Direct lamination of a melamine layer to a magnesium oxide core
Embodiments of the present disclosure include a floor panel having a melamine-impregnated layer laminated on a layered magnesium-oxide core. The layered magnesium-oxide core can comprise one or more adhesion-promoting layers including an adhesion-promoting agent, such as cellulosic fibers, polymers, or adhesive.
1 . A floor panel comprising:
a layered core comprising:
a first layer comprising magnesium oxide and cellulosic fibers;
a second layer disposed directly below the first layer, the second layer comprising magnesium oxide and being substantially free of cellulosic fibers, wherein a density of the second layer is greater than or equal to a density of the first layer, and
a first melamine-impregnated layer disposed above the first layer and directly bonded to a top surface of the first layer of the layered core;
wherein the first layer comprises from 25% by weight to 50% by weight of the cellulosic fibers.
2 . The floor panel of claim 1 , wherein the cellulosic fibers comprise at least one of wood, bamboo, or rice straw fibers.
3 . The floor panel of claim 1 , wherein the floor panel comprises a locking mechanism for interconnecting the floor panel with a subsequent floor panel.
4 . The floor panel of claim 3 , wherein the layered core comprises an internal bond strength of at least 1.5 N/mm 2 .
5 . The floor panel of claim 1 , further comprising a third layer disposed below the second layer, the third layer comprising magnesium oxide and a second adhesion-promoting additive.
6 . The floor panel of claim 5 , comprising a second melamine-impregnated layer disposed below the third layer and directly bonded to a bottom surface of the third layer of the layered core.
7 . A method for making a floor panel comprising:
forming a layered core comprising:
creating a second layer comprising magnesium oxide, the second layer being substantially free from cellulosic fibers;
applying a first layer directly on top of the second layer, the first layer comprising magnesium oxide and cellulosic fibers;
wherein a density of the second layer is greater than or equal to a density of the first layer;
and laminating a melamine-impregnated layer directly to a top surface of the layered core using a hot-press process.
8 . A floor panel comprising:
a layered core comprising:
a first layer comprising magnesium oxide and an adhesion-promoting additive comprising cellulosic fibers;
a second layer disposed directly below the first layer, the second layer comprising magnesium oxide and being substantially free of the adhesion-promoting additive comprising cellulosic fibers, wherein a density of the second layer is greater than or equal to a density of the first layer; and
a first melamine-impregnated layer disposed above the first layer and directly bonded to a top surface of the first layer of the layered core.
9 . The floor panel of claim 8 , wherein the cellulosic fibers comprise at least one of wood, bamboo, or rice straw fibers.
10 . The floor panel of claim 9 , wherein the cellulosic fibers comprise wood.
11 . The floor panel of claim 1 , wherein the first melamine-impregnated layer has been bonded to the top surface of the first layer of the layered core using a hot-press process.
12 . The floor panel of claim 6 , wherein the second melamine-impregnated layer has been bonded to the bottom surface of the third layer of the layered core using a hot-press process.