COMPOSITE MATERIAL AND METHOD FOR MANUFACTURING SAME

Abstract

A composite material and a method for manufacturing same such that the composite material includes a laminate structure and a substrate. The substrate is a flexible substrate. The laminate structure has an upper surface and a lower surface. The laminate structure includes at least one paper and a resin, for example at least one resin impregnated paper. The laminate structure is bonded to the substrate. The laminate structure includes a plurality of slots extending from the upper surface of the laminate structure towards the substrate to thereby impart flexibility on the composite material.

Claims

1.-32. (Cancelled).

33. A composite material comprising a laminate structure and a substrate, said laminate structure having an upper surface and a lower surface, said laminate structure comprising at least one paper and a resin, said laminate structure being bonded to said substrate, said laminate structure including a plurality of slots extending from said upper surface of said laminate structure towards said substrate.

34. The composite material according to claim 33, wherein the laminate structure has a laminate structure thickness and wherein at least 50% of the slots of said plurality of slots have a depth corresponding to at least 70% of the laminate structure thickness.

35. The composite material according to claim 33, wherein the laminate structure comprises a dcor layer in the form of a printed and/or colored paper layer impregnated with a first resin, and at least one additional layer, said at least one additional layer being an overlay on an upper surface of said dcor layer and/or a core layer on a lower surface of said dcor layer.

36. The composite material according to claim 33, wherein the laminate structure comprises a dcor layer in the form of a printed paper layer which is not impregnated, and at least two additional layers, which two additional layers are resin impregnated papers with the dcor layer sandwiched between said two additional layers, and with said at least one additional layer being a resin impregnated overlay on an upper surface of said dcor layer and/or a resin impregnated core layer on a lower surface of said dcor layer.

37. The composite material according to claim 34, wherein said laminate structure thickness is between 0.2 and 4.0 mm.

38. The composite material according to claim 33, wherein said laminate structure is bonded to said substrate by means of an adhesive layer.

39. The composite material according to claim 33, wherein said laminated structure is directly bonded to said substrate.

40. The composite material according to claim 33, wherein said plurality of slots forms a pattern comprising intersecting slots,.

41. The composite material according to claim 40, wherein the grid structure is made up of laminate structure islands and said plurality of slots, wherein the laminate structure islands combine to provide a laminate structure surface area, wherein the laminate structure islands and the plurality of slots extends over a grid structure surface area, wherein the ratio of laminate structure surface area to grid structure surface area lies between 30% and 95%.

42. The composite material according to claim 33, wherein said plurality of slots is rectilinear.

43. The composite material according to claim 33, wherein said plurality of slots has a slot width at said upper surface of said laminate structure, said slot width being at least 5% of said laminate structure thickness.

44. The composite material according to claim 33, wherein said plurality of slots is at least partially filled with a lacquer.

45. The composite material according to claim 44, wherein said lacquer is PU-based, acrylic-based or latex, the lacquer being transparent and/or colored.

46. The composite material according to claim 44, wherein the lacquer comprises additives selected from the group consisting of anti-abrasive particles including corundum, matting agents, easy-cleaning additives, and anti-slip additives.

47. The composite material according to claim 44, wherein the laminate structure comprises a dcor layer in the form of a printed and/or colored paper layer impregnated with a first resin, and at least one additional layer, said at least one additional layer being an overlay on an upper surface of said dcor layer and/or a core layer on a lower surface of said dcor layer, wherein said additional layer is said overlay and said lacquer fills said plurality of slots up to said overlay such that said overlay is exposed.

48. The composite material according to claim 44, wherein said lacquer completely fills said plurality of slots and forms an upper surface of said composite material.

49. The composite material according to claim 33, wherein said substrate is selected from the group consisting of woven or nonwoven webs, textile cloths, foamed sheets, thermoplastic films, elastomeric sheets, rubber sheets and metal foils.

50. The composite material according to claim 49, wherein said substrate has a basis weight of from 150 to 600 gsm and/or a substrate thickness of between 0.1 and 3.0 mm.

51. The composite material according to claim 33, wherein said substrate has a substrate thickness of between 25% and 300% of the laminate structure thickness.

52. The composite material of claim 33, wherein the substrate is a flexible substrate.

Description

[0051] In the following, various non-limiting aspects of the present invention will be described in greater detail by way of example only and with reference to the attached drawings, in which:

[0052] FIGS. 1 to 4 schematically illustrate various embodiments of the composite material of the present invention, seen in cross-section;

[0053] FIGS. 5 to 7 schematically illustrate various grid-structures attainable with the composite material of the present invention;

[0054] FIGS. 8 to 11 schematically illustrate possible slot profiles for use with the present invention;

[0055] FIGS. 12 and 13 schematically illustrate various embodiments of the composite material of the present invention, seen in cross-section;

[0056] FIG. 14 is a block diagram of a method for manufacturing a composite material according to the invention;

[0057] FIG. 15 is a schematic perspective view of apparatus for forming a plurality of slots when manufacturing a composite material according to the present invention;

[0058] FIG. 16 schematically illustrates a decorative panel according to the present invention, seen in cross-section, and

[0059] FIG. 17 is a schematic cross-sectional view of two decorative panels according to the present invention coupled together using mechanical locking means.

[0060] In the drawings, reference number 10 denotes a composite material in accordance with the present disclosure. With reference to FIG. 1, the composite material 10 comprises a laminate structure 12 and a substrate 14. The laminate structure has an upper surface 16 and a lower surface 18 and a laminate structure thickness t.sub.1. The laminate structure 12 comprises at least one paper and a resin. For example, the paper and the resin can be in the form of a resin impregnated paper. In the illustrated embodiments, the resin-impregnated paper is a dcor layer 20 in the form of a printed paper layer impregnated with a first resin. The laminate structure 12 may comprise at least one additional layer.

[0061] As is illustrated in FIG. 2, the at least one additional layer may be constituted by an overlay 22 on an upper surface 24 of the dcor layer 20 and/or one or more core layers 26 on a lower surface 28 of the dcor layer. In FIG. 2, the laminate structure 12 includes both an overlay 22 and three core layers 26.

[0062] The laminate structure 12 may be a so-called HPL (High Pressure Laminate) or a CPL (Continuous Pressed Laminate). Both laminates consist of cellulose fiber sheets, preferably papers, impregnated with thermosetting resins. CPL is preferably produced in continuous double belt presses with a pressure between 30 and 70 bar and temperatures between 140 C. and 190 C., or using press rollers. HPL can be produced in a discontinuous press. When the resin cures, a substantially rigid laminate structure is attained.

[0063] By way of example, the paper layer forming the dcor layer 20 may be constituted by a 50-160 g/m.sup.2 printed paper impregnated with a similar amount of resin. One example is a 70 g/m.sup.2 printed paper impregnated with about 70 g/m.sup.2 of a thermosetting resin such as UF, MUF or MF. The decor layer may be a pigmented paper layer of any desirable colour. For example the paper layer can be incorporated with colorants. The dcor layer may be printed with any image, such as a wood print, a stone print, a carbon-fibre image, a fancy pattern or a logo with or without text. The image may be printed using any known printing technique, such as digital printing, rotogravure, etc. Due to its boundless flexibility, digital printing using computer-controlled ink jet printers is preferred.

[0064] The overlay 22 is provided when increased wear/scratch resistance of the laminate structure 12 is desired. The overlay 22 generally comprises a paper layer impregnated with a thermosetting resin which is compatible with, preferably identical to, the resin used in the decor layer 20. To ensure transparency after curing, the paper layer should be thin, for example about 25 g/m.sup.2, and consist essentially entirely of pure alpha-cellulose. The amount of resin may be about 3 times the basis weight of the paper. Thus, for a paper layer of 25 g/m.sup.2, the amount of resin may be about 75 g/m.sup.2. To improve abrasion resistance, and as is illustrated in FIG. 3, the overlay 22 may include hard particles 30 such as corundum or aluminium oxide.

[0065] Each core layer 26 may be a resin impregnated kraft paper, for example sodium kraft paper. Typically, the kraft paper may have a basis weight of 70-300 g/m.sup.2. The resin amount may be between 70 and 300 g/m.sup.2.

[0066] Depending i.a. on the intended application and the number of paper layers, the laminate structure 12 may have a thickness t.sub.1 of between 0.20 mm and 4.0 mm, preferably between 0.5 mm and 2.5 mm.

[0067] In accordance with one aspect of the present invention, the laminate structure 12 is bonded to the substrate 14. The choice of material for the substrate will depend on the intended use of the composite material, and may include woven or nonwoven webs, textile cloths, foamed sheets (preferably a flexible foamed sheet) and extruded films. The substrate 14 may have a basis weight of from 150 to 3000 g/m.sup.2 and/or a substrate thickness t.sub.2 of between 0.10 and 3.0 mm. In one embodiment, the substrate thickness t.sub.2 may be between 25% and 300% of the laminate structure thickness t.sub.1.

[0068] Bonding of the laminate structure 12 to the substrate may be attained by means of an adhesive layer 32. Alternatively, and as is illustrated in FIG. 4, the laminated structure 12 may be directly bonded to the substrate 14. As will be described below, when the laminate structure and flexible laminate are directly bonded to each other, adhesion between the laminate structure 12 and the substrate 14 is attained by means of some of the resin in the laminate structure 12 partially impregnating the substrate 14 and, upon curing of the resin, hardening. Although in FIG. 4 the composite material 10 is depicted as having a laminate structure 12 with an overlay 22, it is to be understood that direct bonding of the laminate structure 12 to the substrate 14 can be attained with any previously described laminate structures 12.

[0069] To render the composite material 10 flexible, the laminate structure 12 includes a plurality of slots 34 extending from the upper surface 16 of the laminate structure 12 towards the substrate 14. The plurality of slots 34 may have a depth d corresponding to at least 70% of the laminate structure thickness t.sub.1, preferably at least 90% of the laminate structure thickness t.sub.1. In some embodiments, the plurality of slots 34 extends through at least 99% of the laminate structure thickness t.sub.1 or, as illustrated in the drawings, through the entire thickness of the laminate structure 12. The plurality of slots 34 may extend over the entire upper surface 16 of the laminate structure 12 or only in selected regions in which flexibility of the composite material 10 is desired.

[0070] As is depicted in FIGS. 5 to 7, the plurality of slots 34 may form a grid structure 36 made up of intersecting rows of the plurality of slots 34. Consequently, the laminate structure 12 is divided into laminate structure islands 38. The shape of the islands 38 will depend on the course of the intersecting rows, but they may for example be square, oblong, triangular, polygonal or rhomboid. These shapes can be attained when the plurality of slots 34 is rectilinear. In non-illustrated alternative embodiments, at least some of the plurality of slots 34 may be non-rectilinear, for example having the shape of a sine wave. In FIG. 7, the laminate structure islands 36 are essentially circular. It is to be understood that the composite material 10 may comprise regions of different shapes of laminate structure islands 38.

[0071] The degree of flexibility of the composite material 10 will, at least in part, be dictated by the dimensions of the plurality of slots 34 and the distribution density of the slots. In various embodiments, the plurality of slots 34 may have a slot width w at the upper surface 16 of the laminate structure 12 which is at least 5% of the laminate structure thickness t.sub.1, preferably at least 10%, more preferably at least 20% and most preferably at least 30% of the laminate structure thickness t.sub.1. The actual widths of the slots making up the plurality of slots 34 may vary. Irrespective of any variation in the width of the slots 34, the laminate structure islands 38 combine to provide a laminate structure surface area The grid structure 38 made up of the laminate structure islands 38 and the plurality of slots 34 extends over a grid structure surface area. The ratio of laminate structure surface area to grid structure surface area may lie between 30% and 95%.

[0072] With particular reference to FIGS. 8 to 11, each slot of the plurality of slots 34 may have an essentially constant slot width w throughout the depth d of the slot. Alternatively, some or all slots of the plurality of slots 34 may have a width which varies from the upper surface 16 of the laminate structure 12 towards the substrate 14. Thus, each slot has a cross-sectional profile P and a grid structure 36 may include a plurality of slots 34 having the same or a number of different cross-sectional profiles. FIG. 8 depicts a cross-section through a theoretical grid structure made up of slots of differing profiles P.sub.1 to P.sub.12. The profiles are shown in greater detail in FIGS. 9 to 11. With reference to FIG. 9, a first slot may have a cross-sectional profile P.sub.1 in which the width w of the slot is constant from the upper surface 16 of the laminate structure 12 to the substrate 14. A second slot may have a profile P.sub.2 that has an opening 40 which is tapered or bevelled and which transitions into a lower slot portion 42 with parallel, vertically disposed side walls. The profile denoted P.sub.3 is similar to that of P.sub.2 except that the opening 40 is rounded. The profile P.sub.4 has a slot width w that increases constantly from the opening 40 to the substrate 14 to thereby form a slot having a frustoconical profile. Turning now to FIG. 10, a fifth slot may have a profile P.sub.5 in which the slot width increases from the upper surface 16 of the laminate structure to a maximum value and then decreases towards the substrate 14.

[0073] The profile denoted P.sub.6 is similar to that of P.sub.3 except that the opening 40 is more rounded. The profile P.sub.7 has a V or truncated V-shape. In this embodiment, the slot has opposing side walls 44, each of which subtends an angle A from a normal N to the upper surface 16 of between 5 and 60, preferably up to 45. With reference to FIG. 11, the profile denoted P.sub.8 is in the form of a trough with inclined opposing side walls 44 and a base 46. The profile denoted P.sub.9 is essentially rectangular, though with the opposing side walls having concave portions 48 along their respective lengths. The profile denoted P.sub.10 is in the form of an oblique slot tapering inwardly towards the substrate. The profile denoted P.sub.11 has a rectangular shape whereas the profile denoted P.sub.12 is rounded and the slot is accommodated within the laminate structure 12. Although the profile P.sub.12 is illustrated as having the shape of a semi-circle, it is to be understood that any suitably curved profile may be adopted.

[0074] In accordance with a further aspect of the present invention, the plurality of slots 34 may be at least partially filled with a lacquer 50. In the examples a) to d) illustrated in FIG. 12 the lacquer 50 completely fills the plurality of slots 34 and forms an upper surface 52 of the composite material 10. It will be recognised that example a) utilizes the composite material of FIG. 1, example b) utilizes the composite material of FIG. 2, example c) utilizes the composite material of FIG. 3 and example d) utilizes the composite material of FIG. 4.

[0075] In a similar vein, FIG. 13 illustrates various examples of a composite material comprising a laminate structure with a plurality of slots which are at least partially filled with lacquer. By way of example, example a) illustrates the composite material of FIG. 1, with the lacquer 50 completely filling the plurality of slots such that the upper surface 52 of the resulting composite material 10 is constituted in part by the dcor layer 20 of the laminate structure islands 38 and in part by the lacquer 50 in the plurality of slots 34. It is to be understood that any of the FIGS. 1 to 4 embodiments of composite material 10 may utilise lacquer in the manner illustrated in example a) of FIG. 13. In example b) of FIG. 13, the composite material 10 of FIG. 2 is utilized, with the lacquer 50 filling the plurality of slots 34 to a level slightly below the upper surface 52 of the resulting composite material 10, though slightly above the dcor layer 20. Consequently, the upper surface 52 of the resulting composite material 10 is constituted in part by the overlay 22 of the laminate structure islands 38 and in part by the lacquer 50 in the plurality of slots 34. Again, it is to be understood that any of the FIGS. 1 to 4 embodiments of composite material 10 may utilise lacquer in the manner illustrated in example b) of FIG. 13. In example c) of FIG. 13, the composite material 10 of example b) of FIG. 13 is utilized, though with an additional lacquer layer 54 forming the upper surface 52 of the resulting composite material. In example d) of FIG. 13, the composite material 10 of FIG. 4 is utilized, with the lacquer 50 filling the plurality of slots 34 to a level slightly below the upper surface 52 of the resulting composite material, though slightly above the dcor layer 20. Consequently, the upper surface 52 of the resulting composite material 10 is constituted in part by the overlay 22 of the laminate structure islands 38 and in part by the lacquer 50 in the plurality of slots 34. Common to examples a), b) and d) of FIG. 13 is that the only elements of the composite material 10 that are exposed to possible wear are the laminate structure 12 and the lacquer 50. Furthermore, optical properties of the lacquer may be balanced to those of the laminate structure islands 38 to give a desirable aesthetic appearance.

[0076] The lacquer itself, as well as the additional lacquer layer 54, may be water-based and/or curable (such as curable by thermal energy or UV/LED radiation). The specific composition of the lacquer will influence the flexible properties of the composite material and may be chosen to impart a desired degree of flexibility. Typically, the lacquer will be PU-based, acrylic-based or latex. It is not inconceivable that the lacquer may be in the form of a thermosetting plastic. To impart a desired visual effect, the lacquer may by transparent, translucent and/or coloured. The lacquer may comprise additives selected from the group consisting of anti-abrasive particles such as corundum, matting agents, easy-cleaning additives, and anti-slip additives.

[0077] An advantage offered by an embodiment having an additional lacquer layer 54, such as example c) of FIG. 13, is that additives may be included only in the additional lacquer layer, thereby reducing the amount of additives that would otherwise be needed.

[0078] A further aspect of the present invention relates to a method for manufacturing a composite material of the type described above in relation to FIGS. 1 to 13. To recap, such composite material 10 comprises a laminate structure 12 and a substrate 14. The laminate structure 12 has an upper surface 16 and a lower surface 18. The laminate structure 12 comprises at least one paper layer and a resin, for example at least one resin-impregnated paper. With reference to FIG. 14, the method for manufacturing the composite material comprises the steps of: [0079] i) composing the laminate structure 12; [0080] ii) bonding the laminate structure 12 to the substrate 14, and [0081] iii) forming a plurality of slots 34 extending from the upper surface 16 of the laminate structure 12 towards the substrate 14.

[0082] The step i) of composing the laminate structure includes compiling the various paper layers, e.g. one or more core layers 26, the dcor layer 20 and/or the overlay, together with possibly an additional resin. In embodiments in which the laminate structure is an HPL (High Pressure Laminate) or a CPL (Continuous Pressed Laminate), the constituent paper layers are each impregnated with resin or some paper layers are impregnated with resin, and are brought into overlying relationship with each other and united under heat and pressure such that the resin cures to create a substantially rigid laminate structure 12. The step ii) of bonding the laminate structure to the substrate 14 may then be attained by providing the substrate and/or the laminate structure with an adhesive layer 32.

[0083] In an alternative embodiment, the step of composing the laminate structure includes bringing the constituent paper layers into overlying relationship not only with each other but also with the substrate to form a stack. The stack is then subjected to heat and pressure, for example in a continuous press or in a short-cycle press, to thereby directly bond the laminate structure to the substrate. The resulting composite material may be termed a DPL (Direct Pressure Laminate).

[0084] Irrespective of how the laminate structure 12 is bonded to the substrate 14, a plurality of slots 34 is formed in the laminate structure. In accordance with step iii) of the method according to the invention, the plurality of slots 34 extends from the upper surface 16 of the laminate structure 12 towards the substrate 14. In one embodiment of the method according to the present invention, the plurality of slots 34 may be formed simultaneously with the bonding of the laminate structure to the substrate. This can be attained by providing the press with a press plate having projections corresponding to the plurality of slots. Alternatively, the plurality of slots may be formed once the laminate structure has been bonded to the substrate. The plurality of slots may be formed in a milling operation, or using a laser, for example a CO.sub.2 laser.

[0085] A method for forming the plurality of slots 34 is depicted in FIG. 15. In this drawing, the upper surface 16 of the laminate structure 12 is being treated using a laser 56 mounted for displacement along a cross-beam 58. The laser 56 generates a beam which removes material from the laminate structure 12. As a result of relative displacement between the laser 56 and the laminate structure, a plurality of slots 34 is produced. Displacement of the laminate structure 12 with respect to the cross-beam 58, the laser 56 along the cross-beam and deflection of the laser beam are advantageously computer-controlled to thereby create a desired grid structure 36 and slot profile P, examples of which have been described above in relation to FIGS. 5 to 7 and 8 to 11, respectively. It is to be understood that neither the grid structure nor the slot profile needs be uniform over the entire upper surface 16 of the laminate structure. Instead, there may be regions on the upper surface having different grid structures and/or different slot profiles. There may also be regions having no grid structure. In this manner, the composite material 10 may have regions of differing flexibility.

[0086] The laminate structure 12 of FIG. 15 is shown purely by way of example as having a dcor layer printed with a wood-grain pattern. In addition to the plurality of slots 34, the upper surface 16 of the laminate structure 12 may also be provided with (not shown) embossments in register with the wood-grain pattern. These embossments may be provided prior to the formation of the plurality of slots, for example by providing protrusions on a press plate used in the forming of the laminate structure. Alternatively, the embossments may be created by a laser before, during or after the formation of the plurality of slots.

[0087] With reference to FIG. 14, the method according to the invention may include a further step iv) of at least partially filling the plurality of slots 34 with a lacquer 50. This method may result in embodiments of the composite material 10 as illustrated by way of example in FIG. 13. In a further embodiment, the step iv) of at least partially filling the plurality of slots 34 with a lacquer 50 may include completely filling the plurality of slots such that the lacquer forms an upper surface 52 of the composite material 10. Utilizing this step may result in embodiments of the composite material 10 as illustrated by way of examples in FIG. 12. Step iv) may include partially filling the plurality of slots with a first lacquer 50 and then completely filling the slots with an additional lacquer 54, as shown in example c) of FIG. 13.

[0088] In a further aspect of the invention, the composite material 10 described above may be used in a decorative panel 60. Thus, and with reference to FIGS. 16 and 17, a decorative panel 60 according to the present invention comprises a carrier substrate 62 and a composite material 10. Examples of possible composite materials are described above in relation to FIGS. 1 to 13. Examples of suitable materials for the carrier substrate 62 include wood-based boards such as MDF/HDF, particle board and plywood, mineral based board, and resilient plastics such as PVC and polypropylene, elastomeric boards, such as EPDM, rubber or TPU (thermoplastic polyurethane). The composite material may be bonded to the carrier substrate 62 using any known techniques such as by means of a (not shown) adhesive layer between the composite material 10 and the carrier substrate 62. The carrier substrate can be bonded to the flexible & laminate structure during a pressing step.

[0089] The carrier substrate has a thickness t.sub.3. The thickness will depend i.a. on the intended use of the decorative panel 60 and may lie between 1.0 mm and 20.0 mm, preferably between 3.0 mm and 15.0 mm. The carrier substrate thickness t.sub.3 may be sufficient to allow the carrier substrate 62 to be provided with mechanical coupling parts 64 enabling adjacent decorative panels 60 to be coupled together. In FIG. 17, mechanical coupling parts 64 are illustrated in the form of a milled tongue-and-groove connection, for example of the type described in WO-A-97/47834. However, it is to be understood that the carrier substrate 62 may be provided with mechanical coupling parts 64 of the fold-down or push-down type and preferably of the type that undergoes a snap-action during joining.

[0090] In a particular embodiment, the decorative panel 60 may include a composite material 10 that has a substrate 14 of a foamed material. This provides a cushioning effect for any load placed on the decorative panel. This may be advantageous when the decorative panel is used in a floor covering.

[0091] The composite material of the present invention may be used for any applications in which flexibility of the composite material is desirable. For example, the composite material may exhibit drapeability, thereby mimicking a fabric. This allows the composite material to be used in applications such as clothing, footwear, home furnishings, upholstery, interior surfaces for vehicles, luggage, flooring-for example as an alternative to a carpet-, covering of metal surfacesfor example surfaces of refrigerators or heaters, etc.

[0092] Here below three specific examples are discussed:

EXAMPLE 1

[0093] The built up (from top to bottom) is the following: [0094] Impregnated overlay paper with a thermoset melamine formaldehyde resin: alpha-cellulose paper 20 gsm, impregnated with resin towards 100 gsm, including 15 gsm corundum (particle size of corundum: 50-80 micron) [0095] non-impregnated decor paper: digitally printed 70 gsm paper [0096] impregnated overlay paper with a thermoset melamine formaldehyde resin: alpha-cellulose paper 20 gsm, impregnated with resin towards 100 gsm [0097] Impregnated kraft papers (with a MF/PF mixture): 2 sheets of 160 gsm kraft paper each treated with resin towards 280 gsm [0098] between 50 and 200 gsm glue application [0099] microfiber textile backing (1 mm thickness, 500 gsm, being a mixture of PU and PA)

[0100] In this example firstly a HPL is created comprising said papers resulting in a thickness of between 650 and 800 m, as such creating the laminate structure. Then this HPL is glued to said microfiber textile backing (said substrate) resulting in a thickness of between 1,65 and 1,8 mm. Then a pattern is lasered with the aid of a CO.sub.2 laser throughout the entire thickness of the HPL, the pattern comprising squares.

EXAMPLE 2

[0101] In this example the use of melamine resin is avoided to reduce the hardness, resulting in easier lasercutting (and also less toxic fumes/emissions/dust during lasercutting) and a more flexible end product.

[0102] The built up (from top to bottom) is the following: [0103] Impregnated overlay paper with a waterbased polyurethane dispersion resin: alpha-cellulose paper 20 gsm, impregnated with resin towards 100 gsm, including small micro particles to enhance scratch resistance (corundum platelets of between 5 and 15 micron) [0104] impregnated decor paper: digitally printed 70 gsm paper, with a PU dispersion towards 130 gsm. [0105] Impregnated kraft papers (with a PU dispersion): 2 sheets of 160 gsm kraft paper each treated with resin towards 280 gsm [0106] between 50 and 200 gsm glue application [0107] microfiber textile backing (1 mm thickness, 500 gsm, being a mixture of PU and PA)

[0108] In this example firstly a HPL is created comprising said papers resulting in a thickness of between 650 and 800 m, as such creating the laminate structure. Then this HPL is glued to said microfiber textile backing (said substrate) resulting in a thickness of between 1,65 and 1,8 mm. Then a pattern is lasered with the aid of a CO.sub.2 laser throughout the entire thickness of the HPL, the pattern comprising squares.

EXAMPLE 3

[0109] In this example an acrylic resin is used and the pattern (the grid structure) is created by pressing. No additional laser and/or cutting step is needed.

[0110] The built up (from top to bottom) is the following: [0111] impregnated decor paper: digitally printed 70 gsm paper, with an acrylic thermoset coating [0112] impregnated kraft papers (with a PU/acrylic dispersion): 2 sheets of 160 gsm kraft paper each treated with resin towards 280 gsm [0113] between 50 and 200 gsm glue application [0114] rubber matt (3 mm thickness, density of 700 kg/m.sup.3, shore hardness 40 A)

[0115] These layers are pressed in one pressing operation, wherein an embossed pressing plate is used on top. The pressing conditions can be 180 C., pressure of 80 kg/cm.sup.2 and this during 30 seconds. The rubber matt is here the substrate, the said papers form the laminate structure and the said glue connects the laminate structure to the substrate. The embossed pressing plate forms the slots during the pressing operation, as such forming the composite material in one pressing operation.

[0116] According to a deviating variant, the invention concerns a composite material comprising a laminate structure, as mentioned above, slots as mentioned abovewhich do or do not go through the entire thickness of the laminate structureand optionally a lacquer as mentioned above, wherein this composite material does not comprise said substrate, such that said deviating variant only comprises a laminate structure, slots and optionally a lacquer.

[0117] The invention also concerns two other deviating variants being a method to produce the abovementioned deviating composite material and a decorative panel comprising a carrier substrate and said deviating composite material. The additional features of the first mentioned composite material, method and decorative panel are also combinable with the above-mentioned deviating variants, according to all non-contradictory combinations. With the aid of said deviating composite material, shine-trough effects/see through effects can be created, better acoustic properties can be obtained, a breathable structure can be created.

[0118] The invention has been described above by way of non-limiting embodiments and examples. The skilled person will understand that the invention may be varied within the scope of the appended claims.