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 the cavities, 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 panel comprising: at least one core layer, the core layer comprising at least 20% by weight of a mineral material, wherein the core layer comprises a top surface and a bottom surface, and wherein at least part of the bottom surface of the core layer is provided with a plurality of impressed cavities, wherein the panel is one of a floor panel, a wall panel or a ceiling panel.

2. The panel according to claim 1, wherein the plurality of impressed cavities define a repeated cavity pattern.

3. The panel according to claim 1, wherein a plurality of cavities have, a maximum width W and a maximum length L, wherein the ratio between the maximum width W and the maximum length L is between 0.2 and 1.

4. The panel according to claim 1, wherein adjacent cavities are separated by at least one separating wall, making integral part of the core layer, wherein the thickness of the separating wall is less than 50% of the maximum width W of each of the adjacent cavities.

5. The panel according to claim 4, wherein at least one separating wall extends in multiple directions with respect to a plane defined by the bottom surface.

6. The panel according to claim 1, wherein the bottom surface of the core layer is composed of an impressed portion formed by said plurality of impressed cavities and a remaining unimpressed portion, wherein the footprint of the impressed portion covers at least 50%, of the surface area of the bottom surface of the core layer.

7. The panel according to claim 1, wherein the cross-sectional shapes, of a number of cavities are chosen from the group of polygons, curvilinear shapes and/or combinations thereof.

8. The panel according to claim 1, wherein a number of cavities is substantially prism shaped comprising a prism base chosen from the group consisting of: a curvilinear prism base, a circular prism base, an n-sided polygonal prism base, wherein n≥3.

9. The panel according to claim 1, wherein the depth of at least one cavity varies as seen in at least one cross-sectional direction of said cavity.

10. The panel according to claim 1, wherein the depth of at least a number of cavities is situated in between 10 and 30% of the maximum thickness of the core layer.

11. The panel according to claim 1, wherein the panel is a rectangular panel defining a first longitudinal direction, wherein at least of number of cavities has an elongated shape defining a second longitudinal direction, wherein the first longitudinal direction and the second longitudinal direction mutually enclose an angle within the range of 30-90 degrees.

12. The panel according to claim 1, wherein at least a number of cavities is configured to attenuate sound with a frequency of ranging from 500 to 10,000 Hz.

13. The panel according to claim 1, wherein the volume of at least a number of cavities ranges from 5 cubic millimetre to 2 cubic centimetre.

14. The panel according to claim 1, comprising at least one backing layer, wherein the backing layer forms a sound attenuating barrier and covers at least part of the bottom surface of the bottom layer, wherein at least part of the sound attenuating barrier includes vibrating materials.

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

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

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

18. The panel according to claim 1, wherein the core layer comprises at least one binder, wherein the ratio of weight percentages of mineral material relative to said binder is at least 1.

19. A method for producing a panel, such as a floor panel, a wall panel, or a ceiling panel, comprising the steps of: providing a composite material, comprising at least 20% by weight of mineral material, forming a core layer of said composite material wherein said core layer has a top surface and a bottom surface, impressing a plurality of cavities in at least part of the bottom surface of the core layer, and enabling hardening and/or curing of the core layer.

20. The method according to claim 19, wherein impressing of the core layer is performed by guiding the core layer through at least two rollers, wherein at least one of the rollers is provided with a surface structure configured to provide a plurality of cavities in at least part of the bottom surface of the core layer.

Description

[0076] The invention will now be elucidated into more detail with reference to the following non-limitative figures. Herein show:

[0077] FIGS. 1a-1d each a bottom view of possible embodiments of a panel according to the present invention;

[0078] FIGS. 2a-2e each a cross section of possible embodiments of a panel according to the present invention;

[0079] FIG. 3a a bottom view of another possible embodiment of a panel according to the present invention;

[0080] FIG. 3b a roller which could be applied to manufacture a panel according to the present invention;

[0081] FIGS. 3c-3h a bottom view of various possible embodiments of a panel according to the present invention; and

[0082] FIGS. 4a-4i cross sectional view of various possible embodiments of cavities according to the present invention.

[0083] Within these figures, similar references correspond to similar or equivalent components and/or technical features.

[0084] 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 the cavities 102 which extend 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] FIG. 3a shows a schematic representations of possible embodiment of a panel 300 according to the present invention. The figure shows a bottom view of the panel 300. The panel comprises a core layer 301, preferably comprising a composite material comprising a mixture of mineral material and thermoplastic material. The core layer 301 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 301 is provided with a plurality of cavities 302. The cavities 302 extends towards the top surface of the core layer 301. The cavities 302 are integrally formed cavities 302. In the shown embodiment, the cavities 302 define a cell pattern, in particular a polygon cell pattern. The figure show that the cavities 302 are separated via partitions 303, wherein at least part of the partitions 303 between the cavities 302 have a thickness which is smaller than the length and/or width of the cavities 302. In the shown embodiment, the cavities 302 are imprinted into the bottom surface of the core layer 301. Hence, the cavities 302 are imprinted cavities 302.

[0090] FIG. 3b shows a roller 330 which could be applied to manufacture a panel 300 according to the present invention, in particular as shown in FIG. 3a. The plurality of cavities can be provided by subjecting at least part of the bottom surface of a core layer to a (rotary) imprinting process. This can be done substantially directly after extrusion of the core layer. It is for example conceivable that the core layer is led through at least two rollers 330, wherein at least one of the rollers is provided with a surface structure 331 configured to provide a plurality of cavities in at least part of the bottom surface of the core layer.

[0091] FIGS. 3c-3h show a bottom view of various further possible embodiments of a panel according to the present invention. The figures are in line with FIG. 3a, and show a bottom view of part of a panel according to the present invention. The figures show for each embodiment a plurality of impressed cavities 302, in particular in a repeated pattern. The cavities 302 are separated via partitions 303, wherein at least part of the partitions 303 between the cavities 302 have a thickness which is smaller than the length and/or width of the cavities 302.

[0092] FIGS. 4a-4i show cross sectional views of various possible embodiments of impressed cavities 402 according to the present invention. It can be seen that the cavities 402 have rather clear boundaries, wherefore the cavities 402 could also function as attenuation chambers.

[0093] 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.

[0094] 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.

[0095] 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. Within the scope of this invention, where the term ‘impressed cavity’ is used, also the term ‘cavity’ could be applied, or vice versa.