Panels and decorative panel

Abstract

Disclosed is a panel comprising a substrate (1), wherein the outer surface of the substrate (1) is covered with a coating layer (8), wherein one edge of the substrate (1) is provided with a recess (3), and a groove (4) is arranged inside the substrate (1) adjacent and interconnected to the recess (4), and wherein the opposite edge of the substrate (1) is provided with a protrusion (7) that can be fitted into the recess (3), and a tongue (6) is extended from the protrusion (7) that can fitted into the groove (4). The substrate is made of 100 parts by mass of PVC resin or PVC powder, 25-45 parts of styrene elastomer, 180-280 parts of stone powder, sawdust or rock, 1-10 parts of an additive, and 1-4 parts of an elastomer coupling agent. Also disclosed is a decorative panel formed by arranging and interlocking the panels in sequence by fitting the protrusion of a panel into the recess of a neighboring panel, as well as a panel installation process.

Claims

1. A panel comprising: a substrate (1), wherein: an outer surface of the substrate (1) is covered with a coating layer, a patterned paper, a film or wax (8); a first edge of the substrate is provided with a recess (3) and a groove (4) inside the substrate (1); the groove (4) is adjacent and interconnected to the recess (3); a second edge of the substrate (1) is provided with a protrusion (7) and a tongue (6) extending from the protrusion (7); the second edge is opposite to the first edge; the protrusion (7) is configured to be fitted into the recess (3); the tongue (6) is configured to be fitted into the groove (4); and the substrate (1) is composed of materials at mass ratios as follows: TABLE-US-00005 PVC resin or PVC powder 100 parts, styrene elastomer 25-45 parts, stone powder, sawdust or rock 180-280 parts, an additive 1-10 parts, and an elastomer coupling agent 1-4 parts; the additive is one or more selected from the group consisting of a stabilizer, stearic acid, PE wax, chlorinated polyethylene, a modifier, a dye, a brightener and a plasticizer, and the elastomer coupling agent is obtained by polymerization of a polyol, allylic acid, styrene or derivatives, and vinyl chloride.

2. The panel according to claim 1, wherein: a locking groove (5) is provided on the protrusion (7); and a locking protrusion (2) is provided on the recess (3) and is configured to be fitted into the locking groove (5).

3. The panel according to claim 1, wherein the substrate (1) is a wood board, a bamboo board, a metal board, a stone composite plate, a WPC board, a PVC board, a LVT board, a calcium silicate board, an aluminum composite board, a plastic film, a PVC coil, a bamboo wood composite board, a magnesium oxide board, a biological composite board, a wood composite board, a stone plate, a limestone plate, or a calcium silicone carbonate plate.

4. The panel according to claim 1, wherein the coating layer (8) is patterned or provided with three-dimensional lines, and coated on the substrate (1) at an amount of 5-500 g/m.sup.2 (0.147-14.75 oz/yd.sup.2).

5. The panel according to claim 1, further comprising a structure enabling the panel to bend, wherein the structure is at least one groove or cut where the panel is easily bent, wherein a depth of the groove or cut is not greater than a thickness of the substrate.

6. The panel according to claim 1, wherein an upper or lower surface of the substrate (1) is provided with intersecting or parallel grooves, or other patterns.

7. The panel according to claim 6, wherein the intersecting or parallel grooves, or other patterns are 0.1-8 mm (0.0039-0.315 inch) in depth and 0.1-10 mm (0.0039-0.394 inch) in width, and coated with a coating.

8. The panel according to claim 7, wherein 1%-100% of an area with the intersecting or parallel groove or other patterns is covered with the coating.

9. The panel according to claim 1, wherein the elastomer coupling agent is prepared by a method comprising the steps of: 1) adding a polyol and allylic acid into a polymerization reactor in turn, reacting the resultant mixture under an acid catalyst for 0.1-0.5 hours at 80-120 C., removing water and obtaining a mixture; and 2) reacting the obtained mixture with styrene or derivatives and vinyl chloride at 120-160 C. at the presence of an initiator for 1-2 hours, raising the temperature to 200-240 C., and allowing the reaction to proceed for another 1-3 hours to obtain the elastomer coupling agent.

10. The panel according to claim 9, wherein the polyol, allylic acid, styrene or derivatives, and vinyl chloride are at a molar ratio of 1:2-6:5-15:5-15.

11. The panel according to claim 9, wherein the polyol is one or more selected from the group consisting of glycol, 1,2-propanediol, dipropylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, triethylene glycol, diethylene glycol, trihydroxymethyl propane, pentaerythritol and glycerol.

12. A decorative panel formed by arranging and interlocking multiple panels according to claim 1, wherein the protrusion (7) of a first panel of the multiple panels is fitted into the recess (3) of a second panel of the multiple panels, and a new recess (9) is formed on a resulting joint.

13. The decorative panel according to claim 12, wherein the recess (9) on the joint is filled with a wax sealing layer or a sealing bar.

14. The decorative panel according to claim 12, further provided with coordinating trims at the edges to cover the edges.

15. The decorative panel according to claim 14, wherein the trims are made of PVC, WPC, SPC, ceramic, metal, calcium silicate, or wood.

16. A panel installation process comprising the steps of: providing a plurality of panels according to claim 1; covering the panels at a back with an adhesive; arranging and seamlessly interlocking the panels in at least one of a longitudinal direction or widthwise direction; fixing panel connections using a nail gun at a joint recess; and covering the edges of panels with no further panel connection using trims with a trim adhesive.

17. The panel installation process according to claim 16, wherein a first panel of the plurality of panels and a second panel of the plurality of panels perpendicular to the first one are connected and fixed with the trim using the trim adhesive at a right angle corner during panel installation.

18. The panel installation process according to claim 16, wherein a respective panel of the plurality of panels is bent at a right angle corner during panel installation and then interlocked with another panel of the plurality of panels in a new installation plane.

19. The panel installation process according to claim 16, wherein a corner clip (30) is used at a right angle corner during panel installation, wherein the corner clip is composed of an arc or right angle shaped angle plate (31) and two side plates (32, 33), one of the two side plates is perpendicular to the other, the two side plates are connected respectively to two ends of the angle plate (31), two further plates (34, 35) are respectively arranged on the side plates, each in parallel to one side plate and perpendicular to the other, wherein the panels installed at the corner are respectively attached to the two side plates (32, 33) and arranged against the two further plates (34, 35).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram showing the structure of a panel in an embodiment.

(2) FIG. 2 is a schematic diagram showing the panels when installed together in an embodiment.

(3) The reference numerals in FIG. 1 and FIG. 2 are: 1substrate; 2locking protrusion; 3recess; 4groove; 5locking groove; 6tongue; 7protrusion; 8coating layer; 9sealing bar; 10first panel; 20second panel.

(4) FIG. 3 is a schematic diagram showing the panel installation process in an embodiment.

(5) FIG. 4 is a schematic diagram showing the panel installation process in an embodiment.

(6) FIG. 5 is a schematic diagram showing the panel installation process in an embodiment.

(7) FIG. 6 is a schematic diagram showing the panel installation process in an embodiment.

(8) FIG. 7 is a schematic diagram showing the panel installation process in an embodiment.

(9) FIG. 8 is a schematic diagram showing the panel installation process in an embodiment.

DETAILED DESCRIPTION OF THE DISCLOSURE

(10) As shown in FIG. 1, the present embodiment provides a panel comprising a substrate 1, wherein the outer/upper surface of the substrate 1 is provided with a coating layer 8, a moisture-proof and flame-retardant patterned paper, a film, or PE wax, to improve the appearance and durability of the substrate. One can choose different coating layers according to actual needs to achieve different effects.

(11) The substrate 1 is a plank-like panel, and comprises, in the installation direction, two joint edges respectively provided with mechanisms that can be engaged to interlock two adjacent panels.

(12) The substrate 1 is a wood board, a bamboo board, a metal board, a stone composite plate, a PVC board, a WPC board, a LVT board, a calcium silicate board, an aluminum composite board, a plastic film, a PVC coil, a bamboo wood composite board, a glass magnesium oxide plate, a biological composite board, a wood composite board, a stone plate, a limestone plate, or a calcium silicon carbonate plate. The metal board includes a steel plate, an aluminum plate, an alloy plate and other metal plates. The SPC board is a kind of stone composite board, including the LVT board (stone composite flooring). If the surface of substrate 1 is not to be further processed, then the SPC plate is preferred. The WPC board is a kind of wood composite board, which is prepared by uniformly mixing wood and thermoplastic materials and then molding the resultant mixture, and thus has the characteristics of both wood and plastics, making the board look nice. The PVC board is a plate made of PVC with an inner honeycomb-like structure, and has good chemical stability, corrosion resistance, high hardness, high strength, UV resistance (aging resistance), fire resistance (with self-extinguishing property), reliable insulation, neat smooth surface, no water absorption, and no deformation, and is easy to be processed, which improves the practicability. The aluminum composite plate is a three-layered composite plate with plastic as the core layer and aluminum as two surface layers, and is covered with decorative and protective coating or film on plate surfaces. The substrate 1 can be made of different materials according to actual needs in consideration of cost issue.

(13) The left (or right) side of the substrate 1 is arranged with a recess 3 and a groove 4 to the inner side of the recess 3. The distal end of the recess 3 is provided with a locking protrusion 2. The structures are designed to restrict the movement of the mechanism fitted into the recess. The recess 3 is generally arranged on the upper surface (or the lower surface) of the substrate 1.

(14) The right (or left) side of the substrate 1 is provided with a coordinating protrusion 7 that can be fitted into the recess 3. A tongue 6 is provided at the distal end of the protrusion which coordinates and fits into the groove 4. The protrusion 7 is further provided with a locking groove 5 that coordinates and fits into the locking protrusion 2. With such structure design, the up-down and left-to-right movements of two adjacent interlocked panels can be better restricted. The protrusion 7 is generally arranged on the lower surface (or upper surface) of the substrate 1.

(15) The mechanisms on the left and right sides of the substrate 1 may seamlessly interlock two panels and restrict their mutual movements so as to improve the performance in use.

(16) The present embodiment also provides the application of the above panels.

(17) A large decorative panel can be obtained by arranging and interlocking several panels of the disclosure. As shown in FIG. 2, the decorative panel is obtained by arranging and interlocking several panels of the disclosure in sequence. Two panels (i.e., a first panel 10 and a second panel 20) are taken as an example to illustrate the panel installation. The protrusion 7 of the second panel 20 is fitted into the recess 3 of the first panel 10, and a recess is formed on the joint. These panels look like tiles or wood panels such that people will be satisfied with the overall appearance.

(18) When the above two panels are interlocked in the tongue/protrusion-and-groove/recess manner, the recess at the joint is filled with a sealing wax or a sealing bar 9, so that the installed panels are moisture-proof and have not bacteria accumulated. Such panels can be installed in hospitals.

(19) The present disclosure also discloses processes for installing the panels as wall panels or flooring panels, as shown in FIGS. 3 to 6. The processes are as follows.

(20) As a first step, as shown in FIGS. 3 and 4, the panel back 301 is covered with the double sided adhesive tape 302 and coated with some other adhesives. The double sided adhesive tape is made of plastic foam, PET, PVC film, non-woven fabric, or thin film, and covers the panel back in parallel lines in the longitudinal direction and/or widthwise direction with the same or different distances between adjacent two lines, wherein the part of the panel covered by the double sided adhesive tape is slightly shorter than the panel length or width.

(21) In the present embodiment, one panel 400 is covered on the back with 4 pieces of double sided adhesive tapes 410, 420, 430, 440 in the longitudinal direction, coated with silica gel around the adhesive tapes every 4 to 40 cm (1.57 to 15.75 inches), and then attached on the wall on the most left.

(22) As the second step, as shown in FIG. 5, several panels 510, 520 are arranged and seamlessly interlocked on the same plane in a certain direction, with recesses formed on the joints.

(23) As the third step, as shown in FIG. 5, the connection of adjacent two panels 510, 520 are further fixed at the joint 550 using a nail gun.

(24) As the fourth step, as shown in FIG. 6, a panel edge 610 with no panel connection is covered with a trim 620 using an adhesive.

(25) There are several ways to install panels at wall corners.

(26) The first way to install panels at a wall corner is to connect and fix a first panel 710 and a second panel 720 perpendicular to the first panel 710 using a trim with an adhesive, as shown in FIG. 7.

(27) The second way is shown in FIG. 8. In particular, a corner clip 30 is arranged at a right angle corner using a nail gun. The corner clip 30 is composed of an arc shaped angle plate 31, a first side plate 32 and a second side plate 33 perpendicular to the first side plate 32. The two side plates are connected respectively to two ends of the angle plate, and two further plates 34 and 35 are respectively arranged on the side plates, each in parallel to one side plate and perpendicular to the other. The panel 40 and panel 50 to be installed at the corner are bonded with the side plate 32 and the side plate 33, respectively.

(28) The third way to deal with the panel installation at a wall corner is to cut a groove at the back of a certain panel, bend the panel with a 90 angle, and bond the panel at the corner. Next, a panel is arranged and interlocked with the bent panel.

Effects of the Present Embodiment

(29) In the present embodiment, the panels of the disclosure are seamlessly interlocked by fitting the protrusion and the tongue respectively into the recess and the groove, wherein the joint seams are not visible at the distance of 1.5 m (59.06 inches). The recess formed on the joint is filled with a sealing wax or a sealing bar, so that the installed panels are moisture-proof and have not bacteria accumulated. The outer/upper surface of the substrate is provided with a coating layer to provide protective and/or decorative effects. Further, one may choose a substrate taking cost into consideration. In this respect, one can save cost but still use nice looking panels that are visually similar to ceramic tiles or wood boards.

Embodiments with Modifications Based on the Above Embodiment

Modified Embodiment 1

(30) The coating layer 8 is patterned to provide nice appearance. Also, the coating layer 8 may be colored to further improve the appearance.

Modified Embodiment 2

(31) The outer surface of the substrate 1 is provided with intersecting grooves or other patterns to improve the appearance and at the same time to allow water drops slide down. In this respect, the practicability is improved.

Modified Embodiment 3

(32) The grooves or other patterns in Modified Embodiment 2 are covered with a coating, so as to provide a longer service life.

Modified Embodiment 4

(33) The surface of the decorative panel is covered with a coating to prolong the service life.

Modified Embodiment 5

(34) The substrate 1 is prepared by mixing the following materials at specified mass ratios and subjecting the mixture to extrusion molding.

(35) TABLE-US-00002 PVC resin 100 parts; TPEE 25 parts; Stone powder 130 parts; Perlite 30 parts; A stabilizer 1.5 parts; Stearic acid 0.8 part; PE wax 0.2 part; ACR modifier 2 parts; Titanium dioxide 1 part; A brightener 0.01 part; Elastomer coupling agent 5# 2.5 parts.

(36) The elastomer coupling agent 5 #is prepared by adding 1 eq glycol and 2 eq allylic acid into a polymerization reactor in turn, reacting the resultant mixture at the presence of an acid phase transfer catalyst for 0.5 hour at 120 C., raising the temperature to 160 C., adding to the reactor 5 eq styrene, 5 eq vinyl chloride and an alkali, reacting the obtained mixture for 1 hour, raising the temperature to 240 C., and allowing the reaction to proceed for 1.5 hours.

(37) Such a substrate is a particularly suitable substrate to be used in a panel installed at a corner. In panel installation, the panel is cut at a proper position, bent at a certain angle, and attached and fixed at the corner using an adhesive and a nail gun. Then, panel installation proceeds in the new installation plane.

Modified Embodiment 6

(38) The substrate 1 is prepared by mixing the following materials at specified mass ratios and subjecting the mixture to extrusion molding, and 0.5 mm (0.02 inch) thick.

(39) TABLE-US-00003 PVC resin 100 parts; TPE 45 parts; Sawdust 280 parts; A stabilizer 1.5 parts; Stearic acid 1.5 parts; PE wax 1 part; Chlorinated polyethylene 1.5 parts; ACR modifier 3 parts; An antioxidant 0.5 part; A dye 1 part; Elastomer coupling agent 6# 2 parts.

(40) The elastomer coupling agent 6 #is prepared by adding 1 eq glycol and 2 eq allylic acid into a polymerization reactor in turn, reacting the resultant mixture at the presence of concentrated sulfuric acid for 0.2 hour at 100 C., raising the temperature to 120 C., adding to the reactor 10 eq styrene, 15 eq vinyl chloride and an initiator, reacting the obtained mixture for 1 hour, raising the temperature to 200 C., and allowing the reaction to proceed for 3 hours.

(41) Such a substrate is a particularly suitable substrate to be used in a panel installed at a corner. In panel installation, the panel is cut at a proper position, bent at a certain angle, and attached and fixed at the corner using an adhesive and a nail gun. Then, panel installation proceeds in the new installation plane.

Modified Embodiment 7

(42) The substrate 1 is prepared by mixing the following materials at specified mass ratios and subjecting the mixture to extrusion molding, and 0.3 mm (0.012 inch) thick.

(43) TABLE-US-00004 PVC powder 100 parts; Polystyrene elastomer 35 parts; Sawdust 200 parts; Perlite 20 parts; A stabilizer 1 part; Stearic acid 0.3 part; PE wax 1 part; Elastomer coupling agent 7# 0.5 part.

(44) The elastomer coupling agent 7 #is prepared by adding 1 eq triethylene glycol and 2.5 eq allylic acid into a polymerization reactor in turn, reacting the resultant mixture at the presence of concentrated sulfuric acid for 0.2 hour at 100 C., raising the temperature to 160 C., adding to the reactor 15 eq styrene, 5 eq vinyl chloride and an initiator, reacting the obtained mixture for 1 hour, raising the temperature to 240 C., and allowing the reaction to proceed for 1.2 hours.

(45) Such a substrate is a particularly suitable substrate to be used in a panel installed at a corner. In panel installation, the panel is cut at a proper position, bent at a certain angle, and attached and fixed at the corner using an adhesive and a nail gun. Then, panel installation proceeds in the new installation plane.