnesiumoxysulphate. Said intermediate layers 25-26 are intermediate to the centrally located layer 14 and the outer layers 15-16 situated at the surface of the board 11. The centrally located layer 14 comprises 0 to 6 wt %, of cellulose based material, said outer layers 15-16 each have a cellulose content of 15 wt % or more and said intermediate layers 25-26 have an intermediate cellulose content, preferably of 5 to 15 wt % or 6 wt % to 15%. The intermediate layers 25-26 may be based on either of magnesiumoxychloride and magnesiumoxysulphate. Preferably, the intermediate layers 25-26 are based both on only one and the same of either magnesiumoxychloride and magnesiumoxysulphate. Most preferably, said intermediate layers are both based on magnesiumoxychloride. In such case, the illustrated example further shows the characteristic that the tongue 7, or at least that part of the tongue 7 that protrudes beyond the upper edge is entirely realized in layers that are based on magnesiumoxychloride, namely in the centrally located layer 14 and the upper intermediate layer 25. The part of the groove 8 cooperating with said part of the tongue 7 is also entirely realized in layers that are based on magnesiumoxychloride. As these layers 14-25-26 are based on magnesiumoxychloride an enhanced strength is obtained of the locking in the vertical direction V1.
[0210] A second difference is in that the board 11 of the FIG. 3 embodiment comprises a decorative layer 12 including, next to a printed paper sheet 17 and an overlay, also an underlay. The underlay is, in this example, a paper sheet 27 treated with melamine formaldehyde resin, having a raw paper weight of 8 to 30 grams per square meter and a resin content of 20 to 80 grams per square meter dry weight. Even though the floor panel of FIG. 3 has a different decorative top layer 12 as compared to the example of FIG. 2, it does form an example of the first independent aspect of the invention as well, wherein the embodiment of FIG. 3 comprises the optional paper sheet 27, or underlay, below the printed paper sheet 17.
[0211] It is clear that the above two differences need not necessarily be combined.
[0212] With regard to FIG. 3, it is further remarked that, in this example the contact surfaces 33-34 between the tongue 7 and the bottom of the upper lip 20 of the groove 8 are entirely realized in the intermediate layer 25 adjacent to the upper outer layer 15.
[0213] FIG. 4 schematically shows a method for manufacturing a coated panel similar to the panels illustrated in FIGS. 2 and 3. FIG. 4 illustrates that the printed paper sheet 17, the overlay with the transparent paper sheet 18, the optional paper sheet 27 for the underlay and the counterbalancing layer 13 is in the example, as well as is the case for the embodiments of FIGS. 1 to 3, cured, consolidated and adhered to the board 11 during one and the same pressing operation between heated press elements 28, for example using a DPL process. As shown here, the press element 28A contacting the overlay may be structured in order to from a relief in the surface or top side of the obtained coated panel 1A-1B. Such relief may correspond to the print 29 contained on the printed paper sheet. For example in the case of a wood print impressions imitating wood grains or grain lines may be provided in the surface. Preferably such wood grains or grain lines follow the course of the printed pattern 29.
[0214] The higher cellulose content at the upper outer layer 15 of the board 11 may accommodate deformations due to the forming of said relief. As shown here, the press element 28A is designed to form relatively deep relief or structure features, for example having a depth of 0.35 millimeter or more. The formation of deep structure features can also be eased due to the availability of said underlay.
[0215] In the present example, next to deep embossments formed in the actual upper surface of the coated panel 1, structure features forming a lower edge area at one or more of the edges of the coated panel 1 are achieved. In this case the lower edge area forms a bevel 30. FIG. 4 also illustrates by means of the contours 1A-1B of the obtained coated panels, that the upper outer layer 15 may be deformed somewhat to accommodate the deepest structure features, such as said bevels 30.
[0216] FIG. 4 further illustrates the presence of hard particles 31, such as particles of aluminum oxide at that side of the overlay which faces the printed paper sheet 17. The available resin 32 on the respective paper sheets 17-18-19-27 is also illustrated.
[0217] It is noted that, by means of the DPL pressing operation larger coated boards, or pressed wholes, are formed from which, by means of a dividing operation, such as a sawing operation, several floor panels 1A-1B may be formed. In FIG. 4 the contours of two floor panels 1A-1B adjacent in the larger coated boards are illustrated by means of the dashed lines.
[0218] In FIG. 4 an increased delamination resistance is obtained since the outer layers 15-16 are based on, or comprise, magnesiumoxysulphate and, in this case, also a cellulose content.
[0219] FIG. 5 illustrates a variant where the board 11A comprises an aminoplast treated substrate 35 incorporated thereto during the production of the board 11A. The board 11A may for example be obtained, or be obtainable through a method according to the fourth or fifth independent aspect of the invention. In this case, said aminoplast treated substrate 35 is a paper sheet 36 impregnated with melamine resin 32. The aminoplast treated substrate 35 is provided at that surface of the board 11′ upon which the printed paper sheet 17 is to be adhered. The printed paper sheet 17, the overlay with the transparent paper sheet 18 and the counterbalancing layer 13 have the same or substantially the same properties as described in connection to FIG. 4. In the obtained coated panel, said aminoplast treated substrate 35 will be available instead of said paper sheet forming the underlay in FIG. 4, and may be seen as part of the decorative layer 12 applied to the top of the board 11. Although not illustrated here, an aminoplast treated substrate may also available at the surface of said board 11A opposite to said surface upon which the printed paper sheet 17 is to be adhered.
[0220] FIG. 6 illustrates a method which is generally the same as the method illustrated in FIG. 4, with this difference that the board 11 comprises a structured surface 37 upon which the decorative layer 12 is to be adhered. The board 11 is obtained or is obtainable with a method in accordance with the sixth independent aspect of the present invention. As is illustrated here, the structured surface 37 comprises some features of the finally to be obtained surface structure of the coated panels, for example at least a structured surface 37 coinciding or about coinciding with lowered edge areas forming a bevel 30. Relief features with a more limited size or depth can exclusively be realized by means of respective protrusions 38 on the press element 28A, here illustrated in the case of protrusions 38 for wood pore imitations. For example, relief features having a depth of 0.15 or less may be realized exclusively by means of respective protrusions on the press element 28A, while at least relief features forming lowered edges are formed in the surface of the board 11 during its production, in accordance e.g. with the sixth independent aspect of the present invention.
[0221] Using a prestructured board 11, as in FIG. 6, leads to a minimized risk of pressure defects in areas having deep relief features.
[0222] It is noted that the boards 11 illustrated in the FIGS. 1 to 6 are symmetric or substantially symmetric through their thickness, i.e. the layers 15-16-25-26 at both sides of a centrally located layer 14 show a thickness, composition and order that results in a symmetric build-up as seen from the middle of the thickness of the board 11.
[0223] FIG. 7 shows a coated panel in the form of a floor panel 1 with the characteristics of the eighth independent aspect of the present invention. The floor panel 1 comprises a board 11 that comprises MOC and/or MOS with a decorative layer 12 formed at the surface of said board 11. The decorative layer 12 is free from paper layers and comprises a mix 39 of at least aminoplast resin, stone powder, e.g. particles of aluminumoxide, and coloring pigments. The coloring pigments are available from the top surface upto a depth D1 in said panel of 0.25 millimeter or more.
[0224] In the represented example said mix 39 has been provided in one of the outer layers 15 of a three layered board. Such an embodiment may be obtained through the second possible method for manufacturing a coated panel having the characteristics of the eighth aspect, as mentioned in the introduction.
[0225] FIG. 8 illustrates that a board 11B may be manufactured, in accordance with the tenth independent aspect of the invention, by at least extruding a suitable slurry 40, for example one of the slurries disclosed in the introduction, through a die 41. In this case the extrusion operation is a continuous operation. The subsequent curing operation is not illustrated here.
[0226] In the illustrated example, the slurry 40 is extruded on top of a board 11, which is in itself a board of MOC or MOS.
[0227] As illustrated here, the extruded slurry 40 is textured by means of an embossing roller 42 in line with the extrusion. In so doing a method also having the features of the sixth independent aspect may be obtained, and the produced board 11B will have a structured surface 37, for example comparable to the structured surface 37 of the board 11 in FIG. 6.
[0228] FIG. 11 shows an insulated panel 42 in accordance with the eleventh independent aspect of the present invention. The panel 42 comprises a thermally insulating material 43, centrally located between a top layer 44 and bottom layer 45 based on MOS or MOC. In this case the insulating material 43 is a foam, preferably a rigid foarm, for example PIR or phenol foam. The top layer 44 and bottom layer 45 form a skin to the thermally insulating material 43.
[0229] The illustrated insulated panel 42 comprises at least two opposite edges having a tongue 7 and groove 8 structure. Upon connection a seamless joint can be obtained, completely shielding the thermally insulating material 43 from the exterior. Next to an enhanced fire resistance, a barrier against leaching of thermally insulation gas from within cells of the thermally insulating foam is obtained, and the insulation capability of the thermally insulation material 43 may decay at a lowered rate.
[0230] FIG. 10 illustrates a method for manufacturing a board 11 having a structured surface 37. The method represents the characteristics of the twelfth independent aspect of the present invention. A structured element 28A is provided. On the structured element 28A several powders 46A-A6B are deposited in subsequent scattering stations 47. In the represented example a three layered board 11 is obtained, wherein the outer layers 15-16 comprise MOS, while the centrally located layer 14 comprises MOC. Clearly the powder 46A for forming said outer layers 15-16 comprises at least MgO and MgSO4, while the powder 46B for forming the centrally located layer 14 comprises at least MgO and MgCl2. It is further noted that the respective powders 46A-46B may comprises further components such as a content of cellulose, for example in accordance with the content contained in the board 11 of FIG. 2.
[0231] FIG. 10 further illustrates that the first deposited powder 46A is that for the outer layer 15 that it is to form the top layer of the board 11.
[0232] FIG. 10 further illustrates that an embossment is also formed at the bottom of the board 11 by means of an additional press element 28B used on top of the finally deposited powder 46A, i.e. the powder for forming the outer layer 16 present at the bottom of the board 11. Said embossing can be carried out in one and the same press treatment as a press treatment used for solidifying or curing the deposited powders 46A-46B. Preferably all deposited layers, namely the powder for the outer layers 15-16 and the powder for the centrally located layer 14, are cured at once.
[0233] FIG. 11 shows an example of a board 11 obtained or obtainable through a method in accordance with the twelfth independent aspect of the invention. In this case, the structured surface 37 comprises lower edge areas 48 imitating one or more groutlines. The structured surface 37 further comprises one or more areas 49 imitating stone or ceramic surfaces. In the example, said areas 49 are adjacent to one ore more of said lower edge areas 48 imitating groutlines.
[0234] FIG. 12 show a variant of the method illustrated in FIG. 11, wherein said powders 46A-46B are deposited on said structured element 28A with the intermediate of a base layer 50. The base layer 50 is preferably a white printable paper layer. The adherence of said base layer 50 with the deposited powder 46A is obtained upon solidification of the deposited powder, for example in a subsequent pressing operation as illustrated by means of FIG. 10. In this way a board 11 can be obtained having a structured top surface with excellent printability for example apt for receiving a digital inkjet print with waterbased inks. The obtained board 11 may comprise titaniumoxide or be white at the printable surface, for example in that said base layer 50 is a paper layer filled with titaniumoxide.
[0235] FIG. 13 shows a floor panel 1 comprising a board having the characteristics of the thirteenth independent aspect of the present invention. The board 11 comprises MOS or MOC and further comprises rock wool fibers. In the example, said rockwool fibers are contained in a layer 51 of said board 11 which is substantially free from MOS and MOC. The layer 51 having the rockwool fibers is an outermost layer, namely a layer present at the top surface of said board 11, or in other words a top layer of the board 11, and provides for an increased delamination resistance of the decorative layer 12. Said layer 51 having the rockwool fibers has a density of 800 kg per cubic meter or more and essentially comprises rockwool fibers bound by means of an aminoplast glue, preferably ureum formaldehyde and/or melamine formaldehyde.
[0236] The board 11 of the floor panel 1 further comprises a layer 52 that comprises MOC and/or MOS. In the example the board 11 is essentially composed of the layer 51 having the rockwool fibers and the layer 51 comprising the MOC and/or MOS.
[0237] The decorative layer 12 of the floor panel 1 of FIG. 13 may further show the same or similar properties as is the case for the floor panels of FIGS. 1 to 3 and may be obtained through a method similar or the same as the method illustrated in FIGS. 4 to 6.
[0238] According to an embodiment not illustrated here, said layer 50 comprising the rockwool fibers may extend exclusively at a level above the tongue 7 and groove 8, i.e above the vertically active contact surfaces 33-34 at the top of the tongue and the bottom of the upper lip 20 of the groove 8. According to still another embodiment not illustrated here, a layer comprising rockwool fibers may also be available at the bottom of the board 11, such that said layer 51 comprising MOC or MOS is a centrally located layer situated between two layers comprising rockwool fibers and potentially aminoplast glue.
[0239] FIG. 14 illustrates a method for manufacturing a board 11 having multiple layers 12-14-15-16, including a decorative layer 12, of different mineral materials. Said board 11 is manufactured by serial depositing of slurries 40A-40B-40A′-40C having a respective mineral material composition. The depositing of the respective layers is carried out by means of depositing stations or pouring stations 53A-53B-53C-53D positioned along the trajectory of a conveying means 54. In the represented example, the board 11 is manufactured by
depositing or pouring a first MgO containing slurry 40A from a first pouring station 53A on a conveyor means 54, such as a conveyor belt. Said first MgO containing slurry 40A may be a slurry 40A suitable to form MOC or MOC;
depositing or pouring a second MgO containing slurry 40B from a second pouring station 53B on said conveyor means 54, i.e. preferably on top of said first MgO containing slurry 40A. Said second MgO containing slurry 40B is preferably different from said first MgO containing slurry 40A;
depositing or pouring a third MgO containing slurry 40A′ from a third pouring station 53C on said conveyor means 54, i.e. preferably on top of said second MgO containing slurry 40B. Said third MgO containing slurry 40A′ is substantially the same as said first MgO containing slurry 40A;
depositing or pouring a final slurry 40C from a fourth pouring station 53D on said conveyor means 54, i.e. preferably on top of said third MgO containing slurry 40A′, wherein said final slurry comprises a mineral material different from MgO and is preferably free from MgO. Preferably said mineral material comprises concrete, for example so-called UHPC.
[0240] It is clear that after deposition of the respective slurries 40A-40B-40A′-40C, the deposited material may be solidified, e.g. by curing, to form the board 11. Preferably the final slurry 40C forms the decorative layer 12 of a panel, such as floor panel or wall panel, comprising such board material.
[0241] FIGS. 15 and 16 illustrate some steps in a method for manufacturing a board 11 in accordance with the fifteenth independent aspect of the present invention. The method comprises extruding a slurry 40 suitable for forming MOC or MOS through a die 41. In accordance with said fifteenth aspect, the method comprises the step S of forming profiles 55 to one or more edges 2-3 of the extruded material. The profiles 55 are formed prior to the extruded material becoming solid or cured for example in a subsequent solidification or curing step.
[0242] In the example said step S of forming is realized by means of two shaped elements 56 indenting the slurry 40. The shaped elements 56 are rollers having a structured circumference. One shaped element 56 indents said slurry 40 from the bottom and the other shaped element 56 indents said slurry 40 from the top. Preferably said two shaped elements 56 are active, as illustrated here, at least partially vertically above each other.
[0243] The profiles 55 comprise coupling parts 6 as illustrated in FIG. 16. The illustrated coupling parts 6 in a coupled condition result in a locking between the respective edges 2-3 in a horizontal direction H1. The profiles 55 are free from contour portions that are both vertically underneath the top surface and vertically underneath the bottom surface of the slurry 40.
[0244] It is clear that the method illustrated by means of FIGS. 15 and 16 also shows the features of the tenth independent aspect of the invention. The extrusion die 41 is here located above the conveyor means 54, and the slurry 40 is bent and conveyed transversely along the trajectory of said conveyor means 54. In dashed line 57 an alternative set-up is shown, wherein the extrusion die 41 is directed parallel or about parallel with the trajectory of the conveyor means 54. In this case the slurry 40 in the dashed line is extruded in line or about in line with the trajectory it is to take on the conveyor means. It is further noted that, in accordance with a not represented embodiment, several extrusion dies may be used to deposit extruded slurry, potentially of mutually different composition, for example in order to form a three layered board. One or more of such extrusion dies may be positioned vertically above the trajectory of the conveyor means, and one or more of such extrusion dies may be positioned parallel, or practically parallel, with said trajectory. In the case of a three layered board, preferably the extrusion die for depositing the material of the centrally located layer is positioned inline, or practically in line with the trajectory. In the case of a three layered board, one and the same extrusion die may be used for forming both more outwardly situated layers, in that the extruded slurry is split after extrusion into the material of the respective more outwardly situated layers and in that the material of said centrally located layer is extruded in between.
[0245] FIG. 17 illustrates some steps in a method in accordance with the sixteenth independent aspect of the present invention. Using subsequent scattering stations 47 a powder 46 is deposited on a conveyor means 54. The scattering stations 47 and powders 46A-46B from FIG. 10 or 12 may be used. The powder is deposited on a lower Teflon belt 54A, and is conveyed between said lower Teflon belt 54B and an upper Teflon belt downstream of said scattering stations 47. The Teflon belts 54A-54B convey the deposited powder toward and through a twin belt press, in this case an isochoric steel belt press 58, where the powder is compressed.
[0246] Several heaters 59 or coolers 60 may be available along the trajectory of said conveyor means and/or twin belt press 58. A separate thickness calibration unit 61 may be available downstream of said twin belt press.
[0247] FIG. 17 further illustrates that a web-shaped material 62 may be conveyed along with and on top of the deposited powder 46. This web-shaped material 62 may be either of an aminoplast treated substrate, a printable layer, a decor layer or a reinforcement layer, such as a glass fiber layer, woven or non-woven. In case the web-shaped material 62 is an aminoplast substrate an embodiment of the fifth independent aspect may be attained, wherein the deposited powder 46 is allowed to become at least partially sintered, in the presence of said aminoplast treated substrate, namely in said twin belt press. In case the web-shaped material 62 is a printable layer a board may be obtained that at a surface thereof comprises titaniumoxide and/or is white. Preferably such printable layer is a printing base paper having a Gurley value of 25 seconds or below.
[0248] It is remarked that in accordance with all methods disclosed herein, larger boards may be formed from which by means of a dividing operation, such as a sawing or water cutting operation, smaller panels can be obtained, for example panels having the approximate dimensions of a final finished floor panel or wall panel. Preferably said larger board is divided in smaller panels after being solidified or cured. It is further clear that the provision of the decorative layer 12 may either be obtained during the formation of the board, i.e. before solidifying or curing of the board, after solidifying curing of the board but before said dividing operation, or after said dividing operation.
[0249] Throughout the description deposition or scattering of powder, dry blends or particles has been used interchangibly and these terms should be understood as referring to the deposition or scattering of a uniform or premixed particulate material as the case may be.
[0250] The aspects and concepts disclosed in the claims and drawings may be combined with one another as long as they are not mutually contradictory.
[0251] The present invention is in no way limited to the above described embodiments, but such methods, boards and coated panels may be realized according to several variants without leaving the scope of the invention.
