Pressed laminate panel with a single layer elastomeric treated paper

Abstract

A laminated panel is provided which comprises, or consists of, a core panel to which an elastomeric resin impregnated single finishing printed paper layer has been applied. The paper for the single finishing printed paper layer is printed to provide a design feature on the laminated panel. Preferably, the design feature has been printed on a lower surface of the single finishing printed paper layer. As a result of the resin impregnation and heating and pressing operations, the single finishing printed paper layer becomes translucent or transparent, and thus allows the printed design feature to become visible. The design feature can be printed onto the single finishing printed paper prior to treatment with the elastomeric resin, or printed onto the previously treated elastomeric resin impregnated paper. The laminated panels can be used in the production of laminated flooring, wall panels or furniture panels.

What is claimed is: 
     
         1 . A laminated panel consisting of a core panel and a treated layer on at least one side of the core panel, which treated layer is a single printed finishing paper layer which single printed finishing paper layer has been treated with, or impregnated with an elastomeric resin, before or after printing an image onto said paper layer, and prior to production of said laminated panel. 
     
     
         2 . A laminated panel as claimed in  claim 1 , wherein said single finishing printed paper layer is printed, before or after treatment, or impregnation, of the paper with the elastomeric resin. 
     
     
         3 . A laminated panel as claimed in  claim 2  wherein said image on said paper layer is printed after treatment, or impregnation, of the single finishing printed paper with the elastomeric resin. 
     
     
         4 . A laminated panel as claimed in  claim 1  wherein said image printed onto said single finishing printed paper, is applied to the side of the single finishing printed paper which will be located next to the core panel. 
     
     
         5 . A laminated panel as claimed in  claim 1  wherein said single finishing printed paper includes abrasion resistant particles. 
     
     
         6 . A laminated panel as claimed in  claim 1  wherein said single finishing printed paper is, or becomes, translucent or transparent after application of the elastomeric resin, and/or after pressing to form the laminated panel. 
     
     
         7 . A laminated panel as claimed in  claim 1  wherein said elastomeric resin comprises natural and/or synthetic resins, or combinations thereof, having with elastomeric properties including any one or a combination of elastomeric thermosetting or thermoplastic resins including polyethylene (PE); Polyurethanes; Polypropylene; Ethylene vinyl acetates; Ethylene vinyl alcohol; Polyesters; Polyolefin; elastomeric-modified Melamine thermoset resins, Urea and Urea-modified thermoset resins; ESI (ethylene styrene interpolymer), or any of the styrene acrylic copolymers and Acrylic resins; rubber based materials, silicone, fluorocarbon, acrylamide, epichlorohydrin, and/or carboxylated natural and synthetic latexes; or combinations thereof. 
     
     
         8 . A laminated panel as claimed in  claim 7  wherein said polyethylene grade is LLDPE (Linear Low-density Polyethylene), LDPE (Low-density Polyethylene), MDPE (Medium-density Polyethylene) or HDPE (High-density Polyethylene), said Polyolefin is TPO (Thermoplastic polyolefin), or wherein said rubber based material is NBR (nitrile butadiene), SBR (styrene butadiene) or CR (chloroprene). 
     
     
         9 . A laminated panel as claimed in  claim 1  wherein said core panel is a natural wood core. 
     
     
         10 . A laminated panel as claimed in  claim 1  wherein said core panel is particleboard, MDF or HDF board, plywood, or a wood-based panel made from natural fibers. 
     
     
         11 . A laminated panel as claimed in  claim 1  wherein said core panel is a wood-plastic composite material, a plastic material, or a metallic material. 
     
     
         12 . A laminated panel as claimed in  claim 1  wherein said core panel is a base panel covered with a wood veneer. 
     
     
         13 . A laminated panel as claimed in  claim 1  wherein said core panel is covered on one side with a single finishing printed paper layer, in the absence of a backing layer on the opposite side of the core panel. 
     
     
         14 . A laminated panel as claimed in  claim 1  consisting of a core panel and a single finishing printed paper layer on both sides of said core panel, wherein each single finishing printed paper layer has been treated with, or impregnated with an elastomeric resin, before or after printing an image onto a paper layer, and prior to production of said laminated panel. 
     
     
         15 . A laminated panel as claimed in  claim 14  wherein the image printed onto the single finishing printed layer applied to the two sides of the core panel, differ one from the other, so that the laminated panel has a different appearance on, or has different properties on, each side of the panel. 
     
     
         16 . A method for the manufacture of a laminated panel consisting of:
 (i) preparing a flexible, treated or impregnated single finishing printed paper layer by:
 (a) printing an image onto a paper layer, and treating the resultant printed paper layer with an elastomeric resin, and thus produce the flexible, treated or impregnated single finishing printed paper layer; or 
 (b) treating a paper layer with an elastomeric resin to produce a treated or impregnated paper layer, and then printing an image onto said treated or impregnated paper layer to produce the flexible, treated or impregnated single finishing printed paper layer; 
   (ii) placing the flexible, treated or impregnated single finishing printed paper layer adjacent to at least one side of a core panel, as a laminate structure, in a laminate panel press;   (iii) pressing said laminate structure, with heating, in said press; and   (iv) optionally embossing said laminate structure in said press, so as to produce a laminated panel.   
     
     
         17 . A method as claimed in  claim 16  wherein said image printed onto said paper is a colour or image which covers only a portion of the paper, and thus, allows at least part of the surface of the core panel to be visible, or wherein said image printed onto said paper is a solid printed image, or a printed background colour, which ensures that the final printed image will substantially block the visibility, or the colour, of the core panel. 
     
     
         18 . A method as claimed in  claim 16  wherein said elastomeric resin comprises natural and/or synthetic resins, or combinations thereof, having with elastomeric properties including any one or a combination of elastomeric thermosetting or thermoplastic resins including polyethylene (PE); Polyurethanes; Polypropylene; Ethylene vinyl acetates; Ethylene vinyl alcohol; Polyesters; Polyolefin; elastomeric-modified Melamine thermoset resins, Urea and Urea-modified thermoset resins; ESI (ethylene styrene interpolymer), or any of the styrene acrylic copolymers and Acrylic resins; rubber based materials, silicone, fluorocarbon, acrylamide, epichlorohydrin, and/or carboxylated natural and synthetic latexes; or combinations thereof. 
     
     
         19 . A method as claimed in  claim 18  wherein said polyethylene grade is LLDPE (Linear Low-density Polyethylene), LDPE (Low-density Polyethylene), MDPE (Medium-density Polyethylene) or HDPE (High-density Polyethylene), said Polyolefin is TPO (Thermoplastic polyolefin), or wherein said rubber based material is NBR (nitrile butadiene), SBR (styrene butadiene) or CR (chloroprene). 
     
     
         20 . A method as claimed in  claim 16  wherein said laminate structure is pressed with said single finishing paper on one side of the core panel, in the absence of a backing layer on the opposite side of the core panel.