Abstract
The invention relates to a decorative panel, in particular a floor panel, ceiling panel, wall panel, or alternative surface covering panel. The invention also relates to a decorative covering, in particular a floor covering, ceiling covering, wall covering, or alternative surface covering, including a plurality of decorative panels according to the invention. The invention further relates to a method for producing a decorative panel, in particular a decorative panel according to the invention. The invention furthermore relates to a system for producing a decorative panel, in particular a decorative panel according to the invention and/or wherein is use made of the method according to the invention.
Claims
1. 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 decorative print layer forming at least one d?cor image, at least one substantially transparent or translucent covering structure at least partially covering said print layer, wherein the core comprises at least one recycled ocean thermoplastic material recovered from oceans and/or waterways.
2. The decorative panel according to claim 1, wherein at least one recycled ocean thermoplastic material is a recycled ocean polyolefin.
3. The decorative panel according to claim 2, wherein at least one recycled ocean thermoplastic material is recycled ocean polyethylene.
4. The decorative panel according to claim 3, wherein said recycled ocean polyethylene is high-density polyethylene (HDPE).
5. The decorative panel according to claim 3, wherein said recycled ocean polyethylene is ultra-high molecular weight polyethylene (UHMW-PE) and/or high-performance polyethylene (HPPE) and/or high-modulus polyethylene.
6. The decorative panel according to claim 2, wherein at least one recycled ocean thermoplastic material is recycled ocean polypropylene.
7. The decorative panel according to claim 1, wherein the core comprises at least one photo-oxidation based reaction product of at least one recycled ocean thermoplastic used in said core.
8. The decorative panel according to claim 1, wherein at least one recycled ocean thermoplastic used in said core comprises chain cleaved polymer fragments originating from the original thermoplastic material used in the core, wherein said polymer fragments preferably comprise 18 carbon atoms or less, more preferably 9-18 carbon atoms.
9. The decorative panel according to claim 1, wherein the core comprises at least one substance having at least one vinyl group and/or vinylene group, wherein said substance is preferably embedded in a matrix of at least one recycled ocean thermoplastic used in said core.
10. The decorative panel according to claim 1, wherein the core comprises at least one cross-linking agent, wherein said cross-linking agent is preferably embedded in a matrix of at least one recycled ocean thermoplastic used in said core.
11. The decorative panel according to claim 1, wherein the core comprises at least one flame retarding agent.
12. The decorative panel according to claim 1, wherein the core comprises at least one heat-resistant agent.
13. The decorative panel according to claim 1, wherein the core is an extruded core or hot-pressed core.
14. The decorative panel according to claim 1, wherein the core comprises a mixture of differently coloured, recycled ocean thermoplastic materials.
15. The decorative panel according to claim 1, wherein the core comprises a mixture of recycled ocean thermoplastic materials having a mutually different glossiness.
16. The decorative panel according to claim 1, wherein the core is recycled ocean thermoplastic chips or flakes based core.
17. The decorative panel according to claim 1, wherein the core comprises a scattered and/or spotted outer surface, wherein preferably a dotted or flake pattern, more preferably a random dotted or flake pattern, is formed on the surface of the molded product.
18. The decorative panel according to claim 1, wherein the core comprises at least one virgin thermoplastic material, wherein at least one virgin thermoplastic material and at least one recycled ocean thermoplastic material used in the core are based upon the same polymer and/or the same type of polymer, and, wherein the melting point of the virgin thermoplastic material is higher than the melting point of the recycled ocean thermoplastic material.
19. The decorative panel according to claim 1, wherein the density of the core is lower than 1 kg/dm3.
20. The decorative panel according to claim 1, wherein at least one layer of the covering structure is formed by a substantially transparent or translucent three-dimensional embossing structure at least partially covering said decorative print layer, wherein said layer is an Electron Beam (EB) cured layer.
21. The decorative panel according to claim 1, wherein at least one layer of the covering structure is formed by a substantially transparent or translucent three-dimensional embossing structure at least partially covering said decorative print layer, wherein the embossing structure is an at least partially digitally printed embossing structure.
22. The decorative panel according to claim 1, wherein a first panel edge comprises a first coupling profile, and a second panel edge, preferably opposite to the first panel edge, comprises a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent surface covering element, both in horizontal direction and in vertical direction, wherein the first coupling profile and the second coupling profile are preferably configured such that two of such panels can be coupled to each other by means of a lowering movement.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0167] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures, wherein:
[0168] FIGS. 1a-1e show a part of the manufacturing process according to the invention;
[0169] FIGS. 2a and 2b show a schematic representation of a panel according to the invention;
[0170] FIG. 3 shows another example of a decorative panel according to the invention;
[0171] FIGS. 4a and 4b show non-limiting examples of coupling profiles according to the present invention; and
[0172] FIG. 5 shows a schematic overview of a production line for manufacturing a panel according to the invention.
DESCRIPTION OF THE INVENTION
[0173] FIGS. 1a-1e show an example of subsequent steps of a method according to the present invention. FIG. 1a shows a schematic representation of a cross section of a decorative panel (110). The figure shows the core (100) of the panel (110). The core (100) comprises, preferably at least 80% by weight of the core (100), recycled plastic, in particular recycled ocean (thermos)plastic. The core (100) can e.g. be produced by means of extrusion or by means of hot pressing. The used recycled plastic material can be in powder form or in small fragments (106), such as chips, beads, flakes, etcetera, to form a core (100). The small fragments (106) can visually be observed in the core (100) due to difference in color and/or size of the small fragments (106). As shown in FIGS. 1a-1e this could lead to a random flake pattern (chip pattern or dot pattern). The small fragments (106) can be recycled plastic chips, flakes or particles comprising different colors and/or different sizes and/or different gloss levels. The recycled plastic material, preferably waste plastic recollected from oceans, other waterways, and/or the land, has typically undergone at least one photo-oxidation and thermo-oxidation process, in particular as a result of exposure to (sun)light. This typically leads to reaction products, such a polymer fragments have a relatively short cleaved polymer chain (CC backbone The core (100) may therefore comprise e.g. one or more fragment products of the group consisting of: hydroperoxides, ketones, conjugated ketones, vinyl groups, t-vinylene, acetone, or a combination thereof. A d?cor image is formed onto the upper side (100A) of the core (100) by means of printing, in particular digital printing. Optionally, a primer may be applied prior to applying a d?cor image onto the upper side (100A) of the core (100). Said primer may for example be applied in an amount situated between 15 g/m2 and 30 g/m2, preferably between 20 g/m2 and 24 g/m2. It is conceivable that said primer is a UV-curable primer, which may be cured by means of a mercury light source, wherein the light energy is adjusted to any value in the range of 190 to 280 mJ. FIG. 1b show that a liquid base layer (101) is applied on the d?cor image formed at the upper side (100A) of the panel (110). The liquid forming the liquid base layer (101) is for example a UV material. The liquid base layer (101) generally has a relatively high surface tension in order to allow precise embossing in the liquid base layer (101). The base layer (101) is preferably at least partially cured prior to applying the embossing. FIG. 1c shows that a plurality of embossing droplets (102) is position-selectively printed on the still liquid, or partially liquid base layer (101). This is done such that the thickness of the base layer (101) changes on the positions where the embossing droplets (102) are spayed on. Alternatively or additionally, the embossing droplets (102) may inhibit the curing of the base layer (101) locally, such that after curing the base layer (101), the embossing droplets (102) remain liquid and may be removed by means of e.g., a brush. FIG. 1d shows that this results in that positions indentations (103) are formed in the liquid base layer (101) at the positions where the embossing droplets (102) are sprayed on, or removed by means of a brush as discussed above. Subsequently an elevated pattern layer is formed by position-selectively printing of a plurality elevations on the base layer (101). The elevation droplets (104) applied onto the panel (110) are shown in FIG. 1d. The pattern layer obtained via the position-selectively printing of the elevations (105) is subsequently at least partially cured. FIG. 1e shows the application of a finishing layer or top coating (109) is applied on top of the base layer (101) and the elevations (105). Preferably, the top coating (109) is applied in a dosage situated between 8 g/m2 and 16 g/m2, preferably 10 g/m2 and 14 g/m2. The top coating (109) is preferably an Electron Beam curable coating, cured via Electron Beam radiation at an energy adjusted to any value in the range of 25 kGy to 45 kGy, preferably 30 kGy to 40 kGy. The finishing layer (109) is in particular cured by means of Electron Beam curing. This may provide a matt look of the surface of the panel. Alternatively or additionally, also a part of the base layer (101) and/or a part of the elevations (105) may be partially cured by means of Electron Beam curing. By using this curing technique, layers may be mutually chemically bonded together, establishing a better attachment therebetween. In particular chemical bonding between the finishing layer, or top coating (109). In general the base layer (101) may also be referred to as the wear layer (101) of the panel which preferably is substantially transparent or translucent. It is preferred that this wear layer (101) is applied in an amount situated between 60 g/m2 and 100 g/m2. The wear layer may in particular be UV-curable, by means of a mercury light source having an energy adjusted to any value in the range of 240-280 mJ. Via the steps shown in FIGS. 1a-1e, a decorative panel (110) is obtained, comprising a core (100) and a decorative top structure affixed on the upper side (100A) of the core (100). The decorative top structure comprises a decorative print layer forming at least one d?cor image and a substantially transparent or translucent multi-layered covering structure at least partially covering said print layer. At least one layer of the printed multi-layered covering structure, in particular the wear layer (101), is formed by a substantially transparent or translucent three-dimensional embossing structure, said embossing structure optionally is a multi-layer embossing structure which comprises a base layer (101) provided with a plurality of indentations (103) and an elevated pattern layer formed by a plurality of elevations (105) printed on top of said base layer (101). It can be seen that the indentations (103) and the elevations (105) can overlap, such that a panel (110) having an irregular height structure is obtained. The plurality of indentations (103) of the base layer (101) forms a discontinuous indentation pattern. The panel (110) may possibly comprise multiple coupling profiles for coupling multiple panels (110). The panel (110) may also comprise a backing layer (not shown) affixed to a lower side of the core (100).
[0174] FIGS. 2a and 2b show a schematic representation of a panel (220) according to the invention. FIG. 2a shows the panel (220) prior to application of the top coating (209). The panel (220) comprises a core (200) having an upper and lower side, wherein a decorative top structure is provided onto the core (200). On the upper side of the core (200) a primer may be applied prior to applying a d?cor image thereon. Said primer may for example be applied in an amount situated between 15 g/m2 and 30 g/m2, preferably between 20 g/m2 and 24 g/m2. It is conceivable that said primer is a UV-curable primer, which may be cured by means of a mercury light source, wherein the light energy is adjusted to any value in the range of 190 to 280 mJ. On top of the d?cor image (not shown) a substantially transparent or translucent covering structure may be provided. Of said covering structure only the at least one wear layer (201) is shown in FIG. 2a. It is preferred that this wear layer (201) is applied in an amount situated between 60 g/m2 and 100 g/m2. The wear layer may in particular be UV-curable, by means of a mercury light source having an energy adjusted to any value in the range of 240-280 mJ. Said wear layer (201) may be provided with a plurality of indentations (203) and elevations (205) such that said an embossing structure is formed. At least a part of the indentations (203) may be applied by means of an embossing liquid. Said embossing liquid may for example be a UV inhibitor, which prevents curing of (a part of) the wear layer (201) under UV curing station. The uncured portion may be removed by means of a brushing action. However, indentations may also be formed by means of Electron Beam embossing. By directing at least one Electron Beam to the uncured, or partially cured, or fully cured wear layer (201) material may be locally removed via the high energy of the Electron Beam. Since this technique does not require a liquid, a bigger design flexibility may be achieved. That is, the indentations (203) may be formed with sharper corners compared to embossing liquid, yielding a more natural look. FIG. 2b shows the panel (220) after application of the top coating (209). Preferably, the top coating (209) is applied in a dosage situated between 8 g/m2 and 16 g/m2, preferably 10 g/m2 and 14 g/m2. The top coating (209) is preferably an Electron Beam curable coating, cured via Electron Beam radiation at an energy adjusted to any value in the range of 25 kGy to 45 kGy, preferably 30 kGy to 40 kGy. The top coating (209) and wear layer (201) together defined the substantially transparent or translucent multi-layered covering structure according to the invention. In this respect, at least one of the layers of the covering structure may be formed by a substantially transparent or translucent three-dimensional embossing structure, in particular the wear layer (201) thereof. The figure further shows that a chemical bonding (211) is established between parts of the top coating (209) and the wear layer (201), this may be achieved since the top coating (209) is at least partially cured via Electron Beam curing. It is also conceivable that Electron Beam curing may be applied to, at least partially, curing the wear layer (201), such that a chemical bond may be formed between the wear layer (201) and the d?cor image and/or the primer and/or the core (200). Therefore, Electron Beam curing contributes to the overall integrity of the panel (220).
[0175] FIG. 3 shows a schematic representation of a further example of a decorative panel (330) according to the present invention. The figure show a cross section of a decorative panel (330), in particular a floor panel (330). The panel (330) comprises a core (300) provided with an upper side and a lower side. A decorative print layer (301) is indirectly affixed on the upper side of the core (300). A carrier layer (302) formed by a primer (302) is present in between the core (300) and the decorative layer (301) in order to provide better adhesion of the decorative layer (301). Said primer (302) may for example be applied in an amount situated between 15 g/m2 and 30 g/m2, preferably between 20 g/m2 and 24 g/m2. It is conceivable that said primer (302) is a UV-curable primer, which may be cured by means of a mercury light source, wherein the light energy is adjusted to any value in the range of 190 to 280 mJ. Optionally an intermediate layer (303) may be present on top of the printed decorative top layer (301). The intermediate layer (303) may be formed by a transparent or translucent thermoplastic layer (303). The thermoplastic layer (303) is in this non-limitative embodiment provided onto the printed decorative layer (301) by means of a hot melt glue layer (304). However, it is also conceivable that said thermoplastic layer (303) is provided by other means, such as chemical bonding via Electron Beam curing. A substantially transparent or translucent multi-layered covering structure (305) is positioned directly or indirectly on top op of aforementioned layers (300, 301, 302, 303, 304). The covering structure (305) may in particular be a multi-layered covering structure (305) comprising at least one wear layer (306A, 306B) and at least one top coating (309), provided directly or indirectly on top of said at least one wear layer (306A, 306B). It is preferred that at least one wear layer (306A, 306B) is applied in an amount situated between 60 g/m2 and 100 g/m2. The wear layer (306A, 306B) may in particular be UV-curable, by means of a mercury light source having an energy adjusted to any value in the range of 240-280 mJ. Preferably, the top coating (309) is applied in a dosage situated between 8 g/m2 and 16 g/m2, preferably 10 g/m2 and 14 g/m2. The top coating (309) is preferably an Electron Beam curable coating, cured via Electron Beam radiation at an energy adjusted to any value in the range of 25 kGy to 45 kGy, preferably 30 kGy to 40 kGy. The wear layer and top coating are in this particular embodiment formed by a substantially transparent or translucent three-dimensional embossing structure (305). The embossing structure (305) is a multi-layer embossing structure (305) which comprises two at least partially cured base layers (306A, 306B) provided with a plurality of indentations (312). A part of each base layer (306A, 306B) is free of indentations. The embossing structure (305) also comprises an elevated pattern layer (307) formed by a plurality of elevations printed on top of the upper base layer (306B). The elevations are both printed on parts of the base layer (306B) that respectively provided with indentations and parts that are free of indentations. Despite not shown, it is also conceivable that an embossing layer is present on top of the lower base layer (306A). A secondary printed decorated layer (308) is affixed to the lower base layer (306A). This printed decorative layer (308) is affixed to the parts of the base layer (306A) which is free of indentations. The entire panel (330) is covered with a top coating (309), in particular an Electron Beam cured top coating (309). The panel (330) benefits of the presence of two printed decorative layers (301, 308), resulting in that a unique visual pattern can be obtained. The indentations provided in the base layer (306A, 306B) may be provided via different techniques. In this non limitative embodiment, a part of the indentations (312) are provided via embossing droplets, as described with respect to FIGS. 1a-1e. Two indentations shown in FIG. 3 are however provided by means of Electron Beam application. This technique for providing negative embossing has turned out to provide more realistic indentations (312). In particular the sharp corners as present in natural wood nerves may be more realistically applied. This is due to the relatively high energy of Electron Beams, which may be used to locally disrupt the surface hence generating the indentation. By tuning the energy of the Electron Beam, different indentation depths may be achieved. Moreover, the indentations provided via Electron Beam may be established at the same time the base layer (306A, 306B) is cured. This may decrease the amount of production steps required. The figure also indicates that the top coating (309) locally established a chemical bond (311) with the adjacent layer.
[0176] FIGS. 4a and 4b show non-limiting examples of coupling profiles (401A, 401B, 402A, 402B) used in panels (400A, 400B) according to the present invention. A first panel edge (440A) comprises a first coupling profile (401A), and a second panel edge (440B) opposite to the first panel edge (440A), comprising a second coupling profile (401B) being designed to engage interlockingly with said first coupling profile (401A) of an adjacent panel, both in horizontal direction and in vertical direction, wherein the first coupling profile (401A) and the second coupling profile (401B) are configured such that two of such panels can be coupled to each other by means of a lowering movement. This is shown in FIG. 4a. FIG. 4b show the panel comprising a third coupling profile (402A) and a coupling profile (402B) located respectively at a third panel edge (441A) and a fourth panel edge (441B). The third coupling profile (402A) and the fourth coupling profile (402B) are configured such that two of such panels (440A, 440B) 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 an upward locking element of said second panel is inserted into the second downward groove of said first panel.
[0177] FIG. 5 depicts a simplified schematic overview of a system for manufacturing a panel according to the invention. In this non-limitative embodiment, the system (550) comprises a core feed station (501) comprising recycled plastic powder, particles, flakes or chips, in particular ocean recycled plastic powder, particles, flakes or chips. The core feed station (501) may be a core extrusion device (501) for extruding a slab of core material (500) or a hot pressing device for producing a pressed composite comprising small fragments of recycled plastic material. For extrusion, recycled plastic material in powder form may be used to form an extruded slab of core material. For hot pressing, recycled plastic material in powder form or in small fragments may be used to form a pressed composite. Typically, the small fragments can visually be observed in the core (500) if the core (500) is produced by a hot pressing device (501). The small fragments can e.g. be observed due to difference in color and/or size. The recycled plastics are PE and PP, in particular HDPE, UHMWPE and UHMW. The density of the recycled plastics are below 1 kg/cm3, resulting in a lighter panel compared to conventional panels. In addition, said plastics normally have long polymer chains resulting in core (500) with a high impact strength compared to thermoplastic materials used in conventional panels. The core material (500) is transported, for example by the conveyor (512), to a first station. In this case the first station (502) is formed by a primer station (502) for applying a primer layer onto the core material (500). Said primer may for example be applied in an amount situated between 15 g/m2 and 30 g/m2, preferably between 20 g/m2 and 24 g/m2. It is conceivable that said primer is a UV-curable primer, which may be cured by means of a mercury light source, wherein the light energy is adjusted to any value in the range of 190 to 280 mJ. It is also conceivable that, in case of multiple primer stations (502) are provided, that the total amount of primer applied by subsequent primer stations (502) adds up to the mentioned amount per square meter. The primer layer may provide for a better attachment of the decorative print layer. The decorative print layer is applied by a decorative printing station (503), which may apply, preferably digitally, a d?cor image onto the primer layer that is applied. Downstream of the printing station (503) a first coating station (504) is arranged. The first coating station (504) applies, in this case via at least one application roller (505) a first UV curable wear layer onto the slab. It is preferred that this wear layer is applied in an amount situated between 60 g/m2 and 100 g/m2. When multiple first coating stations (504) are arranged, the total amount of primer added by each of the stations (504) preferably adds up to the aforementioned amount per square meter. The first UV curable wear layer is cured via the first UV curing station (506), located downstream of the first coating station (504). Preferably said first curing station (506) cures the coating by means of a mercury light source having an energy adjusted to any value in the range of 240-280 mJ. Downstream thereof, a second coating station (508), for applying a top coating, and a second curing station (510) may be arranged. The second coating station (508) may apply, for example via a roller (509) a curable coating, preferably a coating curable via Electron Beam curing. Preferably, the top coating (109) is applied in a dosage situated between 8 g/m2 and 16 g/m2, preferably 10 g/m2 and 14 g/m2. When multiple second coating stations (508) are arranged, the total amount of top coating added by each of the stations (508) preferably adds up to the aforementioned amount per square meter.
[0178] The second curing station (510) is configured for curing the second coating, via Electron Beam radiation at an energy adjusted to any value in the range of 25 kGy to 45 kGy, preferably 30 kGy to 40 kGy. Via Electron Beam curing the top coating may be chemically bonded to the at least one wear layer applied. It is conceivable that between the first curing station (506) and the second coating station (508) a plurality of further coating and/or curing stations are arranged, for applying additional wear layers. It is also conceivable that between the first coating station (504) and the first curing station (506) an embossing station is arranged, for applying an embossing structure to the panel. The embossing structure may for example be applied as described within this application. This may for example be realized by means of an embossing liquid station, for applying position selectively an embossing liquid onto the core material (500), which may to this end be partially cured.
[0179] Hence, 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.
[0180] 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.
[0181] 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.
