The present invention relates to a wrapping foil, a method of manufacturing said wrapping foil, as well as to a finishing profile, in particular to a finishing profile for a covering, such as a floor covering, ceiling covering, or wall covering, which is covered with such wrapping foil.

Finishing profiles such as skirting boards or transition profiles are widely known per se. They may be used for example for finishing the edges of a floor covering. Profiles of this kind may consist of a core material, for example of MDF, HDF, multiplex, plastic, and a layer shaped covering. Said layer shaped covering may for example be performed to match the floor covering. According to the prior art, such layer shaped covering may be performed in various possible ways. It may consist of wood veneer, for example matching a parquet floor, of a decorative plastic film, or of laminate. Such laminate may comprise two paper sheets, namely a printed paper sheet and a heavy carrier sheet, wherein both sheets are provided with a maximum amount of resin, for example melamine-based resin. Although laminate is accepted as a good-quality coating, it shows disadvantages regarding processability and the logistic effort required for manufacturing laminates that for example match a laminate floor covering. For example, it may be difficult for corner portions of profiles with small radii to be coated at high speed without formation of cracks of the laminate. The laminates must be attached to the core material with PU adhesives, and the provision of decorative paper provided with resin specifically for skirting boards requires an intensive planning, wherein surpluses are difficult to avoid.

The present invention relates firstly to an alternative laminate, which may be used as a wrapping foil and which, according to various preferred embodiments, offers advantages compared to the laminates of the prior art.

For this purpose, according to its first aspect the invention relates to a wrapping foil, with the characteristic that this wrapping foil is assembled from: - a, preferably transparent or translucent, paper sheet with a paper weight from 15 to 30 grams per square meter that is provided with resin, wherein the dry weight of the applied resin is at least as much as the paper weight, and preferably is at least 150% or at least 200% of the paper weight, wherein amounts of resin of 250% or 300% or more are not excluded;

- a printed paper sheet with a paper weight from 50 to 90 grams per square meter, and better still 60 to 80 grams per square meter, which is resin-free or is provided with an amount of resin for which the dry weight is less than half the paper weight;

- a carrier sheet with a paper weight less than or equal to the paper weight of the aforementioned printed paper sheet, wherein this carrier sheet is resin-free or is provided with an amount of resin for which the dry weight is less than half the paper weight of the carrier sheet in question.

It is to be noted that during assembly of the wrapping foil, the resin of said paper sheets will be redistributed, and that mainly the resin of the transparent or translucent paper sheet will migrate through the printed paper sheet to the carrier sheet.

Because the wrapping foil is assembled in the aforementioned manner, a more flexible carrier sheet is produced, which can be used more easily and more smoothly, i.e. at high speeds, in a wrapping process, for example for the production of finishing profiles that have corner portions with small radii, for example less than 3 mm, or less than 1.5 mm. This advantage is obtained through the combination of specific low paper weights and limited application of resin on the bottommost paper layers, namely the printed paper sheet and the carrier. In addition, by using a paper sheet above the printed paper sheet, namely by applying a translucent or transparent varnished paper sheet, an increased wear resistance is obtained. Further, the inventor has noted that, despite the limited weight of the carrier, the abovementioned composition of the wrapping foil still provides an acceptable impact strength. Moreover, sufficient penetration of the resin into the underlying layers is obtained, so that when a profile wrapped with said foil is sawn, no, or an acceptable, fraying of for example the printed paper sheet is obtained. The aforementioned, preferably transparent or translucent paper sheet, preferably relates to a paper sheet that is free from fillers, such as titanium dioxide, and/or has an ash content of less than 0.5 weight percent, and even better of 0 or almost 0 weight percent. Preferably it relates to an alpha-cellulose paper sheet, for example a paper sheet known under the denomination "overlay".

According to a particular embodiment, the preferably transparent or translucent paper sheet and/or the printed paper sheet are provided with wear-resistant particles, such as aluminum oxide particles. Said particles may be present in the bulk of the paper sheet, and/or may be applied in a mixture together with the aforementioned resin. Said particles preferably have an average particle size between 10 and 100 micrometers. Namely when the wrapping foil is used in heavily loading circumstances, for example in a floor surface or on a staircase, preferably at least 5 grams per square meter of such particles is applied. Preferably said particles are present in the wrapping foil on a position above the print of the printed paper sheet.

According to a particular possibility of the abovementioned particular embodiment, the wear-resistant particles, preferably aluminum oxide particles, are applied by scattering on the side of the transparent or translucent paper sheet that faces outwards in the wrapping foil. The inventors have noted that this embodiment gives rise to a tactile sensation of the surface of the wrapping foil that strongly resembles that of wood veneer. Such embodiment is hence especially advantageous in case the printed paper sheet shows a wood pattern. The paper sheets of the aforementioned composition relate to impregnatable papers, namely paper that shows a Gurley value (Tappi T460) of less than 30 seconds, and preferably of 20 seconds or less. The flow of the resin from the preferably transparent or translucent paper sheet to the underlying paper sheets is thus promoted. Preferably the wrapping foil is free from further paper sheets or sheets of material. It is clear that further paper sheets may partly nullify the recovered flexibility and processability of the laminate. Preferably at least the printed paper sheet is resin-free. Hereby the important advantage is obtained that the logistic effort required for impregnating the decorative paper falls away. In addition, if there are surpluses, less waste will be produced, since no resin is present on the printed paper to be removed.

Preferably the carrier sheet is resin-free. Because the carrier sheet is resin-free, a maximum flexibility is obtained in the final wrapping foil. In addition, a situation may be reached in which the underside of the carrier sheet remains substantially resin-free, or at least shows resin-free paper fibers. This condition is interesting for gluing the related wrapping foil to the core material of a finishing profile. Scouring operations or other roughening treatments, such as plasma treatment, can be avoided. In addition, wrapping foil of this kind can be glued using a polyolefin glue. With the same purpose as in the first aspect, according to a second independent aspect the present invention further relates to a wrapping foil, with the characteristic that the aforementioned wrapping foil comprises a preferably transparent or translucent paper sheet, a printed paper sheet and a carrier sheet, and further comprises a resin, wherein the total weight of the paper sheets present in the wrapping foil is less than 175 grams per square meter, and that the wrapping foil comprises an amount of resin for which the dry weight is less than the total weight of paper present in the wrapping foil. It is clear that such wrapping foil may optionally be assembled as described in the context of the aforementioned first aspect of the invention, and may have similar advantages and preferred embodiments.

Preferably the aforementioned total paper weight of the wrapping foils of the first and/or second aspect is between 100 and 150 grams per square meter. The weight is preferably higher than 100 grams per square meter in order to obtain sufficient impact strength and opacity, and so that sufficient resin may be obtained in the wrapping foil. One or more paper sheets namely also have, according to the invention, the function of resin carrier. The total weight of the paper is preferably less than 150 grams per square meter with a view to maintaining sufficient flexibility and good resin penetration. Preferably the wrapping foil comprises an amount of resin for which the dry weight is less than 100 grams per square meter. Preferably the underside of the wrapping foil is not saturated with resin and/or free paper fibers are present on the underside of the wrapping foil, i.e. paper fibers not provided with resin. An underside of this kind allows simple gluing of the wrapping foil to a core material of a finishing profile, for example even by means of a polyolefin glue.

Preferably the aforementioned resin is a melamine-based resin, such as a melamine- formaldehyde resin. Alternatively, another thermosetting resin may be used, such as a urea-formaldehyde resin or a phenol-formaldehyde resin. As mentioned above, a melamine-based resin, for example melamine-formaldehyde, is preferably selected for the thermosetting resin of the wrapping foil, or at least of the preferably transparent or translucent paper sheet. Of course, the resin may comprise one or more additives. Flow improvers, such as polyglycol ether, epsilon-caprolactam, ethylene glycol, phthalic acid, phthalates or butanediol, hardeners, such as maleic acid, monobutylphosphoric acid, p-toluenesulfonic acid, citric acid, a mixture of one or more of these acids, aluminum sulfate, ammonium chloride or ammonium sulfate or other acids or salts which produce an acid pH in solution, release agents, and the like may be used as additives. An especially useful additive is a part of an acrylate resin, a polyol, such as butanediol or polyurethane diol, a polyol acrylate or some other hydroxy- functional acrylate. Said resin may be at least partially crosslinked or cured, while still maintaining sufficient processability of the wrapping foil. Working with a hydroxy- functional acrylate, or in other words with an acrylate that comprises an OH group, has the advantage that OH groups may be introduced into the melamine, because the acrylate is soluble in melamine. It is for example possible to work with 30-75 parts by weight of liquid melamine- formaldehyde resin with for example 15 to 45 weight percent solids, 5-10 parts by weight of a polyol or polyol acrylate and 2-3 parts by weight of flow improver.

According to a particular embodiment the aforementioned resin thus further comprises an acrylate resin, a polyol, such as butanediol or polyurethane diol, a polyol acrylate or another hydroxy-functional acrylate. On the basis of said additive, the flexibility of a cured or semi-cured resin, such as a melamine-based resin, may be improved. In this way, even corner portions with small radii, for example 1.5 mm or smaller, can be coated easily.

With the same viewpoint as in the first and second aspect, the present invention further relates, according to its third independent aspect, to a method of manufacturing a wrapping foil, with the characteristic that following paper sheets are laminated by means of a, preferably heated, pressing operation:

- a, preferably transparent or translucent, paper sheet with a paper weight from 15 to 30 grams per square meter that is provided with resin, wherein the dry weight of the applied resin is at least as much as the paper weight;

- a printed paper sheet with a paper weight from 50 to 90 grams per square meter, and better still 60 to 80 grams per square meter, which is resin-free or is provided with an amount of resin for which the dry weight is less than half the paper weight;

- a carrier sheet with a paper weight less than or equal to the paper weight of the aforementioned printed paper sheet, wherein this carrier sheet is resin-free or is provided with an amount of resin for which the dry weight is less than half the paper weight of the carrier sheet in question.

It is self-evident that the method of the third aspect may be used for manufacturing a wrapping foil according to the first and/or second aspect and/or the preferred embodiments thereof, and that the wrapping foil obtained gives rise to similar advantageous effects. It is clear that, according to a fourth independent aspect, the invention further relates to a finishing profile for finishing a covering, such as a floor covering, wall covering or ceiling covering, wherein the aforementioned finishing profile substantially consists of a core and a layer shaped covering, with the characteristic that the layer shaped covering is obtained by wrapping with a wrapping foil according to, respectively manufactured according to, one of the foregoing aspects and/or the preferred embodiments thereof.

Preferably the aforementioned layered covering is applied in one piece over a corner portion of the finishing profile, wherein the radius of the angular part is less than 3 mm, preferably less than 1.5 mm. It is clear that it is precisely the wrapping foil of the present invention according to its first, second and/or third aspect that allows said wrapping. Preferably the finishing profile relates to a skirting board, wherein said corner portion forms the transition between the front side and the top side of said skirting board. Skirting boards wrapped with laminate are known per se, for example from WO 2005/059270.

It is clear that instead of a skirting board, the aforementioned finishing profile may also be a transition profile, an expansion profile, a stair nosing profile, a corner profile or an end profile. Transition profiles, expansion profiles, end profiles and stair nosing profiles are for example known per se from EP 2 388 388 and EP 1 836 363 and may be used for finishing a, whether or not floating, floor covering. Corner profiles may be used for example for finishing the edges of a ceiling. The wrapping foil of the present invention may also be used as a decorative covering of ceiling, wall and/or floor panels. According to a particular embodiment said wrapping foil is used for covering shell-shaped elements that may be used for covering stair treads, wherein the surface of the stair tread or a part thereof, together with the stair nosing and/or a part of the riser, is covered by means of said shell-shaped element.

It is clear that the aforementioned carrier sheet in the wrapped finishing profile is located closest to the core material, and that the printed paper sheet is positioned between the carrier sheet and the, preferably translucent or transparent, paper sheet, wherein the latter, together with the resin present thereon, preferably forms the outer side of the finishing profile. This last-mentioned paper sheet may optionally have a structure of recesses, which for example imitates a wooden structure. Other structures such as stone structures are of course possible. Preferably a structure is used that matches, or may even be completely in accordance with, the printed paper sheet.

Further, it is clear that the printed paper sheet preferably shows a print such as those usually employed for imitation floor panels, for example such as a print in the form of a wood pattern or a stone pattern.

The print of the paper sheet may be obtained in various ways, for example by means of rotogravure. According to a particular embodiment the paper sheet is printed by means of an inkjet. The inventors have noted that precisely because of the composition of the wrapping foil according to one or more of the foregoing aspects, an inkjet printed paper sheet can be used smoothly. Normally printing by means of inkjet makes impregnation of a paper sheet difficult, since the inks form an almost impenetrable film on the surface of the paper sheet. In the composition of the wrapping foil according to the invention, a complete resination of the printed paper sheet is not desirable and is preferably excluded. Nevertheless, the inventors have noted that the wrapping foil obtained does not suffer delamination. This is probably due to the pressing operation, which may be used for laminating the constituent paper sheets, wherein the resin then penetrates the ink film under pressure. The present invention is by no means limited to the embodiments described above; however said wrapping foils, methods and finishing profiles can be produced according to different variants while remaining without leaving the scope of the present invention.