Abstract
The invention relates to a floor panel, in particular a magnesium oxide based floor panel, which is preferably provided with interconnecting coupling parts for mutually connecting adjacent floor panels to each other. The invention also relates to a method of producing a floor panel, in particular a magnesium oxide based floor panel.
Claims
1. A floor panel, comprising a laminate of: a magnesium oxide based core layer; at least one magnesium oxide based upper crust layer positioned on top of said core layer, wherein the density of said upper crust layer is larger than the density of the core layer; and at least one upper reinforcing layer situated in between said core layer and said at least one upper crust layer.
2. The floor panel according to claim 1, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising complementary coupling parts allowing to mutually couple of plurality of floor panels to each other.
3. (canceled)
4. The floor panel according to claim 2, wherein the floor panel, in particular the core layer, comprises a second pair of opposite edges, wherein both pairs of opposite edges comprise coupling parts allowing to mutually couple a plurality of floor panels to each other.
5. The floor panel according to claim 1, wherein the core layer comprises one or more of the group consisting of (magnesium sulphate, magnesium chloride, wood fibres).
6. The floor panel according to claim 1, wherein the upper crust layer comprises magnesium sulphate and/or magnesium chloride.
7. (canceled)
8. The floor panel according to claim 1, wherein the upper crust layer comprises wood fibres.
9. The floor panel according to claim 8, wherein the core layer comprises wood fibres, and the weight content of wood fibres in the core layer is larger than the weight content of wood fibres in the upper crust layer.
10. The floor panel according to claim 1, wherein both the core layer and the upper crust layer comprise water, and wherein the weight content of water in the core layer is larger than the weight content of water in the upper crust layer.
11. (canceled)
12. The floor panel according to claim 1, wherein the upper reinforcing layer comprises a fiberglass mesh.
13. The floor panel according to claim 12, wherein the fiberglass mesh has a mesh size of at least 55 mm.
14. The floor panel according to claim 12, wherein the fiberglass mesh has an area weight of at least 90 g/m.sup.2.
15. The floor panel according to claim 1, wherein the fiberglass mesh is provided with a coating.
16. The floor panel according to claim 1, wherein the density of the core layer is between 1000 and 1800 kg/m.sup.3, preferably between 1100 and 1500 kg/m.sup.3, more preferably between 1200 and 1400 kg/m.sup.3.
17. The floor panel according to claim 1, wherein the density of the upper crust layer is between 1100 and 2000 kg/m.sup.3, preferably between 1400 and 1800 kg/m.sup.3, more preferably between 1500 and 1600 kg/m.sup.3.
18. The floor panel according to claim 1, wherein said laminate further comprises: at least one magnesium oxide based lower crust layer positioned underneath the core layer, wherein the density of said at least one lower crust layer is larger than the density of the core layer; and at least one lower reinforcing layer situated in between said core layer and said at least one lower crust layer.
19. The floor panel according to claim 18, wherein the laminate comprises a plurality of lower reinforcing layer stacked on top of each other.
20. The floor panel according to claim 19, wherein the laminate comprises a plurality of lower crust layers, wherein at least one lower crust layer is positioned in between at least two lower reinforcing layers, and wherein at least one lower crust layer is positioned underneath a lowest, lower reinforcing layer.
21. The floor panel according to claim 18, wherein the density of the lower crust layer is between 1100 and 2000 kg/m.sup.3, preferably between 1400 and 1800 kg/m.sup.3, more preferably between 1500 and 1600 kg/m.sup.3.
22. The floor panel according to claim 18, wherein the lower crust layer comprises magnesium sulphate and/or magnesium chloride.
23. The floor panel according to claim 18, wherein the lower crust layer is free of wood fibres.
24. The floor panel according to claim 18, wherein both the core layer and the lower crust layer comprise water, and wherein the weight content of water in the core layer is larger than the weight content of water in the lower crust layer.
25. (canceled)
26. The floor panel according to claim 18, wherein the lower reinforcing layer comprises a fiberglass mesh.
27. The floor panel according to claim 26, wherein the fiberglass mesh has a mesh size of at least 55 mm.
28. The floor panel according to claim 26, wherein the fiberglass mesh has an area weight of at least 90 g/m.sup.2.
29. The floor panel according to claim 26, wherein the fiberglass mesh is provided with a coating.
30. (canceled)
31. (canceled)
32. The floor panel according to claim 1, wherein the laminate comprises a top structure attached, preferably glued, to the upper crust layer, wherein said top structure comprises a decorative layer and a wear layer covering said decorative layer.
33. The floor panel according to claim 1, wherein the laminate comprises a urea-formaldehyde impregnated, decorative paper layer, attached, preferably glued, to the upper crust layer.
34. The floor panel according to claim 18, wherein the density of each crust layer is between 8% and 12% larger, in particular about 10% larger, than the density of the core layer.
35. A method of producing a floor panel, comprising the steps of: A) providing a laminate of: a magnesium oxide based core layer; at least one magnesium oxide based upper crust layer positioned on top of said core layer, wherein the density of said upper crust layer is larger than the density of the core layer; and at least one upper reinforcing layer situated in between said core layer and said at least one upper crust layer; and B) reducing the thickness of at least one upper crust layer by subjecting said upper crust layer to a sanding treatment.
36. The method according to claim 35, wherein during step A) a laminate is provided, which laminate additionally comprises: at least one magnesium oxide based lower crust layer positioned underneath the core layer, wherein the density of said at least one lower crust layer is larger than the density of the core layer; and at least one lower reinforcing layer situated in between said core layer and said at least one lower crust layer; wherein the method also comprises step C) comprising reducing the thickness of at least one lower crust layer by subjecting said upper crust layer to a sanding treatment.
37. (canceled)
Description
[0023] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures. Herein:
[0024] FIG. 1 in top plan view represents a panel, more particularly a floor panel, according to the invention;
[0025] FIGS. 2 and 3, at a larger scale, represent cross-sections according to the lines II-II and in FIG. 1;
[0026] FIGS. 4 and 5 represent how the panels can be interconnected at their long sides;
[0027] FIGS. 6 and 7 represent how the panels fit into each other at their short sides;
[0028] FIG. 8 represents how a plurality of panels from FIG. 1 can be connected to each other;
[0029] FIG. 9, at a larger scale, represents the portion indicated by F9 in FIG. 8;
[0030] FIG. 10 represents a detailed side view of an alternative floor panel according to the invention;
[0031] FIGS. 11a-11c represent successive process steps for manufacturing the panel shown in FIG. 10; and
[0032] FIG. 12 represents a detailed side view of yet another floor panel according to the invention.
[0033] In the represented example shown in FIGS. 1-7, the panel 1 is made as an oblong rectangular strip and thus comprises a first pair of opposite edges 2-3, which in this case form the long sides of the panel 1, and a second pair of opposite edges 4-5, which form the short sides of the panel 1. Typically, the floor panel 1 has a width in the range of 100 to 600 mm and a length in the range of 300 to 2500 mm. As is represented more in detail in FIGS. 2 and 3, both pairs of opposite edges 2-3 and 4-5 comprise coupling parts 6-7, 8-9, respectively, which allow to mutually couple a plurality of such panels 1 to each other. As specifically represented in the FIGS. 4 and 5, coupling parts 6-7 at the first pair of opposite edges 2-3 are configured such that two of such panels can be coupled to each other at these edges 2-3 in a locking manner by means of a turning movement. Herein, the coupling parts 6-7 form a first locking system which effects a locking in the plane of the panels 1 and perpendicularly to said edges 2-3, thus, in this case in the horizontal direction, as well as form a second locking system, which effects a locking perpendicularly to the plane of the panels 1, in this case, thus, in the vertical direction. To this aim, the coupling parts 6-7 are constructed as a tongue 10 and a groove 11, which provide for the vertical locking and comprise locking parts 12-13, which, in the coupled condition, prevent the shifting apart of the tongue and groove. Herein, it is preferred that, as indicated, the groove 11 is limited by a lower lip 14 and an upper lip 15, and that the locking parts 12 and 13 are performed in the form of cooperating projections, at the lower side of the tongue 10 and at the upper side of the lower lip 14, respectively. The cooperation is performed by means of locking surfaces 16 and 17 provided for this purpose. As also represented, it is also preferred that the lower lip 14 extends laterally up to beyond the distal end of the upper lip 15, more particularly such that the locking surface 17 is situated entirely in that portion of the lower lip 14 which is situated beyond the upper lip 15. As schematically represented in FIGS. 6 and 7, the coupling parts 8-9 at the second pair of opposite edges 4-5 are configured such that two of such panels 1 can be coupled to each other by means of a downward movement of one panel in respect to the other. This downward movement will be discussed more detailed below. As is clearly visible in FIG. 7, the coupling parts 8-9 herein also form a first locking system, which effects a locking in the plane of the panels 1 and perpendicular to said edges 4-5, thus, in the case in the horizontal direction, as well as a second locking system, which effects a locking perpendicularly to the plane defined by the panels 1, in this case, thus, the vertical direction. The first locking system is substantially formed of an upwardly directed lower hook-shaped portion 18 situated at the edge 5, as well as of a downwardly directed upper hook-shaped portion 19 which is situated at the opposite edge 4, which hook-shaped portions can be engaged one behind the other by said downward movement. The lower hook-shaped portion 18 consists of a lip 20, which extends laterally from the lower edge of the panel 1 and which is provided with an upwardly directed locking element 21 with a locking surface 22, whereas the upper hook-shaped portion 19 consists of a lip 23, which extends laterally from the upper edge of the panel 1 and which is provided with a downwardly directed locking element 24 with a locking surface 25. The second locking system of the edges at the short sides is formed by locking parts 26-27, which are situated next to the proximal extremity 28 of the lower hook-shaped portion 18 and the distal extremity 29 of the upper hook-shaped portion 19, respectively. The locking parts 26-27 consist of projections engaging one behind the other, which define locking surfaces 30-31. It is noted that the coupling parts 8-9 principally also may be considered a tongue and groove coupling, wherein the locking part 27 functions as a tongue, whereas the groove in which this tongue gets seated, is defined by the locking part 26 functioning as the upper lip, and the first hook-shaped portion 18 functioning as the lower lip. It is noted that the space between the vertically active locking part 26 and the horizontally active locking element 21, which is also indicated by opening H, functions as a female part 32, whereas the locking element 24 is made as a male part 33, which fits into the female part 32. The panel 1 is substantially formed on the basis of magnesium oxide (MgO). More specifically, it comprises a core layer (substrate), which is realized on the basis magnesium oxide, commonly enriched with at least one binder, such as magnesium sulphate and/or magnesium chloride. The core layer is indicated by reference 34 in FIGS. 2-7. In these figures, this substrate is schematically depicted as a single layer. In reality, this may be a single layer as well as several layers, which not all have to comprise magnesium oxide. Usually, a top layer 35 is provided on the core layer 34, which in FIGS. 2-7 also is represented by a single layer, however, in reality also may consist of several layers, typically at least a decorative layer covered by at least one wear layer. The top layer 35 has at least the aim of providing a decorative upper side 36 at the panel 1, preferably in the form of a printed decor and, at least in the case of a floor panel, providing for offering a wear-resistant surface. As indicated in FIG. 7, the panels have a total thickness T. The thickness T preferably has a value situated between 3 and 10 mm. In particular in a practical embodiment, this value will be situated between 4 and 7 mm.
[0034] In FIGS. 8 and 9, it is schematically represented how the panels 1 can be installed. In order to explain the method, a number of the panels 1, in order to differentiate additionally, are indicated by references 1A, 1B, 1C. The panels 1 are laid down row per row and coupled to each other. In order to obtain that the panels are coupled at the edges 2-3 as well as 4-5, the method comprises at least the following steps: installing a first panel 1A intended for forming part of a first row of panels; coupling a second panel 1B to said first panel 1A, such at first edges 2-3, wherein this second panel 1B is intended for forming part of a second row successive to said first row of panels; coupling in the second row a third panel 1C both to said second panel 1B as to the first panel 1A, wherein the third panel 1C is coupled to the first panel 1A by means of a turning movement, wherein the third panel 1C, from an upwardly pivoted position, is brought into substantially the same plane as the first and second panels, whereas, as a result of this movement and the downward movement created therein, the hook-shaped portions 18-19 engage into each other between the third and second panel. It is clear that normally, between installing the first panel 1A and coupling the second panel 1B thereto, first also all further panels of the row in which the first panel 1A is situated, are installed. Coupling the second panel 1B to the first panel 1A also is performed by connecting the panel 1B at its edge 2, by means of a turning movement as represented in FIG. 4, to the edge 3 of the first panel 1A and possible other panels of the row of the panel 1A. When connecting the panel 1C to the panel 1A, also a turning movement, as in FIG. 4, is applied. Herein, a downward movement M is performed at the short edges 4-5, by which the coupling parts 8 and 9 are engaged into each other. By this downward movement M, in a very broad sense each form of movement is meant in which, in a cross-section as seen in FIGS. 6 and 7, the one panel is let down from a higher position in relation to the other. This movement M does not necessarily have to be a rectilinear movement, and during this movement, temporary deformations in the panels and more particularly in the hook-shaped portions 18 and 19 may occur. Theoretically, a downward movement M, which, seen in cross-section, is rectilinear or almost rectilinear, may be used for engaging a panel 1C into a panel 1B, which means that the right-hand panel in FIG. 6, seen in cross-section, simply is pressed straight down into the position of FIG. 7. It is clear that herein effectively small local deformations will occur, as the locking parts 26 and 27 have to be pressed home one behind each other by means of a snap effect. Herein, the snap effect is obtained by (some) elasticity of the magnesium oxide based material of the core layer 34 and the bending actions in the component parts and compressions in the material occurring as a result thereof.
[0035] FIG. 10 shows a detailed side view of an alternative floor panel 40 according to the invention, though which may be the same floor panel 1 as shown in FIGS. 1-9. Floor panel 40 comprises a laminate of layers stacked onto each other, wherein said laminate comprises, from bottom to top, the following layers: [0036] a backing layer 41, [0037] a lower crust layer 42, [0038] two lower fibreglass meshes 43a, 43b, [0039] a core layer 44, [0040] an upper fibreglass mesh 45, [0041] an upper crust layer 46, and [0042] a top layer 47 and/or top structure 47.
[0043] The backing layer 41 may be composed of paper, in particular resin impregnated paper. Here, melamine resin-impregnated paper is preferably used. A backing layer 41 is helpful in providing an optimum interface between the panel and the underlying surface on which the panels are applied. The crust layers 42, 46 have a higher density compared to the density of the core layer 44, which provide rigidity to the floor panel 40. Moreover, this allows, in combination with the fibreglass meshes 43a, 43b, 45, acting as reinforcement layers, sanding (sandblasting) of the crust layers 42, 46 during production. The crust layers 42, 46 and the core layer 44 comprise magnesium oxide, a binder, such as magnesium chloride and/or magnesium sulphate, and additives. A typical composition of the three layers is given below.
TABLE-US-00001 Layer Material Ratio Upper crust Magnesium Oxide 13.4% layer 46 Magnesium sulphate 5.4% heptahydrate Water 6.0% Modifier aluminium 0.1% sulphate Fly ash 4.7% Wood fibres 1.1% Core layer 44 Magnesium Oxide 13.4% Magnesium sulphate 5.4% heptahydrate Water 10.7% Modifier aluminium 0.1% sulphate Fly ash 4.7% Wood fibres 4.7% Lower crust Magnesium Oxide 13.4% layer 42 Magnesium sulphate 5.4% heptahydrate Water 6.7% Modifier aluminium 0.1% sulphate Fly ash 4.7%
[0044] The top layer 47 may consist of one or more layers, and may include a urea-aldehyde resin impregnated decorative paper layer, being attached, preferably by means of one or more glues, to the upper crust layer 46. As shown in FIG. 10 a pair of opposite side edges of the floor panel 40 is provided with complementary coupling parts, in particular a male coupling part 48 and a complementary female coupling part 49, allowing panels to be interconnected, as discussed extensively above. The remaining edges (not shown) of the floor panel 40 may be provided with the same and/or an alternatively shaped set of coupling parts. The male coupling part 48, having the shape of a tongue, is composed of core material, and also includes the upper fibreglass mesh 45. Optionally, a thinned (sanded) part of the upper crust layer 46 may also be included in the male coupling part 40. The female coupling part 49 constitutes a groove configured to accommodate a complementary tongue of an adjacent floor. Said groove is enclosed by an upper lip 49a formed by the upper crust layer 46 and the top layer 47, and a lower lip 49b formed by the core layer 44, both lower fibreglass meshes 43a, 43b and the backing layer 41. The lower part of the groove is formed within the core layer 44, at a distance from the lower fibreglass meshes 43a, 43b. The distance between the lower fibreglass meshes 43a, 43b may be zero, though it is also imaginable that the meshes 43a, 43b are positioned at a distance from each other, wherein material of the lower crust layer 42 is positioned in between both meshes 43a, 43b.
[0045] In FIGS. 11a-11c successive method steps for manufacturing the floor panel 40 as shown in FIG. 10 are shown. In FIG. 11a a starting laminate with a originally, relatively thick upper crust layer 46 is shown. Typically this upper crust layer 46 is applied as slurry (paste) on top of the upper mesh 45 positioned on top of the core layer 44. By means of known high-precision sandblasting equipment 50, the thickness of the upper crust layer 46 is reduced by removing material from said upper crust layer 46 until a desired panel thickness is achieved (FIG. 11b). Subsequently, shown in FIG. 11c the top layer 47 is applied, preferably by gluing on top of the upper crust layer 46, resulting in the final floor panel 40 as shown in FIG. 10. Optionally, also the lower crust layer 42 could be subjected to a sanding treatment (prior to applying the backing layer 41), which provides more flexibility and freedom in adjusting the panel thickness based upon a (uniform, and typically oversized) starting laminate.
[0046] FIG. 12 shows a detailed side view of yet another floor panel 51 according to the invention, though which (also) may be the same floor panel 1 as shown in FIGS. 1-9. Floor panel 51 comprises a laminate of layers stacked onto each other, wherein said laminate comprises, from bottom to top, the following layers: [0047] a first lower crust layer 52, [0048] a first lower fibreglass mesh 53 [0049] a second lower crust layer 54, [0050] a second lower fibreglass mesh 55, [0051] a core layer 56, [0052] an upper fibreglass mesh 57, [0053] an upper crust layer 58, [0054] a PVC sublayer 59, and [0055] a PVC top layer 60 or top structure 60.
[0056] In this embodiment, the PVC top layer 60 consists of a PVC dcor layer covered by a PVC wear layer. The PVC sublayer 59 is preferably free of any plasticizer. The sublayer 59 is positioned between the core layer 56 and the top layer 60 in order to reach a desired effect such as sound improvement, indentation resistance improvement. The composition of the other layers 52-58 may be identical to the equivalent layers shown in FIG. 10. The distance between both lower meshes 53, 55 is about 1 mm. As shown in FIG. 12 a pair of opposite side edges of the floor panel 51 is provided with complementary coupling parts, in particular a male coupling part 61 and a complementary female coupling part 62, allowing panels to be interconnected, as discussed extensively above. The remaining edges (not shown) of the floor panel 51 may be provided with the same and/or an alternatively shaped set of coupling parts. The male coupling part 61, having the shape of a tongue, is composed of the core layer 56, the upper fibreglass mesh 57, and the upper crust layer 58. The female coupling part 62 constitutes a groove configured to accommodate a complementary tongue of an adjacent floor. Said groove is enclosed by an upper lip 62a formed by the upper crust layer PVC sublayer 59 and the top layer 60, and a lower lip 62b formed by the core layer 56, both lower fibreglass meshes 53, 55, and the first and second lower crust layers 52, 54. The lower part of the groove is formed within the core layer 44, at a distance from the lower fibreglass meshes 43a, 43b to secure sufficient rigidity and strength of the female coupling part 62. The floor panel 51 shown in FIG. 12 is waterproof, fire-resistant, and rigid.
[0057] 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.
[0058] 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.
[0059] 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.
