Decorative Panel Suitable for Assembling a Floor, Ceiling or Wall Covering by Interconnecting a Plurality of Said Panels With Each Other, and Decorative Covering of Such Interconnected Panels

Abstract

The invention relates to a decorative panel suitable for assembling a floor, ceiling or wall covering by interconnecting a plurality of said panels with each other. The panel has a substantially planar top surface, and a substantially planar bottom surface, at least four substantially linear side edges of which at least one pair of side edges are provided with interconnecting coupling means for interconnecting one panel with another, the panel having a laminated structure including a core layer having an upper side and a lower side and a decorative top layer connected to the upper side of the core layer. The core layer includes a layer of a cementitious mineral material which includes a cement and a dispersant. The invention further relates to a decorative covering, in particular a decorative floor covering, decorative ceiling covering, or decorative wall covering, including a plurality of interconnected decorative panels.

Claims

1. A decorative floor panel suitable for assembling a floor covering by interconnecting a plurality of said panels with each other, wherein the panel has a substantially planar top surface, and a substantially planar bottom surface, at least four substantially linear side edges of which at least one pair of side edges are provided with interconnecting coupling means for interconnecting one panel with another, the panel having a laminated structure comprising at least one core layer having an upper side and a lower side and a printed decorative top layer connected, directly or indirectly, to the upper side of the core layer, wherein a first panel side edge comprises a first coupling profile, and a second panel side edge comprises a second coupling profile designed to interconnect with a first coupling profile of a second, identical panel, both in horizontal direction and in vertical direction, wherein the first coupling profile comprises: an upward tongue, at least one upward flank lying at a distance from the upward tongue, an upward groove formed in between the upward tongue and the upward flank wherein the upward groove is adapted to receive at least a part of a downward tongue of a second coupling profile of another, identical panel, and preferably, at least one first locking element, preferably provided at a distant side of the upward tongue facing away from the upward flank, and wherein the second coupling profile comprises: a first downward tongue, at least one first downward flank lying at a distance from the downward tongue, a first downward groove formed in between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a part of an upward tongue of a first coupling profile of another, identical panel, and preferably, at least one second locking element adapted for co-action with a first locking element of the other identical panel, said second locking element preferably being provided at the downward flank, wherein a third panel side edge comprises a third coupling profile, and a fourth panel side edge comprises a fourth coupling profile designed to interconnect with a third coupling profile of a another, identical panel, both in horizontal direction and in vertical direction, wherein the third coupling profile comprises: a sideward tongue extending in a direction substantially parallel to the upper side of the panel, at least one second downward flank lying at a distance from the sideward tongue, and a second downward groove formed between the sideward tongue and the second downward flank, wherein the fourth coupling profile comprises: a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile of a second identical panel, said third groove being defined by an upper lip and a lower lip, wherein said lower lip is provided with an upward locking element, wherein the third coupling profile and the fourth coupling profile are configured such that the third and fourth coupling profiles of two identical panels can be coupled to each other by means of a turning movement, which involves at least a part of the sideward tongue of a first panel being inserted into the third groove of the other identical panel, and wherein at least a part of the upward locking element of the other panel is inserted into the second downward groove of the first panel, wherein the core layer comprises at least one layer of a cementitious mineral material which includes a cement and a dispersant.

2. The decorative panel according to claim 1, wherein the dispersant comprises polycarboxylate ethers (PCEs), and preferably comprises lignosulphonate (LS) as a second dispersant.

3. The decorative panel according to claim 2, wherein the content of lignosulphonate lies in the range of 1.0 to 30 wt. % of the total weight of polycarboxylate ethers and lignosulphonate, and preferably in the range of 5.0 to 30 wt. % of said total weight.

4. A decorative panel according to claim 1, wherein the weight content of the dispersant relative to the weight of the cementitious mineral material, is at most 1%, possibly at most 0.5%.

5. The panel according to claim 1, wherein the cement is a calcium based cement, a calcium silicate based cement, and/or a magnesium based cement.

6. The panel according to claim 1, wherein the cementitious mineral material includes particulate material that is dispersed in the cementitious mineral material.

7. The panel according to claim 1, wherein the cementitious mineral material is composed of concrete, magnesia, aerated concrete, and/or gypsum.

8. The panel according to claim 1, wherein the core layer comprises at least 50% by weight, preferably in between 50 and 90% by weight, of cementitious mineral material.

9. The panel according to claim 1, wherein a reinforcement layer is included in the core layer.

10. The panel according to claim 1, wherein a waterproof layer is situated between the core layer and the top layer, preferably in the form of a waterproof adhesive that adheres the top onto the core layer.

11. The panel according to claim 1, wherein the cementitious mineral material comprises or consists of aerated concrete which is composed of a matrix of concrete material in which air pockets in the form of cells are present, wherein either the cells in the aerated concrete make up 60 to 85 vol. % of the total volume of the aerated concrete, or the density of the aerated concrete is in the range of 400 to 800 kg/m3.

12. The panel according to claim 11, wherein the cells are for a major part of a closed cell type, the major part being preferably at least 80%, most preferably at least 90% of the cells.

13. The panel according to claim 11, wherein a major part of the cells in the aerated concrete are of a size which is sufficiently small to absorb water by capillary action.

14. The panel according to claim 11, wherein the cement is a calcium silicate hydrate mineral, such as Tobermorite, i.e. Ca5Si6O16(OH)2.Math.4H2O and/or Ca5Si6(O,OH)18.Math.5H2O.

15. The panel according to claim 11, wherein a particulate material is dispersed in the aerated concrete, which particulate material comprises sand, pulverized fuel ash, fly ash, lime, and/or aluminium oxide powder.

16. The panel according to claim 1, wherein the cementitious mineral material comprises or consists of magnesia which comprises a magnesia cement based on at least one of the following compounds: magnesium oxide and/or magnesium hydroxide, both preferably in hydrated form; magnesium chloride; magnesium oxychloride; 5Mg(OH)2 MgCl2.Math.8H2O; Mg2(OH)ClCO3.Math.3H2O; magnesite, in particular hydromagnesite (Mg5(CO3)4(OH)2.Math.4H2O); monoammonium dihydrogen phosphate (NH4H2PO4); struvite (NH4MgPO4.Math.6H2O) and/or dittmarite (NH4MgPO4.Math.H2O) MgHPO4; monopotassium phosphate (KH2PO4); magnesium potassium phosphate hexahydrate (MgKPO4.Math.6H2O); at least one borate; magnesium sulphate, in particular heptahydrate sulphate mineral epsomite (MgSO4.Math.7H2O); 5Mg(OH)2MgSO4.Math.3H2O (513-phase) and/or 3Mg(OH)2MgSO4.Math.8H2O (318-phase); 5Mg(OH)2.Math.MgSO4.Math.5H2O (515-phase) and/or Mg(OH)2.Math.MgSO4.Math.7H2O (517-phase).

17. The panel according to claim 16, wherein the magnesia further comprises particulate matter dispersed in the magnesia, which particulate matter preferably comprises cellulose based particles.

18. The panel according to claim 16, wherein the cellulose based particles comprise lignocellulose, such as wood material, and preferably at least a part of the cellulose based particles are fibres.

19. The panel according to claim 16, wherein the magnesia layer has at least a partially foamed structure containing pores.

20. The panel according to claim 1, wherein the cementitious mineral material comprises or consists of gypsum which comprises hydrated plaster according to the structural formula CaSO4.Math.2H2O.

21. The panel according to claim 20, wherein the gypsum has a foamed structure containing pores.

22. The panel according to claim 20, wherein the total dispersant content in the gypsum is 0.05 wt % to 0.5 wt. %.

23. The panel according to claim 1, wherein the core layer comprises at least one reinforcement layer, such as a textile layer, cellulose layer, a carbon fibre layer and/or a glass fibre layer.

24. The panel according to claim 23, wherein the core layer comprises at least two layers of a cementitious mineral material which includes a cement and a dispersant, wherein at least one reinforcement layer is situated in between two layers of a cementitious mineral material

25. The panel according to claim 1, wherein at least a part of each coupling profile is integrally formed with the core.

26. The panel according to claim 1, the printed decorative top layer is covering only at least a part only of the upper side of the core layer.

27. The panel according to claim 1, wherein the side of the upward tongue facing towards the upward flank is the inside of the upward tongue and the side of the upward tongue facing away from the upward flank is the outside of the upward tongue, and wherein the side of the downward tongue facing towards the downward flank is the inside of the downward tongue and the side of the downward tongue facing away from the downward flank is the outside of the downward tongue, wherein at least a part of the inside of the upward tongue is inclined towards or away from the upward flank, and wherein at least a part of the inside of the downward tongue is inclined towards or away from the downward flank.

28. The panel according to claim 1, wherein the printed decorative layer comprises a base layer or film, onto which a decorative image is printed.

29. A decorative floor covering, comprising a plurality of interconnected decorative panels according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0170] The invention will be further explained with reference to the appended figures, wherein:

[0171] FIG. 1 shows in perspective a panel according to the invention;

[0172] FIG. 2 shows a transversal cross-section of a panel according to the invention;

[0173] FIGS. 3 and 4 show in transversal cross-section two embodiments of coupling profiles of panels that are interconnected according to the invention;

[0174] FIG. 5 shows a longitudinal cross-section of a panel according to the invention;

[0175] FIG. 6 shows in longitudinal cross-section one embodiment of coupling profiles of panels that are interconnected according to the invention.

DESCRIPTION OF THE INVENTION

[0176] FIG. 1 shows a decorative panel 1 which upper side 2 is provided with a decorative top layer 12. The panel is of a rectangular shape having a length extending longitudinally along line B-B, and a width extending transversally along line A-A.

[0177] At side edges 9 resp. 10, a first coupling profile 7 resp. a second coupling profile 8 is provided. At side edges 3 resp. 4, a third coupling profile 5, resp. a fourth coupling profile 6 is provided.

[0178] FIG. 2 shows a transversal cross-section of a panel 1 shown in FIG. 1, along line A-A. The panel 1 has a core layer 10 that is made from a layer of aerated concrete, which contains small air bubbles 11 of a closed cell type. Onto the upper side of the aerated concrete layer an decorative top layer 12 is adhered, preferably by means of a thin waterproof adhesive layer. Onto the lower side of aerated concrete layer 10, a backing layer is adhered. The side edges 3 resp. 4, are provided with a third coupling profile 5, resp. a fourth coupling profile 6.

[0179] As a variant of the panel 1, the core layer 10 may alternatively be a foamed magnesia layer, or a foamed gypsum layer.

[0180] FIG. 3 shows the third and fourth coupling profiles 5 and 6, as depicted in FIG. 2, in detail when connecting two panels 1 and 1′ with each other.

[0181] The third coupling profile 5 of panel 1′, comprises a sideward tongue 51 extending in a direction substantially parallel to the upper side of the panel, one second downward flank 53 lying at a distance from the sideward tongue 51, and a second downward groove 54 formed between the sideward tongue 51 and the second downward flank 53.

[0182] The fourth coupling profile 6 of panel 1, comprises a third groove 61 configured for accommodating at least a part of the sideward tongue 51 of the third coupling profile 5 of a second identical panel 1′, said third groove 61 being defined by an upper lip 62 and a lower lip 63, wherein said lower lip is provided with an upward locking element 64.

[0183] In the situation shown in FIG. 3, the third coupling profile and the fourth coupling profile 6 are configured such that the respective panels 1 and 1′, can be coupled to each other by means of a turning movement as indicated by arrow T, which involves the sideward tongue of panel 1′ being inserted into the third groove of the other identical panel 1, wherein the upward locking element 64 of the panel 1, is inserted into the second downward groove 54 of the panel 1′.

[0184] FIG. 4 shows analogously to FIG. 3, a different design of coupling profiles 5 and 6, having rounded features at tongue 51 and at third groove 61. The turning movement for coupling may also be referred to as a hinging movement in this alternative embodiment to FIG. 3. All other functional features and their numerals are the same as already defined for FIG. 3.

[0185] FIG. 5 shows a longitudinal cross-section of a panel 1 shown in FIG. 1, along line B-B. The panel 1 has a core layer 10 that is made from a layer of aerated concrete, which contains small air bubbles of a closed cell type. Onto the upper side of the aerated concrete layer 10 an decorative top layer 12 is adhered.

[0186] At side edges 9 resp. 10, a first coupling profile 7 resp. a second coupling profile 8 is provided.

[0187] The first coupling profile 7 comprises an upward tongue 71, an upward flank 72 lying at a distance from the upward tongue 71, an upward groove 73 formed in between the upward tongue 71 and the upward flank 72 wherein the upward groove 73 is adapted to receive at least a part of a downward tongue 81 of a second coupling profile 8 of another, identical panel, and at least one first locking element 75, preferably provided at a distant side of the upward tongue 71 facing away from the upward flank 72.

[0188] The second coupling profile 8 comprises a first downward tongue 81, a first downward flank 82 lying at a distance from the downward tongue 81, a first downward groove 83 formed in between the downward tongue 81 and the downward flank 82, wherein the downward groove 83 is adapted to receive at least a part of an upward tongue 71 of a first coupling profile 7 of another, identical panel, and a second locking element 85 adapted for co-action with a first locking element 75 of the other, identical panel, which is provided at the downward flank 82.

[0189] FIG. 6 shows how the first and second coupling profiles 7 and 8 of a panel can interact, when connecting the respective profiles 7 and 8 of a panel 1 and a panel 1′, depicted at the far left. The panel 1′ is hereby moved vertically downwards wherein the profiles 7 and 8 engage with each other by receiving upward tongue 71 in downward groove 83 and receiving downward tongue 81 in upward groove 73.