Panel and methods for manufacturing panels

Abstract

A panel may include at least a substrate and a top layer provided on the substrate. The top layer may include a vinyl-based synthetic material layer. The substrate may be a wood-based substrate. A primer may be provided between the substrate and the vinyl-based synthetic material layer.

1 .- 3 . (canceled) 
     
     
         4 . A method for manufacturing a panel having at least a substrate and a top layer provided on the substrate, the top layer including a thermoplastic synthetic material, the method comprising:
 subjecting the thermoplastic synthetic material to a first temperature and a first pressure; and   forming a structure in the thermoplastic synthetic material by subjecting the thermoplastic synthetic material to a second temperature and a second pressure;   wherein the first temperature is higher than the second temperature and the second pressure is higher than the first pressure.   
     
     
         5 . The method of  claim 4 , further comprising forming a consolidated package that includes at least a motif and the thermoplastic synthetic material;
 wherein the consolidated package is formed prior to or in connection with subjecting thermoplastic synthetic material to the first temperature and the first pressure.   
     
     
         6 . The method of  claim 4 , wherein the first temperature reaches at least 50 percent of the glass transition temperature of the thermoplastic synthetic material. 
     
     
         7 . The method of  claim 4 , wherein an infrared lamp is applied for generating the first temperature. 
     
     
         8 . The method of  claim 4 , wherein a structured press element is applied for generating the second temperature. 
     
     
         9 . The method of  claim 4 , wherein the second temperature is between 20 and 55° C. 
     
     
         10 .- 16 . (canceled) 
     
     
         17 . A method for manufacturing a panel having at least a substrate and a top layer provided on the substrate, the top layer including at least a synthetic material film, the method comprising:
 providing the synthetic material film on the substrate by means of a press treatment at increased temperature.   
     
     
         18 . The method of  claim 17 , further comprising:
 providing a primer on the substrate.   
     
     
         19 . The method of  claim 17 , wherein the substrate relates to a wood-containing or wood-based substrate. 
     
     
         20 . The method of  claim 17 , wherein the substrate includes a foamed synthetic material. 
     
     
         21 . The method of  claim 17 , wherein the top layer includes at least two synthetic material films. 
     
     
         22 . The method of  claim 21 , further comprising, prior to the press treatment, laminating the two synthetic material films to a composed film. 
     
     
         23 . The method of  claim 17 , wherein the increased temperature is situated between 80 and 150° C. 
     
     
         24 . The method of  claim 17 , wherein the press treatment is performed with a pressing time shorter than one minute. 
     
     
         25 . A method for manufacturing a panel having at least a substrate and a top layer provided on the substrate, the top layer including at least a printed motif and a transparent or translucent synthetic material layer provided above the printed motif, the method comprising:
 providing, over the printed motif, a vinyl-containing paste to form at least a portion of the transparent or translucent synthetic material layer; and   providing, by means of a press treatment, a relief in the transparent or translucent synthetic material layer.   
     
     
         26 . The method of  claim 25 , wherein the vinyl-containing paste relates to a suspension of PVC in plasticizer. 
     
     
         27 . The method of  claim 25 , wherein the vinyl-containing paste is provided over a synthetic material film or a synthetic material layer, which is provided with the printed motif. 
     
     
         28 . The method of  claim 25 , wherein the transparent or translucent synthetic material layer includes at least a back layer and a synthetic material film;
 wherein the printed motif is provided on the synthetic material film; and   wherein the back layer and the synthetic material film are provided over each other prior to providing the vinyl-containing paste.   
     
     
         29 . The method of  claim 25 , wherein the top layer or a portion thereof that includes the printed motif, is provided on the substrate after the vinyl-containing paste has been provided over the printed motif. 
     
     
         30 . The method of  claim 25 , wherein the vinyl-containing paste, prior to the press treatment, is at least partially hardened or gelled. 
     
     
         31 . The method of  claim 25 , wherein by means of the press treatment, heat is supplied to the transparent or translucent synthetic material layer. 
     
     
         32 . The method of  claim 25 , wherein the transparent or translucent synthetic material layer is formed substantially by the vinyl-containing paste.