LAMINATE AND METHOD FOR PRODUCING A LAMINATE

Abstract

 Laminate comprising a decorative layer and one or more polymeric interlayers, wherein the decorative layer comprises one or more impregnated papers, a finish foil, a nonwoven, a veneer based on wood, a ceramic material, a high pressure laminate, a continuous pressure laminate or a low pressure melamine or combinations thereof.

Description

[0001] The present invention relates to a laminate and a method for producing a laminate.

[0002] Laminates with a decorative surface are well known, including HPL (high pressure laminate), CPL (continuous pressure laminate), LPM (low pressure melamine) and furthermore include finish foils, nonwovens, veneers based on wood, and thin ceramic material. Decorative laminates with multilayer structures may be used in the construction of a wall, ceiling, door, room divider, benchtops, cabinetry, furniture, flooring or alternative decorative applications.

[0003] It is known that laminate surfaces based on thermosetting melamine formaldehyde resins, such as high pressure laminate (HPL) and continuous pressure laminate (CPL), are thin and hard and when damaged can release sharp hazardous shards of material. Thin hard ceramic materials are also susceptible to breakage.

[0004] The surface of a LPM panel is usually created in a hot press during the partial flow of resin from the impregnated decor paper into a woodpanel substrate such as particleboard or MDF/HDF (fibreboards). This process of attaching the impregnated papers to a woodpanel substrate is irreversible. For laminates such as HPL or CPL the surface is created when combining impregnated papers in a hot press before the laminate is later glued to a substrate using only sufficient adhesive to bond the laminate to a substrate and avoid leakage of the adhesive from the edges. Decorative materials such as finish foils, nonwovens, wood based veneers or thin ceramic materials are also glued to a substrate, therefore along with HPL and CPL it remains possible to influence at least one or more characteristics during the construction of the final multilayer laminate structure.

[0005] The optical impression of a smooth HPL, CPL or LPM surface or an over-all texture does not always meet current market demands that the laminate look less synthetic. The surface of a laminate is a mirror image of a pressplate or endless belt used during the thermohardening of the melamine-formaldehyde resin (MF resin) under pressure in a hot press. The surface may be smooth, matte or have an abstract embossing design, or have a structure such as a woodgrain pattern. There are several influences to consider when attempting to have an embossing that co-ordinates with a printed design of a laminate surface, known as Embossed in Register (E-I-R). The specification of the decor paper for a controlled expansion of the printed decor paper during impregnation and controlled placement of the impregnated paper and substrate in the hot press equipped with cameras are examples of the considerable amount of technical development that have occurred to achieve a texture on the surface of a laminate that is substantially in register with the printed design, realising an Embossed-in-Register (E-I-R) effect. Nevertheless, there are numerous older hot presses still operating that are not equipped for controlled placement of the laminate components relative to the press tool to ensure excellent E-I-R where there would be an economic benefit for the laminate manufacturer from being able to emboss the laminate surface substantially In- Register to a printed design.

[0006] It is an object of the present invention therefore to provide a laminate having improvements in safety aspects in the use and functions of decorative laminates and multilayer structures incorporating the decorative laminate, and to improvements in thermal efficiency, fire retardancy, and optical aspects of decorative laminates and multilayer structures. Improvements in thermal efficiency and fire retardant characteristics add commercial attractiveness to decorative laminates and multilayer structures incorporating the decorative laminate. From the visual aspect the embossing of a decorative laminate surface in register with the printed motif is a desirable attribute.

[0007] Multilayer structures using HPL, CPL, finish foils, a nonwoven, a wood based veneer or thin ceramic material as the decorative surface will, with enhanced safety, improved thermal insulation, improved fire retardancy and a visually pleasing embossing in register with the printed motif, present an attractive commercial advantage in the marketplace.

[0008] It has been found that the above-mentioned objectives can be dealt with when a laminate is provided comprising a decorative layer and one or more polymeric interlayers, wherein the decorative layer comprises one or more impregnated papers, a finish foil, a nonwoven, a veneer based on wood, a ceramic material, a high pressure laminate, a continuous pressure laminate or a low pressure melamine or combinations thereof.

[0009] Thus, the decorative layer is selected from the group consisting of one or more impregnated papers, a finish foil, a nonwoven, a veneer based on wood, a ceramic material, a high pressure laminate, a continuous pressure laminate and a low pressure melamine or combinations thereof. The one or more impregnated papers can be impregnated with a resin, preferably a MF resin.

[0010] The improved safety objectives of the invention are achieved by adhering one or more polymeric interlayers to the non-decorative side of the decorative layer material. A polymeric interlayer may include an embedded wire connected to a sensor for data collection. An embedded measurement device (sensor), whether contained in the polymeric interlayer or situated elsewhere in the laminate construction, may be included to capture one or more measurements, for example a pressure sensor, a vibration sensor, an air quality sensor or a resistive thermal device such as a Pt100 thermocouple device. The embedded wire may be used to increase the temperature of the decorative surface.

[0011] In the case of thin hard decorative materials, the result of the polymeric interlayer being securely adhered to the decorative layer, such as HPL, CPL or thin ceramic material, is that if any damage occurs, the adhesion to the polymeric interlayer minimizes the possibility that any shards or larger sharp pieces separate from the surface and create a hazard.

[0012] Pre-impregnated finish foils can be produced on a paper machine and later as a unicolour or printed product are glued to a substrate. Nonwoven materials can also be produced on a paper machine and consist of cellulose or synthetic fibres. Pre-impregnated finish foils and nonwovens are usually manufactured with latex binder without any added formaldehyde. Nonwovens have a low wet expansion which is advantageous for Embossed-in-Register applications. In general, standard wood based veneers are usually between 0.4 - 0.6mm and thin ceramic material usually between 3 - 6mm.

[0013] Preferably, the laminate further comprises a substrate supporting the one or more polymeric interlayers and the decorative layer. The substrate can be a reconstituted woodpanel, a plywood, a cross laminated timber, a plasterboard, a fibre-cement sheet, a hardboard, a brick or concrete or a solid wood structure. As reconstituted woodpanel a particleboard, fibreboard or oriented strand board (OSB) can be used. The substrate may have fire retardant characteristics, or have a fire retardant coating on one or more sides. The multilayer composite product comprising the decorative layer and the one or more polymeric interlayers and optionally a thermal insulation layer, and/or a fire retardant layer, may be directly attached to substrate.

[0014] The material of the one or more polymeric interlayers is preferably selected from the group consisting of ionoplast material, polyvinyl butyral, ethylene vinyl acetate and thermoplastic polyurethane or combinations thereof. Polymeric interlayers of various material, thicknesses and functions are commercially available, for example an ionoplast (ionomer based) material (e.g. Kuraray SentryGlas^®) or polyvinyl butyral (e.g. Kuraray Trosifol^®) or ethylene vinyl acetate (e.g. Folienwerk-Wolfen evguard^®, Satinal Strato^® or SWM Intl. ArgoBond^® SE-381) or thermoplastic polyurethane (TPU) (e.g. Huntsman Krystalflex^®), or a wire embedded polymeric interlayer (AGP Plastics). In one embodiment the polymeric interlayer is attached to the non-decorative side of the decorative layer, such as the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material, before combining with a substrate. Alternatively, the polymeric interlayer may be attached to a substrate and later the decorative layer is attached to form the laminate in form of a multilayer composite product. An advantage would be to combine at least the decorative layer, at least one polymeric interlayer, and the substrate to form the laminate in form a multilayer composite product in a single process, which includes embossing the laminate surface in register with the printed design on the laminate surface.

[0015] Polymeric interlayers are commercially available with a thickness of about 3mm or less, for example Kuraray SentryGlass^® ionoplast interlayers are available in standard thicknesses between 0.76mm and 3.04mm, while Kuraray Trosifol^® PVB interlayers are available in standard thicknesses between 0.38mm and 2.28mm. Evguard^® EVA polymeric interlayer is available in thicknesses from 0.2 - 1.4mm. Commercially available polymeric interlayer material is available in widths up to about 3.2m in sheet or roll form. The choice of polymeric interlayer can be influenced by a number of factors, such as dwell time and temperature in a press. According to literature from Kuraray, SentryGlas^® is up to 100 times stiffer than polyvinyl butyral, and SentryGlas^® ionoplast interlayer has a higher thermal stability compared to polyvinyl butyral interlayer.

[0016] One or more polymeric interlayers of different thickness or different raw material, or to achieve different objectives may be incorporated in one laminate product. As the polymeric interlayer is not intended as a visible external layer of the laminate product, there is no need for the polymeric interlayer to meet any specification for light transmission, it may even be used when having exceeded the manufacturer's recommended use-by-date.

[0017] Preferably, one polymeric interlayer is directly attached to the decorative layer. This polymeric interlayer is preferably irreversibly attached, more preferably glued, to the decorative layer. The further polymeric interlayers can be attached to other polymeric interlayers or further layers of the laminate.

[0018] Thus, in some cases it may be necessary to use an adhesion promotor with the polymeric interlayer, or in certain circumstances further improve the bond between the decorative layer and the polymeric interlayer with an additional amount of adhesive. In an embodiment the use of an elevated temperature to combine the various layers of a multilayer laminate product and to cause the polymeric interlayer to itself form an adhesive nature is preferred.

[0019] Preferably, the laminate according to the invention comprises one or more protective layers. Preferably, one of the protective layers is directly attached to the side of the polymeric interlayer that is not attached to the decorative layer. Each of the further protective layers can be attached to the layer that is directly attached to the polymeric interlayer or to any other layer of the multilayer laminate.

[0020] The one or more protective layers can be polyethylene terephthalate films, quartz cellulose papers or retardant felts. The protective layers may differ from each other or be the same. A protective layer or layers may be incorporated to enhance the performance of the polymeric interlayer, for example Trosifol^® PET (Kuraray) adhered to the side of the polymeric interlayer not attached to the laminate to avoid sticking in a hot press. Thus, the material of the one or more protective layers is selected from the group consisting of polyethylene terephthalate, a mixture of quartz and cellulose and a fire retardant felt material or combinations thereof.

[0021] The protective layer may itself present a decorative aspect or a company logo on the reverse side of the laminate, such as a HPL or CPL laminate. A protective layer used to prevent the polymeric interlayer sticking in the hot press may itself have a technical function, such as providing a fire retarding function. More than one protective layer may be included in the multilayer laminate construction.

[0022] To improve the fire retardancy of a laminate construction, e.g. a laminate based on any of HPL, CPL, finish foils, a nonwoven, wood based veneer or a thin ceramic material, and having a polymeric interlayer, a protective layer such as a fire retardant material based on quartz and/or fire retardant felt is included in the laminate multilayer construction. A suitable protective layer in the form of a fire retardant layer is a paper based on a mixture of quartz and cellulose. Alternatively, a fire retardant felt based on cotton linters and a flame retardant may be used as protective layer. It may be advantageous to use both in combination to achieve a higher fire retardant performance.

[0023] Preferably, the laminate comprises a thermal insulation layer. The thermal insulation layer is preferably made of expanded polystyrene. The thermal insulation layer preferably has a thickness in the range from 2 to 10 mm. However, even a thicker thermal insulation can be used. Nevertheless, it is an advantage to achieve the thermal insulation without having to substantially increase the thickness of the multilayer construction. Expanded polystyrene such as Neopor^® containing graphite provides thermal insulation with a 4mm thickness equal to a 262mm thick concrete.

[0024] According to the invention, the polymeric interlayer, preferably a dispersion containing a recycled polymeric interlayer material from which the polymeric interlayer can be made, can be used to impregnate or coat the one or more protective layers, for example a glass nonwoven material, or fire retardant felt and/or a quartz cellulose paper.

[0025] A suitable press for combining the layers of the laminate may be a short-cycle press or a compression molding press. The laminate may be also prepared without a press, for example using hot roll lamination or manual lay-up techniques.

[0026] In a preferred embodiment, the decorative layer has an embossing on the side facing away from the one or more polymeric interlayers. Preferably, the embossing is in register with a printed pattern on the decorative layer.

[0027] To impart an embossing substantially in register (E-I-R) with the print design in the surface of an already manufactured decorative layer requires the surface of the decorative layer to accept the ingress of the embossing tool surface into the hard surface. This must be achieved without causing lasting damage to the surface, which is by design capable of withstanding in-use wear and tear. The MF resin used to create the decorative layer surface may contain additives to enable deep textures to be pressed during the original laminate manufacturing process, however this is not providing a benefit when applying the E-I-R texture after the original manufacturing process. The depth of E-I-R textures range from a few tens of microns to more than one hundred microns, however unlike the 3D shape postforming of a HPL or CPL where all layers of the HPL or CPL are stretched to form an arc with a radius many times the thickness of the laminate, during embossing according to the invention the laminate, e.g. HPL, CPL or LPM, remain in a planar position while the "hills and valleys" of the texture are forced only into the upper MF resin layer. There is no need to heat the laminate through and through as required for postforming, it is sufficient and preferred that the laminate remains in a planar state and the heating of the laminate surface is localised to the upper surface strata. The textured press tool may be heated or unheated when applying the embossing to the laminate surface. Textures that are not required to be In-Register with a printed pattern may also be produced according to the invention.

[0028] In an embodiment the decorative layer surface is subjected to radiation that softens its outermost region. Immediately thereafter the laminate is placed in a press where a textured press tool is brought into contact with the softened decorative layer surface and pressure applied to form an embossing substantially in register with the printed design of the laminate surface. The choice of radiation equipment is not limited by wavelength, it may be UV, IR or microwave. If the softening of the decorative layer surface could be achieved when the decorative layer is positioned in the press, that would avoid handling of the laminate while the surface is in the softened phase. The E-I-R embossing of a decorative surface material, e.g. HPL or CPL material, may be completed before the decorative surface is combined with at least one polymeric interlayer, any protective layers and a substrate. In general, a decorative layer, e.g. a LPM panel, embossed according to the invention requires no further lamination, except for sealing the edges with an edgebanding. However, it is a practical option that the newly embossed decorative layer according to the invention is coated with a clear coating.

[0029] A press for consolidating various layers of the laminate may also be used to provide an embossing using a textured pressplate, alternatively an embossing can be applied from one or more embossing rolls. In an embodiment, the texture of the embossing roll or rolls is co-ordinated with the printed pattern using a camera vision system to control the start position of the embossed roll or rolls relative to the print. The use of more than one embossing roll enables more sophisticated surface texturing to be applied. The press tool may be heated or be used without heating.

[0030] According to the invention, the laminate can comprising a further decorative layer arranged on the side of the laminate opposite to the other decorative layer.

[0031] The present invention is further directed to a method for producing the laminate according to the invention. A laminate according to the invention can be prepared by a method comprising the step of combining a decorative layer with one or more polymeric interlayers. Preferably, the combining step includes the step of adhering one of the polymeric interlayers to the decorative layer and/or the step of increasing the temperature. According to the invention, the polymeric interlayer can be combined with a substrate before being combined with the decorative layer.

[0032] The method can comprise the step of embossing the decorative layer. Preferably, the combining step and the embossing step are carried out simultaneously.

[0033] The embossing step can comprise the step of softening, preferably by irradiating, the surface of the decorative layer.

[0034] The method can comprise the step of producing the polymeric interlayer. Preferably, the polymeric interlayer is produced by forming a dispersion from recycled polymeric interlayers. Preferably, the one or more polymeric interlayers are formed from recycled polymeric interlayer material. From an environmental and possibly cost perspective the polymeric interlayer may be manufactured from recycled polymeric interlayer materials. A polymeric interlayer can be manufactured from 100% recycled PVB trimmings, and due to changes in light transmission properties, and contamination, the recycling of PVB polymeric interlayer is limited, and most PVB polymeric interlayer recovered when recycling automotive windshields are incinerated or buried. Therefore, in an effort to reduce the environmental impact, it would be preferable to use a polymeric interlayer manufactured from recycled material recovered from windscreens or other laminated glass materials. Recycled PVB polymeric interlayer material in the form of a dispersion is commercially available and may be used with or without a crosslinking agent, for example a blocked isocyanate containing crosslinking agent.

[0035] The combining step of the method according to the invention preferably comprises the step of coating the decorative layer with a mixture comprising the polymeric interlayer material and/or a mixture from which the polymeric interlayer is formed. In an embodiment the polymeric interlayer is formed from recycled polymeric interlayer material, and either coated directly to the non-decorative side of the decorative layer or coated into and onto a substrate, such as a carrier material, which is subsequently attached to the non-decorative side of the decorative layer. In an alternative embodiment the polymeric interlayer in either sheet or roll format is attached on the non-decorative side of the decorative layer in the lay-up with the impregnated papers that will form the decorative layer.

[0036] The method can comprise one or more, so also all, of the steps of adding a substrate, adding one or more protective layers, adding a thermal insulation layer, adding an embedded measurement device (sensor), pressing the obtained product.

[0037] In a first example of the invention, at least one polymeric interlayer with an outermost protective film is combined with 2 or more impregnated papers in a hot press to form a hybrid HPL or hybrid CPL sheet. The meaning of hybrid is that the HPL or CPL sheet differs from standard HPL and CPL which do not incorporate a polymeric interlayer.

[0038] In a second example of the invention, at least one polymeric interlayer and at least one fire retardant material layer is combined with 2 or more impregnated papers in a hot press to form a hybrid HPL or hybrid CPL sheet.

[0039] In a third example of the invention, at least one polymeric interlayer is adhered to the non-decorative side of a HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material, and the composite material attached to a substrate.

[0040] In a fourth example of the invention, at least one polymeric interlayer and at least one fire retardant layer is adhered to the non-decorative side of a HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material, and the composite material attached to a substrate.

[0041] In a fifth example of the invention, the HPL or CPL or LPM surface is preheated immediately before an embossing of the laminate surface. The embossing may be In-Register with a printed design.

[0042] In a sixth example of the invention, HPL or CPL, and at least one polymeric interlayer are combined with a substrate in a press using a press tool to impart an embossing to the laminate surface. The surface of the laminate is preheated immediately prior to the embossing action, and the embossing may be substantially In-Register with the printed design of the laminate surface.

[0043] In a seventh example of the invention, a fire retardant layer is included in the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material multilayer composite product, located between the polymeric interlayer and the substrate.

[0044] In an eighth example of the invention, a thermal insulation layer is included in the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material multilayer composite product, located between the polymeric interlayer and the substrate.

[0045] In a ninth example of the invention, the fire retardant layer is combined with the impregnated papers and the polymeric interlayer in the manufacture of a HPL or CPL product, where for clarity the lay-up is impregnated papers / polymeric interlayer / fire retardant layer = laminate according to the invention. In this case a thermal insulation layer may be attached in a separate process step to a substrate, and the laminate attached to the thermal insulation layer side of the substrate. This concept is also applicable where there is no fire retardant layer used in the manufacture of HPL or CPL with a polymeric interlayer, meaning that the impregnated paper / polymeric interlayer is in a separate process step attached to the thermal insulation / substrate.

[0046] In a tenth example of the invention, the polymeric interlayer is a dispersion manufactured from recycled polymeric interlayers and is coated on and into a carrier material, for example a fire retardant material layer, and later the coated carrier material layer in attached to the non-decorative side of the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material. Alternatively the recycled polymeric interlayer dispersion is coated directly onto the non-decorative side of the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material. The recycled polymeric interlayer may include an embedded measurement device (sensor).

[0047] In an eleventh example of the invention, the polymeric interlayer has an embedded wire used to increase the temperature of the decorative surface. The increase in surface temperature may provide a pleasing effect if the application should be for example as a flooring component. The increase in surface temperature may change the colour of all or part of the decorative surface if the decorative surface contains thermochromic pigments or dyes.

[0048] In a twelfth example of the invention, an embedded measurement device is placed in the polymeric interlayer and records changes in room temperature.

[0049] The embedded measurement device is connected to a microprocessor and programmed to regulate the heating or cooling system of the room.

[0050] The 12 examples present only a limited number of possible process steps or combinations and are not limiting different process steps or combinations to achieve the objectives of the invention. Furthermore, the number of layers that form the multilayer laminate product is not restricted in any way and the laminate may have 2 decorative sides, and not necessarily be a symmetric construction.

[0051] The description of the laminate according to the invention and of the method according to the invention are to be provided as complementary to one another, so that information concerning the method, which is explained in connection with the laminate, is likewise to be understood individually or in a combined manner as information concerning the method. Features of the laminate which are explained in connection with the method according to the invention are to be understood individually or combined with one another also as features of the laminate according to the invention.

[0052] Preferred embodiments of the present invention are described with reference to the drawings as follows.

Fig. 1A illustrates a high pressure laminate according to the state of art and Fig. 1B the broken laminate of Fig. 1A. The laminate according to the state of art has no polymeric interlayer. The adhesion of to the polymeric interlayer according to the present invention minimizes the possibility that any shards or larger sharp pieces separate from the surface and create a hazard, as shown in Fig. 1B.

Fig. 2 illustrates a laminate according to the present invention comprising an OSB-layer as substrate, a polymeric interlayer and a HPL layer as decorative layer.

Fig. 3 illustrates a laminate according to the present invention comprising material past the recommended use-by-date, namely a 0.38mm PVB layer as polymeric interlayer supplied by HT Troplast AG in 2004 that was combined in 2021 with a HPL and OSB panel using a multi-purpose adhesive (Selleys^® Allfix^®).

Fig. 4 illustrates a laminate according to the present invention comprising material past the recommended use-by-date, namely a 0.76mm PVB layer as polymeric interlayer supplied by HT Troplast AG in 2004 combined with a nonwoven (Ahlstrom-Munksjo grade Ma 8737-080) and attached to an OSB panel.

Fig. 5 illustrates a comparison of the thermal insulation performance of 4mm Climapor^® based on Neopor^® to other materials. Climapor^® is available with a backing material of paperboard, nonwoven or aluminium foil. Neopor^® F grades contain a polymeric flame retardant and are available based on renewable raw materials - Neopor^® BMB.

Fig. 6 illustrates a laminate according to the present invention comprising a HPL layer as decorative layer, a polymeric interlayer, denoted as polymeric interlayer, a flame retardant paper in form of a FHB1 felt, a QU50 quartz paper, and a a thermal insulation layer.

Fig. 7 illustrates a laminate according to the present invention comprising a HPL layer as decorative layer, a polymeric interlayer, denoted as polymeric interlayer, a QU50 quartz paper, a fire retardant felt, a thermal insulation layer and a 6mm OSB woodpanel as substrate.

Claims

1. Laminate comprising a decorative layer and one or more polymeric interlayers, wherein the decorative layer comprises one or more impregnated papers, a finish foil, a nonwoven, a veneer based on wood, a ceramic material, a high pressure laminate, a continuous pressure laminate or a low pressure melamine or combinations thereof.

2. Laminate according to claim 1 further comprising a substrate supporting the one or more polymeric interlayers and the decorative layer, wherein the substrate is preferably a reconstituted woodpanel, a plywood, a cross laminated timber, a plasterboard, a fibre-cement sheet, a hardboard, a brick or concrete or a solid wood structure.

3. Laminate according to claim 1 or 2, wherein the material of the one or more polymeric interlayers is selected from the group consisting of ionoplast material, polyvinyl butyral, ethylene vinyl acetate and thermoplastic polyurethane or combinations thereof, preferably wherein the one or more polymeric interlayers are formed from recycled polymeric interlayer material.

4. Laminate according to any of claims 1 to 3, wherein one of the polymeric interlayers is attached, preferably irreversibly attached, more preferably glued, to the decorative layer.

5. Laminate according to any of claims 1 to 4 comprising one or more protective layers, wherein one of the protective layers is preferably attached to the side of the polymeric interlayer that is not attached to the decorative layer.

6. Laminate according to claim 5, wherein the one or more protective layers are polyethylene terephthalate films, quartz cellulose papers or fire retardant felts, wherein the protective layers are the same or different.

7. Laminate according to any of claims 1 to 6 comprising a thermal insulation layer, which is preferably made of expanded polystyrene.

8. Laminate according to any of claims 1 to 7, wherein the decorative layer has an embossing on the side facing away from the one or more polymeric interlayers, preferably wherein the embossing is in register with a printed pattern on the decorative layer.

9. Laminate according to any of claims 1 to 8 comprising a further decorative layer arranged on the side of the laminate opposite to the other decorative layer.

10. Laminate according to any of claims 1 to 9, wherein the laminate contains an embedded wire and/or an embedded measurement device, preferably a sensor.

11. Method for producing a laminate according to any of claims 1 to 10 comprising the steps of combining a decorative layer with one or more polymeric interlayers, preferably wherein the combining step includes the step of adhering one of the polymeric interlayers to the decorative layer and/or the step of increasing the temperature.

12. Method according to claim 11 comprising the step of embossing the decorative layer, preferably wherein the combining step and the embossing step are carried out simultaneously.

13. Method according to claim 12, wherein the embossing step comprises the step of softening, preferably by irradiating, the surface of the decorative layer.

14. Method according to any of claims 11 to 13, comprising the step of producing the polymeric interlayer, preferably by using a dispersion produced from recycled polymeric interlayers.

15. Method according to any of claims 11 to 14, wherein the combining step comprises the step of coating the decorative layer with a mixture comprising the polymeric interlayer material.

16. Method of coating the polymeric interlayer dispersion onto a protective or carrier material where the polymeric interlayer is formed.

17. Method according to any of claims 11 to 16 comprising one or more of the steps of

adding a substrate,

adding one or more protective layers,

adding a thermal insulation layer,

adding an embedded measurement device, preferably a sensor,

pressing the obtained product.

Drawing