Decorative Panel, and Decorative Floor Covering Consisting of Said Panels

Abstract

The invention relates to a panel, in particular a decorative panel, a floor panel, a ceiling panel or a wall panel. The invention also relates to a covering consisting of a plurality of mutually coupled panels according to the invention, in particular a floor covering consisting of a plurality of mutually coupled panels, according to the invention.

Claims

1-47. (canceled)

48. A decorative panel, in particular a floor panel, ceiling panel or wall panel, comprising: a core provided with an upper side and a lower side, a decorative top structure affixed, either directly or indirectly, on said upper side of the core, a first panel edge comprising a first coupling profile, and a second panel edge comprising a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, both in horizontal direction and in vertical direction, wherein said core comprises at least one wool layer at least partially formed by man-made vitreous fibres bonded together by at least one cured thermoset polymeric binder material, and wherein the decorative top structure comprises at least one ceramic layer and/or glaze layer, and optionally at least one digitally printed decorative layer covered by said glaze layer, wherein the decorative top structure is adhered onto the core by means of a waterproof adhesive.

49. The decorative panel according to claim 48, wherein at least a fraction of the man-made vitreous fibres are made of at least one material selected from the group consisting of: stone wool, mineral wool, slag wool, basalt wool, and glass fibres.

50. The decorative panel according to claim 48, wherein at least one binder material is a material selected from the group consisting of: a urea-modified phenol formaldehyde resin, and an alkanolamine/carboxylic acid anhydride reaction produce.

51. The decorative panel according to claim 48, wherein at least one binder material is a material selected from the group consisting of: acrylic resin, and an epoxy resin.

52. The decorative panel according to claim 48, wherein at least one binder material is formed by a sugar component selected from the group consisting of: sucrose, reducing sugars in particular dextrose, polycarbohydrates, and mixtures thereof.

53. The decorative panel according to claim 48, wherein the core comprises at least one main binder material is a material selected from the group consisting of: a urea-modified phenol formaldehyde resin, and an alkanolamine/carboxylic acid anhydride, and wherein the core comprises at least one co-binder material selected from the group consisting of: an acrylic resin and an epoxy resin.

54. The decorative panel according to claim 48, wherein the core comprises a mixture of binder materials, wherein a first binder material has a higher curing temperature and/or curing rate than at least one second binder material.

55. The decorative panel according to claim 48, wherein the core comprises at least one fluorescent compound chosen from the group consisting of: xanthenes, acridines, quinine, quinine derivatives, coumarins, aryl sulfonates.

56. The decorative panel according to claim 48, wherein the fibre orientation in at least one wool layer of the core is substantially vertical.

57. The decorative panel according to claim 48, wherein the core comprises at least one base wool layer comprising a first mineral wool, and at least one top wool layer, positioned on top of said base wool layer, comprising a second mineral wool, wherein the first wool and the second wool have different material compositions and/or different structural properties.

58. The decorative panel according to claim 48, wherein at least one core has a density lower than 1.200 kg/m.sup.3.

59. The decorative panel according to claim 48, wherein the decorative top structure is fused onto the core without using a separate adhesive.

60. The decorative panel according to claim 48, wherein a lower side of the decorative top structure penetrates into an upper side of the core.

61. The decorative panel according to claim 48, wherein the decorative top structure comprises at least one digitally printed decorative layer and at least one transparent wear layer covering said digitally printed decorative layer, wherein the top structure comprises at least one translucent, in particular transparent, glaze layer, wherein said wear layer is formed by said glaze layer.

62. The decorative panel according to claim 48, wherein the top structure comprises at least one layer at least partially composed of a material selected from the group consisting of: glaze, ceramic, stone, linoleum, ceramic, stone, concrete, mineral porcelain, glass, quartz, soapstone, mosaic, granite, limestone and marble.

63. The decorative panel according to claim 48, wherein the top structure comprises a textured upper surface.

64. The decorative panel according to claim 48, wherein the first coupling profile comprises: an upward tongue, at least one upward flank lying at a distance from the upward tongue, an upward groove formed in between the upward tongue and the upward flank wherein the upward groove is adapted to receive at least a part of a downward tongue of a second coupling profile of an adjacent panel, and at least one first locking element, preferably provided at a distant side of the upward tongue facing away from the upward flank, and wherein the second coupling profile comprises: a first downward tongue, at least one first downward flank lying at a distance from the downward tongue, a first downward groove formed in between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a part of an upward tongue of a first coupling profile of an adjacent panel, and at least one second locking element adapted for co-action with a first locking element of an adjacent panel, said second locking element preferably being provided at the downward flank; and/or wherein the panel comprises at least one third coupling profile and at least one fourth coupling profile located respectively at a third panel edge and a fourth panel edge, wherein the third coupling profile comprises: a sideward tongue extending in a direction substantially parallel to the upper side of the core, at least one second downward flank lying at a distance from the sideward tongue, and a second downward groove formed between the sideward tongue and the second downward flank, wherein the fourth coupling profile comprises: a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile of an adjacent panel, said third groove being defined by an upper lip and a lower lip, wherein said lower lip is provided with an upward locking element, wherein the third coupling profile and the fourth coupling profile are configured such that two of such panels can be coupled to each other by means of a turning movement, wherein, in coupled condition: at least a part of the sideward tongue of a first panel is inserted into the third groove of an adjacent, second panel, and wherein at least a part of the upward locking element of said second panel is inserted into the second downward groove of said first panel.

65. The decorative panel according to claim 48, wherein at least a part of each coupling profile is integrally made from material of the core.

66. The decorative panel according to claim 48, wherein at least one wool layer has a varying density in the thickness direction of said wool layer.

67. A decorative covering, in particular a decorative floor covering, decorative ceiling covering, or decorative wall covering, comprising a plurality of mutually coupled decorative panels according to claim 48.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0224] The terms Fig., Figs., Figure, and Figures are used interchangeably in the specification to refer to the corresponding figures in the drawings.

[0225] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures, wherein:

[0226] FIG. 1 shows a rectangular floor panel according to the present invention;

[0227] FIG. 2 shows a transversal cross-section along line A-A in FIG. 1, of respective side edges;

[0228] FIG. 3 shows a method of coupling of the side edges shown in FIG. 2;

[0229] FIG. 4 shows in a transversal cross-section, the side edges of FIG. 2 in coupled condition;

[0230] FIG. 5 shows a longitudinal cross-section along line B-B in FIG. 1 of respective side edges;

[0231] FIG. 6 shows a method of coupling of the side edges shown in FIG. 5;

[0232] FIG. 7 shows in a longitudinal cross-section, further details of respective side edges when in coupled condition;

[0233] FIG. 8 shows an alternative embodiment of the side edges of FIG. 2 which allow for another method of coupling;

[0234] FIG. 9 shows another alternative embodiment of the side edges of FIG. 2.

DESCRIPTION OF THE INVENTION

[0235] FIG. 1 shows a decorative panel 1 which upper side 2 is provided with a decorative top structure 12 (see also FIG. 2). The panel is of a rectangular shape having a length extending longitudinally along line B-B, and a width extending transversally along line A-A. The plane of the panel is hence determined by the combination of lines A-A and B-B. At opposite side edges 3 and 4, a first coupling part in the form of profile 5, resp. a second coupling part in the form of profile 6 is provided. At opposite side edges 9 and 10, a third coupling part in the form of profile 7 resp. a fourth coupling part in the form of profile 8 is provided.

[0236] FIG. 2 shows in transversal cross-section the first coupling part 5 at side edge 3. The first coupling part 5 comprises a sideward tongue 20 which comprises a front region 21 and a back region 22, wherein a bottom surface 23 and/or a side surface 23 of said front region 21 is rounded at least partly, wherein a top surface 24 of the front region 21 is at least partially inclined downwardly in a direction away from the back region 22, and wherein a bottom surface 26 and/or side surface 26 of the back region 22 of said sideward tongue 20 defines a first contact portion 26, and wherein the sideward tongue 20 comprises a passive bottom surface 27 situated adjacent to the first contact portion 26, wherein said passive bottom surface 27 is defined by a cut-out portion at a lower side of the sideward tongue 20. The passive bottom surface 27 herein extends over an intermediate region 28 between the back region 22 and the front region 21, and is substantially flat. The passive bottom surface 27 is inclined downwardly in a direction towards the front region 21, such that the inclined top surface 24 of the sideward tongue and the inclined passive bottom surface 27 converge in a direction away from the back region of the sideward tongue. Furthermore, the second coupling part 6 comprises a recess 30 for accommodating at least a part of the sideward tongue 20 of a further panel, said recess 30 being defined by an upper lip 31 and a lower lip 32, wherein the lower lip 32 extends beyond the upper lip 31, and wherein the lower lip 32 is provided with a upwardly protruding shoulder 33 defining a second contact portion 34 configured to actively co-act with a first contact portion 26 of another panel, in coupled condition of such panels as will be discussed with reference to FIG. 4. A top surface 35 of the lower lip 32 is smoothly curved at least partially and is configured as sliding surface for the at least partially rounded bottom surface 23 and/or side surface 23 of the front region 21 of the sideward tongue 20 of another panel during coupling of a first and second coupling part. The upper surface 35 of the lower lip is provided with a staggered cut-out portion 35s, which is at least partially located underneath the upper lip 31, and which is configured to accommodate a terminal portion of the sideward tongue 20 of another panel.

[0237] The panel 1 comprises a core 1a, and a decorative top structure 12 affixed, either directly or indirectly, on top of said core. An optional backing layer 105 is attached to a lower side of the core 1a. The core 1a comprises at least one (mineral) wool layer at least partially, and optionally entirely, formed by man-made vitreous fibres bonded together by at least one cured thermoset polymeric binder material, typically a resin. Preferably, at least a fraction of the man-made vitreous fibres are made of at least one material selected from the group consisting of: stone wool, mineral wool, slag wool, basalt wool, and glass fibres. It is imaginable that the core 1a comprises a plurality of different wool layers and/or at least one non-wool layer, such as for example a glass fibre layer, a thermoplastic layer, and/or a cementitious layer. The top structure 12 can be of various nature, wherein two embodiments 12a, 12b are shown in FIG. 2. In a first embodiment 12a, the top structure has a laminated structure, and comprises a decorative layer, in particular a thermoplastic or paper film carrying a, preferably digitally printed, decorative image, and at least one protective layer, such as a finishing layer, and/or a wear layer, and/or a lacquer, positioned on top of said decorative layer. Further embodiments have been described in the above description. Alternatively, or additionally, the top structure 12b may comprises a tile, in particular a mineral tile, preferably at least partially made of ceramic and/or stone, and/or any material chosen from the group consisting of: ceramic, stone, concrete, mineral porcelain, glass, quartz, soapstone, mosaic, granite, limestone and marble. Typically, these tiles are hardeven impossibleto profile, as a result of which the profile core offers a solution to manufacture interlockable mineral tiles. The top structure 12 may be glued, by means of an adhesive, and/or fused onto the core 1a.

[0238] The backing layer 105 is attached, directly or indirectly, to a rear side of the core 1a. The at least one backing layer is preferably at least partially made of a flexible material, preferably an elastomer. The thickness of the backing layer typically varies from about 0.1 to 2.5 mm. Non-limiting examples of materials whereof the backing layer can be made of are polyethylene, cork, polyurethane and ethylene-vinyl acetate. The thickness of a polyethylene backing layer 105 is for example typically 2 mm or smaller. The backing layer 105 commonly provides additional robustness, dimensional stability, and/or impact resistances to the panel as such, which increases the durability of the panel. Moreover, the (flexible) backing layer 105 may increase the acoustic (sound-dampening) properties of the panel 1.

[0239] In the following figures, the backing layer 105 and the top structure 12 have not been shown separately for clarity reasons, but may be incorporated in each of the figures shown.

[0240] FIG. 3 shows a method of coupling of two panels 1 and 1, each being provided with first and second coupling parts 5 and 6 as shown in FIG. 2. The two panels are coupled to each other by an angling movement over arrow MA. As evident from FIG. 3, the curvature of top surface of the lower lip 32 functions as sliding surface for the at least partially rounded bottom surface 23 and/or side surface 23 of the tongue 20.

[0241] FIG. 4 shows the coupling parts 5 and 6 of the two panels 1 and 1 once the coupling shown in FIG. 3 has been completed by the angling movement. The respective contact portions 26 and 34 in the shown coupled status, together create a tension force (T1) which forces the side edges 3 and 4 towards each other.

[0242] Further in the shown coupled status, the at least partially curved top surface 35 of the lower lip 32 and the passive bottom surface 27 of the sideward tongue 20 are mutually situated such that an intermediate space S is present adjacent to actively co-acting first and second contact portions 26 and 34. The passive bottom surface 27 is depicted as a substantially flat surface, but may alternatively have a concave or convex surface, as long as an amount of intermediate space S is maintained between tongue and recess in coupled status. A lower surface 36 of the upper lip 31 is at least partially inclined and configured to abut at least a part of the top surface 24 of the front region of the sideward tongue 20. The top surface 35 of the lower lip defines a deepest point 38 of the recess, wherein the shoulder 33 of the lower lip defines a highest point 39 of the lower lip, wherein said deepest point and highest point define a lower lip depth (LLD). On the upper side of the panels 1 and 1 which are forced together by the tension force from contact portions 26 and 34, a seam 40 is present which defines a vertical plane VP which subdivides the lower lip 32 into an inner lower lip part 32i and an outer lower lip part 320. The top surface of the shoulder part 33 is herein located at a distance from first coupling part 5, so that an intermediate space is present at this part as well.

[0243] FIG. 5 shows a longitudinal cross-section of a panel 1 shown in FIG. 1, along line B-B. At side edges 9 resp. 10, a third coupling part in the form of profile 7 resp. a fourth coupling profile in the form of profile 8 is provided. The third coupling part 7 comprises an upward tongue 71, an upward flank 72 situated at a distance from the upward tongue and an upward groove 73 formed in between the upward tongue 71 and the upward flank 72, wherein the upward groove is adapted to receive at least a part of a downward tongue 81 of the fourth coupling part 8 of another panel. The side of the upward tongue 71 facing the upward flank 72 is the inside 77 of the upward tongue, and the side of the upward tongue 71 facing away from the upward flank 72 is the outside 76 of the upward tongue. A first locking element 75 is provided at an outside of the upward tongue 71 facing away from the upward flank 72. The fourth coupling part 8 comprises a downward tongue 81, a downward flank 82 situated at a distance from the downward tongue, and a downward groove 83 formed in between the downward tongue 81 and the downward flank 82, wherein the downward groove 83 is adapted to receive at least a part of the upward tongue 71 of the third coupling part 7 of another panel. The side of the downward tongue 81 facing the downward flank 82 is the inside 87 of the downward tongue and the side of the downward tongue 81 facing away from the downward flank 82 is the outside 86 of the downward tongue 81. A second locking element 85 adapted for co-action with a first locking element 75 of another panel, is provided at the downward flank 82.

[0244] FIG. 6 shows how the third and fourth coupling profiles 7 and 8 of FIG. 5 can be coupled to each other when connecting a panel 1 and a panel 1 to each other. The panel 1 is hereby moved vertically downwards along the arrow, wherein the profiles 7 and 8 engage with each other by receiving upward tongue 71 in downward groove 83 and receiving downward tongue 81 in upward groove 73.

[0245] FIG. 7 shows in more detail the side edges 7 and 8 in coupled condition, after the coupling by vertical movement as shown in FIG. 6 has been completed. It is noted that the side edges 7 and 8 of the embodiment of FIG. 7 contain some slight adaptations over the embodiment shown in FIGS. 5 and 6, which are directly visible from the figures, and further explained below. As far as FIGS. 5-7 have the same features in common, these are indicated by the same reference numerals. The inside 77 of the upward tongue 71 is in contact with the inside 87 of the downward tongue 81 of another panel, such that the panels create a tension force (T2) which forces the side edges 7 and 8 towards each other. Part of the inside 77 of the upward tongue is inclined towards the upward flank 72, and part of the inside 87 of the downward tongue 81 is inclined towards the downward flank 82, such that the two coupled panels are interlocked in a direction perpendicular to the plane of the panels (i.e. in a vertical direction). Additionally, the first and second locking elements 75 and 85 interlock with each other, further contributing to the vertical interlocking of the coupled panels. The first locking element is a bulge 75, the second locking element is a recess 85. The bulge 75 has an upper portion 90 and an adjoining lower portion 88, wherein the lower portion 88 comprises an inclined locking surface and the upper portion 90 comprises a, preferably curved, guiding surface. The recess 85 comprises an upper portion 94 and an adjoining lower portion 92, wherein the lower portion 92 comprises an inclined locking surface.

[0246] The respective upper portions 90 and 94 are at a distance from each other, thus allowing for an intermediate space. At the upper side of the coupled side edges 7 and 8, the upper contact surfaces 95 and 96 are forced together due to the interaction of the insides 77 and 87. In addition, the respective upper contact surfaces 95 and 96 are provided with a bulge 98 and a recess 97, which interlock with each other in the coupled state. Above the bulge 98 and recess 97 respective inclined contact surfaces 99a and 99b are provided which engage with each other.

[0247] FIG. 8 shows an alternative embodiment of the side edges 3 and 4 according to FIG. 2, wherein the upper surface 24 of the front region 21 of the sideward tongue and a side surface 23 of the front region 21 of the sideward tongue are connected by means of a transitional convex surface 100, and the lower surface 36 of the upper lip 31 and a side surface 102 of the upper lip 31 are connected by means of a transitional convex surface 104. All other features of the side edges 3 and 4 are similar to FIG. 2. The shown embodiment allows for a coupling movement by shifting the panels towards each other in a planar direction as indicated by the arrow Snap.

[0248] FIG. 9 shows an alternative embodiment of the side edges 3 and 4 according to FIG. 2, wherein the upper surface 35 of the lower lip 32 has a staggered cut-out portion 35s which is complementary in size to the terminal portion 23 of the tongue 20, so that it encloses the portion 23 in a clamping way. All other features of the side edges 3 and 4 are similar to FIG. 2.

[0249] 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.

[0250] 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.

[0251] 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.