Wall or floor covering element

Abstract

A covering element includes a carrier plate having a mineral material, the carrier plate formed as a flat mineral carrier plate with a content of cement larger than 35 percent by volume and with a content of natural fibers of 1 to 40% by volume. The carrier plate has a thickness between 3 and 15 mm and carries a polymer-containing decor layer on a front side of the carrier plate. Complementary recesses and protrusions are provided on opposing lateral edges of the carrier plate of the covering element, such that in an assembled condition of two or more covering elements the complementary recesses and protrusions engage with each other, wherein a portion of a polymer contained in the polymer containing decor layer penetrates into the carrier plate.

Claims

1. A covering element comprising: a carrier plate comprising a mineral material, wherein the carrier plate is formed as a flat mineral carrier plate with a content of cement larger than 35% by volume, a content of natural fibers of 1 to 40% by volume, and a thickness between 3 and 15 millimeters (mm); complementary recesses and protrusions formed, respectively, on opposing lateral edges of the carrier plate, such that, in an assembled condition of two or more covering elements, the complementary recesses and protrusions are configured to engage with complementary protrusions and recesses, respectively, of another of the two or more covering elements; and a decor layer that comprises a polymer and is provided on a front side of the carrier plate, such that a portion of the polymer of the decor layer penetrates into the carrier plate.

2. The covering element of claim 1, wherein the natural fibers are cellulose fibers.

3. The covering element of claim 1, wherein the natural fibers are configured to provide for adhesion with the decor layer.

4. The covering element of claim 1, wherein the decor layer comprises a foil.

5. The covering element of claim 4, wherein the foil is a printed paper.

6. The covering element of claim 5, wherein: the foil is adhered to the carrier plate by glue; and the portion of polymer penetrating into the carrier plate comprises or consists of the glue.

7. The covering element of claim 4, wherein the foil is selected from the group consisting of polyvinylchloride, polypropylene, polyethylene terephthalate and polyolefin.

8. The covering element of claim 1, wherein: the decor layer comprises at least one color pigment-containing base layer on the carrier plate; at least one color pigment-containing digital printing layer is arranged at least partially on the base layer; at least one polymer-containing transparent top layer having a textured surface is arranged on the digital printing layer.

9. The covering element of claim 8, wherein the polymer-containing transparent top layer contains PUR or acrylic.

10. The covering element of claim 1, comprising a polymer-containing transparent top layer on the decor layer, wherein the polymer-containing transparent top layer comprises corundum particles.

11. The covering element of claim 10, wherein the polymer-containing transparent top layer is textured.

12. The covering element of claim 1, wherein the carrier plate is a multi-layered board.

13. The covering element of claim 1, wherein the carrier plate has an insulating layer on a rear side of the carrier plate, the insulating layer being an elastomer layer or a product of comprising cork.

14. A covering element comprising: a carrier plate comprising a mineral material, wherein the carrier plate is formed as a flat mineral carrier plate with a content of cement larger than 35% by volume, a content of natural fibers of 1 to 40% by volume, and a thickness between 3 and 15 millimeters (mm); complementary recesses and protrusions formed, respectively, on opposing lateral edges of the carrier plate, such that, in an assembled condition of two or more covering elements, the complementary recesses and protrusions are configured to engage with complementary protrusions and recesses, respectively, of another of the two or more covering elements; a decor layer that comprises a polymer and is provided on a front side of the carrier plate, such that a portion of the polymer of the decor layer penetrates into the carrier plate; and a transparent polymer-containing layer provided over the decor layer, wherein the transparent polymer-containing layer is textured and comprises corundum particles; wherein the decor layer comprises a printed paper; and wherein the natural fibers of the carrier plate are cellulose fibers.

15. The covering element of claim 14, wherein the carrier plate is a multi-layered board.

16. The covering element of claim 14, wherein the carrier plate has an insulating layer on a rear side of the carrier plate, the insulating layer being an elastomer layer or a product comprising cork.

17. The covering element of claim 14, wherein the natural fibers are configured to provide for adhesion with the decor layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is described below by way of example by the schematic drawing, wherein:

(2) FIG. 1 shows a cross-section through a first covering element, which comprises a decor layer in the digital printing method; and

(3) FIG. 2 shows a cross-section according to FIG. 2 of a second covering element, which comprises a mineral carrier plate with a mixed layer applied in liquid or solid form.

DETAILED DESCRIPTION

(4) FIG. 1 shows a plate-shaped covering element 10, which, with other covering elements 10, can be composed in a planar manner to a floor covering, ceiling covering and/or wall covering, for outdoor use as well. The covering element 10 contains a mineral-containing carrier plate 12, which, at its lateral edges 17, 19 facing away from each other, comprises either protrusions 14 or recesses 16, which, with covering elements situated next to each other, form mating tongue/groove connections. So, in covering elements 10 situated next to each other, the protrusions 14 of one covering element 10 engage the recess 16 of the adjacent covering element 10. Optionally, an insulation layer 18 can be arranged on the rear side, underside, respectively, of the carrier plate 12 for footfall sound insulation and/or thermal insulation. This layer preferably is provided directly on the carrier plate 12 or glued thereon.

(5) On the front side, upper side, respectively, of the carrier plate 12 there is first of all a basic layer 20, which comprises color pigments in order to give the front side, upper side, respectively, of the carrier plate 12 a desired basic color. This basic layer preferably is optional, because basically, with a corresponding choice of the material of the carrier plate 12, the color of the carrier plate can be suitable as a basis for a subsequent digital printing method. A digital print layer 22 is provided on the basic layer 20 in a digital printing method, wherein this digital print layer 22 may be provided not over the entire surface, but only in the areas to be printed. Onto this digital print layer, basic layer 20, respectively, at least one top layer 24 is provided, which in particular consists of a UV-hardening polyurethane or acrylic. A structure 26 is provided on this top layer 24 by an embossing roller, in particular by the hot coating method, which structure preferably reinforces the impression created by the digital print layer 22. In this manner, a covering board is created, which reflects the impression of a desired material very well, for example, a wood layer, a leather layer, a stone layer or a cork layer.

(6) The top layer 24 can also be formed by a plurality of layers of an in particular UV-hardening polymer. The application of the top layer 24 and the profiling thereof preferably is performed in the hot coating method by means of a hot roller. The hot coating method is known as such,

(7) FIG. 2 shows an alternative embodiment of a covering element, wherein identical or functionally identical parts in respect to FIG. 1 are provided with the same reference numerals. The floor covering element 30 from FIG. 2 also comprises a carrier plate 12, which is mineral-containing and comprises protrusions 14 and recesses 16 on lateral edges 17,19 facing away from each other. The protrusions and recesses of this tongue/groove system are shown only schematically. In practice, the protrusions 14 and recesses 16 are manufactured as described in document EP 0843763, which document hereby is made subject of the present application. In this context, it should be clarified that a covering element of the invention usually is rectangular, in particular square, and that the recesses and protrusions are formed on four sides, wherein the recesses 16 preferably are arranged on two sides situated next to each other and the protrusions 14 on the other two sides situated next to each other.

(8) On the rear side or underside thereof, the mineral carrier plate 12 optionally comprises an insulation layer 18, as already known from FIG. 1. This insulation layer is optional and only necessary if a desired footfall sound insulation and/or thermal insulation are desired. Moreover, this insulation layer, if required, can also be applied as a counterbalancing backing layer. On its upper side, the carrier plate 12 comprises a mixed layer 32 of a polymer and a filler. As a filler, for example, leather, cork, wood, stone, mineral powders, sand are suitable, wherein these materials can be provided in the polymer matrix of the mixed layer either as particles or as fibers. The mixed layer preferably is an elastomer layer, which in particular hardens to a modulus of elasticity of 0.05-0.5 GPa, by which it achieves a rubber-like elasticity. In this manner, for example, an impression of cork, wood or leather can be pronounced very well. Such covering element is very suitable as a wall covering element.

(9) The invention is not limited to the represented exemplary embodiments but can be varied at choice within the scope of protection of the accompanying claims.

REFERENCE NUMERAL LIST

(10) 10 Wall, ceiling or floor covering element (first embodiment) 12 mineral carrier plate 14 protrusion—tongue of the tongue/groove connection 16 recess—groove of the tongue/groove connection 17 first lateral edge 18 insulation layer 19 second lateral edge 20 basic layer—primer coupling agent 22 digital printing layer 24 transparent top layer 30 wall, ceiling or floor covering element (second embodiment) 32 mixed layer, in particular applied in liquid form 34 optionally structured surface, in particular by embossing roller