U.S. patent application number 10/866342 was filed with the patent office on 2004-12-23 for floor panel and method for manufacturing such floor panels.
Invention is credited to De Boe, Lode Hubert Lieven, Thiers, Bernard Paul Joseph, Vanhastel, Luc Dirk Daniel.
Application Number | 20040255541 10/866342 |
Document ID | / |
Family ID | 34862390 |
Filed Date | 2004-12-23 |
United States Patent
Application |
20040255541 |
Kind Code |
A1 |
Thiers, Bernard Paul Joseph ;
et al. |
December 23, 2004 |
Floor panel and method for manufacturing such floor panels
Abstract
Floor panel, of the type consisting of a laminate panel which
comprises at least a printed decorative layer (8) and a top layer
(9) forming the upper surface (10) of the floor panel (1), more
particularly a so-called overlay, whereby this top layer (9), or,
thus, overlay, is realized on the basis of a thermosetting resin,
characterized in that in the upper side (11) of the floor panel
(1), indentations (12) are formed and in that at last in a number
of these indentations (12), a component (13) is provided, which is
obtained in that it has been provided in those indentations (12)
after the provision of the indentations (12).
Inventors: |
Thiers, Bernard Paul Joseph;
(Oostrozebeke, BE) ; De Boe, Lode Hubert Lieven;
(Moorslede, BE) ; Vanhastel, Luc Dirk Daniel;
(Tielt, BE) |
Correspondence
Address: |
BACON & THOMAS, PLLC
625 SLATERS LANE
FOURTH FLOOR
ALEXANDRIA
VA
22314
|
Family ID: |
34862390 |
Appl. No.: |
10/866342 |
Filed: |
June 14, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60477326 |
Jun 11, 2003 |
|
|
|
Current U.S.
Class: |
52/578 ;
52/506.01 |
Current CPC
Class: |
E04F 15/04 20130101;
B32B 27/04 20130101; E04F 15/02011 20130101; B32B 2307/554
20130101; B44F 9/04 20130101; B44C 5/0469 20130101; B44C 1/24
20130101; E04F 15/02016 20130101; E04F 15/02 20130101; E04F
15/02033 20130101; B44F 9/02 20130101; E04F 2201/0115 20130101;
E04F 2201/0153 20130101; B32B 3/30 20130101; B44C 1/20 20130101;
B32B 2260/046 20130101; B32B 2260/028 20130101; B32B 2419/04
20130101; B32B 27/06 20130101 |
Class at
Publication: |
052/578 ;
052/506.01 |
International
Class: |
E04B 002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 4, 2003 |
BE |
2003/0339 |
Oct 31, 2003 |
BE |
2003/0585 |
Claims
1. A laminated floor panel comprising at least a printed decorative
layer and a top overlay layer forming the upper surface of the
floor panel, said overlay layer comprising a thermosetting resin,
wherein in the upper side of the floor panel, indentations are
formed and a component is provided in a plurality of said
indentations.
2. The floor panel according to claim 1, wherein said top layer
comprises a melamine resin.
3. The floor panel according to claim 1, wherein the printed
decorative layer represents a wood pattern.
4. The floor panel according to claim 3, wherein said indentations
are related in form to the wood pattern, and follow the lines of
the wood pattern and/or represent the wood pores.
5. The floor panel according to claim 1, wherein said component
comprises a colored product.
6. The floor panel according to claim 5, wherein the printed
decorative layer represents a pattern and wherein said component is
chosen such that it displays a patinated effect to the pattern of
the printed decorative layer.
7. The floor panel according to claim 6, wherein the panel is
imitative of a colored wood surface, and comprises, a wood pattern
represented on the decorative layer, and a component in the
indentations, said component comprising a colored product.
8. The floor panel according to claim 5, wherein the floor panel,
at least at one upper edge, is cut-away leaving a cut-away surface
and wherein the cut-away surface is provided, at least partially,
with a finish, wherein the appearance of the cut-away surface is
related the effect obtained by the colored product in said
indentations.
9. The floor panel according to claim 8, wherein said cut-away
surface is colored at least partially with a color product of the
same or substantially the same color as the colored product
comprising said component.
10. The floor panel according to claim 1, wherein said overlay is a
colored transparent layer.
11. The floor panel according to claim 10, wherein said overlay
comprises a colored resin.
12. The floor panel according to claim 6, wherein said overlay
comprises a colored transparent layer; and whereby the colored
overlay, together with said colored product, commonly contribute to
an imitation of a colored or patinated floor.
13. The floor panel according to claim 1, wherein the indentations
have a small dimension in at least one direction dimension, for the
major part of such indentations, is less than 2 mm.
14. The floor panel according to claim 1, wherein said component
comprises at least one active agent.
15. The floor panel according to claim 14, wherein the active agent
is one or more products selected from the group consisting of
anti-bacterial, anti-static, dirt-repellent, mildew-repellent,
fluorescent, and phosphorescent.
16. The floor panel according to claim 1, wherein said panel it is
a DPL (Direct Pressure Laminate).
17. The floor panel according to claim 1, wherein said component is
comprises an amount of component wiped into the indentations and
cured, said wiping resulting from one or more processes selected
from a group consisting of rolling wiping and doctoring.
18. The floor panel according to claim 1, wherein said component is
disposed on exterior surfaces of the panel defining.
19. A floor panel comprising a laminated assembly including a
decorative layer which is provided with a pattern, and a colored or
"patinated" appearance formed at least by means of indentations
containing a component in the form of a color product.
20. The floor panel according to claim 19, wherein the pattern
represents a wood pattern.
21. The floor panel according to claim 19, wherein the panel
comprises colored transparent overlay layer.
22. The floor panel according to claim 21, wherein the top layer
comprises a thermosetting resin and said top layer comprises a
colored resin.
23. A floor panel comprising a laminated assembly including a top
layer comprising, synthetic material, said floor panel having
deepened parts at its upper side, and including, at least at the
location of the deepened parts, a component comprising at least an
active agent.
24. The floor panel according to claim 23, wherein the deepened
parts comprise either or both local indentations of small
dimensions and the remaining exposed surface of parts which are
formed by removing material parts at the upper side of the floor
panel.
25. A floor panel comprising a laminated assembly including at
least one decorative layer which is provided with a selected
pattern, and at least an overlay layer which is colored and
transparent covering the decorative layer.
26. The floor panel according to claim 25, wherein said overlay
layer comprises a colored resin.
27. A floor panel comprising a laminated assembly including at
least a decorative layer which is provided with a pattern imitating
a stone floor tile, said panel, at an upper edge, being provided
with a chamfer.
28. The floor panel according to claim 27, wherein the chamfer
extends along an upper edge portion of the panel and is defined by
panel material that has been removed along the respective upper
edge in the form of either a bevel or rounding.
29. The floor panel according to claim 27, wherein said chamfer
extends along the entire periphery of the floor panel.
30. The floor panel according to claim 27, wherein the floor panel
imitates a single tile only, whereby the pattern of the decorative
layer is free of printed joints.
31. The floor panel according to claim 27, wherein a coating is
provided on the surface of the chamfer.
32. The floor panel according to claim 31, wherein the coating on
said chamfer either imitates a joint material, or, at least in
respect to the color of the coating, is adapted to the color of the
upper surface of the floor panel.
33. A floor panel comprising a laminated assembly including a
resin-based top layer, said top layer provided with a polished
glossy surface.
34. The floor panel according to claim 33, wherein the glossy
surface is the result of a process whereby said top layer first has
been roughened and afterwards has been polished.
35. (Canceled)
36. A method for manufacturing a floor panel according to claim 1,
said method comprising at least a first step wherein one or more
basic layers, a decorative layer and a transparent so-called
overlay, by means of a thermosetting synthetic material, are
pressed together to a whole in a heated press, and, simultaneously
with the pressing, indentations are formed in the upper side of the
panel; and at least a second step comprising introducing a
component into the indentations.
37. The method according to claim 36, wherein said component is
introduced the indentations by depositing an amount of the
component into the indentation.
38. The method according to claim 36, wherein larger boards from
which several floor panels can be manufactured are produced and
provided with indentations; and said component is introduced into
the indentations; then forming several separate floor panels from
the larger boards.
39. The method according to claim 36, wherein larger boards from
which several floor panels can be manufactured are produced and
provided with indentations; and then several separate floor panels
are formed from the larger boards, and then a component is
introduced into the indentations.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a floor panel, as well as to a
method for manufacturing such floor panel.
[0003] In particular, the invention relates to so-called laminate
panels for forming a floor covering.
[0004] It is known that in such laminate panels for floors, the
appearance of wood, more particularly parquetry or the like, or the
appearance of stones or ceramic tiles, is imitated by providing the
floor panels, in the proximity of their upper surface, with a
decorative layer printed with a pattern, for example, a wood
pattern or tile pattern, over which a transparent synthetic layer
is provided.
[0005] Usually, the printed decorative layer consists of printed
paper, whereas the clear synthetic layer normally consists of a
synthetic resin or one or more transparent or clear
resin-impregnated material layers, for example, paper layers, in
which possibly also products can be incorporated in order to
enlarge, for example, the wear and tear resistance of the final
upper surface. Generally, said synthetic layer, at least when it
also forms the top layer or, thus, uppermost layer of the floor
panel, is named "overlay".
[0006] It is also known to provide certain laminate panels with
indentations and to provide an amount of paint, printing ink or the
like in these indentations, in order to underline certain aspects
of the pattern to be imitated.
[0007] 2. Discussion of the Related Art
[0008] A known technique for realizing this is described in DE 29
26 983. According to this known technique, a layer, impregnated in
resin, is provided on top of the decorative layer, and subsequently
the whole assembly is brought into a press, on one hand, in order
to let the whole already partially harden, and, on the other hand,
to realize indentations in the upper side during pressing.
Subsequently, an amount of paint is doctored into the indentations,
after which again a resin-impregnated layer is provided on top of
the whole, and finally the whole is hardened completely by the
influence of pressure and temperature. This technique has the
disadvantage that it is complex and, consequently, time-consuming
and that it must be performed rather precisely, in consideration of
the fact that two layers must be provided on top of each other and
care must be taken in particular that the intermediate hardening is
performed to a proper degree. Another disadvantage consists in that
one always has to work with at least two top layers, which can
exert a disadvantageous influence on the clearness with which the
pattern of the printed decorative layer finally is visible, and by
which the pattern, formed by the paint in the indentations, is
softened.
[0009] Thus, the complex and rather expensive procedure described
in the German DE 29 26 983 is less suitable for producing larger
volumes at a minimum cost price, as desirable in the production of
floor panels.
[0010] Another known technique, which, amongst others, is described
in GB 2,054,458, consists in that, during the formation of the
indentations, also an amount of colour product, more particularly,
ink, is printed onto the laminate, possibly into the indentations,
by means of the press with which the indentations are formed. This
known technique requires particularly expensive equipment for,
during pressing the laminate panels, simultaneously performing a
printing action, which renders this technique thus little suitable
for the production of floor panels. As the colour product is
provided during the formation of the indentations, as well as is
formed by means of a printing process, moreover an appearance
similar to printed matter is obtained, which renders the imitation
effect less than optimum, at least for certain applications. As the
ink is provided in the indentations during pressing, only very thin
coatings can be obtained. Also, this technique is exclusively
suitable for printing of larger deepened parts.
[0011] Further, it is also known to apply techniques whereby the
application of colour products on certain locations in recesses is
coupled specifically to particular surface treatments, as a
consequence of which the typical characteristics of the normal
panel surface can not be guaranteed any longer.
SUMMARY OF THE INVENTION
[0012] According to a first aspect, the present invention aims at a
floor panel whereby, on one hand, the advantages of classical
laminate panels for floors are maintained, however, on the other
hand, additional components can also be incorporated in the surface
in an optimum manner. Furthermore, the invention aims at a floor
panel which can be realized smoothly, with minimum production
costs.
[0013] To this aim, according to a first aspect, the invention
relates to a floor panel of the type consisting of a laminate panel
which comprises at least a printed decorative layer and a top layer
forming the top surface of the floor panel, more particularly a
so-called overlay, whereby this top layer is realized on the basis
of a thermosetting resin, with the characteristic that in the upper
side of the floor panel, indentations are formed and in that at
least in a number of these indentations, a component is provided,
which component has been obtained in that it has been provided in
those indentations after the provision of the indentations.
[0014] As the indentations are situated in the upper side of the
floor panel, and this upper side, with the exception of the
indentations, remains unchanged, the floor panels will keep their
classical advantages in respect to wear resistance, cleaning
features and the like at their surface which is walked upon. As
said component is provided in the indentations, the former is
little or not at all subject to wear and tear, in particular when
said indentations are realized with relatively small dimensions.
Due to the fact that said component is no longer covered by an
additional overlay, the clarity of the pattern or such formed by
said component, in the case such component consists of a colour
product, is not affected by such overlay.
[0015] Preferably, the invention is applied in combination with
floor panels, said top layer of which being a layer based on
melamine resin, because such top layer as such, as is known, is
very suitable for floor panels.
[0016] Although the invention can be applied in combination with
different kinds of patterns for the printed decorative layer, it
offers in particular special advantages in embodiments in which the
printed decorative layer represents a wood pattern, as in such
manner particularly good imitations of post-treated, in particular
coloured, for example, lime-treated, wooden floor parts or
parquetry parts, sometimes also called "patinated" oder "cerused"
floor parts or parquetry, often in short denominated with the
French term "ceruse", can be realized.
[0017] An obvious solution for imitating such coloured or
"patinated" floor by means of laminate panels consists in providing
the decorative layer with a printed pattern representing a
patinated wooden floor part or parquetry part and subsequently
applying a classical overlay on top thereof. Practice has shown
that in such specific application, it is difficult to arrive at a
good imitation of a really coloured wooden floor.
[0018] However, by providing the floor panels, in accordance with
the present invention, on one hand, with a decorative layer printed
with a wood pattern, and, on the other hand, with indentations in
which a colour product is provided, a considerably better imitation
can be realized. Hereby, the printed wood pattern either may
consist of a traditional print, as the one applied for imitating a
non-coloured floor, whereby the imitation effect of the coloration
then is exclusively obtained by the colour product in the
indentations, as well as of a particular print which indeed
represents certain aspects of the coloration, whereby the imitation
effect of the coloration then is obtained by the combination of the
special print and the colour product in the indentations. According
to the latter manner, by means of the print of the decorative layer
at least the discoloration of a treated wood surface can be
imitated, whereas by means of the colour product in the
indentations, residual colour materials, which remain in the real
pores or other recesses in the wood in a treatment of a real wooden
floor, can be imitated.
[0019] Preferably, in order to imitate coloured, "patinated" or
lime-treated wood, said component will consist of a colour product
with a light colour, in particular white. However, colour products
of another colour are not excluded. These colour products as such
preferably are little or not at all transparent.
[0020] When imitating wood, it is preferred that said indentations
are provided in function of the wood pattern, and even better
follow the lines of the wood pattern. In the case that said
component then consists of a colour product, it is obtained that
the pattern created by this colour product is optimally adapted to
the underlying printed pattern of the decorative layer. In the case
that said component does not consist of a colour product, but, as
will be explained in the following, has other purposes, and, for
example, consists of a colourless or almost colourless agent, the
advantage is created that the presence of such component will be
less apparent, as said agent is distributed over the surface of the
floor panel in accordance with the underlying printed pattern.
[0021] The aforegoing does not exclude that such colour component,
provided in indentations, can also be applied in combination with
patterns other than a wood pattern.
[0022] It is noted that the floor panels according to the invention
can be provided at one or more of their upper edges with a cut-away
material part in order to create a particular profile at those
edges. By means of such cut-away part, for example, a so-called
"chamfer" can be formed, or simply a rectangular recess, which,
when laying several floor panels adjacent to each other, forms a
groove. According to a particular embodiment of the present
invention, in such case the surface created by cutting away said
material part is provided, at least partially, with a finish, such
that the appearance of the surface is adapted to the effect
obtained by the colour product in said indentations.
[0023] Adapting the colour of the surface at the location where a
part has been cut away to the colour of the applied component can
be performed in any manner. To this aim, for example, a covering
layer can be provided on this surface, said covering layer showing
a matching colour or a matching pattern. For providing such
covering layer, for example, use can be made of transfer printing,
as described, amongst others, in the international patent
application WO 01/96688.
[0024] According to a particular variant, however, said surface
will be coloured at least partially with a colour product having
the same tint or almost the same tint as the colour product used
for said component. In a particular form of embodiment, even the
same agent, for example, the same paint, shall be applied to this
aim. The advantage of this technique consists in that the finish of
said surface, in other words, the finish of the "chamfer",
automatically is adapted to the upper surface of the floor panel in
an optimum manner, contrary to a coating provided by means of
transfer printing, as with transfer printing, separate materials
are used which then specifically must be adapted to the upper
surface of the floor panel.
[0025] According to a particular characteristic of the invention,
said floor panel is provided with a coloured transparent top layer,
in other words, a coloured "overlay".
[0026] Up to the present, overlays, at least in case they are
applied in combination with a printed decorative layer, always are
realized such that they, after the floor panel has been formed,
thus, after curing, are as transparent as possible and also as
colourless as possible, in order to thereby render the printed
decorative layer optimally visible. To this aim, "overlays" then
are formed of an in its turn very pure paper which is impregnated
with resin. The pure paper itself as such is white, however, after
impregnation with resin and after pressing the overlay, it becomes
almost colourless.
[0027] By using, according to the invention, as aforementioned, a
coloured "overlay", particular new effects can be realized. By a
"coloured overlay", hereby an "overlay" is to be understood which,
in applied condition, clearly gives the floor panel a certain tint,
in other words, is not colourless. Hereby, such tint can be of any
colour, including black or white.
[0028] Basically, such tint in the top layer or, thus, overlay, can
be realized by using coloured paper for the paper carrier of the
overlay, however, preferably the overlay or, thus, top layer shall
be coloured in that this layer is formed on the basis of coloured
resin. By colouring the resin itself, on one hand, a tint is
obtained, however, on the other hand, the transparency of the
overlay is little or not affected.
[0029] According to a particular form of embodiment, the coloured
overlay is chosen such that, on one hand, this overlay, by means of
its tint, and, on the other hand, said colour product present in
the indentations, commonly contribute to a "patinating" or
"colouring" effect. In such case, a classical imitated wood pattern
can be used for the printed decorative layer; the coloured tint to
be imitated, which is present over the entire surface, can be
obtained by means of the coloured overlay; and the colour product
present in the indentations can be used as an imitation of the
colour product which normally in reality remains in the wood pores
and the like.
[0030] Of course, such coloured overlay also can be used for
creating other particular effects.
[0031] It is noted that the use of such coloured "overlays" allows
to realize different final results, starting from one and the same
printed decorative layer. In the case of the imitation of parquetry
or wooden floor parts, for example, an imitation of a non-coloured
floor then can be realized by means of a printed decorative layer
with a clear overlay only, whereas, in case of an imitation of a
coloured embodiment, one starts with one and the same printed
decorative layer, which, however, in that case will be provided
with a coloured overlay.
[0032] Preferably, the coloured overlay hereby is monochromatic and
thus free of any well-defined fixed pattern, with the advantage
that, when forming the boards of which the floor panels are
realized, the overlay must not be especially positioned in respect
to the possible pattern of the printed decorative layer.
[0033] Preferably, said indentations have a small dimension in at
least one direction, more particularly a width which, for the major
part of such indentations, is less than 2 mm and even better less
than 1 mm. By using relatively small indentations, the component
present in the indentations is not or almost not strained during
the use of the floor panels.
[0034] According to an important variant of the invention, said
component comprises at least one active agent. By an active agent,
each product has to be understood which renders well-defined
features, other than features exclusively aiming at determining the
appearance or forming a top layer. To this aim, products can be
applied having, for example, one or more of said features:
anti-bacterial, anti-static, dirt-repellent, mildew-repellent.
[0035] The application of other active agents is not excluded.
Another application consists, for example, in applying materials
creating a certain optical effect, such as materials having
reflecting and/or fluorescent and/or phosphorescent features. This
may be for decorative purposes as well as practical purposes, for
example, as an emergency lighting in corridors or passages and/or
for indicating an emergency exit on the floor and the like. So, for
example, micro-indentations can be provided in the surface, which
represent an arrow or another symbol and are filled with a
component 13 lighting up in darkness, whereas with normal light
conditions, this arrow is not visible.
[0036] The component in the indentations may also comprise
particles which enhance wear resistance, such as corundum.
[0037] It is clear that according to the present invention, such
products can be optimally utilized in combination with floor
panels, on one hand, because said component is little or not at all
strained when using the floor panel and thus is very little subject
to wear and tear, and, on the other hand, the respective component
still can be freely present at the upper surface and consequently
can be optimally active.
[0038] It is clear that the application of an active agent for said
component provided in the indentations also can be combined with a
colour product, for example, in that active ingredients, such as
anti-bacterial products, anti-static products or the like, are
blended into the colour product.
[0039] The floor panels of the invention preferably are realized as
DPL (Direct Pressure Laminate).
[0040] Said component present in the indentations preferably
consists of a cured matter, such as a paint paste, a hardenable
product containing active agents or the like, which matter
preferably is created as a consequence of the fact that a certain
amount thereof is brought into the indentations in that it is
deposited therein, for example, rolled thereinto, wiped thereinto,
doctored thereinto, sprayed thereinto or the like, contrary to
high-pressure printing techniques.
[0041] It is noted that the above-described possibility of
imitating a post-treated wooden floor or parquetry floor, more
particularly, a wooden floor or parquetry floor coloured with
colour substance or the like, by means of laminate panels,
according to which use is made of a decorative layer printed with a
wood pattern and of indentations provided with a colour product,
also can be utilized in other kinds of laminate panels, regardless
whether further intermediate layers and additional covering
overlays are applied, regardless of how the component is provided
in the indentations, regardless of the material of which the
possible overlay consists, and regardless of the fact whether an
overlay is applied or not.
[0042] According to a second aspect, the invention thus also
relates to a floor panel, of the type consisting of a laminate
panel comprising a decorative layer which is printed and/or
provided with a pattern, with the characteristic that the floor
panel is provided with a coloured or "patinated" appearance, which
is realized at least by means of indentations in which a component
in the form of a colour product is provided.
[0043] Further is noted that for laminate panels, also the use of
an active component, provided in parts which are deepened in
respect to the upper surface, regardless whether those are
indentations or not, and regardless of the further composition of
the laminate panel, can be advantageous, as such deepened parts
often allow the application of such active component in a better
manner than in case such active component must be provided over the
entire surface. In consideration thereof, the invention, according
to a third aspect, also relates to a floor panel of the type
consisting of a laminate panel with a top layer based on synthetic
material, whereby this floor panel shows deepened parts at its
upper side, with the characteristic that, substantially at the
deepened parts, a component comprising at least one active agent is
provided.
[0044] As already discussed, the deepened parts may consist of
indentations, preferably local indentations of small dimensions.
According to another important possibility, such deepened parts are
formed by the surface of parts which are formed in that at the
upper side of the floor panels, whether at the edge thereof or not,
material parts have been removed, for example, the surface of a
so-called "chamfer", the surface of a rectangular recess, and so
on.
[0045] Also, the use of a coloured so-called overlay in combination
with a printed decorative layer in its turn offers important
advantages, amongst others, in that thereby a new technical
construction is obtained which allows to realize new creations,
more particularly patterns, appearances and the like, independent
of possible other characteristics. Also, the use of a coloured
overlay offers the advantage that certain decors, the practical
realization of which had been problematical before, now can be
realized more adequately.
[0046] So, for example, it is known that it is difficult to realize
very light decors, for example, so-called "crus", as well as very
dark decors in a proper manner, as with the techniques known up to
now, whereby the decor is determined substantially by the printed
decorative layer, the richness of the obtained decor often is
considerably less than intended.
[0047] Also, it is known that with very light or very dark decors,
a large quantity of printing ink or other printing medium must be
applied on the decorative layer in order to arrive at a proper
appearance. On one hand, this poses the problem that such thick
printing is difficult to perform. On the other hand, such thick
printing results in that the decorative layer hardly takes up any
resin and the necessary resin treatment or impregnation is rendered
difficult. Also, this results in that more or less a layered
structure is formed, as a lesser adhesion between the decorative
layer and the overlay occurs, whereby, when milling the edges of
the floor panels, pieces of the upper side may come off.
[0048] In consideration of the above, according to a fourth aspect
the invention thus also relates to a floor panel of the type
consisting of a laminate panel comprising at least a decorative
layer provided with a certain pattern, with the characteristic that
the floor panel also comprises at least a so-called overlay, which
is coloured, but transparent. This overlay is of course situated
above the decorative layer, however, according to the fourth aspect
of the invention, must not necessarily form the uppermost layer of
the panel. In fact, it is not excluded to provide a clear
colourless overlay on top of the coloured overlay.
[0049] This technique creates new possibilities.
[0050] One of those possibilities consists in that light or dark
decors can be produced with a greater richness and with less
problems by colouring the overlay with a light tint, for example, a
white colour product, in the case of a light decor and colouring
the overlay with a dark tint in the case of a dark decor. The
inventor has found out that thereby rich decors can be realized
without necessitating an extra thick print on the decorative layer,
as a consequence of which the aforementioned disadvantages can be
excluded.
[0051] According to a variant of the invention, instead of the
aforementioned coloured overlays, also coloured resins can be used
for impregnating the decorative layer, by which similar effects as
described above can be realized. Also, a combination of, on one
hand, the use of a decorative layer resin-treated with a coloured
resin, and, on the other hand, the use of one or more coloured
overlays is possible.
[0052] A fifth independent aspect of the invention relates to
laminate tiles imitating stone tiles, in other words, which have a
decorative layer with an image imitating the surface of such stone
tiles, whereby by "stone tiles" ceramic tiles as well as tiles of
natural stone or other stone-material tiles have to be
understood.
[0053] Laminate tiles imitating a stone tile are already
well-known. As aforementioned, these laminate tiles comprise at
least a core consisting, for example, of MDF, HDF or another
material, and a printed decorative layer. Further, they are
preferably also provided with an overlay and a backing layer.
[0054] In the known embodiments, when imitating stone tiles, it is
common to represent wide joints with a width of approximately 1 cm
between the imitated tiles, such by means of the print on the
decorative layer. These imitated joints, which mostly imitate a
cement joint, either may coincide with the peripheral edge of the
floor panel or not. Also, the panel, and more particularly the top
layer, can be somewhat indented at the location of the printed
joints in order to even better imitate a real joint. Also, it is
known to have the surface of such floor panel correspond in size
either to the surface of one tile to be imitated, or to the surface
of several tiles to be imitated.
[0055] As a consequence of the fact that relatively wide joints are
imitated, the advantage is created that differences which
inevitably occur, on one hand, as a result of extension and
crimping in the printed paper of the decorative layer before this
is provided on the core material, and, on the other hand, as a
result of production tolerances when processing the pressed basic
boards to form floor panels, will be less apparent. When a wide
joint is imitated by representing half a joint at the respective
edges of adjoining floor panels, whereby such half joint also is
rather wide, it will be less apparent if the pattern is somewhat
shifted in respect to the edge of the floor panel, as such shifting
only results in that the half joint, at one side, will become
somewhat narrower than it should be, whereas, on the other side, it
will become somewhat too wide. Also when the imitated joints are
not situated at the edges, but extend transversely over the floor
panels, differences will hardly show, as the imitated joints, in
view of their width, will still be at least partially aligned, even
with a mutual shifting.
[0056] Nowadays, there is a tendency to apply very fine joints for
real stones, for example, with a width of several millimetres to
less than 1 mm, or even to lay the stones directly against each
other, whereby in the last case, due to the irregularity of the
edge of a real stone tile, still a tiny joint remains visible. With
laminate tiles, it is rather difficult to imitate thin joints by
means of printing, in particular when joints of half the width must
be provided along the peripheral edge of a floor panel. The least
divergence between the printed pattern and the real edge of the
floor panel then results in that the printed joint either
completely drops off the floor tile, or appears completely on the
floor tile, at a distance to the edge of the floor tile, which
renders such floor tiles unusable. Also if the printed joints are
provided such that they extend transversely over such final floor
tile, the application of such printed narrow joints results in that
divergences, more particularly a shifting of the printed pattern in
respect to the edge of the floor panel, will be very apparent, such
because then it may occur that the printed joints of adjoining
floor tiles are shifted completely in respect to each other, which
is experienced as very annoying.
[0057] Basically, the laminate floor tiles might be realized
without printed joint and, during laying, might be placed with
their flat upper sides directly against each other. Tests, however,
have shown that this leads to a very bad optical result.
Furthermore, when wet-cleaning such tiles, moisture might penetrate
between the floor tiles, which then is immediately taken up under
the decorative layer into the core material, which results in that
the core material swells up and pushes the decorative layer, as
well as the top layer present thereabove, upward. This results in
that the upper surface, at the location of the upwardly pushed
edges, wears faster, which finally leads to the occurrence of ugly
edges. Hereby, it is noted that this risk is rather high with
laminate tiles imitating stone tiles, as the users of such laminate
tiles often have the habit to regularly wet-clean these tiles, just
as real stone floor tiles.
[0058] Thus, the present invention aims at a laminate tile whereby
the aforementioned disadvantages are excluded. To this aim, the
invention, according to a fifth aspect, relates to a floor panel of
the type consisting of a laminate panel which comprises at least a
printed decorative layer which is provided with a pattern imitating
a stone floor tile, characterized in that this floor panel, at its
upper edge, is provided with a chamfer. When such floor panels
according to the fifth aspect of the invention are installed
adjacent to each other, the chamfer results in that an effect is
created as if real stone floor tiles were concerned which are laid
against each other with a narrow joint. It is clear that hereby, it
is no longer necessary to print joints on the decorative layer and
that consequently the aforementioned problems, which are created by
divergences in the position of these printed joints, will not
occur.
[0059] Preferably, the chamfer consists of a material part which
has been removed along the respective upper edge, more
particularly, milled off. In the most preferred form of embodiment,
this chamfer is formed by a bevel or bevelled edge, for example, at
45 degrees, or a rounding, however, other shapes of removed
material parts, for example, a small rectangular recess, are not
excluded.
[0060] Said chamfer preferably extends along the entire periphery
of the floor panel. Furthermore, one floor panel imitates
preferably only one real tile. According to another possibility,
one floor panel also may imitate a plurality of stone floor tiles,
whereby the chamfer then preferably is provided along the entire
periphery of the floor panel, whereas the intermediate joints
extending transversely over the floor panel are obtained by a print
on the decorative layer or by means of a locally milled-in groove
or in any other manner.
[0061] It is clear that the floor panels, more particularly floor
tiles, which are realized according to the fifth aspect of the
invention, may have different forms and dimensions and thus may be
square as well as rectangular as have any other shape, although the
square embodiment is preferred.
[0062] Preferably, on the surface of the chamfer, a coating, more
particularly decorative coating, is provided, which preferably also
offers a protection against moisture penetration and which, for
example, is formed by a print, layer of paint or other hardening
substance, or an impregnating agent or a strip, possibly glued onto
the surface. In case of a print, this latter can be realized by
means of transfer printing or any other printing process. In case
of a layer of paint or an impregnating agent, or another liquid
component, this latter can be provided, for example, by means of
small paint rollers, by means of a spraying or sputtering technique
or any other technique. Also, dry techniques, such as powder
coating, are not excluded. According to another possibility, the
groove formed by the chamfer at two adjoining panels also might be
filled with a strip or jointing material.
[0063] According to an important preferred characteristic of floor
panels according to the fifth aspect of the invention, the coating
on said chamfer shall either imitate a jointing material, for
example, cement joint, or be adapted, at least in respect to the
colour, to the colour of the upper surface of the floor panel, more
particularly, show the same or approximately the same tint.
[0064] According to another important preferred characteristic, the
chamfer, measured at the upper side of the floor panel, shall
extend over a distance which is of the order of magnitude of 1
millimetre or smaller.
[0065] By providing a coating on the chamfer, the immediate
penetration of moisture under the decorative layer into the core is
prevented, which minimizes the above-mentioned disadvantage
connected therewith.
[0066] It is clear that the floor panels which are realized
according to the fifth aspect of the invention, at their edges
preferably also are provided with coupling means, by which
adjoining panels can be coupled to each other, preferably
glueless.
[0067] According to a sixth independent aspect, the invention
relates to a floor panel, of the type consisting of a laminate
panel, with a resin-based top layer, with the characteristic that
it is provided with a polished glossy surface. The inventor has
found that by polishing such top layer, surprisingly beautiful
glossy surfaces can be realized, such contrary to the general
expectance that such top layer, when being excessively polished,
would be removed and/or damaged.
[0068] By panels with "a resin-based top layer", in particular
laminate panels with a top layer based on thermosetting resin, for
example, melamine resin, are meant.
[0069] According to a diverging form of embodiment of the
invention, polishing is also applied to panels which, at their
upper side, are provided with a lacquer, varnish or the like,
whether resin-based or not. The applied technique then consists in
successively providing the respective lacquer, drying, and
polishing by means of brushing, possibly preceded by
roughening.
[0070] By a glossy surface is understood that there is a clearly
higher degree of gloss than such top layer shows after having been
provided on the floor panel or the basic board, of which such floor
panel is manufactured, thus, before being polished.
[0071] According to an important preferred characteristic, the
glossy effect is realized by first roughening said top layer and
then finishing, more particularly polishing it. By means of the
preceding step of roughening, it was found, rarely enough, that
afterwards, good and even very good degrees of gloss can be
obtained by a rather short finishing process, more particularly
polishing process, which renders this technique optimally
applicable at an industrial level.
[0072] The roughening can be performed in any manner, however, of
course is performed such that the top layer will not be really
damaged. According to a practical form of embodiment, this can be
realized by means of a rotating brush or a rotating brush-like
element provided with an abrasive material at the parts which come
into contact with the top layer. For example, a brush-like element
can be used, with bristles in which abrasive granules are
incorporated, or a brush-like element whereby instead of bristles,
lip-shaped sheets of abrasive paper are used.
[0073] The finishing or polishing is preferably performed by means
of a rotating brush with bristles, although other techniques are
not excluded, for example, by means of flat rotating polishing
wheels.
[0074] It is clear that the sixth aspect of the invention relates
to the floor panels themselves as well as to the aforementioned
methods which can be applied therewith.
[0075] It is clear that according to the sixth aspect, a smooth
method for realizing a glossy surface is offered, which is
considerably easier to realize than trying to realize a gloss by
means of an adapted press plate.
[0076] Such glossy surface is optimum for imitating, for example, a
waxed marble floor, however, can also be employed in combination
with any pattern.
[0077] It is noted that all characteristics of floor panels
according to the first, second, third, fourth, fifth and sixth
aspects can be combined at random.
[0078] Also, at random one or more of all subordinate
characteristics which are described in respect to the floor panel
according to the first aspect of the invention, can be applied in
combination with the main characteristics of the floor panels
according to the second, third, fourth, fifth and sixth aspects,
thus, without having to apply all main characteristics of the first
aspect.
[0079] Also, the subordinate features of floor panels, described
above or in the following, according to one of the aforementioned
aspects, can be applied at random in floor panels according to
another of said aspects, without also applying the main
characteristic of the first-mentioned aspect, such of course
inasmuch the application of such subordinate feature does not
contradict the other features.
[0080] Finally, the invention also relates to a method for
manufacturing a floor panel according to the invention, with the
characteristic that this method comprises at least two main steps,
on one hand, a first step wherein one or more basic layers, a
decorative layer and a transparent so-called overlay, by means of a
thermosetting synthetic material, are pressed together to a whole
in a heated press, whereby, preferably simultaneously with pressing
together, indentations are formed in the upper side, and, on the
other hand, a second step, whereby said component is brought into
the indentations. This method allows for a particularly smooth
production, with relatively low production costs and in a manner
suitable for mass production.
[0081] It is clear that this method can be applied for
manufacturing floor panels according to the different
aforementioned aspects, at least inasmuch as indentations are used
when realizing them.
[0082] It is also clear that the decorative layer and overlay
possibly can be united beforehand.
[0083] In a diverging form of embodiment of the aforementioned
method, the overlay to be pressed is omitted and whether or not
replaced by another layer, whereby the indentations then are formed
in the resin of the resin-treated decorative layer or in said other
layer. This other layer can be of any kind, for example, a
transparent layer of lacquer.
[0084] Generally, the invention does not exclude that apart from
the described layers, additional other layers can be applied.
BRIEF DESCRIPTION OF THE DRAWINGS
[0085] With the intention of better showing the characteristics of
the invention, hereafter, as an example without any limitative
character, several preferred forms of embodiment are described,
with reference to the accompanying drawings, wherein:
[0086] FIG. 1 schematically represents a part of a floor covering
which is composed of floor panels according to the invention;
[0087] FIG. 2 represents a floor panel according to the invention
in plan view;
[0088] FIGS. 3 and 4, at a larger scale, represent cross-sections
according to lines III-III and IV-IV, respectively, in FIG. 2;
[0089] FIG. 5, at a larger scale, represents the part indicated by
F5 in FIG. 3;
[0090] FIGS. 6 to 11 represent different steps of the method
according to the invention;
[0091] FIG. 12 schematically represents an entire process for
realizing floor panels according to the invention;
[0092] FIGS. 13 to 16 represent a number of variants of the
invention;
[0093] FIG. 17 in perspective represents another floor panel
according to the invention;
[0094] FIG. 18, at a larger scale, represents a cross-section
according to line XVIII-XVIII in FIG. 17;
[0095] FIG. 19, at a larger scale, represents the part indicated by
F19 in FIG. 18, however, in a condition in which the panel is
coupled to another similar panel;
[0096] FIG. 20 schematically represents a floor covering formed of
floor panels according to FIG. 17;
[0097] FIG. 21 schematically represents a particular technique for
treating laminate floor panels.
DESCRIPTION OF THE PREFERED EMBODIMENT
[0098] As represented in FIGS. 1 and 2, the invention relates to
floor panels 1, more particularly laminate panels, for forming a
floor covering 2.
[0099] In the represented example, the floor panels 1 are
rectangular, however, it is clear that according to variants not
represented, they also can have another shape and can be, for
example, square or polygonal, such as hexagonal or octagonal.
[0100] Preferably, the floor panels 1 are provided at least at two
opposite edges 3-4, and even better, as represented in FIGS. 2 to
4, at both pairs of edges 3-4, 5-6, respectively, with coupling
means 7, by which several of such floor panels 1 can be mutually
coupled, such that these coupling means 7, in coupled condition,
offer a locking in vertical as well as horizontal directions.
[0101] Such coupling means 7, which, as known, allow to couple the
floor panels 1 without glue, as well as uncouple them again, as
such are well known from the state of the art and are described,
amongst others, in the international patent applications WO
97/47834 and WO 94/26999. Also, it is known that such coupling
means 7 can be realized in different forms and that in function of
the applied form, the coupling of the floor panels 1 can be
realized in different manners, for example, in such a manner that
such floor panels 1 can be mutually coupled by means of translation
movements T1 and/or T2 and/or T3 and/or turning movements W1 and/or
W2, as schematically indicated in FIG. 1.
[0102] It is noted that the present invention, however, is not
limited to floor panels 1 with coupling means 7 providing in a
mechanical locking in the direction R1 and R2, however, as a matter
of fact also can relate to floor panels 1 which, at one or more
edges, are provided with other coupling means, for example, with a
classical tongue and groove, which possibly can be glued into each
other, or even can relate to floor panels 1 comprising no coupling
means at one or more edges.
[0103] As explained in the introduction and as is shown in detail
in the enlarged illustration of FIG. 5, the floor panel 1,
according to a first aspect of the present invention, is formed of
a laminate panel comprising at least a printed decorative layer 8,
as well as a top layer 9 forming the upper surface 10 of the floor
panel 1, more particularly a so-called overlay, whereby this top
layer or overlay 9 is realized on the basis of a thermosetting
resin, and this floor panel further is characterized in that in the
upper side 11 of the floor panel 1, indentations 12 are formed and
that at least in a number of these indentations 12, a component 13
is provided, said component being obtained by having been deposed
in these indentations 12 after the provision of the indentations 12
themselves.
[0104] It is clear that in this manner, a floor panel 1 is obtained
of which large parts 14 of the upper surface 10 still are formed by
a top layer 9 which is realized on the basis of thermosetting
resin, as a consequence of which the important advantages thereof
are maintained, whereas, meanwhile, also an additional component 13
can be incorporated in the upper surface in an optimum manner, such
for the purpose of realizing different effects, as described in the
introduction.
[0105] The top layer 9 preferably is a layer based on melamine
resin, which, for example, is formed of a carrier impregnated with
such resin, such as a resin-impregnated paper.
[0106] It is noted that, according to a variant of the invention,
it is also possible to make no use of a separate overlay. The top
layer 9, in which the indentations are provided, then, for example,
is formed by the resin with which the decorative layer itself is
impregnated.
[0107] The printed decorative layer 8 preferably is printed with a
pattern 15, whereby this pattern then is situated at the upper side
16 of the decorative layer 8, or at least at the upper side of the
carrier of this decorative layer 8.
[0108] The indentations 12 can have different forms and dimensions.
Depending on the intended effect, these indentations 12 either can
be provided in function of the printed pattern 15 or not. By
"provided in function of the printed pattern 15" is meant that the
form and/or dimensions and/or direction according to which these
indentations 12 extend, are adapted to the printed pattern 15,
which does not necessarily mean that they specifically have to
follow this pattern 15 or must be aligned with this pattern 15. In
the case that the pattern 15 consists of a wood pattern, this,
amongst others, may mean that the indentations 12 follow the wood
pattern, or follow it to a certain extent, as described in the WO
01/96689, as well as that the indentations 12 consist of randomly
provided oblong indentations which, globally, seen, extend in the
longitudinal direction of the imitated wood nerves, as this
traditionally is applied for laminate parquetry.
[0109] The application of indentations 12 which are adapted to the
pattern 15, in particular offers important utilization
possibilities in the case that the aforementioned component 13
consists of a colour product. By a "colour product", each agent is
to be understood which is not colourless transparent, but results
in a certain colour effect, including white or black. For such
colour product, for example, use can be made of a paint, more
particularly a water-based paint, or a paint in the form of an
UV-hardening varnish. Also, it is not excluded to apply other
substances, such as, for example, lime or the like.
[0110] As aforementioned, an important application of this
invention consists in imitating coloured or post-treated wooden
floor parts or parquetry parts, often also called "patinated" wood
or parquetry, in an efficient manner. In such case, the printed
decorative layer 8 represents a wood pattern 15, whereas in the
indentations 12, which preferably are adapted to the wood pattern
15, a colour product is provided. Hereby, as schematically
indicated in FIG. 2, it is obtained that the wood pattern 15 is
visible through the transparent top layer 9 and possible other
intermediate layers, whereas the component 13, which is situated in
the proximity of the upper side 11 and which, in FIG. 2, is
schematically indicated by a thicker kind of line, imitates a
colour substance, comparable to a real colour substance, lime or
such of a coloured, for example, lime-treated real wooden
floor.
[0111] In the case that a lime-treated floor must be imitated, for
the component 13 a colour product of a light colour, and in
particular white, is applied.
[0112] According to a variant, the component 13 can also comprise
an active agent, whether or not in combination with a colour
product. As explained in the introduction, such agent may possess,
for example, anti-bacterial and/or anti-static and/or
dirt-repelling and/or mildew-repelling and/or fluorescent and/or
phosphorescent features.
[0113] Such products, and possible carriers to apply the former
thereon, in their turn are sufficiently known from the state of the
art and thus will not be described here in detail.
[0114] In general, it is preferred that the indentations 12, at
least in one direction, show a small dimension, for example, a
width which, for the majority of the indentations 12, is less than
2 mm, and even better less than 1 mm. Also, the majority of these
indentations 12 preferably is oblong, with a length varying between
some millimetres and some centimetres, the latter in particular in
applications whereby the floor panel 1 is provided with a
decorative layer 8 with a wood pattern 15. The depth of the
indentations is random, however, of course is chosen such that no
undesired damages of the surface occur during the formation
thereof.
[0115] The top layer or overlay 9 may consist of a classical
colourless transparent overlay. According to a particular
embodiment of the invention, however, also a coloured transparent
top layer or overlay 9 can be applied, as a consequence of which,
as already explained, particular effects can be created.
[0116] In FIGS. 6 to 11, schematically a method is represented for
realizing a floor panel 1 according to the first aspect of the
invention, at least for realizing the indentations and providing
the component 13 therein.
[0117] In the represented form of embodiment of this method, the
floor panel 1 is realized as so-called Direct Pressure Laminate
(DPL). This technique allows for a smooth production, whereby in
one pressing cycle, boards can be realized which already show the
complete or almost complete layer structure of the end product,
thus, of the floor panels 1 to be formed. This, however, does not
exclude that the invention also can be applied in combination with
other techniques than those applied for manufacturing DPL.
[0118] In the method represented in the figures, first, as
represented in FIG. 6, the different layers with which one starts,
are provided on top of each other. Hereby, this relates to a basic
layer 17, which in its turn may consist of several layers or
composite parts or not, a printed decorative layer 8, a top layer 9
and preferably also a backing layer 18. The basic layer 17
consists, for example, of a MDF/HDF board, particle board,
so-called blockboard or the like. The decorative layer 8 may simply
consist of printed paper, however, preferably has already been
impregnated with resin beforehand. As aforementioned, the top layer
9 consists of a carrier, such as a sheet of paper, impregnated with
thermosetting resin. The backing layer 18, too, consists of a
resin-impregnated carrier.
[0119] Of course, also other intermediate layers can be provided,
such as, for example, additional resin-impregnated layers.
[0120] As represented in FIG. 7, the obtained stack of layers is
brought into a heated press 19, preferably a flat press, with a
lower plate 20 upon which the aforementioned stack is placed, and
an upper plate 21, between which the whole is compressed. The upper
plate 21 is provided with protrusions 22 or such for forming said
indentations 12.
[0121] These indentations 12 are formed at that moment when the
press, as illustrated in FIG. 8, is closed, whereas the
thermosetting resin of the decorative layer 8 and the top layer 9
melt together and harden to a whole, adhered to the basic plate
17.
[0122] From the press 19, a composite board 23 is obtained as
represented in FIG. 9, wherein, in the upper side 11, indentations
12 are present.
[0123] Subsequently, the component 13 is brought into these
indentations. This bringing-in preferably takes place by depositing
an amount of this component 13 in the indentations 12, for example,
by wiping it into the indentations 12, for example, by means of
doctoring, rubbing or rolling it in. FIG. 10 shows how such
component 13 can be provided in the indentations 12 by means of a
doctor blade 24. FIG. 11 shows a variant, whereby a component 13 is
rolled into the indentations 12 by means of a roll 25.
[0124] FIG. 12 represents a global survey of the method. In a first
step 26, a stack 27 of different layers, as aforementioned, is
brought into a press 19, whereby, as explained above with reference
to FIGS. 7 to 9, boards 23 are formed which, at their surface, are
provided with indentations 12. In a subsequent step 28, the
component 13 is deposited in the indentations 12, which in FIG. 12
is indicated schematically by means of a doctor blade 24.
Subsequently, the component 13 can be subjected to a drying in a
forced manner, for example, by means of infrared radiation in case
of thermal drying or by means of ultraviolet radiation in case of
curing, for example, by means of lamps 29, which step is indicated
schematically by reference 30 in FIG. 12. Subsequently, the boards
23 are sawn into floor panels 1, as schematically represented in
step 31, after which coupling means 7 can be formed at these floor
panels 1, for example, by means of the milling cutters 33
schematically represented in step 32.
[0125] It is clear that the application of the component 13 in a
suitable manner possibly may be performed in several steps. So, for
example, in a first step the component 13 may be excessively
provided on the respective surface by means of a roll, doctor blade
or the like, whereas in a second step, the excess amount, or at
least a part thereof, is removed, for example, by means of a
take-up roll or wiping roll. In a practical embodiment, the boards
or panels are transported by means of a transport system along an
entrained applicator roll and a removing roll rotating in
countersense.
[0126] The applicator roll preferably has a soft surface
consisting, for example, of natural rubber. At the surface of the
applicator roll, a film of liquid component 13 is provided, for
example, by means of a dosage roll installed next thereto, whereby
this latter is situated next to the surface of the applicator roll
in such a manner that an amount of liquid component can be
deposited between both rolls which is carried along at the surface
of the applicator roll in the form of a film. By the contact
between the applicator roll and the boards or panels, the component
is forced into the indentations, and part of it also remains
present at the surface.
[0127] The removing roll preferably has a hard smooth surface and
rotates in countersense over the boards or panels. Preferably, to
this aim use is made of a chromium-plated and/or polished metal
roll. Hereby, the component 13 which is situated out of the
indentations substantially is taken along and finally removed from
the removing roll by means of a doctor blade.
[0128] Also, a removing roll can be used which is permanently
rinsed with solvent and thereby moves in countersense with a
solvent film along the treated boards or panels in order to remove
excess component.
[0129] It is obvious that one or more removing rolls can be used.
Preferably, however, successively two removing rolls are used,
namely a first conventional removing roll and a second,
solvent-rinsed removing roll.
[0130] In case that a UV drying is applied, preferably Ga lamps as
well as Hg lamps are applied for realizing a drying in depth as
well as at the surface.
[0131] Also, after drying, a post-treatment may follow, whereby
remaining component 13, which is present on the surface between the
indentations, is wiped away dry, for example, brushed away. Such
post-treatment is especially useful for removing a remaining tinge,
formed by component 13. The brushing-off of said tinge may, for
example, be performed by means of rotating brushes. Hereby, brushes
provided with bristles as well as with other parts with a brushing
function, such as, for example, lips of abrasive paper, may be
concerned.
[0132] Possibly, one or more additional measures can be taken in
order to enhance the adhesion of component 13.
[0133] One measure consists, for example, in making the upper
surface of the boards or panels dust-free, for example, by means of
a brushing process.
[0134] Another measure consists, for example, in heating the upper
surface of the boards or panels, such that this surface becomes
somewhat softer and a better adhesion is realized.
[0135] Still another measure consists in adapting the position of
the tear-resistant particles in the top layer such that these
particles, for example, corundum particles, will be situated closer
to the surface than this usually is the case. Hereby, an
improvement of the adhesion was stated which presumably is the
consequence of the fact that the indentations then extend between
said particles, whereby the adjoining particles then realize a
better adhesion, as well as offer protection for the component 13
situated in between.
[0136] Hereby, it is advantageous to make use of an overlay of the
type whereby the tear-resistant particles are incorporated in the
paper instead of in the resin. Obviously, the particles hereby have
the tendency to sit at one side of the paper. Usually, the overlay
is placed with this side of the paper downward. By now applying the
overlay, however, reversed, the particles will be situated closer
to the upper surface, by which, as aforementioned, a better
adhesion of the component 13 is obtained. Because a film of resin
is present around the paper of the overlay, the tear-resistant
particles do not border the surface, as a result of which the press
plates still remain more or less protected against the abrasive
effect of the tear-resistant particles.
[0137] FIG. 13 illustrates that, as already described in the
introduction, such floor panel 1, at one or more upper edges, in
this case, the upper edge 34, can be provided with a cut-away
material part, whereby the surface 35, which is created by the
cutting away of this material part, is at least partially provided
with a finish, in such a manner that the appearance of the surface
35 matches the effect which is obtained by the colour product
applied in said indentations 12. In FIG. 13, this is a separate
covering layer 36 provided on the surface 35, for example, by means
of transfer print.
[0138] According to a variant, instead of using transfer print,
also a coating can be applied whereby the surface 35 is treated by
means of a colouring substance, such as a paint, varnish, coloured
impregnating agent or the like, whereby this can be provided on the
surface 35 in any manner, for example, by atomising, sputtering,
spraying, by means of a roll or by means of a felt-tip pencil.
[0139] Preferably, in the latter case the surface 35 is coloured
with a colouring product of the same colour, or almost the same
colour, as the colouring product used for said component 13, or
even component 13 itself can be used for the colouring thereof.
[0140] The aforementioned is particularly useful in combination
with floor panels 1 whereby, by the cut-away parts, a so-called
"chamfer" is formed. The cut-away parts, however, also may have
another shape, for example, a rectangular shape, as indicated in
dash-dotted line 37, for imitating a groove between the laid floor
panels 1.
[0141] Finally, it is again underlined that the floor panels 1
which are in accordance with said second or third or fourth aspect
of the invention, do not necessarily have to possess all
characteristics of the floor panels 1 which are realized in
accordance with the first aspect, which hereafter is illustrated by
means of a number of examples.
[0142] The second aspect, for example, relates to the fact that a
laminate panel, realized as a floor panel 1, is provided with a
"coloured" or "patinated" effect, which is realized by combining a
printed decorative layer with indentations in which a component in
the form of a colour product is provided. This means, for example,
that it is not necessarily required to make use of said top layer
9, that said indentations 12 do not necessarily have to be situated
in the uppermost layer, and that, if a top layer 9 is applied, this
latter not necessarily has to consist of a thermosetting resin.
[0143] So, for example, the aforementioned indentations to be
coloured can be provided in a transparent lacquer layer or the
like, which is situated directly or indirectly above the printed
decorative layer.
[0144] Generally, it is noted that the provision of indentations in
said layers does not explicitly mean that these indentations
thereby extend exclusively in said layer. In fact, the indentations
may extend throughout different layers and/or create deformations
therein. In case of layers pressed upon each other, such as the
aforementioned decorative layer and overlay, such layers, during
pressing, flow into each other, such that in the end product, so to
speak, one layer is obtained and, thus, it becomes difficult to
determine up to which layer the indentations are extending.
[0145] According to the third aspect, the invention relates to a
floor panel with a top layer based on synthetic material, whereby
this floor panel, at its upper side, whether in said synthetic
material or not, shows deepened parts, at which a component is
provided which comprises an active agent. These deepened parts may
consist exclusively of indentations 12, as illustrated in FIG. 14,
or exclusively of surfaces 35 which are obtained by cut-away parts,
for example, as illustrated in FIGS. 15 and 16, or also by a
combination of these two possibilities.
[0146] According to the fourth aspect, use is made of a coloured
top layer or overlay in combination with an underlying printed
decorative layer. According to this fourth aspect, the indentations
12 and the deepened parts are optional.
[0147] It is clear that, when, in accordance with the second or
third aspect of the invention, use is made of indentations wherein
a component, according to the second aspect a colouring agent and
according to the third aspect an active agent, is provided, the
forming of the indentations and the application of the component in
this indentations may be performed in a manner analogous to that
described by means of FIGS. 5 to 12. However, other techniques are
not excluded.
[0148] Another technique for providing a component 13 in
indentations 12, after these indentations 12 have been formed,
according to the present invention consists in that the entire
surface of the boards 23, or at least major parts thereof, are
covered entirely or almost entirely with the component 13 and
subsequently these boards 23 are cleaned such that the component 13
substantially remains present in the indentations 12 only, whereas
the component 13 situated on the intermediate parts 14
substantially is removed. This cleaning can be realized in
different manners, for example, by wiping off, brushing or the
like.
[0149] According to a variant of this technique, one will work in
at least two steps, whereby in the first step, one provides for
that a first agent remains exclusively, or almost exclusively, in
the indentations 12 and subsequently, in the second step, a second
agent is provided on the surface which can react and/or which
properly adheres to the first agent, however, reacts little or not
at all or adheres little or not at all to the parts 14 situated
between the indentations 12. These technique is particularly
advantageous when using two-component resins to this aim. In such
case, the board 23 first can be covered with the first component,
which preferably is clear transparent, with the result that the
layer formed by this agent is thicker at the location of the
indentations 12 than at the location of the parts 14. Subsequently,
this first component can be partially evaporated, such that the
thinner quantities on the parts 14 are completely or almost
completely removed, whereas a certain amount of the thicker
quantities at the location of the indentations 12 still remains
present. Thereafter, the second component, of the resin which only
reacts with the first component, is applied on the board 23 and the
resin is cured. Hereby, a curing is exclusively obtained at the
locations where the first as well as the second components are
present, i.e. only, or almost only, in the indentations 12.
Subsequently, the amount of second component which has not reacted
with the first component can simply be removed by washing off,
wiping off, scraping off or the like.
[0150] It is clear that the reacted first and second components of
the two-component resin then together form the intended component
13.
[0151] Also, it is not excluded to apply a component 13 in the
indentations 12, which component, exclusively at the location of
the indentations 12, is covered with an additional layer. So, for
example, may a colouring product be provided at the bottom of the
indentations 12, whereas thereabove a transparent layer is
deposited in order to give additional characteristics to the whole.
Such additional characteristics may consist, for example, in that a
protective layer is formed over the colouring product or that an
active component is integrated in the transparent layer.
[0152] The invention does not exclude that in embodiments according
to the first, second or third aspect component 13 is not only
present in the indentations. According to these aspects, the
product 13 may be present on the parts 14 to a restricted extent,
for example, in the form of small component residues which have
remained on the surface.
[0153] The present invention is in no way limited to the forms of
embodiment described by way of example and represented in the
figures, however, such floor panel, as well as the method for
manufacturing such floor panel, can be realized according to
various variants, without leaving the scope of the invention.
[0154] So, for example, it is not excluded to apply the component
13 in the indentations after the sawing of the boards 23, and even
after milling or the like, as a consequence of which the extent of
the equipment required to this aim can be restricted. If this takes
place after milling, or in between certain milling cycles, an
already formed possible "chamfer" or, thus, bevelled edge, or
another deepened part can be provided with a component 13 at the
same time as the indentations.
[0155] By first sawing or cutting the boards 23 into floor panels
and by providing the component 13 before the forming of the
coupling means, it is excluded that component 13 lands onto the
coupling means.
[0156] It is noted that in case that the component 13 first is
provided at the boards and only afterwards floor panels are
produced thereof, it is not excluded that the boards are cut to
smaller boards preceding to the application of the component.
[0157] Also, the invention relates to a "method" for imitating a
coloured surface in laminate panels, more particularly for
imitating coloured wood, whereby one proceeds as described in the
aforegoing.
[0158] In FIGS. 17 to 20, laminate panels are represented which are
realized in accordance with the aforementioned fifth aspect of the
invention. These floor panels 1 are provided with a printed
decorative layer 8 having a pattern which imitates the appearance
of a stone floor tile, either a ceramic tile, or a natural stone
tile. The pattern 38 in its turn does not have a printed joint,
however, the imitation of a joint is obtained in that at the floor
panels 1 a chamfer 39 is provided at the upper edge, which chamfer,
in the represented example, is formed by an inclination at 45
degrees. Preferably, the distance Z over which this inclination
extends, is very limited, as discussed in the introduction.
[0159] At the surface of the chamfer 39, as represented, preferably
a coating 40 is provided which is realized in accordance with the
description in the introduction.
[0160] FIG. 19 also shows that such floor panels 1 preferably are
provided with coupling means by means of which they can be locked
to each other in a glue-free manner. It is, however, clear that the
invention is not limited to the represented form of such coupling
means.
[0161] In FIG. 21 is schematically represented how floor panels
according to the sixth aspect of the invention can be provided with
a surface with an enhanced gloss degree. As represented, the floor
panels 1, or the basic boards from which they are sawn, for this
purpose preferably first are roughened, which is schematically
represented by means of the illustrated tool 41, after which the
top layer is finished, which is schematically represented by means
of the illustrated tool 42. Hereby, tool 41, as aforementioned,
consists of a rotating element which is provided with lips 43
formed by abrasive paper, whereas tool 42 consists of a brush with
bristles 44. It is noted that hereby, an intensive brushing process
is concerned, which can not be compared to the brushing process
which, as aforementioned, is applied for removing the tinge of
component 13 from the floor panels. However, this does not exclude
that the same brush might be used, such on one and the same floor
panel, whereby in a first phase said tinge and/or excess remainders
are removed, whereas in a next phase, whether following immediately
or not, a polishing process is realized.
[0162] It is clear that all aspects of the invention are intended
in particular for being used in combination with floor panels of
the type consisting of so-called DPL (Direct Pressure
Laminate).
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