U.S. patent application number 11/223127 was filed with the patent office on 2006-05-11 for decorative laminate board.
This patent application is currently assigned to PERGO (EUROPE) AB. Invention is credited to Patrick Smith.
Application Number | 20060099386 11/223127 |
Document ID | / |
Family ID | 36060309 |
Filed Date | 2006-05-11 |
United States Patent
Application |
20060099386 |
Kind Code |
A1 |
Smith; Patrick |
May 11, 2006 |
Decorative laminate board
Abstract
A decorative laminate board having edges, a decorative upper
layer and a rear layer. The decorative laminate board includes at
least a base layer, an intermediate decor layer and a wear layer
where at least one of said layers comprises polymers. Predetermined
portions of the decorative upper layer is provided with an embossed
surface through means of a laser beam.
Inventors: |
Smith; Patrick; (Raleigh,
NC) |
Correspondence
Address: |
STEVENS DAVIS MILLER & MOSHER, LLP
1615 L STREET, NW
SUITE 850
WASHINGTON
DC
20036
US
|
Assignee: |
PERGO (EUROPE) AB
Trelleborg
SE
|
Family ID: |
36060309 |
Appl. No.: |
11/223127 |
Filed: |
September 12, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60609252 |
Sep 14, 2004 |
|
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Current U.S.
Class: |
428/151 ;
428/192; 428/60 |
Current CPC
Class: |
B32B 2262/062 20130101;
E04F 15/02 20130101; B32B 3/30 20130101; Y10T 428/195 20150115;
B32B 21/14 20130101; B32B 27/12 20130101; B32B 2419/04 20130101;
B32B 21/10 20130101; B44C 1/228 20130101; Y10T 428/24777 20150115;
B32B 2250/03 20130101; B32B 21/02 20130101; B32B 2255/26 20130101;
B32B 2260/023 20130101; B32B 2260/046 20130101; E04F 15/02033
20130101; B32B 5/26 20130101; B32B 2255/02 20130101; B32B 3/06
20130101; B44C 5/043 20130101; Y10T 428/24438 20150115 |
Class at
Publication: |
428/151 ;
428/192; 428/060 |
International
Class: |
D06N 3/00 20060101
D06N003/00 |
Claims
1. A decorative laminate board having edges, a decorative upper
layer and a rear layer, that the decorative laminate board includes
at least a base layer, an intermediate decor layer and a wear layer
where at least one of said layers comprises polymers wherein
predetermined portions of the decorative upper layer is provided
with an embossed surface through means of a laser beam.
2. A decorative laminate according to claim 1, wherein the
decorative upper layer is provided with a heat activated expansion
agent wherein heat caused by the laser beam will cause local
expansion in the perimeter of the surface.
3. A decorative laminate according to claim 1, wherein the laser
beam removes portions of the decorative upper layer.
4. A decorative laminate according to claim 3, wherein the portions
of the decorative upper layer is removed by being charred,
scorched, gasified, burnt away or incinerated.
5. A decorative laminate according to claim 2, wherein the laser
beam is emanating from one or more laser emitters.
6. A decorative laminate according to claim 3, wherein the laser
beam is emanating from one or more laser emitters.
7. A decorative laminate according to claim 5, wherein the laser
beam has a first and second periphery and an intermediate zone,
that an energy profile within the zone between the first and second
periphery is adjusted to create embossing effects selected from the
group consisting of radius, steps, ridges and angles.
8. A decorative laminate according to claim 7, wherein the
embossing by means of laser beams is followed by a milling
operation.
9. A decorative laminate according to claim 7, wherein the
embossing by means of laser is followed by a broaching
operation.
10. A decorative laminate according to claim 4, wherein the charred
surface remaining after the embossing operation is coated.
11. A decorative laminate according to claim 8, wherein the milled
surface remaining after the embossing operation is coated.
12. A decorative laminate according to claim 9, wherein the
broached surface remaining after the embossing operation is
coated.
13. A decorative laminate according to claim 9, wherein the coating
comprises a substance selected from the group consisting of wax,
oil, lacquer, polymer, resin and paint.
14. A decorative laminate according to claim 11, wherein the
coating comprises a substance selected from the group consisting of
wax, oil, lacquer, polymer, resin and paint.
15. A decorative laminate according to claim 12, wherein the
coating comprises a substance selected from the group consisting of
wax, oil, lacquer, polymer, resin and paint.
16. A decorative laminate according to claim 1, wherein the wear
layer comprises cellulose and thermosetting resin.
17. A decorative laminate according to claim 16, wherein the wear
layer further comprises hard particles selected from the group
consisting of aluminum oxide, silicon oxide and silicon
carbide.
18. A decorative laminate according to claim 16, wherein the
thermosetting resin is selected from the group consisting of
melamine formaldehyde resin, urea formaldehyde resin and a
combination thereof.
19. A decorative laminate according to claim 1, wherein the decor
layer comprises cellulose and thermosetting resin.
20. A decorative laminate according to claim 19, wherein the decor
layer further comprises hard particles selected from the group
consisting of aluminum oxide, silicon oxide and silicon
carbide.
21. A decorative laminate according to claim 19, wherein the
thermosetting resin is selected from the group consisting of
melamine formaldehyde resin, urea formaldehyde resin and a
combination thereof.
22. A decorative laminate according to claim 1, wherein the base
layer comprises a board selected from the group consisting of
medium density fiber board, high density fiber board, particle
board, oriented strand board and the like.
23. A decorative laminate according to claim 1, wherein the base
layer is wood based.
24. A decorative laminate according to claim 1, wherein the base
layer is polymer based.
25. A decorative laminate according to claim 1, wherein the wear
layer comprises a UV-curing lacquer.
26. A decorative laminate according to claim 25, wherein the wear
layer further comprises hard particles selected from the group
consisting of aluminum oxide, silicon oxide and silicon carbide.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a decorative laminate board
with a surface structure achieved through means of laser beam.
[0003] 2. Description of Related Art
[0004] Products coated with thermosetting laminates are frequent
today. They are foremost used where the demand for abrasion
resistance is high, but also where resistance towards different
chemicals and moisture is required. As an example of such products
floors, floor beadings, table tops, work tops and wall panels can
be mentioned.
[0005] The abrasion resistance is usually achieved by adding very
small hard particles like silicon carbide to the wear layer. Such a
wear laver may also include cellulose and a thermosetting resin
like melamine formaldehyde resin. Also UV-curing lacquers are
used.
[0006] The hard particles will of course cause wear on the tools
used for milling these boards into user friendly formats. It is
also known that cutting tools will cause an undesired whitening
effect on the machined edge of a wear layer and decor layer. On
closer inspection this problem actually is a number of different
effects. As the wear layer normally is very hard and a bit brittle,
microscopic cracks will sometimes occur during the milling. Optical
dispersion will make such an edge look brighter than the
surrounding material. Another problem related to this, is when
smaller pieces of the edge is chipped away, due to its brittle
nature, during the machining operation. The edge will here not be
straight but a bit jagged and irregular. Yet another, but unrelated
cause to the problem, is when subjacent layers of the laminate are
white or have bright colors. In this case they will simply be
exposed. There is accordingly a problem where machining like edge
trimming and embossing in the surface is desired.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention relates to a decorative
laminate board having edges, a decorative upper layer and a rear
layer. The decorative laminate board includes at least a base
layer, an intermediate decor layer and a wear layer where at least
one of said layers comprises polymers. The invention is
characterized in that predetermined portions of the decorative
upper layer is provided with an embossed surface through means of a
laser beam.
[0008] According to one alternative embodiment of the invention the
decorative upper layer is provided with an heat activated expansion
agent wherein heat caused by the laser beam will cause local
expansion in the perimeter of the surface. This expansion agent
can, for example, be added to the glue bonding the decor layer to
the base layer or the resin or lacquer of the wear layer. It is
alternatively possible to print the decor on a foil containing
expansion agent. This foil is then used as a decor layer.
[0009] The lamination of the different substrates into a finished
laminate will often comprise heat together with pressure to melt
merge and cure the resins of the substrates. The pressure is
maintained during cooling thereby preventing the expansion agent to
expand. Once heated by the laser beam it will expand where
illuminated.
[0010] It is alternatively possible to use different temperature
ranges where a lower temperature range is used for setting the
substrates of the laminate and a higher temperature range for
activating the expansion agent.
[0011] According to a preferred embodiment of the invention the
laser beam removes portions of the decorative upper layer. The
portions of the decorative upper layer is removed by being charred,
scorched, gasified, burnt away or incinerated.
[0012] The laser beam is emanating from one or more laser emitters.
It is for example possible to use one laser emitter and to
dissipate this in a desired way through means of optics. According
to one embodiment of the invention the laser beam has a first and
second periphery and an intermediate zone. An energy profile within
the zone between the first and second periphery is adjusted to
create embossing effects selected from the group consisting of;
radius, steps, ridges and angles. It is for example possible to use
one laser emitter and to dissipate the beam in a desired way
through means of optics. It is also possible to use several
emitters with different energy settings and to arrange these in a
way so that the desired energy profile is achieved. It is possible
to use optics also when several emitters are used.
[0013] The embossing by means of the laser beam is according to a
special embodiment of the invention followed by a milling
operation. In an alternative embodiment of the invention the
embossing by means of the laser beam is followed by a broaching
operation. Accordingly the hard upper surface, containing hard
particles, is eroded by means of the laser beam. After this
operation a normal milling operation with rotating or stationary
tools, if at all necessary, can safely be implemented on the laser
treated surface. On certain embodiments, like on wood based
materials, the laser treated surface will be charred and an
undesired smear effect may appear. It is here suitable to coat the
charred surface remaining after the embossing, milling or broaching
operation. The coating suitably comprises a substance selected from
the group consisting of; wax, oil, lacquer, polymer, resin or
paint.
[0014] It is, as an alternative to milling and broaching after the
laser embossing, also possible to use brushing, blasting or high
pressure air to remove some of the charred remnants.
[0015] According to one embodiment of the present invention the
wear layer of the decorative laminate comprises cellulose and
thermosetting resin. The wear layer suitably comprises hard
particles selected from the group consisting of; aluminum oxide,
silicon oxide or silicon carbide. These hard particles suitably
have an average particle size in the range 100 nm to 150 .mu.m. The
thermosetting resin in the wear layer is suitably selected from the
group consisting of; melamine formaldehyde resin, urea formaldehyde
resin or a combination thereof.
[0016] The decor layer of the decorative laminate suitably
comprises cellulose and thermosetting resin. The thermosetting
resin is suitablv selected from the group consisting of; melamine
formaldehyde resin, urea formaldehyde resin and a combination
thereof. The decor layer may according to a special embodiment of
the invention further comprise hard particles selected from the
group consisting of; aluminum oxide, silicon oxide or silicon
carbide. These hard particles suitably have an average particle
size in the range 1 .mu.m to 150 .mu.m.
[0017] According to one embodiment of the present invention the
base layer of the decorative laminate is wood based.
[0018] The base layer of the decorative laminate suitably comprises
a board selected from the group consisting of; medium density fiber
board, high density fiber board, particle board, oriented strand
board and the like.
[0019] According to another embodiment of the present invention the
base layer of the decorative laminate is polymer based.
[0020] According to an alternative embodiment of the invention the
wear layer of the decorative laminate comprises a UV-curing
lacquer. Here, the wear layer suitably further comprises hard
particles selected from the group consisting of; aluminum oxide,
silicon oxide or silicon carbide.
[0021] It is known by the one skilled in the art of making
thermosetting laminate the milling operations, besides quickly
blunting the tools, also have the problem that whitening effect is
created in the milling zone. This effect is in most cases
undesired. It will, by utilizing the steps described in the present
invention, be possible to achieve well defined embossing without
blunting tools and not leaving any white marks or other
imperfections as discussed previously.
[0022] The decorative laminate board of the present invention is
foremost used for floor panels, floor tiles, wall panels and
ceiling panels. The embossing herein described is suitable for
simulating ship deck flooring and grouted tile flooring. Also other
types of embossing like logotypes or other patterns can easily be
made. It is also very easy to create nonlinear patterns of for
example grout lines if a more rugged and rustic design pattern is
desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention is described further together with enclosed
drawing showing different embodiments of the invention wherein;
[0024] FIG. 1 shows an embossed decorative laminate board 1
according to the invention.
[0025] FIG. 2 shows schematically an energy profile of a laser
beam.
[0026] FIGS. 3a-3d shows different embodiment examples of an
embossed decorative laminate board 1 according to the
invention.
DETAILED DESCRIPTION OF EMBODIMENT EXAMPLES
[0027] FIG. 1 shows, in cross-section portions of a decorative
laminate board 1 having edges 2, a decorative upper laver 3 and a
rear layer 4. The decorative laminate 1 board includes a base layer
5, an intermediate decor layer and a wear laver which comprises
cellulose and thermosetting resin. Predetermined portions of the
decorative upper layer 3 is provided with an embossed 6 surface
through means of a laser beam. Portions of the decorative upper
layer 3 is removed by being burnt away by the laser beam. The laser
beam was emanating two laser emitters. The embossed 6 surface was
charred after the operation.
[0028] As best shown in FIG. 2 the laser beam had a first and
second periphery Ph.sup.1 and Ph.sup.2 respectively and an
intermediate zone. An energy profile within the zone between the
first and second periphery was adjusted to create an embossing 6
effect having a radius towards the untreated portions of the
decorative upper layer 3.
[0029] Referring again to FIG. 1 where the uppermost portions of
the charred remnants was removed by brushing. The embossed 6
surface was then coated with lacquer 6.sup.I.
[0030] The decorative laminate board 1 in the embodiment example
comprised an MDF board base layer 5, an intermediate decor layer of
melamine-formaldehyde resin impregnated paper layer being provided
with a decorative print and a wear layer of melamine-formaldehyde
resin impregnated paper and aluminum oxide particles with an
average particle size of 70 .mu.m.
[0031] The decor layer may according to one alternative embodiment
of the invention be comprised of a decor which is printed directly
on the base layer 5.
[0032] According to another embodiment of the present invention the
wear layer may be constituted of lacquer which suitably also
contains hard particles of for example aluminum oxide, silicon
oxide or silicon carbide.
[0033] One object of the invention is to create embossing 6 on the
surface of a type of laminate which is created for resisting great
amounts of wear. Examples of such embossing 6 is shown in FIGS. 3a
- 3d.
[0034] FIG. 3a shows in perspective view portions of a decorative
laminate board 1 having an embossed 6 edge simulating an irregular
grout line.
[0035] FIG. 3b shows in perspective view portions of a decorative
laminate board 1 having a decor where screws are depicted in the
decor. A narrow embossing 6 is created around the depicted screw to
enhance the effect. Also portions of the screw itself is enhanced
by embossing. The embossing 6 procedure is guided by means of a
digital camera guiding the laser beam.
[0036] FIG. 3c shows in perspective view portions of a decorative
laminate board 1 having a decor depicting weathered and aged wood.
The embossing procedure is used for simulating drying cracks. Also
here the embossing procedure is guided by means of a digital camera
guiding the laser beam.
[0037] FIG. 3d shows in perspective view portions of a decorative
laminate board 1 having a decor depicting a wood block design where
three rows of wood blocks are simulated on each board. The
embossing procedure is used for simulating a very narrow embossing
6 between each row of blocks. It is also here suitable to guide the
embossing procedure by means of a digital camera guiding the laser
beam.
[0038] It is suitable to secure the embossed 6 surface by means of
coating. In cases where the embossing 6 is thin (<3 mm) or very
thin (<1 mm) it is most often adequate to use oil or wax for
coating. In cases where a more impervious coating is desired, like
on wider (>3 mm) embossing 6 close to a board edge 2, it is
advantageous to use a lacquer. This lacquer may be reinforced with
hard particles as described earlier. The lacquer may be a UV-curing
or radiation curing type of lacquer.
[0039] The invention is limited to the shown embodiments since they
be altered in different ways within the scope of the invention.
* * * * *