BOARD AND METHOD FOR MANUFACTURING A BOARD

Abstract

A board consisting at least of a substrate formed at least of a gypsum-based and/or cement-based basic material layer. The board is provided with a chamfer extending through the basic material layer.

Claims

1. A board, wherein the board consists at least of a substrate which is formed at least of a gypsum-based or cement-based basic material layer with a compressive strength of 30 kg/cm.sup.2 and a resin-based covering provided on at least one side of the substrate, in the form of a laminate layer directly pressed onto the substrate; wherein the resin-based covering comprises a first material sheet; wherein the first material sheet comprises a first paper sheet impregnated with resin; wherein the resin of the first material sheet is a thermohardening resin; wherein the first paper sheet comprises a printed decor; wherein the first material sheet is bonded onto the substrate by a resin bond provided by the thermohardening resin of the first material sheet; wherein the board is a floor panel, a wall panel or a ceiling panel; wherein the board has a decorative appearance; wherein the substrate comprises wood fibers, wherein the wood fibers are provided substantially over an entire thickness of the substrate; wherein the thermohardening resin of the first material sheet adheres to the wood fibers of the substrate to form a connection.

2. The board of claim 1, wherein the basic material layer has a compressive strength of at least 70 kg/cm.sup.2.

3. The board of claim 1, wherein the basic material layer has a compressive strength in the order of magnitude of 90 kg/cm.sup.2 or more.

4. The board of claim 1, wherein the aforementioned resin-based covering is situated at that side of the board which is intended for forming the front side.

5. The board of claim 1, wherein a resin bond is continuously present from on the resin-based covering up into the gypsum-based and/or cement-based material of the basic material layer.

6. The board of claim 5, wherein the resin of said resin bond extends at least up to a depth in said gypsum-based and/or cement-based material which is at least 0.5 millimeters.

7. The board of claim 1, wherein in the upper side thereof a relief is provided, formed by embossments.

8. The board of claim 1, wherein the board shows a pattern as well as embossments in the surface, and wherein the embossments are in register with the image of the pattern.

9. The board of claim 1, wherein the thermo-hardening resin of the first material sheet is a melamine resin.

10. The board of claim 1, wherein the board, on at least two opposite edges, comprises coupling parts arranged for coupling two of such boards to each other, wherein the coupling parts are configured, in a coupled condition, to provide for a locking in a direction in a plane of the coupled boards and perpendicular to the coupled edges, and in a direction perpendicular to the plane of the coupled boards; wherein the coupling parts are made substantially or entirely in one piece in the substrate; and wherein the wood fibers extend into the coupling parts.

11. The board of claim 10, wherein the coupling parts provide at least an overlap of material of the substrate.

12. The board of claim 10, wherein the coupling parts provide at least a tongue and groove profile.

13. The board of claim 10, wherein the coupling parts are provided with a material layer or material strip, which provides for a sealing of the coupling parts against absorption of moisture.

14. The board of claim 1, wherein in the proximity of the front side of the board, at the corner edge between the front side and at least one of said two edges, a chamfer is present in the form of a bevel or rounding.

15. The board of claim 1, wherein said wood fibers are blended together with the material of the cement-based and/or gypsum-based basic material layer.

16. The board of claim 1, wherein the resin-based covering comprises a second material sheet; wherein the second material sheet comprises a second paper sheet impregnated with resin; wherein the resin of the second material sheet is a thermohardening resin; wherein the second material sheet is provided onto the first material sheet; wherein the first material sheet is bonded to the second material sheet by the thermohardening resin of the first material sheet and the thermohardening resin of the second material sheet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0132] FIG. 1 schematically represents a preferred embodiment of such board 1, wherein it is attached as a wall covering board or wall panel against a lath structure 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0133] The basic material layer 3 is a gypsum or fiber cement board. On top of this, a DPL layer 4 is pressed, which as such comprises one or more resin-impregnated sheets. Possibly, a counter layer 5 is provided. Compressing usually is performed at an increased temperature.

[0134] The coupling means 6 preferably are of the type which locks in two directions D1 and D2, as indicated. Preferably, they are also of the type which allows joining by means of a turning movement R.

[0135] As represented, herein preferably use is made of a longer rearmost lip 7, which is provided with a locking element 8.

[0136] At the front corner edge a chamfer 9 can be provided.

[0137] A preferably strip-shaped element 10, preferably provided at the locking element 8, can result in a pretension and/or result in a seal and/or result in a heat-activatable fire-retarding joint.

[0138] A recess 11 offers space for the head of a nail or the like, such that the whole is nailable or screwable.

[0139] Of course, the present invention is not limited to the example represented in the FIGURE.

[0140] Also, the FIGURE is schematically illustrative for floor panels, wherein then the back side of the represented panel has to be understood as underside. Locking coupling parts and other characteristics, such as chamfers 9, can be employed analogous in floor panels.

[0141] The most intended applications of the invention are floor panels and wall panels. With wall panels, this preferably are room-high panels which are provided with coupling parts at their edges, which edges are to be mounted vertically, said coupling parts being, for example, of the type as represented in the accompanying FIGURE. With floor panels, this preferably relates to smaller panels, which are provided at their four edges with coupling parts allowing a mutual coupling and locking, in order to be able to form, as usual, a so-called floating floor covering. Wall panels of fiber cement have the great advantage to be fire-resistant, whereas floor panels of this material will hardly expand as a result of temperature changes and the like.

[0142] The invention also relates to the obtained substrates as such, without these being already finished further by means of top layers or the like.

[0143] It is noted that all information comprised in WO 2018/138273 also has to be understood as incorporated in the present application, as alternative possibilities in combination with the herein above-described possibilities of the present application.

[0144] According to another preferred embodiment, the coupling parts are provided with a waterproof or moisture-repelling substance.

[0145] In a particular embodiment, the invention relates to a board, more particularly a panel in the form of a floor panel and/or wall panel and/or ceiling panel, preferably of the type which is at least intended for interior application, wherein this panel comprises a basic material layer or substrate which is cement-based, which basic material layer as such can comprise one or more layers of cement-based basic material, wherein one or more of these layers and preferably the entire basic material layer preferably is on the basis of fiber cement, wherein this panel comprises a top layer which comprises one or more synthetic material layers, which, at least in their entirety, have a thickness of 0.5 and still better 1 mm. This can be a vinyl-based layer, such as with LVT. In this manner, delamination in the fiber cement is avoided as the top layer then is sufficiently strong.

[0146] Alternatively, the top layer can also be a HPL layer glued onto the basic material layer. Such HPL layer provides for a strong surface, and delamination is almost excluded.