Abstract
The invention relates to a decorative panel, in particular a floor panel, ceiling panel or wall panel. The invention also relates to a decorative panel covering, such as a decorative floor covering, decorative ceiling covering or decorative wall covering, including a plurality of panels according to the invention, wherein the panels are preferably interconnected.
Claims
1-64. (canceled)
65. 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, directly or indirectly, on said upper side of the core, said decorative top structure comprising: at least one digitally printed decorative print layer forming at least one d?cor image, and a plurality of substantially transparent or translucent cover layers covering said decorative print layer, said cover layers comprising at least one base cover layer, and at least one, at least partially digitally printed, textured cover layer, covering said base cover layer, wherein said textured cover layer comprises at least one digitally created first texture, and wherein the upper side of the core and/or at least one layer of the decorative top structure comprises at least one mechanically created second texture, wherein at least one second texture is located at at least one panel edge and forms at least one bevel and/or at least one grout.
66. The panel according to claim 65, wherein the first texture is at least partially defined by at least one, at least partially cured base layer provided with a plurality of indentations.
67. The panel according to claim 65, wherein the base layer is a printed base layer.
68. The panel according to claim 65, wherein the indentations provided in the base layer have a depth situated in between 2 micron and 100 micron.
69. The panel according to claim 65, wherein at least a part of the indentations of the base layer is aligned in register with at least a part of at least one d?cor image formed by the decorative print layer, in particular at least one pattern defined by at least one d?cor image formed by the decorative print layer.
70. The panel according to claim 65, wherein the indentations provided in the base layer have been formed by material removal from the initial base layer, wherein the indentations provided in the base layer have been created by digitally printing of reactive droplets onto the base layer, onto the initially liquid base layer.
71. The panel according to claim 65, wherein the impressions are obtained by means of a pressing mould, such as a pressing plate and/or an embossing roll.
72. The panel according to claim 65, wherein at least a part of the impressions of the second texture is aligned in register with at least a part of at least one d?cor image formed by the decorative print layer, in particular at least one pattern defined by at least one d?cor image formed by the decorative print layer.
73. The panel according to claim 65, wherein the maximum depth of the second texture exceeds the maximum depth of the first texture, with respect to a top surface of the panel.
74. The panel according to claim 65, wherein at least one wear layer of the decorative top structure comprises the second texture.
75. The panel according to claim 65, wherein at least one first wear layer of the decorative top structure comprises the first texture, and wherein at least one second wear layer of the decorative top structure the second texture.
76. The panel according to claim 65, wherein at least a part of the decorative layer is deformed by the second texture.
77. The panel according to claim 65, wherein a first panel edge comprises a first coupling profile, and a second panel edge, opposite to the first 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.
78. The panel according to claim 65, wherein at least one second texture defines a thinned section of the textured cover layer, which is realized by material removal of said cover layer.
79. The panel according to claim 65, wherein the at one grout is formed by at least one exposed portion extending along a length of at least one edge, wherein said at least one exposed portion extends outwardly below and away from a top surface of the panel, and is at least partially defined by the decorative top structure
80. The panel according to claim 65, wherein at least one grout and/or at least one bevel comprises a textured upper surface.
81. The panel according to claim 65, wherein the base cover layer has a lower gloss level than the textured cover layer.
82. The panel according to claim 65, wherein the at least one bevel and/or at least one grout is coated by an opaque coating layer and/or by a coloured coating layer.
83. The panel according to claim 65, wherein the base cover layer is free of any first texture and/or wherein the decorative print layer is a flat layer, being free of any first texture and second texture.
84. The panel according to claim 65, wherein at least one second texture is applied underneath the decorative top structure.
85. The panel according to claim 65, wherein at least one first texture and at least one second texture overlap as seen from a top view of the panel.
86. A decorative panel covering, in particular floor covering, ceiling covering, or wall covering, comprising a plurality of decorative panels according to claim 65.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] The terms Fig., Figs., Figure, and Figures are used interchangeably in the specification to refer to the corresponding figures in the drawings.
[0075] The present invention will hereinafter be further elucidated on the basis of the following non-limitative exemplary drawings wherein:
[0076] FIGS. 1A-1E schematically show subsequent steps of creating the decorative panel according to a first embodiment the invention;
[0077] FIGS. 2A-2F schematically show subsequent steps of creating the decorative panel according to a second embodiment of the invention;
[0078] FIGS. 3A-3D schematically represent the subsequent steps of creating the decorative panel according to a third embedment;
[0079] FIGS. 4A-4C schematically represent the subsequent steps of creating the decorative panel according to a fourth embodiment; and
[0080] FIG. 5 schematically shows two interconnected panels with first and second coupling parts according to the present invention.
DESCRIPTION OF THE INVENTION
[0081] In FIG. 1A-1E schematically show the steps for obtaining a decorative panel 112 according to a first non-limitative embodiment of the invention. FIG. 1A shows a schematic representation of a cross section of a decorative panel 112. This figure in particular indicates the core layer 100 of said panel 112, preferably the core is substantially rigid. A decorative print layer 101 is provided on an upper surface of the core layer 100. The decorative print layer 101 is preferably digitally printed on the upper side of the core layer 100. It is noted that the decorative print layer 101 may also be applied on a primer layer (not shown) and/or a white base coat (not shown), said primer layer placed on the upper side of the core layer 100 on which the decorative print layer 101 is printed digitally, and said white base coat applied on top of said primer and/or directly on top of said core layer 100. In order for the decorative print layer 101 to remain visible, it is preferably only covered by (semi-) transparent and/or translucent layers subsequent layers. FIG. 1B shows a liquid base layer 102 provided on top of the decorative print layer 101. It is preferred that said base layer 102 is a printed base layer, printed either directly or indirectly on top of the decorative print layer 101. FIG. 1C shows the application of embossing droplets 103. Said embossing droplets 103 are preferably applied on the base layer 102 before the base layer 102 is fully cured, and the bae layer 102 is therefore at least partially in liquid state during application of the embossing droplets 103. However, it is conceivable that more indentations 104 may be applied by embossing droplets 103 after curing the base layer 102. All indentations 104 together form an indentation pattern. The embossing droplets 103 are position-selectively digitally printed onto the liquid base layer 102 such that a chemical reaction is caused between the embossing droplets 103 and the base layer 102. Moreover, the droplets 103 are preferably positioned in accordance with the decorative print layer 101, such as to enhance the three-dimensional effect of the decorative print layer 101. Subsequently, as shown in FIG. 1D, a plurality of embossing droplets 105 may be provided on the, preferably still not fully cured, base layer 102. The embossing droplets 105 in this step may be of an alternative embossing liquid, such that elevations 106 are formed by the embossing droplets 105. All elevations 106 together form an elevation pattern. The indentation and elevation patterns applied by means of the embossing droplets 103, 105 on the base layer 102 together form a first texture. It is preferred that both embossing droplets 103, 105 are applied in correspondence with the decorative print layer 101. As such, at least a part of the elevations 106 of the elevation pattern and at least a part of the indentations 104 of the indentation pattern are aligned in register with at least a part of at least one d?cor image of the decorative print layer 101. To this end it is possible that some indentations 104 and elevations 105 overlap such that a panel 112 with an irregular height structure is obtained. Subsequent to applying indentations 104 and elevations 106 to the panel 112, a pressing mould 107 could be used to even further enhance the level of detail of the decorative top structure. The pressing mould 107 is depicted in FIG. 1E as a pressing plate 107, however may also be embodied as an embossing roll. The pressing mould 107 is pressed onto the upper surface of the panel 112 that is obtained through FIGS. 1A-1D. After lifting the pressing mould 107 from the panel 112 a second texture 108 is revealed, in addition to the first texture. Moreover, it is preferred that also the second texture 108, which is a result of the impression of the pressing mould 107, is in correspondence with the d?cor image of the decorative print layer 101. By utilizing multiple structure forming techniques, a more detailed texture can be obtained, to form deeper indentations and create a more realistic appearance of the panel 112 as such. Before using the pressing plate 107 to form the second texture layer, preferably the first texture layer is not fully cured. That is, the first texture layer should be in a somewhat deformable state during mechanical pressing. However, it is also possible to fully cure the first texture layer, hence the indentation and elevation patterns, prior to mechanical pressing. If the first texture layer is fully cured prior to mechanical pressing using a pressing mould 107, an additional intermediate base layer (not shown) is applied which remains in a deformable state during mechanical pressing. This may result in a panel 112 having substantially the same appearance, albeit possibly somewhat thicker since an intermediate base layer is applied.
[0082] FIGS. 2A-2F depict a comparable panel 212 as seen in FIGS. 1A-1E, wherein the steps depicted in FIGS. 1C-1D (forming the first texture layer) are replaced by a different approach for forming the first texture layer, as show in FIGS. 2C-2E. FIGS. 2A and 2B respectively show a cross section of the panel 212 formed by a core 200 and a decorative print layer 201 provided on an upper surface of the core 200, and a base layer 202 provided onto the decorative print layer 201. It is noted that between the upper surface of the core layer 200 and the decorative print layer 201 a primer and/or a preferably white base coat (not shown) could be applied. During the steps indicated in FIGS. 2C-2E, the first texture layer is applied. FIG. 2C thereto shows the application of an embossing liquid 203 on the base layer 202 in the form of droplets 203. Preferably, the droplets 203 are applied position-selectively on the base layer 202 in correspondence with the d?cor image of the decorative print layer 201. FIG. 2C shows the accumulation of embossing liquid 203 in the base layer 202 in the form of predetermined indentations 204. Unlike depicted in FIG. 1C, the droplets do not cause the base layer 202 to be removed locally. In order to reveal the final indentations 204, the base layer 202 is at least partially cured in order to harden said base layer 202. During the (partial) curing process the embossing liquid 203 causes the base layer 202, in particular on the predetermined indentations 204, to remain in its liquid state, allowing the base layer 202 in these regions 204 to be subsequently removed by a brush 209. Alternative to the brush 209 depicted in FIG. 2D it is also conceivable that alternative manners are utilized to remove the uncured base layer 202. It is the specific composition of the embossing liquid 203 that allows the predetermined regions 204 where droplets 203 of said embossing liquid 203 are applied to remain in liquid state even after curing of the base layer 202. After all the uncured base layer material 204 is removed, the final indentations 204 remain in the base layer 202. All the indentations 204 again form an indentation pattern. Subsequently, elevations 206 could be similarly applied as shown in FIG. 1D. All elevations 206 together form the elevation pattern. After application of the first texture layer as indicated by FIGS. 2A-2E, a second texture layer, in particular a mechanical texture layer, could be applied. If the first t first texture layer is applied in accordance to the FIGS. 2A-2E, it might be beneficial, due to the partial hardening of the base layer 202 in order to remove the material at the predetermined locations 204, to apply an intermediate base layer (not shown) before applying the mechanical pressing means 207 to form the second texture layer 208. The second, mechanical, texture layer is applied in similar fashion as compared to FIG. 1E.
[0083] FIG. 3 depicts yet another embodiment of the panel 312 according to the invention. To this end a cross sectional schematic view of the core layer 300 is shown in FIG. 3A. Although it is not shown in FIG. 3A, a base and/or primer layer may be applied on the upper surface of the core layer 300. FIG. 3B shows a mechanical pressing plate 307 used to provide a texture layer. The pressing plate 307 provides a texture to the upper surface of the core layer 300 and/or the base layer if applied in the previous step (not shown). The mechanical press 307 could as well be formed by a roller, and is provided with a plurality of impressions 310. After pressing the pressing plate 307 onto the upper surface of the core layer 300, the reflections 311 on the core layer 300 represent the impressions 310 of the pressing structure 307 being left on the core layer. A decorative print layer 301 is applied on the upper surface of the core 300, preferably after pressing said core 300. However, it is also possible to apply the decorative print layer 301 prior to pressing the core layer, to this end due care should be taken to prevent local stretching of the decorative print layer 301, which could negatively affect the d?cor image. Applying a texture to the core layer 300 could enhance the three-dimensional appearance of the d?cor image, since the image of the decorative print layer 301 itself has a relief that could correspond with the image. After application of the texture layer in FIG. 3B, a liquid base layer 302 is applied on top of the decorative print layer 301. FIG. 3C shows that the base layer 302 follows the texture layer that is impressed in the core 300. After application of the base layer 302 an additional texture layer could be applied, by using the techniques shown in FIGS. 1A-1D, or 2A-2E, e.g. by means of chemical embossing using droplets. To this end FIG. 3D shows the end result of a panel 312 to which such a technique has been applied subsequent to applying a texture to the core layer 300. A plurality of indentations 304 are provided in the base layer 302, forming an indentation pattern, as well as a plurality of elevations 306, forming an elevation pattern. Preferably the mechanical impressions shown in FIG. 3B are in accordance with the d?cor image of the decorative print layer 301. To further enhance the appearance of the panel 312, e.g. to accentuate certain features such as knots in a wooden panel, the indentations 304 and/or the elevations 306 are applied in correspondence with the d?cor image of the decorative print layer 301 as well.
[0084] FIGS. 4A-4C depict another embodiment of the panel 412 according to the invention. A cross sectional view of the base layer 400, onto which a decorative print layer 401 is applied is shown in FIG. 4A. The decorative print layer 401 could be applied directly onto the upper surface of the core 400 or alternatively by means of a primer. On top of the decorative print layer 401 a liquid base layer 402 is applied. The liquid base layer 402 is deformed by means of a mechanical pressing means 407, formed by a pressing plate 407 in this figure. To this end it is preferred that the base layer 402 is not fully cured during pressing. It is noted that the pressing plate 407 could be embodied by a roller or other means as well. The protrusions 410 on the pressing plate 407 are impressed into the base layer 402, and leave impressions 411 on those locations. The impressions 411 left by the pressing plate 407 represent a texture layer formed in the base layer 402. FIG. 4B indicates the application of an additional base layer 402, which is applied onto the base layer 402. The additional base layer 402 follows the surface texture of the impressed base layer 402, such that the texture layer is maintained. After application of the additional base layer 402, an additional texture layer may be provided by means of chemical embossing in the additional base layer 402. Although FIG. 4C only shows negative embossing, by means of embossing droplets 403 which react with the material of the intermediate base layer 402 leaving behind indentations 404, it is also possible to provide a positive embossing texture afterward, such as depicted in FIG. 1D or 2E. Optionally, although not shown in any of the figures, one or more finishing layers can be applied to the panel 112, 212, 312, 412, in particular over the uppermost texture layer. It is furthermore noted that although only two base layers 402 and 402 are shown in this figure, the process could be repeated endlessly. This allows to create relatively deep indentations and/or impressions in the panel, such that certain features of the d?cor image of the decorative print layer 401 could be represented realistically. The same applies to FIGS. 1A-1E, 2A-2F, and 3A-3D, wherein it is also conceivable to repeat the depicted process in an arbitrary order, or combine processes, in order to end up with a panel 112, 212, 312, 412 with a realistic texture and appearance.
[0085] FIG. 5 shows a floor panel 112 according to the invention, comprising a first coupling part 2 and a second coupling part 3 in coupled condition. The first coupling part 2 comprises an upward tongue 4, an upward flank 5 lying at a distance from the upward tongue 4 and an upward groove 6 formed in between the upward tongue 4 and the upward flank 5, wherein the upward groove 6 adapted the downward tongue 7 of a second coupling part 3 of another panel 112. The side of the upward tongue 4 facing towards the upward flank is the inside 8 of the upward tongue 4 and the side of the upward tongue 4 facing away from the upward flank 5 is the outside 9 of the upward tongue 4.
[0086] The second coupling part 3 comprises a downward tongue 7, a downward flank 10 lying at a distance from the downward tongue 7, and a downward groove 11 formed in between the downward tongue 7 and the downward flank 10. The side of the downward tongue 7 facing towards the downward flank 10 is the inside 12 of the downward tongue 7 and the side of the downward tongue 7 facing away from the downward flank 10 is the outside 13 of the downward tongue 7.
[0087] The outside 13 of the downward tongue 7 and the upward flank 5 both comprise an upper contact surface 14 at the top of the panel 112, which upper contact surfaces 14 are in contact extend vertically. Adjoining the upper contact surfaces 14 both the downward tongue 7 and the upward flank 5 comprise an inclined contact surface 15, which inclined contact surfaces 15 are in contact, wherein the upper contact surfaces 14 on the one hand, and the inclined contact surfaces 15 of the upward flank 5 and/or the outside 13 of the downward tongue 7 on the other hand preferably mutually enclose an angle ? of approximately 125 degrees. The upper contact surface 14 and the inclined contact surface of the upward flank 5 mutually enclose a first angle of about 125 degrees, and the upper contact surface 14 and the inclined contact surface 15 of the downward tongue 7 mutually enclose a second angle of about 125 degrees.
[0088] Adjoining the inclined contact surface 15 the downward tongue 7 comprises an outer surface 16, and adjoining the inclined contact surface 15 the upward flank 5 comprises an inner surface 17, wherein the outer 16 and inner 17 surface are parallel and vertical. Between the outer surface 16 and the inner surface 17 a space 18 is present.
[0089] The upper contact surfaces 14 define an inner vertical plane 19, wherein the inclined contact surface 15 of the downward tongue 7 extends beyond the inner vertical plane 19 the inclined contact surface 15 of the upward flank 5 lies inward compared to the inner vertical plane 19. A portion 20 of the downward tongue 7 extends beyond the inner vertical plane 19, wherein said portion 20 is substantially trapezium-shaped or wedge-shaped. The inclined contact surfaces 15 are both arranged completely outside and adjoining the inner vertical plane 19. The portion 20 is elongated with a larger vertical portion compared to the horizontal portion.
[0090] The bottom 21 of the downward tongue 7 contacts the upper side 22 of the upward groove 6 at a groove contact surface 23, wherein a gap 24 is present between the first 2 and second 3 coupling parts, extending from the inclined contact surfaces 15 to the groove contact surface 23. Additionally the upper surface 25 of the upward tongue 4 and the upper surface 26 of the downward groove 11, are distanced from each other such that a gap 27 is present between the two surfaces 25, 26.
[0091] The outside 9 of the upward tongue 4 comprises a first locking element 28, in the form of an outward bulge and the downward flank 10 is provided with a second locking element 29, in the form of a recess, wherein the first 28 and at least a part of second 29 locking element are in contact, and form a locking element surface 30.
[0092] 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. The subject-matter of this document, for example, also includes all of the above embodiments of the panel according to the invention, wherein the second texture is omitted, and wherein merely at least one first texture is applied. The subject-matter of this document, for example, also includes all of the above embodiments of the panel according to the invention, wherein the second texture is created in an alternative and/or additional manner, for example, by irradiation (e.g. by using a laser) and/or pneumatically (by using one or more gas nozzles) and/or hydraulically (by using one or more liquid jets, such as water jets). Preferably, these one or more irradiation sources and/or jets are digitally controllable to allow the formation of a digitally predefined second texture.
[0093] The ordinal numbers used in this document, like first, second, third, and fourth are used only for identification purposes. Hence, the use e.g. of the expressions third locking element and second locking element does therefore not necessarily require the co-presence of a first locking element. The decorative panels according to the invention may also be referred to as decorative tiles. By complementary coupling profiles is meant that these coupling profiles can cooperate with each other. However, to this end, the complementary coupling profiles do not necessarily have to have complementary forms. By locking in vertical direction is meant locking in a direction perpendicular to the plane of the panel. By locking in horizontal direction is meant locking in a direction perpendicular to the respective coupled edges of two panels and parallel to or falling together with the plane defined by the panels.
[0094] 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.
[0095] 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.
