Floor panel, methods for manufacturing laminate panels and method for treating material sheets applied herewith

摘要

Floor panel of the type substantially consisting of a substrate and a top layer provided-thereon based on synthetic material. The top layer includes a printed decor and one or more material sheets provided with synthetic material. The floor panel also includes a balancing layer at the underside of the substrate, the balancing layer containing a synthetic material layer which is free from material sheets. Methods used to make the panels are disclosed.

主权项

1. A method for manufacturing flooring panels, wherein the panels comprise at least a substrate arranged between a top layer and a balancing layer, the top layer being arranged for a walking surface, the method comprising the steps:
providing one or more material sheets and a first synthetic material at an upper side of said substrate, the first synthetic material being a first thermosetting resin; forming an underside layer that is directly in contact with an underside of said substrate, the underside of said substrate being opposite from the upper side of the substrate, said underside layer consisting of said balancing layer, the balancing layer consisting of a uniform composition mainly comprised of a second thermosetting resin, wherein the uniform composition of the balancing layer is formed in direct contact with the underside of said substrate; making the top layer by bringing at least said material sheets and the first synthetic material and the substrate in a press device, wherein the material sheets are bonded to the upper side of said substrate by a press treatment performed by said press device; subjecting the uniform composition of said balancing layer along the underside of said substrate to said press treatment, wherein during said press treatment the uniform composition of said balancing layer is brought into contact with a surface of the press device; and wherein said press treatment creates a residual tension in said first thermosetting resin with said one or more material sheets, and a residual tension in said second thermosetting resin of said balancing layer, and wherein said residual tension in said second thermosetting resin of said balancing layer at least partly counteracts a warping tendency created by said residual tension in said first thermosetting resin with said one or more material sheets.