IP Library Granted Patent US 12697836
Granted Patent B2
US 12697836 · App. 18/554,817 · Granted Aug 4, 2026

Decorative panel and method for manufacturing a decorative panel

Inventors: Yu Hin Li (Jiangsu, CN); Jonas Deman (Sint-Amandsberg, BE); Benny Schacht (Vlamertinge, BE)
Assignee: UNILIN BV
B44C5/0453B29D99/0057B32B3/06B32B3/30B32B27/10B32B27/20B32B27/302B32B27/36E04F15/02038E04F15/107B29K2025/06B29K2067/06B29K2105/0002B29K2105/12B29K2105/16B32B2260/028B32B2260/046B32B2270/00B32B2419/04E04F2201/0153E04F2201/023E04F2201/043
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Quick Facts
Patent No.
US 12697836
App. No.
18/554,817
Granted
Aug 4, 2026
Kind
B2
Abstract

A decorative panel includes a substrate and a decorative surface. The substrate includes a copolymer of an unsaturated polyester.

Claims (30)

1 . A decorative panel comprising a substrate and a decorative surface, wherein said substrate comprises a substrate material with a copolymer of an unsaturated polyester;

wherein the substrate comprises at least first and second lavers comprising the copolymer;

wherein the first layer is provided with a first color different from a second color of the second layer;

wherein the first layer includes an integrated motif made up of a coloration including colored regions;

wherein the integrated motif is present at least at a surface of the substrate, and extends at least 0.5 mm into a thickness of the substrate;

wherein said surface is visible at said decorative surface for at least 30% of an area of said decorative surface;

wherein said integrated motif is locally complemented by means of a printed motif.

2 . The decorative panel of claim 1 , wherein said copolymer is a copolymer of an unsaturated polyester and a vinyl monomer.

3 . The decorative panel of claim 2 , wherein said copolymer is a copolymer of an unsaturated polyester and styrene.

4 . The decorative panel of claim 1 , wherein said unsaturated polyester is a dicyclopentadiene resin or is selected from the group consisting of a resin containing primarily terephthalic acid, a resin containing primarily phthalic anhydride, and a resin containing primarily isophthalic acid.

5 . The decorative panel of claim 1 , wherein said substrate further comprises at least 3 weight parts filler materials per part of the copolymer.

6 . The decorative panel of claim 1 , wherein said substrate further comprises at least 5 wt %, reinforcement fibers.

7 . The decorative panel of claim 1 , wherein said substrate further comprises 0.1 to 10 wt % of a metal salt, and/or 0.1 to 10 wt % of an organic peroxide.

8 . The decorative panel of claim 1 , wherein said panel is provided with a lowered edge region obtained by machining away a portion of a top edge of the panel to create a beveled surface, wherein the beveled surface is limited to the first layer and has the same color variations as the surface of the substrate.

9 . A method for manufacturing a decorative panel, wherein said decorative panel comprises a substrate and a decorative surface,

wherein said method comprises at least a step of providing a substrate with a substrate material comprising a copolymer of an unsaturated polyester;

wherein said method further comprises the step of providing a decorative surface to said substrate;

wherein the substrate comprises at least first and second layers comprising the copolymer;

wherein the first layer is provided with a first color different from a second color of the second layer;

wherein the first layer includes an integrated motif made up of a coloration including colored regions;

wherein the integrated motif is present at least at a surface of the substrate, and extends at least 0.5 mm into a thickness of the substrate;

wherein a printed motif is formed on the surface of said substrate;

wherein said surface remains visible at said decorative surface for at least 30% of an area of said decorative surface;

wherein said integrated motif is locally complemented by means of said printed motif.

10 . The method of claim 9 , wherein said step of providing a substrate comprises:

providing a mixture by mixing a resin selected from the group consisting of a dicyclopentadiene resin, a resin containing primarily terephthalic acid, a resin containing primarily phthalic anhydride, and a resin containing primarily isophthalic acid with at least a vinyl monomer; and

shaping and curing said mixture into at least a part of said substrate.

11 . The method of claim 10 , wherein said mixture further comprises filler materials, reinforcement fibers, metal salt and/or organic peroxide.

12 . The method of claim 10 , wherein said shaping and curing said mixture comprises pressing said mixture at a pressure of 1 MPa or above.

13 . The method of claim 10 , wherein said shaping and curing comprises forming said part of said substrate to have a board shape with a decorative relief in at least one of the major surfaces of said board.