Panel and methods for manufacturing a panel

Abstract

A panel includes a substantially plate-shaped polymer core and a decorative and/or wear-resistant layer. The decorative and/or wear-resistant layer is bonded at least partially to and/or in a surface of said polymer core, and the decorative and/or wear-resistant layer comprises a granular and/or fibrous material.

1 .- 84 . (canceled) 
     
     
         85 . A panel comprising a substantially plate-shaped polymer core and a decorative and/or wear-resistant layer,
 wherein said decorative and/or wear-resistant layer is bonded at least partially to and/or in a surface of said polymer core,   wherein said decorative and/or wear-resistant layer comprises a granular material,   wherein a projection of the granular material in a direction perpendicular to said surface of said polymer core covers said surface for at least 90%.   
     
     
         86 . The panel of  claim 85 , wherein the granular material is selected from the group of stone, grit, gravel, quartz, aluminum oxide (Al2O3), polyvinyl chloride (PVC), or combinations thereof. 
     
     
         87 . The panel of  claim 85 , wherein the granular material forms a substantially flat and homogeneous scatter layer on and/or in the surface of said polymer core. 
     
     
         88 . A panel comprising a substantially plate-shaped polymer core and a decorative and/or wear-resistant layer,
 wherein said decorative and/or wear-resistant layer is bonded at least partially to the surface of said polymer core,   wherein the thickness of said decorative and/or wear-resistant layer and the thickness of said polymer core are in a ratio between 1:5 and 5:5.   
     
     
         89 . The panel of  claim 88 , wherein the decorative and/or wear-resistant layer comprises a polymer material, and
 wherein the polymer material of the decorative and/or wear-resistant layer is an extruded polymer material.   
     
     
         90 . The panel of  claim 89 , wherein the polymer material of the decorative and/or wear-resistant layer comprises one or more colorants. 
     
     
         91 . The panel of  claim 85 , wherein the polymer core is an extruded polymer core,
 wherein the polymer core and/or the polymer material of the decorative and/or wear-resistant layer comprise polyvinyl chloride (PVC) and calcium carbonate (CaCO3) as filler,   wherein the calcium carbonate (CaCO3) has a concentration between 60 and 80 wt % and the polyvinyl chloride (PVC) has a concentration between 20 and 40 wt %.   
     
     
         92 . The panel of  claim 85 , wherein the panel is free from resins, adhesives and/or glues between the polymer core and the decorative and/or wear-resistant layer. 
     
     
         93 . The panel of  claim 85 , wherein the panel is a floor board, ceiling board or wall board. 
     
     
         94 . A decorative panel that comprises a substrate and a top layer, a decorative and/or wear-resistant layer,
 wherein the substrate comprises a polymer-based material, a wood-based material or a combination thereof,   wherein the top layer comprises one or more cement-based layers of material.   
     
     
         95 . The decorative panel of  claim 94 , wherein the substrate is almost free from cement-based or cement-bonded material. 
     
     
         96 . The decorative panel of  claim 94 , wherein each of said one or more cement-based layers of material has a thickness of between 0.4 and 1.0 mm. 
     
     
         97 . The decorative panel of  claim 94 , wherein one or more cement-based layers of material have a total thickness between 1.0 and 5.0 mm. 
     
     
         98 . The decorative panel of  claim 94 , wherein the top layer comprises at least 3 cement-based layers of material. 
     
     
         99 . The decorative panel of  claim 94 , wherein at least one of said cement-based layers of material is fiber-reinforced. 
     
     
         100 . The decorative panel of  claim 94 , wherein the top layer comprises an upper sealing layer, which is positioned on top of the uppermost cement-based layer of material. 
     
     
         101 . The decorative panel of  claim 100 , wherein the upper sealing layer contains one or more acrylate compounds. 
     
     
         102 . The decorative panel of  claim 94 , wherein the top layer comprises one or more substrate sealing layers,
 wherein the substrate sealing layers are located between the substrate and the lower cement-based layer of material.