Granted Patent B2

US 12,612,787 · App. 18/500,334 · Granted Apr 28, 2026

Inventors: Joren Nuyts (Wielsbeke, BE); Sara Vanhaverbeke (Wielsbeke, BE); Kristof Van Vlassenrode (Wielsbeke, BE); Ximing Deng (Wielsbeke, BE)

Assignee: UNILIN, BV

E04F13/0871B44C5/04E04F13/0866

Abstract

Claims (29)

1 . A decorative panel having a top surface consisting of a main surface and edge regions adjacent to edges of said top surface, said decorative panel comprising;

a substrate and a top layer;

wherein the top layer comprises a decoration layer and a wear layer, the wear layer is a thermoplastic wear layer provided onto the decoration layer;

wherein said top layer is provided with a main surface top coating provided thereon at said main surface, and at least one of the edge regions is defined as with a lowered edge region lowering to an edge of the edges of the top surface relative to the main surface;

wherein the decoration layer and the wear layer extend continuously from the main surface at least up to and in the lowered edge region, and up to the edge of the top surface adjacent to said lowered edge region, wherein the main surface top coating is absent in at least a portion of the lowered edge region;

wherein at least a portion of said lowered edge region is provided with a lowered edge top coating forming a top coating portion separate from the main surface top coating;

wherein said lowered edge top coating is transparent or translucent, and the lowered edge top coating comprises particles of silica having a surface BET of 200 to 500 m 2 /g, silicic acid or a wax based on polyethylene, polypropylene, carnauba, polytetrafluoroethylene, or amide;

wherein said lowered edge top coating has a degree of gloss matching the degree of gloss of the main surface top coating.

2 . The decorative panel of claim 1 , wherein said main surface top coating has a degree of gloss of 10 or less, as defined in DIN 67530.

3 . The decorative panel of claim 1 , wherein said main surface top coating is a lacquer layer that has been cured at least by means of excimer radiation.

4 . The decorative panel of claim 1 , wherein said lowered edge region is a surface that is inclined downwardly in a distal direction towards the upper edge at a first average angle 5 to 15°.

5 . The decorative panel of claim 1 , wherein said lowered edge top coating comprises a texturizing agent.

6 . The decorative panel of claim 1 , wherein said lowered edge region extends wholly in the wear layer.

7 . The decorative panel of claim 1 , wherein

said lowered edge top coating comprises particles of amorphous silica and/or precipitated silica, having a surface BET of 200 to 500 m 2 /g and/or a median particle size as defined by a D50 value of 3 to 10 μm.

8 . The decorative panel of claim 1 , wherein said lowered edge top coating overlaps a side edge of said main surface top coating.

9 . The decorative panel of claim 1 , wherein the lowered edge top coating has a uniform or about uniform thickness at a location of the portion of said lowered edge region.

10 . The decorative panel of claim 1 , wherein said substrate comprises a thermoplastic material selected from a group of polypropylene, polyethylene, polyethylene terephthalate, and polyvinyl chloride.

11 . The decorative panel of claim 1 , wherein substrate comprises more than 40% by weight of a filler material.

12 . The decorative panel of claim 1 , wherein said lowered edge top coating comprises a coating material, including an acrylate based lacquer.

13 . A method for manufacturing decorative panels according to claim 1 , said decorative panels having a top surface consisting of a main surface and edge regions adjacent to the edges of said top surface, wherein said decorative panels comprise a substrate and a top layer, wherein at least one edge region is defined as a lowered edge region lowering to the edge of the top surface relative to the main surface, said method comprising:

providing a board or slab material comprising at least said substrate and said top layer of one or a plurality of said decorative panels;

the step of providing said board or slab material with a main surface top coating on said top layer, at least by means of roller application of a coating material and/or by hardening a coating material provided on said main surface by ultraviolet and/or excimer radiation;

the step of dividing said board or slab in a plurality of half fabricated panels, having dimensions of said decorative panels;

the step of forming a lowered area adjacent to an upper edge of one or more of said half fabricated panels, comprising removing a material portion from said top layer, said material portion being completely positioned above said decoration laver;

the step of providing said lowered area with a lowered edge top coating, wherein said lowered edge top coating is transparent or translucent, wherein said lowered edge top coating is provided essentially exclusively in or on said lowered area;

wherein said lowered edge top coating is transparent or translucent, and the lowered edge top coating comprises particles of silica having a surface BET of 200 to 500 m 2 /g, silicic acid or a wax based on polyethylene, polypropylene, carnauba, polytetrafluoroethylene, or amide:

optionally the step of postprocessing said lowered edge top coating;

wherein at least a portion of said lowered area that is provided with said lowered edge top coating is comprised in or forms said lowered edge region.

Assignments (2)

Continuity (2)

References Cited (25)