DECORATIVE MINERAL PANEL

Abstract

A decorative panel includes a mineral layer, and a decorative surface. The decorative surface has an embossed pattern, wherein the embossed pattern is provided in the mineral layer

Claims

1.-74. (canceled)

75. A decorative panel comprising a mineral layer; wherein the decorative panel comprises a decorative surface, wherein the decorative surface comprises an embossed pattern, wherein the embossed pattern is provided in the mineral layer.

76. The decorative panel as in claim 75, wherein the embossed pattern comprises undercuts in the surface of the panel.

77. The decorative panel as in claim 75, wherein the mineral layer is provided with a staining pattern, wherein the staining pattern is provided in register with the embossed pattern.

78. The decorative panel as in claim 77, wherein the mineral layer is provided with a sealing agent before or after, or before and after application of the staining.

79. The decorative panel as in claim 75, wherein the decorative surface of the decorative panel comprises one or a plurality of lacquer layers.

80. The decorative panel as in claim 75, wherein the mineral layer is selected from a concrete layer, a magnesium oxide layer, or a gypsum layer.

81. The decorative panel as in claim 75, wherein the mineral layer is a concrete layer comprising ultra, high-performance concrete.

82. The decorative panel as in claim 75, wherein the decorative panel comprises a first pair of parallel opposite edges, wherein the first pair of parallel opposite edges comprises coupling parts, which allow that two of such floor panels mutually can be coupled to each other at the parallel opposite edges; optionally the surface of the coupling parts is at least partly provided with a sealing agent; optionally the coupling parts comprise locking elements which prevent the drifting apart of two coupled panels into the direction perpendicular to the surface of the coupled panels and/or into the direction perpendicular to the respective coupled edges in the plane of the coupled panels.

83. A method to produce a decorative panel, wherein a mold is provided comprising the negative of the embossed pattern of the surface of the decorative panel to be manufactured, optionally spraying a release agent in the mold, pouring a slurry comprising an inorganic binder in the mold to create a mineral layer for the decorative panel, wherein the surface of the mineral layer is to comprise the embossed pattern, demolding the cast panel after the slurry has dried and set.

84. The method an in claim 83, wherein after pouring the slurry into the mold, a carrier layer is applied onto the slurry, in order to provide the mineral layer on a carrier layer in the decorative panel.

85. The method as in claim 83, wherein the embossed pattern provided on the surface of the mineral layer comprises undercuts.

86. The method as in claim 83, wherein the inorganic binder in the slurry comprises anyone of or a combination of one or more selected from Portland cement, Sorel cement, magnesium oxychloride cement, magnesium oxysulphate cement, gypsum or a geopolymer cement binder.

87. The method as in claim 83, wherein a staining is applied onto the embossed surface of the mineral layer.

88. The method as in claim 87, wherein the staining is applied by means of a roller coater or by means of spraying, or by means of digital inkjet printing.

89. A method to produce a decorative panel, wherein a slurry comprising an inorganic binder is extruded or cast on a flat mold or on a flat carrier to produce a mineral layer for the decorative panel, and wherein in a subsequent process step the mineral layer is embossed by means of a structured press plate or by means of an embossing cylinder.

90. The method as in claim 89, wherein the slurry is extruded on a carrier wherein the carrier will form a carrier layer for the mineral layer of the decorative panel.

91. The method as in claim 89, wherein the inorganic binder in the slurry comprises anyone of or a combination of one or more selected from Portland cement, Sorel cement, magnesium oxychloride cement, magnesium oxysulphate cement, gypsum or a geopolymer cement binder.

92. The method as in claim 89, wherein a staining is applied onto the embossed surface of the mineral layer.

93. The method as in claim 92, wherein the staining is applied by means of a roller coater or by means of spraying, or by means of digital inkjet printing.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0099] FIG. 1 schematically represents a portion of a floor covering according to aspects of the invention; and consisting of decorative panels according to aspects of the invention.

[0100] FIG. 2 shows a decorative panel according to the invention, as used in the floor covering of FIG. 1.

[0101] FIG. 3 in perspective, in cross-section and at a larger scale represents a view on the section indicated by F3 in FIG. 2.

[0102] FIG. 4 shows a cross-section along line Iv-Iv shown in FIG. 2.

[0103] FIG. 5 shows decorative panels according to FIGS. 2, 3 and 4 coupled at their first pair of opposite edges.

[0104] FIGS. 6-11 show alternative ways of coupling decorative panels according to the invention.

MODE(S) FOR CARRYING OUT THE INVENTION

[0105] FIG. 1 illustrates an example of a floor covering according to aspects of the invention. The floor covering shown in FIG. 1 consists of decorative floor panels 1 according to aspects of the invention. The decorative panels 1 are rectangular and oblong. FIG. 2 shows a decorative floor panel 1 of FIG. 1 in more detail. The floor panels are only schematically shown in FIG. 1, without the details of their surface texture. The decorative floor panels of FIGS. 1 and 2 comprise a first pair of opposite edges 2, 3 and a second pair of opposite edges 4, 5.

[0106] The decorative floor panels 1 are configured at their edges such that they can be coupled according to the so-called fold-down principle, which is a principle known as such and which consists in that such floor panels 1 can be coupled to each other at the first pair of edges 2, 3 by a turning movement R and at the second pair of edges 4, 5 by a downward movement, wherein the downward movement is the result of the turning movement R and thus is effected substantially simultaneously. The floor panels 1 of the example also are configured such that at their edges 2, 3 and 4, 5 a locking is effected in the direction perpendicular to the surface of the floor covering as well as in the direction parallel to the surface of the floor covering and perpendicular to the coupled edges. The decorative floor panels 1 in FIG. 1 are free floating in the floor covering.

[0107] FIG. 2 shows the decorative floor panels used to install the floor covering of FIG. 1. Both pairs of opposite edges 2, 3, 4, 5 are provided with mechanical coupling means 7, 8, 31, 32. Two such panels can be coupled at their first pair of opposite edges by means of a rotating movement R around the respective edges 2, 3 and/or coupling by means of a sliding movement S in a substantially horizontal manner of the edges to be coupled 2, 3 to each other. FIG. 4 shows the coupling parts at the first pair of opposite edges 2, 3. FIG. 5 shows a detail of two such panels coupled at their first pair of opposite edges 2, 3.

[0108] The decorative panel 1 comprises a decorative surface 15 (shown in FIGS. 2 and 3, not shown in the other figures). The decorative surface comprises an embossed pattern, wherein the embossed pattern is provided in the mineral layer of the decorative panel. The decorative surface 15 of the decorative panel 1 imitates a wood panel, wherein the embossed structure imitates wood nerves and wood pores.

[0109] FIG. 3 in perspective, in cross-section and at a larger scale represents a view on the section indicated by F3 in FIG. 2. The decorative floor panel has a decorative surface 15. The decorative surface comprises an embossed pattern, which is provided in the mineral layer 10. In the example shown, the decorative panel comprises a multilayer structure, wherein the mineral layer 10 is bonded onto a carrier layer 12. However, the carrier layer is optional, the decorative panel can consist of the mineral layer. The embossed pattern comprises elongated recesses 19. At least some of the elongated recesses have a length that is larger than their width.

[0110] FIG. 3 represents that elongated recesses 19 are provided that, over the major part of their length L, have a cross-section which is provided with inclined lateral flanks 20, or at least with one inclined lateral flank 20. The embossed pattern shown in FIG. 3 comprises undercuts 22 on the surface of the panel, the undercuts 22 are provided in the mineral layer 10. The width of the undercut W can be more than 0.5 millimeter, more than 1 millimeter, or even more than 2 millimeter.

[0111] Decorative panels have been made using a magnesium oxide mineral layer as mineral layer. Such magnesium oxide mineral layers for use in the invention can e.g. be made using a slurry having the following formulation: [0112] 34.84 wt % technical grade magnesium oxide, with a particle size smaller than 50 micrometer, [0113] 29.89 wt % technical grade MgCl.sub.2.Math.6H.sub.20, [0114] 18.51 wt % water, [0115] 2.45 wt % phosphoric acid 85%, [0116] 6.84 wt % calcium carbonate, [0117] 6.84 wt % wood dust, [0118] 0.63 wt % PVA-fibers.

[0119] The formulation of the example for the magnesium oxide mineral layer does not limit the invention; the formulation can be varied.

[0120] The recipe of the example comprises magnesium oxychloride as the inorganic binder. It is also possible to use magnesium oxysulphate inorganic binders for producing magnesium oxide mineral layers for use in the invention. A silicone mold has been provided comprising the negative of the embossed pattern of the surface of the decorative panel to be manufactured.

[0121] A wood panel has been used to manufacture the mold. The wood panel has been sanded and brushed. A release agent has been provided on the surface of the wood panel. A thin layer of elastomeric polymer (silicone has been used) was poured on the surface of the wood panel. After the silicone polymer had cured, the silicone polymer layer so formed has been removed from the surface of the wood and used as mold. The mold provided a negative of the textured surface of the wood panel, including of the nerves and even of the undercuts.

[0122] A release agent has been provided in the mold; and the slurry of the formulation of the example given has been cast in the mold. The mineral panel cast this way has been taken out of the mold after the slurry had dried and set. The mineral layer copied nicely the texture of the mold, in which even undercuts have been provided on the surface of the mineral panel cast with the magnesia oxide binder slurry.

[0123] In a similar way as magnesium oxide decorative panels, UHPC (Ultra High Performance Concrete) decorative panels can be made, using the same types of mold as used when manufacturing the magnesium oxide decorative panel. Such UHPC panels can be made using UHPC slurries known in the art. Such slurries can comprise additives such as for instance aluminum oxide, chopped glass fiber and pigments. The slurry can comprise plasticizers as well, e.g. superplasticizers such as polycarboxylates.

[0124] An example of a UHPC decorative panel has been made using the same mold as in the magnesium oxide decorative panel example. The formulation for the UHPC slurry to make the panel consisted of: [0125] 85 wt % commercially available UHPC cement premix; [0126] 2-10 wt % aluminum oxide; [0127] 2 wt % chopped glass fibers; [0128] 0.05-0.5 wt % pigment; [0129] 2 wt % liquid plasticizer; and [0130] 10 wt % water.

[0131] The slurry made with this composition was cast in the mold to make an UHPC panel. The UHPC-panel made was 12 millimeter thick. The UHPC panel showed excellent mechanical properties: [0132] flexural strength 7.7 MPa after one day, 12.0 MPa after 7 days and 16.4 MPa after 28 days. [0133] compressive strength 43.8 MPa after one day, 92.0 after 7 days and 122.5 MPa after 28 days.

[0134] Mineral layers for use in the inventionand especially magnesium oxide mineral layerscan be produced in an alternative way than via casting of a slurry in a textured mold. The slurry can be extruded or cast on a flat mold or on a carrier. The slurry can e.g. be cast on a carrier that will provide the carrier layer in the decorative panel to be made. A structured press plate can be used to provide the surface of the mineral layer with an embossed structure. This press operation can be performed before curing the mineral layer or after partial curing of the mineral layer. Such approach allows to make large boards from which the decorative panels are cut. Coupling parts can be milled in the decorative panels in the mineral layer, or if a carrier layer is provided, partly of fully in the carrier layer. It is preferred when the press operation with the structured press plate is performed before curing the mineral layer.

[0135] The example of a UHPC decorative panelmade using the same mold as in the magnesium oxide decorative panel example and therefore comprising an embossed patternhas been provided with a staining pattern, in register with the embossed pattern. The staining pattern has been provided by means of spraying of a staining liquid comprises nanopigments in a binder onto the embossed UHPC-surface of the panel. The binder of the staining was an UV-curing acrylate. The staining in register with the natural wood embossed structure in the mineral layer simulated the color of a wood panel.

[0136] After application of the staining, three lacquer layers have been applied. First, a primer layer has been applied, followed by a sealer and finally by a top coat. Each of the three lacquer layers have been applied via roller coating (however, other methods of application can be used, e.g. spraying); and comprised aliphatic urethane monomer and oligomer acrylates. The coating layers comprised abrasion resistant particles, but did not comprise matting agents. The lacquer layers have been cured by means of UV-curing.

[0137] In the floor covering of FIG. 1, only the mineral layer of the decorative panels, with its embossments and with its optional staining and its optional lacquer layer(s) is visible in top view of the floor covering.

[0138] FIG. 4 shows a cross-section along line IV-IV shown in FIG. 2. The first pair of opposite edges 2, 3 of the decorative panel 1 is provided with mechanical coupling means 6 that are mainly realized as a tongue 7 and a groove 8 delimited by an upper lip 9 and a lower lip 33, wherein the tongue 7 and the groove 8 are mainly responsible for the locking in a vertical direction, and wherein the tongue 7 and the groove 8 are provided with additional locking elements 34, 35 which are mainly responsible for the locking in a horizontal direction. The locking elements comprise a projection 34 on the underside of the tongue 7 and a recess 35 in the lower groove lip 33. The coupling means 6 shown in FIG. 4 allow at least coupling by means of a rotating movement R (see FIG. 1) around the respective edges 2, 3 and/or coupling by means of a sliding movement in a substantially horizontal manner of the edges to be coupled 2, 3 to each other. The first pair of opposite edges 2, 3 is provided with bevels 25.

[0139] FIG. 5 shows decorative panels according to FIGS. 2, 3 and 4 coupled at their first pair of opposite edges 2, 3.

[0140] In the examples shown in FIGS. 4 and 5, the coupling parts are provided in the carrier layer. This can be realized by milling operations after production of the decorative panel.

[0141] FIGS. 4 and 5 show that the mineral layer 10 of these exemplary decorative panels comprise at the first edge of the first pair of parallel opposite edges a first contact surface 26 and at the second edge of the first pair of parallel opposite edges a second contact surface 27.

[0142] In coupled condition of two such panels, a first such panel and a second such panel, at the first pair of parallel opposite edges, the first contact surface 26 of a first panel contacts the second contact surface 27 of the second panel.

[0143] The first contact surface 26 and the second contact surface 27 are perpendicular to the surface of the decorative panel. The surface of the coupling parts can optionally at least partly be provided with a sealing agent.

[0144] The coupling parts of the decorative panel shown in FIGS. 4 and 5 are provided in the carrier layer 12 which is bonded to the mineral layer 10. It is however also possible to provide the coupling parts partially or completely in the mineral layer 10. When the decorative panel does not comprise a carrier layer, the coupling parts are completely provided in the mineral layer.

[0145] FIGS. 6-11 show alternative ways of coupling decorative panels according to the invention. The embossed structure in the mineral layer is not shown in FIGS. 6-11.

[0146] In the example of FIG. 6, the decorative panels do not comprise a carrier layer, and only have the mineral layer 10, with its embossments and optional staining and lacquer layers. The decorative panels comprise at their first pair of opposite edges 2, 3 coupling means 6. The coupling means comprise a first contact surface 26 and a second contact surface 27. The contact surfaces 26, 27 are horizontal (and thus parallel with the surface of the decorative panels) and overlap in coupled condition of two such panels at their first pair of opposite edges 2, 3. This way, an overlap of the mineral layers 10 of both panels is created. The first pair of opposite edges is optionally provided with bevels 25 in the mineral layer 10. Optionally, grout 37 can be provided at the coupled panel edges. The grout 37 can provide an improved coupling, provide improved water tightness, and provide a realistic simulation of a natural stone tile covering. The contact surfaces 26, 27 can optionally be provided with a sealing agent. It is possible, however not necessarily required, that the panels shown in FIG. 6 are bonded to a supporting layer (e.g. to the floor when the decorative panels are floor panels) by means of an adhesive, e.g. by means of mortar.

[0147] The configuration of FIG. 7 is to a large extent similar to the configuration of FIG. 6. Reference numbers have the same meaning as in FIG. 6. The difference is that recesses 39 are provided in one or in both (as shown in FIG. 7) panel edges 2, 3. An adhesive 38 can be applied in one or both recesses when installing the panels. The adhesive provides a bonding of the decorative panels to each other. Such approach can be used for installing decorative panels that simulate wood panels. It is a benefit that the adhesive is not visible after installation of the decorative panels.

[0148] FIG. 8 shows yet an alternative way of coupling the decorative panels according to the invention. The decorative panels 1 comprise a first pair or parallel opposite edges 2, 3. Both edges of the first pair of parallel opposite edges 2, 3 are each provided with a recess 40provided at the bottom of the decorative panelfor fitting an insert 41. The insert 41 presses the first such panel towards the second such panel by means of an elastic bending force of the insert 41. During installation of the decorative panels, the insert 41, an elongated profile, can be put on the floor and the decorative panelswith their recess 40can be slid over the insert 41. The decorative panel of FIG. 8 comprises a mineral layer 10 and a carrier layer 12, however, this method of coupling can also be used when the decorative panel does not comprise a carrier layer. In the example shown in FIG. 8, the carrier layer 12 is provided with a structured surface 43 at the interface with the mineral layer 10. The decorative panel of FIG. 8 is provided at edges with a bevel 25.

[0149] FIG. 9 shows a variant to the embodiment of FIG. 6. Reference numerals in FIG. 9 have the same meaning as in FIG. 6. The embodiment of FIG. 9 differs from the embodiment from FIG. 6 in that the decorative panels 1 comprise a mineral layer 10 adhered to a carrier layer 12. The coupling parts are entirely provided in the mineral layer 10. It is also possible to provide the coupling parts entirely in the carrier layer 12. The panel edges of the example of FIG. 9 are not provided with bevels, however, it is also possible to provide the panels with bevels.

[0150] FIG. 10 shows another embodiment. The reference numerals have the same meaning as in the other figures. An adhesive 38 is provided between the edges 2, 3 of the coupled panels. The edges 2, 3 are shaped such that when the floor covering comprising such coupling are viewed from above, the adhesive is barely visible because it is provided in the shadow area of the edges. The adhesive 38 provides for a bonding between the decorative panels; and provides water tightness of the joint between the panels. The second pair of opposite edges of rectangularsquare or oblongdecorative panels, can be coupled in the same way. FIG. 10 shows an embodiment without carrier layer, however, the decorative layer can comprise a carrier layer onto which the mineral layer 10 is adhered.

[0151] FIG. 11 shows another embodiment. Reference numerals have the same meaning as in the other figures. The edges comprise coupling parts 6. The coupling is a tongue 7 and groove 8 coupling that can be realized by a turning movement of the edge 2 into the edge 3, wherein a locking is established in the direction perpendicular to the surface of the panels as well as in the plane parallel with the surface of the panels and perpendicular to the coupled edges.

[0152] Some of the examples presented in the figures relate to a decorative panel wherein the mineral layer is bonded onto a carrier layer. Different types of carrier layers are possible, and the carrier layer can be provided in several ways. Of particular interest is a carrier layer that allows to mill coupling parts in the carrier layer, for coupling the decorative panels at their edges. Of particular interest is the use of a cement fiber board as carrier layer.

[0153] The mineral layer can be bonded to the carrier layer by means of an adhesive or by means of cementitious or inorganic binders present in the mineral layer. The carrier layer can be a second mineral layer, having a different composition than the mineral layer.

[0154] The carrier layer can have a lower density than the mineral layer, to provide a lighter decorative panel. To this end, e.g. a HDF-panel can be provided as carrier layer.

[0155] Although most examples show a decorative panel that comprises a multiplayer, more particularly a mineral layer on a carrier layer, the invention is not limited to such multilayers. The invention also relates to decorative panels in which the mineral layer is not provided on a carrier layer.