Decorative Panel, in Particular a Wall, Ceiling or Floor Panel, and a Covering Constructed by a Multitude of Such Panels

Abstract

Panel, in particular a wall, ceiling or floor panel, of a planar design having a top side, a bottom side and side edges, which panel is constructed from a laminate structure of layers that are adhered to each other, wherein the layers include a core layer, a decorative layer which includes a decorative image on its upper side, which decorative layer is provided directly or indirectly on an upper side of the core layer, and -a top coat layer that is transparent and includes a layer of transparent matrix material, which top coat layer is provided directly or indirectly on an upper side of the decorative layer.

Claims

1. A decorative panel, in particular a wall, ceiling or floor panel, of a planar design having a top side, a bottom side and side edges, which panel is constructed from a laminate structure of layers that are adhered to each other, wherein the layers include: at least one core layer, at least one decorative layer which comprises a decorative image, which decorative layer is affixed, either directly or indirectly, on an upper side of the core layer, and at least one substantially transparent top coat layer, affixed, either directly or indirectly, on an upper side of the decorative layer, wherein said top coat layer comprises an at least partially, preferably substantially, transparent matrix material, and a plurality of chips dispersed in said matrix material, wherein the chips have light-interacting properties and comprise one or more of the following types of chips: light reflective chips that have an outer surface of light reflective material, such that preferably more than 50% of incident light is reflected; and/or light absorbing chips that have an outer surface of light absorbing material, such that preferably more than 50% of incident light is absorbed; and/or substantially transparent chips that are made from a substantially transparent material which is preferably transparent for more than 50% of incident light, and which has a different refractive index than the matrix material.

2. The panel according to claim 1, wherein the chips are shaped as non-spheroid particles including rectangular or polyhedral particles, and/or flake-formed particles.

3. The panel according to claim 1, wherein the chips are composed of a composite material, which composite material preferably comprises at least one polymeric material and at least one non-polymeric material.

4. The panel according to claim 1, wherein the chips comprises at least one polymeric material and at least one light reflective non-polymeric flake

5. The panel according to claim 4, wherein the light reflective non-polymeric flake is at least partially composed of a material chosen from the group consisting of: mica, metal, metal oxide, a non-metal, pearls, and glass flakes, in particular quartz glass flakes

6-9. (canceled)

10. The panel according to claim 4, wherein said chips additionally comprises at least one filler dispersed in said polymeric material, wherein said filler selected from the group consisting of: aluminium hydroxide, magnesium hydroxide, calcium hydroxide, zirconium hydroxide, aluminium, calcium carbonate, magnesium oxide, titanium oxide, barium sulphate, silica, quartz, talc, clay, diatomaceous earth, gypsum, powder glass, montmorillonite, bentonite, pyrophyllite, kaolin, powder chalk, marble, limestone, asbestos, mullite, aluminium silicate, aluminium stearate, calcium silicate, anhydrite, -cristobalite, and alumina white.

11. The panel according to claim 4, wherein said composite material comprises a laminate of a first layer based upon said at least one polymeric material, and a second layer based upon at least one light reflective non-polymeric flake

12. The panel according to claim 1, wherein the chips comprises a cured composition comprising a binder at least partially composed of a halogenated alkoxylated diacrylate oligomer and/or halogenated alkoxylated dimethacrylate oligomer.

13. (canceled)

14. The panel according to claim 1, wherein the difference in specific gravity between the chips and the matrix material is less than 0.5 g/cm3.

15. The panel according to claim 1, wherein the chips have a specific gravity of 1.43 to 1.77 g/cm3.

16. The panel according to claim 1, wherein the matrix material has a specific gravity of 1.50 to 1.85 g/cm3.

17. The panel according to claim 1, wherein the specific gravity difference between the matrix material and the chips is 1.85 g/cm3 or less

18. (canceled)

19. The panel according to claim 1, wherein the chips are crushed chips

20. (canceled)

21. The panel according to claim 1, wherein the at least partially transparent matrix material of the top coat layer comprises a polymeric material, in particular a vinyl polymer and/or a thermosetting polymer material, such as melamine-formaldehyde or polyurethane; and at least one non-polymeric additive selected from the group consisting of: aluminium oxide, aluminium hydroxide, barium, precipitated calcium carbonate, stone powders, silica, titanium dioxide, calcium carbonate, metal powder, and a metal salt

22. The panel according to claim 1, wherein the top coat layer, in particular the matrix material, comprises at least one semi-transparent and/or opaque zone.

23-25. (canceled)

26. The panel according to claim 1, wherein the chips are positioned in the transparent matrix material such that their position is in correspondence with the decorative image of the decorative layer.

27-29. (canceled)

30. The panel according to claim 1, wherein the light reflective chips are positioned in correspondence with image parts of the decorative image that are: image parts of a light colour, and/or image parts that depict an elevated zone of a depicted relief structure.

31. The panel according to claim 1, wherein the light absorbing chips are positioned in correspondence with parts of the decorative image that are: image parts of a dark colour, and/or image parts that depict a recessed zone of a depicted relief structure

32-42. (canceled)

43. The panel according to claim 1, wherein the panel comprises at least two opposite side edges which are provided with respective interconnecting profiles that are complementary to each other, such as a tongue and a groove profile

44-51. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0151] The invention will be further elucidated with reference to preferred non-limitative embodiments of the invention that are shown in the appended figures, wherein:

[0152] FIG. 1 shows in perspective a panel according to the invention;

[0153] FIG. 2 shows a cross-sectional view of two panels and their coupling profiles according to the invention;

[0154] FIG. 3 shows a cross-sectional view of two panels having alternative coupling profiles according to the invention;

[0155] FIG. 4 shows a detailed cross-section of a part of the panel.

DESCRIPTION OF THE INVENTION

[0156] FIG. 1 shows a panel 1 suitable as a floor, ceiling or wall panel, which panel is of a planar design having an top side 7, a bottom side and side edges 3a-d which comprise a first side edge 3a provided with a first profile 10 and a second side edge 3c provided with a second profile 11. A top coat layer 30 is present at the top side 7 of the panel which is made of a transparent matrix material. Through the top coat layer 30, a decorative image is visible which comprises grain lines 12 which mimic the appearance of natural wood panels.

[0157] FIG. 2 shows a cross-section of the panel 1 of FIG. 1, perpendicular to the first and second side edges 3a and 3c, which are provided with a first profile 10 and a second profile 11. The bottom side 9 of the panel 1, is laid on a substrate layer for instance a floor surface S. The panel 1 has a structure of laminated layers 28, 29, 30 and 32 that are adhered to each other, which layers extend parallel to the plane of the panel 1, and comprise: [0158] a core layer 28 having a lower side and an upper side, [0159] a decorative layer 29 which comprises a decorative image on its upper side such as for instance the graining lines 12 of FIG. 1, [0160] a top coat layer 30 which is adhered on the upper side of the decorative layer 29, and [0161] a backing layer 32 which is adhered on the lower side of the core layer 28.

[0162] Further in FIG. 2, another identical panel 1 is shown in part, of which the second side edge 3c is to be coupled to the panel 1, by a downward vertical movement indicated by vector D. [0163] The first profile 10 and the second profile 11 of both panels 1 and 1 are mutually interacting profiles that can be coupled to each other and are complementary to each other. During coupling, the second profile 11 of panel 1 is vertically inserted in the first profile 10 of panel 1, which involves the downward tongue 22 of panel 1 being inserted in the first groove 23 of panel 1, and the upward tongue 21 of panel 1 being inserted in the second groove 24 of panel 1. When coupled, the panels 1 and 1 lie in a common plane which is parallel to the floor surface S.

[0164] FIG. 3 shows analogous to FIG. 2, alternative coupling profiles 40 and 41 for connecting two panels 1 and 1 with each other. Features that are equal to the features of FIG. 2 are indicated by the same reference numerals. [0165] The first profile 40 of panel 1, comprises a sideward tongue 51 extending in a direction substantially parallel to the upper side of the panel, one downward flank 53 lying at a distance from the sideward tongue 51, and a downward groove 54 formed between the sideward tongue 51 and the downward flank 53.

[0166] The second profile 41 of panel 1, comprises a groove 61 configured for accommodating at least a part of the sideward tongue 51 of the first profile 40 of a second identical panel 1, said groove 61 being defined by an upper lip 62 and a lower lip 63, wherein said lower lip is provided with an upward locking element 64. [0167] In the situation shown in FIG. 3, the first coupling profile and the second coupling profile 6 are configured such that the respective panels 1 and 1, can be coupled to each other by means of an angling movement as indicated by arrow T, which involves the sideward tongue of panel 1 being inserted into the third groove of the other identical panel 1, wherein the upward locking element 64 of the panel 1, is inserted into the second downward groove 54 of the panel 1.

[0168] It is also envisaged by the invention, that coupling profiles 40 and 41 are provided on the side edges 3b and 3d, while the side edges 3a and 3c are provided with alternative coupling profiles 10 and 11 as shown in FIG. 2.

[0169] FIG. 4 shows a detailed cross-section of a part of the panel shown in FIG. 2, wherein parts of the panel that are identical to FIG. 2 are indicated by the same reference numbers. It is noted that the relative thickness of the respective layers is exaggerated for illustrative reasons and therefore differs from FIG. 2. [0170] The decorative layer 29 is provided with grain lines 12, above which vertical zones 72 and 73 extend which are indicated by the vertical dotted lines. The vertical zones 72 and 73 divide the top coat layer 30 made of transparent matrix material in adjacent sections wherein each vertical zone comprises a predetermined amount of three types of solid particles 100, 101, 102 which have light-interacting properties and which comprise: [0171] spheroid, light reflective solid particles 101 that have an outer surface of light reflective material; [0172] spheroid, light absorbing solid particles 100 that have an outer surface of light absorbing material; and/or [0173] flake-formed, transparent solid particles 102 that are made from a transparent material which has a different refractive index than the transparent matrix material.

[0174] The solid particles in zones 72 are light absorbing solid particles 100 which correspond to the grain lines 12 image parts of the decorative image that are of a dark colour. The zones 73 contains light reflective solid particles 101 and transparent solid particles 102, in order to enhance the visual appearance of the part of the decorative image which does not contain grain lines 12, and which part is of a light colour. [0175] Additionally, the top coat layer 30 comprises at its upper side a relief structure, formed by a layer 70 of transparent material comprises recessed parts 75 and elevated parts 71, which parts are provided in correspondence with the decorative image of the decorative layer, such that the elevated parts 71 correspond with the grain lines 12.

[0176] 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 examples.

[0177] 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. Expression like vertical and horizontal are relative expressions and relate to a plane defined by the panel, wherein vertical means a direction perpendicular to said plane, and wherein horizontal means a direction parallel to and/or coinciding with said plane.