Abstract
The invention relates to a decorative panel, in particular a floor panel, ceiling panel or wall panel. The invention also relates to a decorative covering, in particular a decorative floor covering, decorative ceiling covering, or decorative wall covering, including a plurality of mutually coupled decorative panels according to the invention. The invention further relates to a core for use in a panel according to the invention. The invention additionally relates to a method of producing a decorative panel, in particular a decorative panel according to the invention. The invention also relates to an extruded for use in said method according to the invention.
Claims
1. A decorative panel, in particular a floor panel, ceiling panel or wall panel, comprising: a core provided with an upper side and a lower side, a decorative top structure, either directly or indirectly, affixed on said upper side of the core, a first panel edge comprising a first coupling profile, and a second panel edge comprising a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, both in horizontal direction and in vertical direction, a third panel edge comprising a third coupling profile, and a fourth panel edge comprising a fourth coupling profile being designed to engage interlockingly with said third coupling profile of an adjacent panel, both in horizontal direction and in vertical direction, wherein each panel edge defines at least one vertical plane (VP) perpendicular to a horizontal plane (HP), which horizontal plane (HP) is parallel to the core, wherein the core is provided with at least two vertically extending core grooves having a groove opening connected to the lower side and/or upper side of the core, wherein the entire part of the core grooves is arranged inside the vertical planes (VP) respectively defined by all panel edges, such the core grooves do not intersect any coupling profile of the first coupling profile, the second coupling profile, the third coupling profile, and the fourth coupling profile, wherein each core groove is defined by at least one groove wall, wherein the core and the core grooves are formed by means of an extrusion process.
2. The panel according to claim 1, wherein the lower side and/or upper side of the core and the groove walls of the core grooves have a substantially smooth surface texture.
3. The panel according to claim 1, wherein the core groove depth (GD) of at least one core groove is at least 0.3 times a panel thickness (T).
4-6. (canceled)
7. The panel according to claim 1, wherein the width of the groove opening of at least one core groove is larger than the width of an inner part of said core groove.
8. (canceled)
9. (canceled)
10. The panel according to claim 1, wherein at least one core groove is a discontinuous core groove.
11. The panel according to claim 1, wherein at least two core grooves have mutually different shapes.
12. (canceled)
13. (canceled)
14. The panel according to claim 1, wherein the panel comprising a backing layer, either directly or indirectly, affixed to said lower said of the core.
15-17. (canceled)
18. The panel according to claim 1, wherein the panel comprises at least one reinforcement layer, which extends in only one coupling profile of the first and second coupling profile, and in only one coupling profile of the third and fourth coupling profile.
19-21. (canceled)
22. The panel according to claim 1, wherein the core is at least partially made of at least one polymer, in particular a thermoplastic material and/or a thermoset material.
23-25. (canceled)
26. The panel according to claim 1, wherein the areal density of the core is less than 9000 g/m2.
27. The panel according to claim 1, wherein the decorative top structure comprises at least one digitally printed decorative layer and at least one transparent wear layer covering said decorative layer.
28-32. (canceled)
33. The panel according to claim 1, wherein the total surface area of the groove openings covers at least 20%, of the total surface area of the lower side of the core.
34. The panel according to claim 1, wherein at least panel edge is at least partially formed by at least one core edge.
35. (canceled)
36. The panel according to claim 1, wherein the core comprises a centre portion and a peripheral portion enclosing said centre portion, wherein the panel edges and coupling profiles make part of said peripheral portion, and wherein said peripheral portion is free of core grooves.
37. (canceled)
38. The panel according to claim 1, wherein at least one panel edge is configured to define a plurality of vertical planes (VP), wherein one vertical plane (VP1) coincides with the outer part of a panel edge and at least one other vertical plane (VP2) coincides with a part of a coupling profile of said edge, positioned closest to a centre portion of the core of the panel.
39. (canceled)
40. The panel according to claim 1, wherein the core grooves are positioned at a distance of each vertical plane.
41. (canceled)
42. A decorative covering, in particular a decorative floor covering, decorative ceiling covering, or decorative wall covering, comprising a plurality of mutually coupled decorative panels according to claim 1.
43. A core for use in a panel according to claim 1, wherein said core comprises: an upper side and a lower side, a first core edge comprising a first coupling profile, and a second core edge comprising a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, both in horizontal direction and in vertical direction, a third core edge comprising a third coupling profile, and a fourth core edge comprising a fourth coupling profile being designed to engage interlockingly with said third coupling profile of an adjacent panel, both in horizontal direction and in vertical direction, wherein each core edge defines a vertical plane (VP) perpendicular to a horizontal plane (HP), which horizontal plane (HP) is parallel to the core, wherein the core is provided with at least two vertically extending core grooves having a groove opening connected to the lower side and/or upper side of the core, wherein the entire part of the core grooves is arranged inside the vertical planes (VP) respectively defined by all core edges, such the core grooves do not intersect any coupling profile of the first coupling profile, the second coupling profile, the third coupling profile, and the fourth coupling profile, wherein each core groove is defined by at least one groove wall, wherein the core and the core grooves are formed by means of an extrusion process, such that the lower side and/or upper side of the core and the groove walls of the core grooves have substantially the same surface texture.
44. A method of producing a decorative panel, in particular a decorative panel according to claim 1, comprising the steps of: A) liquifying a polymer based core composition; B) extruding said liquified polymer based core composition to form a liquified core of the panel; C) creating into the liquified core at least two vertically extending core grooves having a groove opening connected to the lower side and/or upper side of the core, such that the core grooves do not intersect any edge of the core; D) allowing the core to solidify; E) applying a decorative top structure, either directly or indirectly, onto the upper side of the core, such that a decorative panel or decorative plate is formed; and F) machining the panel edges, such that a first panel edge is provided with a first coupling profile, and a second panel edge is provided with a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, and such that a third panel edge is provided with a third coupling profile, and a fourth panel edge comprising a fourth coupling profile being designed to engage interlockingly with said third coupling profile of an adjacent panel.
45. (canceled)
46. The method according to claim 44, wherein step B) and step C) at least partially overlap in time.
47-52. (canceled)
53. An extruder for use in a method according to claim 44.
54. The panel according to claim 1, wherein the lower side and/or upper side of the core and the groove walls of the core grooves have substantially the same surface texture.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures. Herein show:
[0062] FIGS. 1a-1e a top and bottom view of schematic representation of possible embodiments of decorative panels according to the present invention;
[0063] FIGS. 2a-2d a side view schematic representation of a cross section of possible embodiments of decorative panels according to the present invention;
[0064] FIGS. 3a-3d a side view schematic representation of a cross section of possible embodiments of decorative panels according to the present invention; and
[0065] FIGS. 4a and 4b a schematic representation of an extruder which can be used for manufacturing a decorative panel according to the present invention.
[0066] Within these figure, similar references refer to similar or equivalent features or elements.
DESCRIPTION OF THE INVENTION
[0067] FIGS. 1a-1e show schematic representations of possible embodiments of decorative panels 100a-100e according to the present invention. The shown panels 100a-100e are rectangular and oblong in this example. In practice, the panels 100a-100e may have an alternative shape, such as square, hexagon, or octagonal. FIG. 1a shows a top view of the panel, which may be used for each of the panel embodiments shown in FIGS. 1b-1e. More in particular, FIGS. 1b-1e show a bottom view of different panels 100b-100e. Each panel 100a-100e comprises a core 105 comprising a first panel edge comprising a first coupling profile 101, and a second panel edge comprising a second coupling profile 102 being designed to engage interlockingly with said first coupling profile 101 of an adjacent panel, both in horizontal direction and in vertical direction. This first set of coupling profiles 101, 102 is positioned at opposite short edges of the panel 100a-100e. The coupling profiles 101, 102 are configured to be coupled by means of a fold-down movement and/or a vertical movement, and these coupling profiles 101, 102 are also referred to as “push-lock” coupling profiles as they can be pushed (and/or hammered) into each other. Each panel 100a-100e further comprises a third panel edge comprising a third coupling profile 103, and a fourth panel edge comprising a fourth coupling profile 104 being designed to engage interlockingly with said third coupling profile 103 of an adjacent panel, both in horizontal direction and in vertical direction. This second set of coupling profiles 103, 104 is positioned at opposite long edges of the panel 100a-100e. The coupling profiles 103, 104 are configured to be coupled by means of an angling-down movement and/or a rotational movement, and these coupling profiles 103, 104 are also referred to as “angling-down” coupling profiles. The push-lock coupling profiles 101, 102 and the angling-down coupling profiles 103, 104 may be identical to the coupling profiles 5, 6, 7, 8 as shown in FIGS. 1-3 of European patent EP3105392, the subject-matter of which European patent is incorporated in this document by reference. Each panel 100a-100e comprises a plurality core grooves provided in the lower side of the core 105, wherein each core groove 106 is defined by at least one groove wall. The groove wall makes (integral) part of the core 105. The core 105 and the core grooves 106 are formed by means of an extrusion process, simultaneously and/or successively. By forming both the core 105 and the grooves 106 during extrusion, the lower side of the core and the groove walls W of the core grooves typically have substantially the same surface texture. The surface texture of the lower side of the core and the surface texture of the core grooves may mutually differ, but since both the lower side of the core and the core grooves are formed by means of extrusion, the surface texture will be relatively smooth and free of dust and (mill) shavings compared to the surface texture of milled core grooves (milled in the core after completion of the extrusion process of the core). FIG. 1a shows that the panel 100a comprises a decorative top structure 109, which is affixed, directly or indirectly, on an upper side of the core of the panel 100a. The decorative structure 109 shown is a non-limiting example of a decorative structure. Typically, the coupling profiles 101, 102, 103, 104 are realized by milling the laminated assembly of the core 105 and the affixed decorative structure 109.
[0068] FIGS. 1-b-1e shows different core groove configurations provided in the lower side of the core 105. As mentioned above the core grooves 106 are applied in the core when the core is still in a liquified (viscous or paste-like) state. This could be realised by an extruding device which may have an adjustable die and/or directly downstream the extruding device when the core is still sufficiently liquid (viscous or paste-like) and deformable to shape the core grooves 106.
[0069] FIG. 1b shows that the core 105 is provided with two vertically extending core grooves 106 having a groove opening connected to the lower side of the core 105, wherein the entire part of the core grooves 106 is arranged inside the vertical planes respectively defined by all panel edges, such that the core grooves 106 do not intersect any coupling profile of the first coupling profile 101, the second coupling profile 102, the third coupling profile 103 and the fourth coupling profile 104. The core grooves 106 are positioned at a distance from all coupling profiles 101, 102, 103, 104, schematically indicated by reference signs X1, X2. This means that the core grooves 106 are provided in a center portion of the core 105, and that a peripheral (edge) portion of the core 106, being provided with the coupling profiles 101, 102, 103, 104, is free of any core grooves 106. The result of this core grooves orientation is that the core 105 is a relatively light-weight core, wherein the core 105 may also have a limited thickness, for example between 2 and 10 mm, and wherein the coupling profiles 101, 102, 103, 104 are designed in a relatively robust manner, and can therefore operate in a relatively reliable and durable manner.
[0070] FIG. 1c shows a further possible structure of the core 105 of the panel 100c. The core 105 is provided with multiple (parallel) core grooves 106. All core grooves 106 are uninterrupted. The dimension of the core grooves 106 may be identical, though may also vary (on purpose) in practice.
[0071] FIG. 1d show structure of the core 105 of a panel 100d wherein the core comprises multiple discontinuous core grooves 106. FIG. 1e shows a structure of the core 105 of a panel 100e wherein the core comprises one core groove 106. The core groove 106 has, in the depicted bottom view, a V-shape over the length of the panel 100e. This structure can be manufactured by making use of an extruder, for example as shown in FIGS. 4a and 4b, where the extruder comprises at least one displaceable mould which is displaceable in both a horizontal and a vertical direction. Hence, different shapes of the core grooves 106 can be provided.
[0072] FIGS. 2a-2d show a schematic representation of a cross section of a decorative panel 200a-200d according to the present invention. The cross section shown in these FIGS. 2a-2d could, for example, be the cross section of the panel according to line A-A shown as in FIG. 1a. Hence, in FIGS. 2a-2d the push-lock profiles of the panel are shown.
[0073] The figures show the first panel edge comprising a first coupling profile 201, and a second panel edge comprising a second coupling profile 202 which are designed to engage interlockingly with said first coupling profile 201 of an adjacent panel. The cross section shown is typically the so-called long-side of the panel 200a-200d. Each panel 200a-200d comprises a core 205 which is provided with core groove(s) 206. Each panel 200a-200d defines a horizontal plane (HP) being parallel to the core 205 of the panel, which is only visualized in FIG. 2a. Each coupling profile 201, 202 defines two vertical planes (VP), and more in particular the first coupling profile 201 defines a vertical outer plane (VP-O1), which coincides with a top outer edge of the first coupling profile 201, and also defines a vertical inner plane (VP-I1), which coincides with a bottom outer edge of the first coupling profile 201. The second coupling profile 202 defines a vertical outer plane (VP-O2), which coincides with a bottom outer edge of the second coupling profile 202, and also defines a vertical inner plane (VP-I2), which coincides with a top outer edge of the second coupling profile 202. In coupled condition of two panels 200a, VP-01 of a first panel will coincide with VP-I2 of a second panel and VP-I1 of said first panel will coincide with VP-O2 of said second panel. As mentioned in the above description, the outer edges (VP-O1, VP-O2) of the panel 200a are often also referred to a vertical plane V1. Additional vertical planes (VP2) can be identified which coincide with a part of a coupling profiles 201, 202, positioned closest to a centre portion of the core of the panel 200a. As can be seen, the core groove(s) 206 is/are positioned at a distance from each of the aforementioned vertical planes (VP-O1, VP-I1, VP-I2, VP-O2, VP1, VP2). The vertical planes are only visualized in FIG. 2a for clarity reasons, but are obviously also present in the further FIGS. 2b-2d. As can be seen in the FIGS. 2a-2c, the core grooves 206 are preferably located at a distance of all vertical planes defined above. It is, however, possible, as shown in FIG. 2d that the core grooves 206 are positioned at a distance of at least one vertical plane of each coupling profile 201, 202.
[0074] The panel 200a shown in FIG. 2a comprises a decorative top structure 209. The panel 200a shows a relatively long and deep core groove 206 which almost extends over the entire length of the panel 200a. However, the core groove 206 starts at a predetermined distance from the panel edges such that the core grooves 206 do not intersect with the first coupling profile 101 and the second coupling profile 102. The core groove depth (GD) of the core groove 206 is more than 0.3 times the panel thickness (T). The lower side of the core and the groove walls of the core grooves 206 have a substantially smooth surface texture.
[0075] FIG. 2b shows a panel 200b comprising an interrupted, discontinuous core groove 206. This may enhance the stability of the panel 200b, for example when the panel is exposed to heavy loads. The core grooves 206 are filled with a material 207, in particular a sound-dampening material 207. The decorative top structure (not shown) is printed directly on top of the core 205 of the panel 200b.
[0076] FIG. 2c shows a further embodiment of a panel 200c according to the present invention. The core groove 206 is shielded by a backing layer 208 which is affixed to the lower side of the core 205. It can be seen that the length lg of the core groove 206 is smaller than the length lb of said backing layer 208. Hence, the backing layer 208 substantially fully covers the core groove 206. It can be seen that the width of the groove opening of the core groove 206 is larger than the width of an inner part of said core groove. The core grooves 206 are air-filled. It is however also conceivable that the core grooves 206 are filled with any suitable filling material. The panel 200c further comprises a decorative top layer 209.
[0077] FIG. 2d shows another possible embodiment of a panel 200d according to the present invention. The panel comprises a core groove 206 wherein the core groove depth (GD) varies along the core groove length lg. The core groove 206 is in particular defined by two terminal portions enclosing a centre portion. The panel 200d further comprises a reinforcement layer 210 and a decorative top layer 209.
[0078] FIGS. 3a-3d show a schematic representation of a cross section of a decorative panel 300a-300d according to the present invention. The cross section shown in these FIGS. 3a-3d could, for example, be the cross section of the panel according to line B-B shown as in FIG. 1a. Hence, in FIGS. 3a-3d the angling down profiles of the panel are shown.
[0079] Each panel 300a-300d comprises a core 305 which is provided with core groove(s) 306. Each panel 300a-300d again defines a horizontal plane (HP) being parallel to the core 205 of the panel, which is only visualized in FIG. 3a, which could be the same horizontal plane (HP) as shown in FIG. 2a. Each coupling profile 301, 302 defines two vertical planes (VP), and more in particular the third coupling profile 301 defines a vertical outer plane (VP-O3), which coincides with a top outer edge of the third coupling profile 301, and also defines a vertical inner plane (VP-I3), which coincides with a bottom outer edge of the third coupling profile 301. The fourth coupling profile 302 defines a vertical outer plane (VP-O4), which coincides with a bottom outer edge of the fourth coupling profile 302, and which also defines a vertical inner plane (VP-I4), which coincides with a top outer edge of the fourth coupling profile 302. In coupled condition of two panels 300a, VP-O3 of a first panel will coincide with VP-I4 of a second panel and VP-I3 of said first panel will coincide with VP-O4 of said second panel. As mentioned in the above description, the outer edges (VP-O3, VP-O4) of the panel 300a are often also referred to a vertical plane V1. Additional vertical planes (VP2) can be identified which coincide with a part of a coupling profiles 303, 304 positioned closest to a centre portion of the core of the panel 300a. As can be seen, the core groove(s) 306 is/are positioned at a distance from each of the aforementioned vertical planes (VP-O3, VP-I3, VP-I4, VP-O4, VP1, VP2). The vertical planes are only visualized in FIG. 3a for clarity reasons, but could obviously be defined in the further FIGS. 3b-3d. As can be seen in the FIGS. 3a-2d, the core grooves 306 are preferably located at a distance of all vertical planes defined above. It is, however, possible that the core grooves 306 are positioned at a distance of at least one vertical plane of each coupling profile 301, 302, which alternative embodiment is not shown in FIGS. 3a-3d.
[0080] FIG. 3a shows that the panel 300a comprises multiple core grooves 306 having a substantially equal width. The panel 300a comprises a backing layer 308 which is configured such that the core grooves 306 are not covered by the backing layer 308.
[0081] FIG. 3b shows a panel 300b comprising core grooves 306 wherein the outer core grooves 306 have a larger depth than the inner core grooves 306. Each groove core 306 is filled with a (sound- and/or impact dampening) material. The panel 300b further comprises a decorative top layer 309.
[0082] The panel 300c shown in FIG. 300c comprises core grooves 306 wherein the width of the opening of the core groove 306 is smaller than the width of a further, inner part of the core groove 306. The backing layer 308 substantially fully covers the core grooves 306. The core grooves 306 are air-filled.
[0083] FIG. 3d shows a panel 300d comprising core grooves 306 wherein the width of the opening of the core groove 306 is larger than the width of an inner part of said core groove 306.
[0084] FIGS. 4a and 4b shows a schematic representation of an extruder 411 which can be used for manufacturing a decorative panel according to the present invention. FIG. 4a shows a front view, where FIG. 4b shows a side view. Both figures show a cross section. The extruder 411 comprises a first mould 412 and a second mould 413. The second mould 413 is displaceable with respect to the first mould 412. The arrows indicates the direction of displacement of the second mould 413. The second mould 413 can in a preferred embodiment be displaced in both a vertical and horizontal direction. This enables a large variety of possible core groove patterns which can be obtained. Reference 414 shows the opening 414 of the first mould 412 which provides for the formation of a panel during the extrusion. The first mould 412 can be a conventional mould as used in an extruder for the manufacturing of panels and/or plate like structures. The extruder 411 according to present invention comprises at least one displaceable second mould 413, which is configured to provide at least two vertically extending core grooves. In the shown embodiment, the second mould 413 comprises a structure provided multiple recesses R and bulges B (or teeth/protrusions) which are configured to provide a structured pattern to the panel, in particular a grooved surface of the lower side (and/or upper side) of the core of the panel. Hence, the core grooves are provided in the panel during the extrusion of the core. Since the second mould 413 is displaceable, it is possible to provide a panel wherein the entire part of each core grooves is arranged inside the vertical planes of the panel, respectively defined by all panel edges, such the core grooves do not intersect any coupling profiles which are to be provided afterwards. A further benefit of the core and the core grooves being formed by means of an extrusion process is that the lower side of the core and the groove walls of the core grooves have substantially the same surface texture. It is also conceivable that the extruded 411 comprises multiple second moulds, in order to provide multiple and/or different core grooves within the panel.
[0085] Hence, 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. It is, for example, imaginable that the invention of creating core grooves in an upper side and/or lower side of a core during extrusion may also be used to create light-weight panels, in particular floor panels, which are not provided with coupling profiles at all or which are provided with only two complementary coupling profiles located at opposite panel edges. In this alternative panel configuration, the decorative structure will typically be affixed, either directly or indirectly, to an upper side of the core. This alternative panel may be used for example as floor panel, wall panel, and/or ceiling panel. Various embodiments of the panel as described above and in the appended claims may be combined with this alternative panel configuration.
[0086] 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.
[0087] 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.
