Antistatic layered panel and method of its manufacture

• US 7,527,856 B2
• Filed: 12/03/2003
• Issued: 05/05/2009
• Est. Priority Date: 12/04/2002
• Status: Expired due to Fees

• Current Assignee: Bureau M.F.J. Bocksteal
• Original Assignee: Flooring Industries Limited (Mohawk Industries Incorporated)
• Inventors: Thiers, Bernard Paul Joseph, Hochepied, Peter
• Primary Examiner(s): KILIMAN, LESZEK B
• Application Number:
  US10/535,188
• Publication Number:
  US 20060008630A1
• Time in Patent Office: 1,980 Days
• Field of Search: 428/423.1, 428/323, 428/330, 427/212, 427/214, 427/322, 427/325, 427/326, 427/393, 427/408
• US Class Current: 428/323
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 2307/21 Anti-static
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/42 comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08K 5/0075 Antistatics
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/10 of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: Y10T 428/249924 Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/258 Alkali metal or alkaline earth metal or compound thereof
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]

Abstract

The invention relates to an antistatic layered panel (1) including a substrate (2) and one or more layers (3, 4) on top of said substrate, said one or more layers comprising a decorative covering layer (3). At least one of the layers on top of said substrate comprises a synthetic resin and is consolidated by pressure with one or more of the other layers. The panel contains at least one antistatic agent evenly distributed in said synthetic resin over the surface of the panel.

The invention relates also to methods of its manufacture and in particular to such antistatic laminated floor panels.

Claims

1. Method for manufacturing a layered floor panel;

said floor panel comprising a substrate, one or more layers on top of said substrate and at least one backing layer underneath said substrate, said substrate being a glued and pressed wood-based board comprising a material selected from the group consisting of MDF, HDF, particle board, oriented structural board and multiplex;

said one or more layers at least comprising a wear resistant surface layer filled with wear resistant additives as a top layer and a decorative covering layer;

said wear resistant surface layer and said decorative covering layer extending over substantially the whole surface of the panel;

at least one of said wear resistant surface layer and said decorative covering layer including a resin impregnated paper layer, said wear resistant surface layer and said decorative covering layer being substantially free from conductive fillers in the form of fibers;

said floor panel containing at least one antistatic agent distributed in said resin;

wherein the method at least comprises the steps of;

dosing and mixing said antistatic agent into the impregnating composition for said resin impregnated paper layer;

impregnating said paper layer, thereafter drying said resin impregnated paper layer;

and thereafter

stacking at least said wear resistant surface layer, said decorative covering layer, said substrate and said backing layer upon each other and consolidating said layers and substrate to form a plate-shaped direct pressure laminate (DPL) by means of hot pressing.

2. Method according to claim 1, wherein said backing layer includes a resin impregnated paper layer, and wherein said antistatic agent also is mixed into the impregnating composition for the sheet of the backing layer and/or into an additional layer.

3. Method according to claim 1, wherein said decorative covering layer includes said resin impregnated paper layer;

wherein said print is provided on said paper layer, and the upper surface of the decorative layer is sprayed with a solution of the antistatic agent and further covered with a surface layer comprising wear resistant additives.

4. Method according to claim 3, wherein the wear resistant additives are distributed in the lower part of said surface layer.

5. Method according to claim 4, wherein said surface layer is a self supporting cellulose fiber sheet impregnated with melamine and/or ureum resin having in its lower part wear resistant corundum particles distributed therein.

6. The method according to claim 1 or 3, wherein said antistatic agent comprises a salt.

7. The method according to claim 6, wherein said salt is NaCl.

8. The method according to claim 6, wherein said salt is KCl or a combination of NaCl and KCl.

9. The method according to claim 1 or 3, wherein said method comprises the step of providing said floor panel with complementary milled-out edge profiles;

said profiles allowing a mutual coupling of the adjacent panels in order to form a floating laminated floor.

10. The method according to claim 1 or 2, wherein said decorative covering layer includes said resin impregnated paper layer and wherein said print is provided on said paper layer.