Floor element for forming a floor covering, a floor covering, and a method for manufacturing a floor element

Abstract

A floor element for forming a floor covering, wherein the floor element comprises a decorative layer made of a ceramic material and a support layer arranged below this decorative layer, wherein the support layer comprises edges provided with coupling elements configured to allow a mechanical coupling with coupling elements of an adjacent floor element and wherein the floor element comprises an intermediate layer having a resin material that permeates a lower surface of the decorative layer.

Claims

1. A floor element for forming a floor covering, wherein the floor element comprises: a decorative layer made of a ceramic material; and a support layer arranged below the decorative layer, wherein the support layer comprises edges provided with coupling elements configured to allow a mechanical coupling with coupling elements of an adjacent floor element, and wherein the floor element comprises an intermediate layer comprising a resin material having a viscosity below 1000 Pas at 20 C. that permeates a lower surface of the decorative layer.

2. The floor element according to claim 1, wherein the resin material comprises epoxy.

3. The floor element according to claim 1, wherein the resin material has a viscosity below 800 Pas at 20 C.

4. The floor element according to claim 1, wherein the intermediate layer covers 80 percent or more of the lower surface of the decorative layer.

5. The floor element according to claim 1, wherein the intermediate layer comprises a resin content of at least 150 g/sqm.

6. The floor element according to claim 1, wherein the intermediate layer is an adhesive layer that bonds together the decorative layer and the support layer.

7. The floor element according to claim 1, wherein the decorative layer has an apparent porosity comprised between 0.1% and 10% measured according to ASTM C373.

8. The floor element according to claim 1, wherein the decorative layer has a volume of open pores comprised between 0.01 cc and 1 cc measured according to ASTM C373.

9. The floor element according to claim 1, wherein the decorative layer comprises a red body ceramic tile.

10. The floor element according to claim 1, wherein the decorative layer comprises a glazed upper surface.

11. The floor element according to claim 1, wherein the support layer comprises rigid polyvinylchloride (PVC).

12. The floor element according to claim 1, wherein the support layer has a flexural modulus between 1.5 and 3.5 GPa.

13. The floor element according to claim 1, wherein the support layer has a thickness of 6 mm or less.

14. A floor covering comprising a plurality of floor elements according to claim 1.

15. A method for manufacturing a floor element, comprising the steps of: providing a decorative layer made of a ceramic material; providing a support layer; providing a resin material for bonding the decorative layer and the support layer together; and pressing the layers together for forming the floor element such that the resin material permeates the ceramic layer, wherein the resin material has a viscosity below 1000 Pas at 20 C.

16. The method of claim 15, wherein the pressing step comprises a pressing time of at least 1 second.

17. The method of claim 15, wherein during the pressing step a pressure of at least 350 kg/sqm is exerted onto the layers.

18. A resin material for bonding together a decorative layer made of a ceramic material and a support layer to form a floor element according to claim 1, wherein the resin material comprises epoxy having a viscosity below 1000 Pas at 20 C.

19. A floor element comprising: a decorative layer made of a ceramic material; and a support layer arranged below the decorative layer, wherein the support layer comprises at least two couples of opposite edges, wherein the opposite edges comprise coupling elements configured to allow a mechanical coupling with coupling elements of adjacent floor elements, wherein the first coupling elements at the first couple of opposite edges are configured for being coupled to the coupling elements of adjacent floor elements by means of an angling motion around a horizontal axis parallel to the respective edges, wherein the second coupling elements at the second couple of opposite edges are configured for being coupled to the coupling elements of adjacent floor elements by means of a translational downward direction of the respective edges towards each other, and wherein the floor element further comprises an intermediate layer comprising a resin material having a viscosity below 1000 Pas at 20 C. that permeates a lower surface of the decorative layer.

20. The floor element according to claim 19, wherein in the coupled condition, said first coupling elements are coupled with play.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) With the intention of better showing the characteristics of the invention, in the following, as an example without any limitative character, several preferred forms of embodiments are described with reference to the accompanying drawings, wherein:

(2) FIG. 1 shows a top view of an embodiment of a floor element of the invention;

(3) FIG. 2 on a larger scale shows a cross section along the line II-II of FIG. 1;

(4) FIG. 3 on a larger scale shows a view on the area F3 indicated on FIG. 2;

(5) FIG. 4 on a larger scale shows a cross section along the line IV-IV of FIG. 1;

(6) FIG. 5 on a smaller scale shows a top plane view of a floor covering comprising a plurality of the floor elements of FIG. 1;

(7) FIG. 6 on a larger scale shows a cross section along the line VI-VI of FIG. 5;

(8) FIG. 7 on a larger scale shows a view on the area F7 indicated on FIG. 6;

(9) FIG. 8 on a larger scale shows a cross section along the line VIII-VIII of FIG. 5;

(10) FIG. 9 on a larger scale shows a view on the area F9 indicated on FIG. 8;

(11) FIG. 10 shows some step of a method for manufacturing a floor element.

DETAILED DESCRIPTION

(12) To facilitate an understanding of the principles and features of the various embodiments of the invention, various illustrative embodiments are explained below. Although exemplary embodiments of the invention are explained in detail as being systems and methods for cleanable and slip resistant tile, it is to be understood that other embodiments are contemplated, such as embodiments employing other types of surfaces, coatings, tiles, or tile manufacturing methods. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or examples. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the exemplary embodiments, specific terminology will be resorted to for the sake of clarity.

(13) It must also be noted that, as used in the specification and the appended claims, the singular forms a, an and the include plural references unless the context clearly dictates otherwise. For example, reference to a component is intended also to include composition of a plurality of components. References to a composition containing a constituent is intended to include other constituents in addition to the one named. In other words, the terms a, an, and the do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

(14) As used herein, the term and/or may mean and, it may mean or, it may mean exclusive-or, it may mean one, it may mean some, but not all, it may mean neither, and/or it may mean both. The term or is intended to mean an inclusive or.

(15) Also, in describing the exemplary embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. It is to be understood that embodiments of the disclosed technology may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to one embodiment, an embodiment, example embodiment, some embodiments, certain embodiments, various embodiments, etc., indicate that the embodiment(s) of the disclosed technology so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase in one embodiment does not necessarily refer to the same embodiment, although it may.

(16) Ranges may be expressed herein as from about or approximately or substantially one particular value and/or to about or approximately or substantially another particular value. When such a range is expressed, other exemplary embodiments include from the one particular value and/or to the other particular value.

(17) By comprising or containing or including is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.

(18) It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a composition does not preclude the presence of additional components than those expressly identified.

(19) The materials described as making up the various elements of the invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, for example, materials that are developed after the time of the development of the invention.

(20) FIG. 1 shows a top view of an embodiment of a floor element 1 according to the invention. The floor element 1 comprises a decorative layer 2 disposed above a support layer 3.

(21) As illustrated, the floor element 1 comprises a rectangular elongated shape. Preferably, the floor element 1 comprises a superficial area of less than 1.5 sqm, preferably less than 1 sqm, more preferably less than 0.4 sqm. For example, the decorative layer 2 comprises edges having a maximum length L of less than 1.5 m, preferably less than 0.9 m.

(22) The decorative layer 1 has an upper face 4 comprising a dcor 5. The dcor 5 can be provided with a variety of textures, designs and colors. In the illustrated example the dcor simulates a wood pattern comprising wood nerves and flakes. Preferably, the dcor 5 is at least partially formed by a print 6. The print 6 is preferably realized by means of digital printing, such as inkjet printing, although screen printing, rotogravure, flexography or off-set printing is not excluded.

(23) FIG. 2 on a larger scale shows a cross section along the line II-II of FIG. 1.

(24) According to the illustrated example the decorative layer 2 comprises a body 7 made of a ceramic material, for example red body ceramic or porcelain.

(25) The decorative layer 2 comprises a background coating 8 covering at least partially the upper surface of the body 7, for example comprising at least a glaze. The background coating 8 is adapted to receive the dcor 5 on its top, for example adapted to receive the print 6 on its top. The background coating 8 can be white, beige, brown or of any color suitable to receive the dcor 7 on its top.

(26) The decorative layer 2 further comprises a protective coating 9 covering at least partially the upper surface of the body 7, for example comprising at least a glaze. The protective coating 9 is adapted to be placed above the dcor 5 and is transparent or translucent.

(27) FIG. 2 also shows that decorative layer 2 has a thickness T1 comprised between 4 and 15 mm, for example 6 mm, preferably above 7 mm, for example 8 or 10 mm.

(28) The support layer 3, according to the example, is made of a polymeric material, preferably a thermoplastic material like PVC. In a preferred embodiment, the support layer is made of a rigid PVC. Within the context of the present description, rigid means that the support layer, taken alone, bends under the own weight thereof less than 10 cm per meter and still better less than 5 cm per meter. The support layer 3 may also comprise a high amount of filler materials, such as chalk, e.g. more than 30 wt % or more than 60% wt of such filler materials.

(29) Moreover, according to the preferred embodiment, the support layer 3 is made of a rigid PVC that may comprise a flexural modulus between 1.5 and 3.5 GPa, for example, approximately 2.6 GPa. The support layer 3 may also comprise a flexural strength between 60 and 90 MPa, for example approximately 76 MPa. Moreover, the support layer 3 may comprise a compressive strength between 40 and 70 MPa, for example approximately 56 MPa.

(30) Furthermore, the support layer 3 preferably has a thickness T2 comprised between 2 and 7 mm, preferably below 6 mm, more preferably about 4 mm or less.

(31) FIG. 2 also shows that the support layer 3 comprises longitudinal edges 10 provided with first coupling elements 11,12 configured to realize a mechanical coupling with coupling elements 11,12 of an adjacent floor element 1. In the illustrated examples the coupling elements 11,12 comprise a male and female parts disposed on opposite longitudinal edges 10.

(32) The first coupling elements 11,12 of the longitudinal edges 10 are configured for being coupled each other by means of an angling motion around a horizontal axis parallel to the longitudinal edges 10. The male and female parts are respectively shaped in form of a tongue 11 and a groove 12 wherein the tongue 11 projects outwardly beyond its respective longitudinal edge 10 in a horizontal direction X and the groove 12 projects inwardly with respect to the respective longitudinal edge 10 in said horizontal direction.

(33) The support layer 3 extends beyond longitudinal edges 26 of the decorative layer 2. In the example, the support layer 3 comprises upper longitudinal edges 27 that extend beyond the longitudinal edge 26 of the decorative layer 2 of a distance D1. Said distance D1 is equal on both the opposite longitudinal edges 26 of the decorative layer 2.

(34) FIG. 2 further shows that the floor element 1 comprises an intermediate layer 13 disposed between the decorative layer 2 and the support layer 3. The intermediate layer 13 comprises a resin material, for example a thermosetting resin or thermoplastic resin. Examples of thermosetting resin are epoxy, polyurethane, cyanoacrylate or acrylic resin. Examples of thermoplastic resin are hot melt, polyester thermoplastic, vinyl etc. Preferably the resin is a rigid resin. In particular, according to the preferred embodiment of the invention the intermediate layer comprises an epoxy resin. It is also preferred that the epoxy is a bicomponent resin, i.e. a thermosetting resin obtained by curing at low temperature (for example at room temperature) a mixture of two components, namely a resin and a hardener.

(35) The resin preferably comprises a tensile strength between 50 and 90 MPa, more preferably between 60 and 80 MPa, for example 75 MPa. Moreover, the resin preferably comprises a compressive strength between 90 and 130 MPa, more preferably between 100 and 120 MPa, for example 110 MPa. It is also preferable that the resin shows a hardness value of at least 50 measured on a Shore D scale.

(36) As illustrated the intermediate layer 13 covers the 100 percent of the lower surface of the decorative layer 2. The resin is preferably provided onto the lower surface of the decorative layer 2 in an amount above 150 g/sqm, more preferably above 200 g/sqm, for example 220 g/sqm.

(37) In the preferred example illustrated in FIG. 2, the intermediate layer 13 is in direct contact with the upper surface of the support layer 3 so that act as a glue between the decorative layer 2 and the support layer 3.

(38) FIG. 3 on a larger scale shows a view on the area F3 indicated on FIG. 2. As illustrated in FIG. 3 the decorative layer 2, more in detail the body 7 thereof, comprises, at least in correspondence of its lower surface, an open porosity 14 adapted permeated by the resin of the decorative layer 2 itself.

(39) Thus, according to a preferred embodiment of the invention the decorative layer 2 comprises an apparent porosity between 0.1% and 10% determined according to ASTM C373, more preferably between 2% and 8%, for example 6%. Furthermore, the decorative layer may preferably have a volume of the open pores 14 comprised between 0.01 cc (cubic centimeter) and 1 cc, more preferably between 0.10 cc and 0.90 cc, for example 0.60 cc.

(40) Therefore, in order to properly flow into said open pores 14 the resin comprises a viscosity at 20 C. below 1000 Pas, preferably below 800 Pas, more preferably below 600 Pas, for example approximately 400 Pas. Within the scope of the invention viscosity means the viscosity of the uncured resin, for example the viscosity of the mixture of the two components before the completion of the curing, i.e. during the so-called pot life.

(41) FIG. 4 shows on a larger scale shows a cross section along the line IV-IV of FIG. 1. According to the embodiment the support layer 3 comprises transversal edges 15 provided with second coupling elements 16, 17 configured to realize a mechanical coupling with second coupling elements 16, 17 of an adjacent floor element 1.

(42) In the illustrated examples the second coupling elements 16, 17 are different from the first coupling elements 11, 12 of the longitudinal edges 10. The second coupling elements 16, 17 of the transversal edges 15 are configured for being coupled each other by means of a translational movement along a substantially vertical direction. In the illustrated examples, said second coupling element 16, 17 are configured for being coupled by means of a translational motion in a downward, e.g. vertical, direction Y.

(43) The support layer 3 extends beyond transversal edges 28 of the decorative layer 2. In the example, the support layer 3 comprises upper transversal edges 29 that extend beyond the transversal edge 28 of the decorative layer 2 of a distance D2. Said distance D2 is equal on both the opposite edges 28 of the decorative layer 2. Moreover, in said preferred example, said distance D2 is equal to the distance D1.

(44) FIG. 5 is a top plane view of a floor covering 18 comprising a plurality of floor elements 1 coupled by means of the first coupling elements 11,12 along the longitudinal edges 10 and by means of the second coupling elements 16,17 along the transversal edges 15.

(45) FIG. 6 on a larger scale shows a cross section along the line VI-VI of FIG. 5. The floor covering 18 comprises a grout 19 filling an intermediate distance I separating the decorative layers 2 of the floor elements 1. According to the illustrated example, the intermediate distance I is twice the distance D1 between the upper edge of the support layer 3 and the edge of the decorative layer 3.

(46) The grout 19 is preferably made of a polymeric material. The grout 19 may be a flexible or rigid grout. A flexible grout 19 may be for example a silicone-based grout whereas a rigid grout may be for example an epoxy-based grout or cement-based grout.

(47) FIG. 6 further shows a section of the mechanical coupling between the firsts coupling elements 11,12 along a plane transversal to the longitudinal edges 10. Said mechanical coupling between the firsts coupling elements 11,12 is described in detail with the aid of FIG. 7.

(48) FIG. 7 on a larger scale shows a view on the area F7 indicated on FIG. 6. According to the preferred example illustrated in FIG. 7, the tongue 11 comprises a horizontal extending lip 20 and a downward projecting hump 21. The groove 12 has a horizontal recess 22, for receiving the lip 20 of the tongue 11, and an upward oriented hollow portion 23, for receiving the hump 21 of the tongue 11, so that tongue 11 can be fitted into the groove 12.

(49) In the coupled condition shown in FIG. 7 the upper edges 27 of the support layers 3 contact each other thereby forming a first set of first locking surfaces 24 limiting the mutual movement of said floor elements 1 in a horizontal direction X perpendicular to the coupled longitudinal edges 10.

(50) FIG. 7 also shows that in said coupled condition, the lip 20 is received by the recess 22. The upper surface of the lip 20 contacts un upper wall of the recess 22 thereby forming a first set of second locking surfaces 25 are formed limiting the mutual movement of said floor elements 1 in a substantially vertical direction Y. It is noted that between the tip of the lip 20 and the bottom of the recess 22 is established a horizontal inoperative space S1. Moreover, between lower surface of the lip 20 and the recess 22 is established a vertical inoperative space S2.

(51) The downward projecting hump 21 of the tongue 11 is received by the hollow portion 23 of the groove 12. The lower surface of the downward projecting hump 21 contacts said hollow portion 23 so that a second set of second locking surfaces 25 is formed. In other words, the lower surface of the tongue 16 contacts the groove 12 exclusively in correspondence of the downward projecting hump 21.

(52) In the coupled condition, of FIG. 7, between the projecting hump 21 and the hollow portion 23 is formed a horizontal play P that allows tiny horizontal movement of the tongue 11 into the groove 12. Said play P and said tiny horizontal movements are limited by a set of first contact surface that may be formed between the projecting hump 21 and the hollow portion 23.

(53) Preferably, said play P is larger than 0.01 mm, preferably larger than 0.03 mm. Moreover, said play P is preferably smaller than 0.10 mm, for example smaller than 0.08 mm.

(54) It is noted that in the coupled condition the tongue 11 and the groove 12 are in an undeformed condition. Further, the whole angling movement that allows the coupling between the tongue 11 and the groove 12 occur without deformation of the first coupling elements 11,12. In fact thank to the play P and the inoperative spaces S1, S2 the coupling between the tongue 11 and the groove 12 is significantly simplified.

(55) FIG. 8 on a larger scale shows a cross section along the line VIII-VIII of FIG. 5. FIG. 8 shows a section of the mechanical coupling between the second coupling elements 16,17 along a plane transversal to the transversal edges 15. Said mechanical coupling between the second coupling elements 16,17 is described in detail with the aid of FIG. 9.

(56) FIG. 9 on a larger scale shows a view on the area F9 indicated on FIG. 8.

(57) The second coupling element elements 16,17 comprise downward-directed upper hook-shaped part 16 is situated on one transversal edge 15 and d upward-directed lower hook-shaped part 17, which is situated on the opposite edge 15. The lower hook-shaped part 17 defines an upward directed cavity forming a female part, whereas the upper hook-shaped part 16 defines a downward-directed lip forming a male part.

(58) Once in a coupled position the downward-directed lip and the upward-directed cavity form the first locking surface 24 for limiting mutual movement of the floor elements 1 in a horizontal direction Z perpendicular to the transversal edge 15.

(59) Moreover, both the upper hook-shaped part 16 and the lower hook shaped part 17 comprise undercut 30 portions so that in the coupled condition the second locking surfaces 25 are formed to limit the mutual movement of the floor elements 1 in the vertical direction Y. More in particular, two sets of said second locking surfaces 25 are formed, for example on opposite sides of the male part and the female part.

(60) Preferably, the lower hook shaped part 17 comprise a flexible lever portion 31 configured to be deformed by the coupling off the upper hook-shaped part 16 lower hook shaped part 17 so that by means of said deformation it is possible the coupling of the undercut portions 30.

(61) FIG. 10 shows some steps of a method for manufacturing a floor element. The method comprises a first step S1 of providing the decorative layer 2. In the step S1 the decorative layer 2 is provided into a resin application station 40 wherein the uncured resin material R is provided, for example according to a pattern, onto a lower surface of the decorative layer 2. The uncured resin R preferably comprises a viscosity at 20 C. lower than 1000 Pas, preferably below 800 Pas, more preferably below 600 Pas, for example approximately 400 Pas. It is noted that in the resin application station 40 the decorative layer is placed with the upper surface, comprising the dcor 6, facing down.

(62) Then, in a step S2 the decorative layer 2 is carried into a placing station 41 wherein the support layer 3 is provided. The support layer 2 is placed below the lower surface decorative layer 3 thereby forming a semi-finished sandwich 42. Preferably, in said placing station 41 the decorative layer 2 and the support layer 2 are properly centered each other.

(63) Successively, in a step S3 the semi-finished sandwich 42 is carried into a pressing station 43 wherein the layers 2,3 are pressed together for forming the floor element 1 such that the resin material permeates the pores of the ceramic material of the decorative layer 2 and forms the intermediate layer 13. Preferably, the pressure is kept for a pressing time of at least 1 second, preferably 30 seconds so that the uncured resin R can flow covering, at least the 80%, preferably the 100% of the lower surface of the decorative layer 2. Moreover, said pressing time is necessary to let the uncured resin R permeates the decorative layer 2. Preferably, during step S4 it is exerted onto the layers a pressure of at least 350 kg/sqm.

(64) Then in a step S4 pressed floor element 1 is then carried into a stocking station 44 wherein for a predetermined stocking time in order to allow the resin R to continue curing before being, packaged, transported and/or used in a floor covering. Preferably the stocking time is such to allow the resin R to be at least 70% cured, preferably 85% cured, more preferably fully cured. For example, said stocking time is at least 0.5 h, preferably more than 1 h, for example 2 h.

(65) The present invention is in no way limited to the hereinabove described embodiments, but such floor elements may be realized according to different variants without leaving the scope of the present invention.

(66) Further, as is clear from the content of the description, the present invention relates to one or more of the items as listed below, numbered from 1 to 28:

(67) 1.A floor element for forming a floor covering, wherein this floor element comprises a decorative layer made of a ceramic material and a support layer arranged below this decorative layer, wherein the support layer comprises edges provided with coupling elements configured to realize a mechanical coupling with coupling elements of an adjacent floor element and wherein the floor element comprises an intermediate layer having a resin material that permeates a lower surface of the decorative layer.

(68) 2.The floor element according to item 1, wherein the resin material comprises epoxy.

(69) 3.The floor element according to any of the preceding items, wherein the resin material has a viscosity at 20 C. below 1000 Pas.

(70) 4.The floor element according to any of the preceding items, wherein the intermediate layer covers 80 percent or more of the lower surface of the decorative layer.

(71) 5.The floor element according to any of the preceding items, wherein the intermediate layer comprises a resin content of at least 150 g/sqm.

(72) 6.The floor element according to any of the preceding items, wherein the intermediate layer is an adhesive layer that bonds together the decorative layer and the support layer.

(73) 7.The floor element according to any of the preceding items, wherein the decorative layer has an apparent porosity comprised between 0.1% and 10% measured according to ASTM C373.

(74) 8.The floor element according to any of the preceding items, wherein the decorative layer has volume of open pores comprised between 0.01 cc and 1 cc measured according to ASTM C373.

(75) 9.The floor element according to any of the preceding items, wherein the decorative layer comprises a red body ceramic tile.

(76) 10.The floor element according to any of the preceding items, wherein the decorative layer comprises a glazed upper surface.

(77) 11.The floor element according to any of the preceding items, wherein the support layer comprises rigid PVC.

(78) 12.The floor element according to any of the preceding items, wherein the support layer has a flexural modulus between 1.5 and 3.5 GPa.

(79) 13.The floor element according to any of the preceding items, wherein the support layer has a thickness below 6 mm.

(80) 14.A floor covering comprising a plurality of floor elements according to any of the preceding items.

(81) 15.A method for manufacturing a floor element, comprising the steps of: providing a decorative layer made of a ceramic material; providing a support layer; providing a resin material for bonding the decorative layer and the support layer together; pressing the layers together for forming the floor element such that the resin material permeates the ceramic layer.

(82) 16.The method of item 15, wherein the pressure is kept for a pressing time of at least 1 second, preferably 30 seconds.

(83) 17.The method according to any of the items 15 or 16, wherein during the pressing step it is exerted onto the layers a pressure of at least 350 kg/sqm.

(84) 18.Use of a resin material for bonding together a decorative layer made of a ceramic material and a support layer to form a floor element, the resin material having a viscosity at 20 C. below 1000 Pas.

(85) 19.Use of a resin material according to item 18, wherein the resin material is epoxy.

(86) 20.A floor element comprising a decorative layer made of a ceramic material, and a support layer arranged below the decorative layer, wherein the support layer at at least two couples of opposite edges comprises coupling elements configured to realize a mechanical coupling with coupling elements of adjacent floor elements, wherein first coupling elements at a first couple of edges are configured for being coupled to the coupling elements of adjacent floor elements by means of an angling motion around a horizontal axis parallel to the respective edges, and wherein second coupling elements at a second couple of edges are configured for being coupled to the coupling elements of adjacent floor elements by means of an translational downward direction of the respective edges towards each other.

(87) 21.Floor element according to item 21, wherein the decorative layer has density as expressed by surface weight of at least 10 kg/sqm, preferably above 15 kg/sqm.

(88) 22.Floor element according to any of the items 20 or 21, wherein the firsts and the second coupling elements are configured such that said mechanical coupling results in a locking between said edges in vertical and/or one or more horizontal directions.

(89) 23.Floor element according to any of the items from 20 to 22, wherein in the coupled condition, said first coupling elements are coupled with play.

(90) 24.Floor element according to item 23, wherein said play is such that the first coupling elements may be coupled each other without being deformed.

(91) 25.Floor element according to any of the items 23 or 24, wherein said play is larger than 0.01 mm and smaller than 0.10 mm.

(92) 26.Floor element according to any of the items from 20 to 25, wherein said second coupling elements are deformed during the relative coupling movement.

(93) 27.A floor element comprising a decorative layer having density as expressed by surface weight of at least 10 kg/sqm, preferably above 15 kg/sqm, and a support layer arranged below the decorative, wherein the support layer at at least two couples of opposite edges comprises coupling elements configured to realize a mechanical coupling with coupling elements of adjacent floor elements, wherein first coupling elements at a first couple of edges are configured for being coupled to the coupling elements of adjacent floor elements by means of an angling motion around a horizontal axis parallel to the respective edges, and wherein second coupling elements at a second couple of edges are configured for being coupled to the coupling elements of adjacent floor elements by means of an translational downward direction of the respective edges towards each other.

(94) 28.Floor element according to item 27, wherein the decorative layer is made of ceramic, natural stone, concrete, quartz, artificial stone, glass or glass-ceramic material.

(95) While certain systems and methods related to composite tile systems and methods have been disclosed in some exemplary forms, many modifications, additions, and deletions may be made without departing from the spirit and scope of the system, method, and their equivalents. The embodiments disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting the claims.

(96) Accordingly, those skilled in the art will appreciate that the conception upon which the application and claims are based may be readily utilized as a basis for the design of other devices, methods, and systems for carrying out the several purposes of the embodiments and claims presented herein. It is important, therefore, that the claims be regarded as including such equivalent constructions.