DECORATIVE PANEL COMPRISING A TEXTILE DECORATIVE LAYER

Abstract

The decorative panel includes a substrate and a top layer. The substrate has at least one of polyvinyl chloride layer. The top layer includes a decorative textile layer providing the surface of the decorative panel. The top layer is laminated onto the substrate by thermal bonding of the top layer onto the substrate; or by a polyvinyl chloride based adhesive layer. The substrate is provided at a first pair of opposite edges with coupling parts, substantially in the form of male coupling parts and female coupling parts, for coupling two such panels to each other at their first pair of opposite edges. The coupling parts are provided with locking means which effects a locking in coupled condition of two such panels in the direction perpendicular to the surface of the coupled panels and/or into the direction perpendicular to the respective edges in the plane of the panels.

Claims

1.-54. (canceled)

55. A decorative panel, comprising a substrate and a top layer, wherein the substrate comprises one or a multiple number of polyvinyl chloride layers, wherein the top layer comprises a decorative textile layer providing the surface of the decorative panel; wherein the top layer is laminated onto the substrate by thermal bonding of the top layer onto the substrate; or by means of a polyvinyl chloride based adhesive layer; wherein the substrate is provided at a first pair of opposite edges with coupling parts, substantially in the form of male coupling parts and female coupling parts, for coupling two such panels to each other at their first pair of opposite edges; wherein the coupling parts are provided with locking means which effects a locking in coupled condition of two such panels in the direction perpendicular to the surface of the coupled panels and/or into the direction perpendicular to the respective edges in the plane of the panels.

56. The decorative panel as in claim 55, wherein the top layer is laminated onto the substrate by means of a polyvinyl based adhesive layer, wherein the polyvinyl based adhesive layer is plasticized polyvinyl chloride; and/or the polyvinyl based adhesive layer comprises one or more than one of cyclohexanone, tetrahydrofuran or butanone.

57. The decorative panel as in claim 55, wherein the top layer comprises a backing layer providing the bottom of the top layer; wherein the backing layer comprises polyvinyl chloride.

58. The decorative panel as in claim 55, wherein the substrate comprises as its upper layer a plasticized polyvinyl chloride layer; wherein said plasticized polyvinyl chloride layer adheres directly or indirectly to the top layer.

59. The decorative panel as in claim 55, wherein the decorative textile layer comprises any one of a nonwoven felt, a layer of flocked fibers, a layer of cut pile yarns, a layer of loop pile yarns, or a woven fabric with or without pile yarns; providing the surface of the decorative panel.

60. The decorative panel as in claim 59, wherein the top layer comprises a carrier substrate onto which the decorative textile layer is adhered; wherein the carrier substrate comprises or consists of a textile nonwoven fabric or a woven fabric.

61. The decorative panel as in claim 55, wherein the substrate comprises a core, wherein the core comprises polyvinylchloride comprising filling material, wherein the filling material comprises one or more of stone particles, chalk, wood fibers or natural fibers.

62. The decorative panel as in claim 61, wherein the polyvinyl chloride of the core or of the polyvinyl chloride matrix is foamed polyvinyl chloride.

63. The decorative panel as in claim 55, wherein the coupling parts of the first pair of opposite edges are configured such that two such panels can be coupled at the first pair of opposite edges by means of a turning movement and/or by means of a sliding movement with snap effect parallel with the surface of the decorative panels.

64. The decorative panel as in claim 63, wherein the coupling parts at the first pair of opposite edges substantially are manufactured of the material of the substrate; wherein the coupling parts at the first pair of opposite edges substantially are realized in the form of a tongue and a groove, which are provided with locking parts, which, in the coupled condition of two of such floor panels, counteract the moving apart of the coupled floor panels in a direction perpendicular to the coupled edges and parallel to the plane of the floor covering; wherein the groove is bordered by an upper lip and a lower lip, which lower lip, in distal direction, extends beyond the distal end of the upper lip, and, the portion of the lower lip that extends beyond the distal end of the upper lip comprises a locking part in the form of an upward-directed locking part.

65. The decorative panel as in claim 55, wherein the coupling parts of the first pair of opposite edges are configured such that two such panels can be coupled at the first pair of opposite edges by means of a substantially downward movement according to a direction perpendicular to the plane of the panels, and/or by means of a turning movement, and/or by means of a sliding movement with snap effect parallel with the surface of the decorative panels.

66. A method for manufacturing a decorative panel comprising a decorative textile layer; wherein the method comprises the steps of: providing a substrate wherein the substrate comprises one or a multiple number of polyvinyl chloride layers; providing a top layer comprising a decorative textile layer; laminating the top layer onto the substrate by thermal bonding of the top layer onto the substrate; or by means of a polyvinyl chloride based adhesive layer, thereby obtaining a board; dividing the board into a plurality of panels each comprising the top layer laminated onto the substrate; providing the panels at least at a first pair of their opposite edges with coupling parts, substantially in the form of male coupling parts and female coupling parts, for coupling two such panels to each other at their first pair of opposite edges; wherein the coupling parts are provided with locking means which effects a locking in coupled condition of two such panels in the direction perpendicular to the surface of the coupled panels and/or into the direction perpendicular to the respective edges in the plane of the panels, wherein the coupling parts are provided substantially in the substrate.

67. The method as in claim 66, wherein the top layer is laminated onto the substrate by thermal bonding, wherein the top layer of the substrate and/or the bottom of the top layer is heated before contacting the top layer onto the substrate.

68. The method as in claim 66, wherein the top layer is laminated onto the substrate by thermal bonding, wherein the top layer is brought in contact with the substrate; and the combination of top layer and substrate passes through heated rollers; or through pressure belts while heat is applied.

69. The method as in claim 66, wherein the top layer is laminated onto the substrate by means of a polyvinyl chloride based adhesive; wherein the polyvinyl based adhesive layer is plasticized polyvinyl chloride and/or the polyvinyl based adhesive layer comprises one or more than one of cyclohexanone, tetrahydrofuran or butanone.

70. A decorative panel, comprising a substrate and a top layer, wherein the substrate comprises one or a multiple number of layers, wherein the top layer comprises a decorative textile layer providing the surface of the decorative panel; wherein the substrate is provided at a first pair of opposite edges with coupling parts, substantially in the form of male coupling parts and female coupling parts, for coupling two such panels to each other at their first pair of opposite edges; wherein the coupling parts are provided with locking means which effects a locking in coupled condition of two such panels in the direction perpendicular to the surface of the coupled panels and/or into the direction perpendicular to the respective edges in the plane of the panels; wherein the substrate comprises a thermoplastic polymer; wherein the top layer is laminated onto the substrate by thermal lamination wherein bonds are formed between the thermoplastic polymer of the substrate and the same thermoplastic polymer in the top layer.

71. The decorative panel as in claim 70, wherein the top layer comprises a backing layer and wherein the same thermoplastic polymer in the top layer is provided in the backing layer of the top layer.

72. The decorative panel as in claim 70, wherein the thermoplastic polymer is selected from polyvinyl chloride, polyethylene, polypropylene, polyester, or polyamide.

73. The decorative panels as in claim 72, wherein the thermoplastic polymer is a polyester, and wherein the thermoplastic adhesive is a co-polyester.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0090] FIG. 1 represents a partially installed floor covering composed of decorative floor panels according to embodiments of several aspects of the invention.

[0091] FIG. 2 shows in top view a decorative floor panel used in the floor covering of FIG. 1.

[0092] FIG. 3 represents a cross-section according to line III-III in FIG. 2.

[0093] FIG. 4 represents a cross-section according to line IV-IV in FIG. 2.

[0094] FIG. 5 shows—in a same view as in FIG. 3—an alternative embodiment of the invention.

[0095] FIGS. 6, 7 and 8 show alternative top layers that can be used in the invention.

MODE(S) FOR CARRYING OUT THE INVENTION

[0096] FIG. 1 represents a partially installed floor covering composed of decorative floor panels 1 according to embodiments of several aspects of the invention. These decorative floor panels 1 comprise coupling parts at the first pair of opposite edges 2, 3—which are the long edges of the rectangular and oblong panels. The coupling parts are substantially provided in the form of male coupling parts and female coupling parts, for coupling two such panels to each other at their first pair of opposite edges. The coupling parts of the first pair of opposite edges 2, 3 are configured such that two such panels can be coupled at the first pair of opposite edges by means of a turning movement.

[0097] The second pair of opposite edges 4, 5—which are the short edges—are also provided with coupling parts provided in the form of male coupling parts and female coupling parts, for coupling two such panels 1 to each other at their second pair of opposite edges. The coupling parts of the second pair of opposite edges 4, 5 are configured such that two such panels 1 can be coupled at the second pair of opposite edges 4, 5 by means of a substantially downward movement according to a direction perpendicular to the plane of the panels. Such downward movement is possible with coupling parts of the so-called “push-down”, “push-lock” or “drop” type.

[0098] Thanks to the specific configuration of the coupling parts, the decorative floor panel 1, starting from an inclined position, can be coupled in a single movement F at its long edge 2 as well as at its short edge 5 to the respective already installed floor panels 1. This installation method of floor panels is known as “fold-down” installation. The fold-down movement F offers the possibility of installing a floor covering in a very simple and efficient manner using decorative floor panels according to the invention.

[0099] FIG. 2 shows in top view a decorative floor panel 1 used in the floor covering of FIG. 1. The decorative floor panel 1 is a decorative panel according to several aspects of the invention. The decorative floor panel 1 is rectangular and in this case oblong and comprises a first pair of opposite edges 2, 3, which form the long edges, and a second pair of opposite edges 4, 5, which form the short edges.

[0100] FIG. 3 represents a cross-section according to line III-III in FIG. 2. The floor panel 1 comprises a layer-shaped substrate 6, as well as a decorative top layer 7 situated above the substrate 6. The top layer 7 comprises a decorative textile layer, in this example comprising loop pile yarns 31 on a backing layer 32 providing the bottom of the top layer 7. In the example shown, the backing layer 32 comprises polyvinyl chloride, e.g. plasticized polyvinyl chloride.

[0101] The substrate 6 comprises at least one layer 6A, which is made on the basis of a composition comprising at least polyvinyl chloride, wherein the composition is free from plasticizers or comprises plasticizers in an amount of less than 20 phr and preferably in an amount between 5 and 15 phr. The result is a rigid layer 6A. The polyvinyl chloride of the layer 6A can be foamed; and may comprise fillers such as mineral fillers or wood-based fillers.

[0102] The substrate 6 comprises a more supple layer 6B situated above the layer 6A. This more supple layer 6B is a polyvinyl chloride layer comprising plasticizers in an amount more than 20 phr. The more supply layer 6B may comprise fillers such as mineral fillers of wood-based fillers.

[0103] Preferably, the layer 6A forms at least half of the thickness of the decorative floor panel 1.

[0104] The top layer 7 is laminated onto the substrate 6 by thermal bonding of the top layer onto the substrate (and more specifically to the more supple layer 6B).

[0105] The first pair of opposite edges 2, 3 is provided with coupling parts 8, 9, which allow effecting a coupled condition between two of such coupling parts 1 by means of a rotation or turning movement R around an axis parallel to the plane of the floor covering and parallel to the edges 2, 3 to be coupled.

[0106] The coupling parts 8, 9 substantially are made from the material of the substrate 6 and more particularly substantially in the rigid layer 6A.

[0107] Substantially, the coupling parts at the first pair of opposite edges are realized in the form of a tongue 10 and a groove 11, which are provided with locking parts 12, 13, which, in the coupled condition of two of such floor panels 1, counteract the moving apart of the coupled floor panels 1 in a direction perpendicular to the coupled edges 2, 3 and parallel to the plane of the floor covering.

[0108] The groove 11 is bordered by an upper lip 14 and a lower lip 15, which lower lip 15 in distal direction reaches beyond the distal end 16 of the upper lip 14 and, beyond the distal end 16 of the upper lip 14, comprises a locking part 13 in the form of an upward-directed locking part 13. This way, a locking in coupled condition of two such panels at their first pair of opposite edges is provided in the direction perpendicular to the surface of the coupled panels and into the direction perpendicular to the respective edges in the plane of the panels.

[0109] FIG. 4 represents a cross-section according to line IV-IV in FIG. 2. The reference figures in FIG. 4 have the same meaning as in FIG. 3. The second pair of opposite edges 4, 5 is provided with coupling parts 17, 18, which allow effecting a coupled condition between two of such floor panels 1 by means of a substantially downward movement M according to a direction perpendicular to the plane of the floor covering. The coupling parts 17, 18 here are made as hook-shaped portions 19, 20, which form a locking system which allows effecting a locking between two of such floor panels 1 in a direction parallel to the plane of the floor covering and perpendicular to the coupled edges 4, 5. The coupling parts 17, 18 further comprise locking parts 21, 22 and locking parts 23, 24, which each form a locking system which allows effecting a locking between two of such floor panels 1 in a direction perpendicular to the plane of the floor covering. The coupling parts 8, 9 and 17, 18 at the first and the second pair of opposite edges 2, 3 and 4-5 allow effecting a coupled condition between a plurality of such floor panels 1 by means of a fold-down movement F, as illustrated in FIG. 1.

[0110] FIG. 5 shows—in a same view as in FIG. 3—an alternative embodiment of the invention. The panel has a similar configuration as the panel shown in FIG. 3. The reference numerals in FIG. 5 have the same meaning as the reference numerals in FIG. 3. The decorative panel illustrated in FIG. 5 differs from the panel illustrated in FIG. 3 in that the top layer is laminated onto the substrate (and more specifically to the more supple layer 6B of the substrate 6) by means of a polyvinyl chloride based adhesive layer 34.

[0111] FIGS. 6, 7 and 8 show alternative top layers that can be used in the invention. The top layer shown in FIG. 6 comprises a backing layer 32 and cut pile yarns 41. And example of such top layer is a tufted or bonded cut pile carpet. The top layer can comprise a precoat and/or a secondary backing layer.

[0112] The top layer of FIG. 7 comprises a backing layer 32 onto which discrete fibers 42 are adhered. The top layer of FIG. 7 can be manufactured by means of flocking: the backing layer—e.g. comprising a woven or nonwoven fabric, e.g. a nonwoven glass fiber fabric—is provided with an adhesive onto which the discrete fibers are applied. This way, the fibers are glued onto the backing layer.

[0113] FIG. 8 shows yet an alternative top layer. The top layer comprises a backing layer 32 onto which a nonwoven 43—e.g. a needlefelt—is adhered, e.g. by means of an adhesive. The use of a top layer which consist of a needlefelt, and thus do not comprise a backing layer is also possible according to the invention.

[0114] The use of the decorative panels is not limited to use in floor coverings. Decorative panels according to the invention can also be used in wall coverings of ceiling coverings.