Panel and Method of Producing a Panel

Abstract

The invention relates to a panel for constructing a floor or wall covering. The panel comprises a substantially planar top surface, at least one core layer composed of a composite material which core layer is provided with at least one cavity, and a bottom surface. The panel further comprises at least one pair of opposite edges, said pair of opposite edges preferably comprising complementary coupling parts configured for mutual coupling of adjacent panels.

Claims

1. A floor panel, a wall panel, or a ceiling panel, comprising: at least one core layer comprising a composite material comprising at least 20% by weight of mineral material, the core layer having a top surface and a bottom surface, and at least one decorative top layer provided at the top surface of the core layer; wherein at least part of the bottom surface of the core layer is provided with a cavity pattern wherein said cavities are formed via hot-pressing.

2. The panel according to claim 1, wherein the cavities extend towards the top surface of the core layer.

3. The panel according to claim 1, wherein the core layer is an extruded layer formed via an extrusion process.

4. The panel according to claim 1, wherein the cavity pattern is formed by a plurality of interconnected cavities.

5. The panel according to claim 1, wherein the panel comprises at least one pair of opposing side edges, said pair of opposing side edges comprising complementary coupling parts configured for mutual coupling of adjacent panels.

6. The panel according to claim 1, comprising at least one backing layer attached to the bottom surface of the core layer.

7. The panel according to claim 6, wherein the backing layer is a balancing layer and/or an acoustic layer.

8. The panel according to claim 6, wherein at least part of the cavities extend from the core into the backing layer.

9. The panel according to claim 1, wherein at least part of the cavities has a depth which is at least 20% of the total thickness of the panel.

10. The panel according to claim 1, wherein at least part of the cavities has a depth which is at most 55% of the total thickness of the panel.

11. The panel according claim 1, wherein the thickness of the panel is in the range of 0.7 to 2.5 cm.

12. The panel according claim 1, wherein at least part of the cavities is at least partially filled with a sound absorbing material and/or soundproofing material.

13. The panel according to claim 1, wherein the core layer comprises at least 40% by weight of mineral material.

14. The panel according to claim 1, wherein the core layer comprises at least one mineral material selected from the group consisting of: magnesium oxide, calcium carbonate, chalk, clay, calcium silicate, limestone and/or talc.

15. The panel according to claim 1, wherein the core layer comprises at least one thermoplastic material selected from the group consisting of: polyvinyl chloride (PVC), polyethylene (PE), polyurethane (PU), acrylonitrile butadiene styrene (ABS) and/or polypropylene (PP).

16. The panel according to claim 1, wherein the core layer further comprises at least one additive chosen from the group consisting of: a pigment, an impact modifier, a lubricant, a stabilizer, a wax, and/or an aid processing agent.

17. The panel according to claim 1, wherein the decorative top layer is chosen from the group consisting of: a high pressure laminate, a plurality of impregnated layers containing lignocellulose, a veneer layer, a thermoplastic layer, a stone veneer, and/or a combination of said decorative top layers.

18. The panel according to claim 1, wherein the flexibility of the panel in the longitudinal direction is substantially equal to the flexibility of the panel in the lateral direction.

19. The panel according to claim 1, wherein the modulus of rigidity of the panel in the longitudinal direction is at least 2500 MPa and/or wherein the modulus of rigidity of the panel in the lateral direction is at least 2500 MPa.

20. A method for producing a panel, in particular a floor panel, a wall panel, or a ceiling panel, according to claim 1, comprising the steps of: providing a substantially liquid composite material comprising at least 20% by weight of mineral material, extruding said substantially liquid composite material such that a core layer is formed having a top surface and a bottom surface, hot pressing a cavity pattern in at least part of the bottom surface of the core layer, enabling hardening and/or curing of the core layer, and optionally, applying a decorative top layer.

Description

[0035] The invention will now be elucidated into more detail with reference to the following non-limitative figures. Herein show:

[0036] FIGS. 1a-1d each a bottom view of possible embodiments of a panel according to the present invention; and

[0037] FIGS. 2a -2e each a cross section of possible embodiments of a panel according to the present invention/

[0038] FIGS. 1a-1d shows schematic representations of possible embodiments of panels 100 according to the present invention. The figures show a bottom view of the panel 100. Each panel 100a, 100b, 100c, 100d can for example be a floor panel 100, a wall panel 100, or a ceiling panel 100. Each panel comprises a core layer 101, preferably comprising a composite material comprising a mixture of mineral material and thermoplastic material. Each core layer 101 has a top surface (not shown) and a bottom surface which is shown in the picture. Part of the bottom surface of the core layer 101 of each panel 100a, 100b, 100c, 100d is provided with at least one cavity 102 which extends towards the top surface of the core layer 101. In the shown embodiments, the panels 100a, 100b, 100c, 100d are not provided with (interlocking) coupling means. However, it is conceivable that said coupling means are applied.

[0039] FIG. 1a shows a panel 100a comprises a plurality of substantially parallel cavities 102. Each cavity 102 is positioned at a predetermined distance from the peripheral edges of the panel 100a. It can also be seen that each cavity 102 extends in longitudinal direction of the panel 100a. FIG. 1b shows a panel 100b wherein the cavities 102 form a network of interconnected cavities 102. It is experimentally found that such embodiment may strengthen the sound dampening effect of the panel 100b. FIG. 1c shows a panel 100c with a plurality of individual cavities 102 which extend substantially in the longitudinal direction of the panel 100c. The cavities 102 are locally widened. At least the locally widened areas may for example be filled with sound absorbing material. FIG. 1d shows a panel 100d having series of substantially V-shaped cavities 102. The cavities 102 are positioned at a predetermined distance from another and do not interfere with an adjacent cavity 102.

[0040] FIG. 2a-2e show further possible embodiments of panels 200 according to the present invention. Each figure shows a side view of a cross section of a panel 200a, 200b, 200c, 200d, 200e which could be a floor panel 200, wall panel 200 or ceiling panel 200. FIG. 2a shows that the panel 200 can optionally be provided with interconnecting coupling parts 203a, 203b. Interconnecting coupling parts 203a, 203b could be applied to any of the embodiments covered by the present invention. Each panel 200 comprises a core layer 201, preferably comprising a composite material comprising a mixture of mineral material and thermoplastic material. Each core layer 201 has a top surface 204 and a bottom surface 205.

[0041] FIG. 2a shows a panel 200a comprising a plurality of cavities 202 which are positioned at predetermined distance from another. The panel 200a further comprises a top layer 206. In the shown embodiment the top layer 206 is a ceramic panel 206 attached to the top surface 204 of the core layer 201. FIG. 2b shows a panel 200b wherein the depth the cavities 202 differs per cavity 202. The cavities 202 are substantially trapezium shaped in cross section. Optionally, the panel 200b may comprise a decorative top layer. FIG. 2c shows an embodiment wherein the cavities 202 have a cross section which is semicircular. The cavities 202 are filled with sound absorbing material 207. The panel 200c further comprises a backing layer 208 which is attached to the bottom surface 205 of the core layer 201. FIG. 2d shows that the height, or depth, h of the cavities 202 is at least 20% of the total thickness t of the panel 200d. In particular, the depth h of the cavities 202 is about ⅓.sup.rd of the thickness t of the panel 200d. FIG. 2e shows a side view of a panel 200e wherein it can be seen that the cavity 202 extends over substantially the entire length of the panel 200e but that the cavity 202 starts and ends at a predetermined distance from the outer ends of the panel 200e. The panel 200e further comprises a backing layer 208, in particular a balancing layer 208. The cavity 202 is free of filling material, such as a sound absorbing material. It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.

[0042] The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.

[0043] The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof When it is referred to reinforcing layer also a reinforcing element can be meant, or vice versa.