PANEL AND METHOD FOR PRODUCING A PANEL

Abstract

The invention relates to a panel, such as a floor panel, a wall panel or a ceiling panel, in particular a decorative panel and to a method for producing such panel. The panel according to the present invention comprises a core layer comprising a first composite material and a second composite material which have different material characteristics. The panel is further provided with a plurality of cavities.

Claims

1. A floor panel, a wall panel or a ceiling panel, comprising: at least one core layer, said core layer comprising: at least one upper core layer comprising a first composite material; and at least one lower core layer comprising a second composite material; wherein at least part of the bottom surface of the lower core layer is provided with a plurality of impressed cavities, and wherein the Vicat softening temperature of the upper core layer is at least 15 degrees Celsius higher than the Vicat softening temperature of the lower core layer.

2. The panel according to claim 1, wherein the lower core layer has a Vicat softening temperature in the range of 50 to 90 degrees Celsius.

3. The panel according to claim 1, wherein the modulus of elasticity of the lower core layer is at most 50% of the modulus of elasticity of the upper core layer.

4. (canceled)

5. The panel according to claim 1, wherein the upper core layer has a Shore D hardness in the range of 85 to 95 and/or wherein the lower core layer has a Shore D hardness in the range of 55 to 65.

6. (canceled)

7. The panel according to claim 1, wherein the first composite material comprises at least 40 wt % of a mineral material and/or wherein the second composite material comprises at most 60 wt % of a mineral material.

8. (canceled)

9. The panel according to claim 1, wherein the first composite material and/or the second composite material comprises at least one mineral material selected from the group consisting of: magnesium oxide, magnesium chloride, magnesium oxy sulphate, calcium carbonate, chalk, clay, calcium silicate and/or talc.

10. The panel according to claim 1, wherein the first composite material and/or the second composite material comprises at least one thermoplastic material selected from the group consisting of: polyvinyl chloride, polystyrene, polyethylene, polyurethane, acrylonitrile butadiene styrene, polypropylene, phenolic, melamine or formaldehyde resins or combinations thereof.

11. The panel according to claim 1, wherein the core layer comprises at least one binder, wherein the ratio of weight percentages of mineral material relative to said binder is at least 1.

12. The panel according to claim 1, wherein the transition temperature of the lower core layer is at least 10 degrees Celsius lower than the transition temperature of the upper core layer.

13. The panel according to claim 1, wherein the upper core layer and the lower core layer are formed via co-extrusion.

14. The panel according to claim 1, wherein the cavities are formed during an extrusion process, or immediately after an extrusion process, or through hot-pressing, or through a curing process and wherein the plurality of impressed cavities define a repeated cavity pattern.

15. (canceled)

16. (canceled)

17. (canceled)

18. (canceled)

19. The panel according to claim 1, wherein the core layer comprises at least one pair of opposing edges, said pair of opposing side edges comprising complementary coupling parts configured for mutual coupling of adjacent panels.

20. (canceled)

21. The panel according to claim 1, wherein the density of the lower core layer is lower than the density of the upper core layer.

22. The panel according to claim 1, wherein the lower core layer is at least partially foamed.

23. The panel according to claim 1, comprising at least one decorative top layer, which is either directly or indirectly, affixed to the core layer.

24. A method for producing a floor panel, a wall panel, or a ceiling panel, comprising the steps of: providing a first composite material; providing a second composite material, wherein the Vicat softening temperature of the first composite material is at least 15 degrees Celsius higher than the Vicat softening temperature of the second composite material; forming a core layer comprising an upper core layer comprising said first composite material and a lower core layer comprising said second composite material, wherein said core layer comprises a top surface and a bottom surface, impressing a plurality of cavities in at least part of the bottom surface of the core layer, and; enabling hardening and/or curing of the core layer.

25. The method according to claim 24, wherein the core layer is formed via co-extrusion.

26. The method according to claim 24, wherein at least part of cavities is obtained via imprinting, rotary imprinting and/or rotary die cutting.

27. The method according to any claim 24, wherein impressing of the core layer is performed by guiding the core layer trough at least two rollers, wherein at least one of the rollers is provided with a surface structure configured to provide a plurality of cavities in at least part of the bottom surface of the core layer.

28. The method according to claim 24, wherein the second composite material has a Vicat softening temperature in the range of 50 to 90 degrees Celsius.

29. (canceled)

Description

[0092] The invention will now be elucidated into more detail with reference to the following non-limitative figures. Herein show:

[0093] FIGS. 1a-1e each a cross section of possible embodiments of a panel according to the present invention;

[0094] FIGS. 2a-2d each a bottom view of possible embodiments of a panel according to the present invention;

[0095] FIG. 3a a bottom view of another possible embodiment of a panel according to the present invention;

[0096] FIG. 3b a roller which could be applied to manufacture a panel according to the present invention;

[0097] FIGS. 3c-3h a bottom view of various possible embodiments of a panel according to the present invention; and

[0098] FIGS. 4a-4i cross sectional view of various possible embodiments of cavities according to the present invention.

[0099] Within these figures, similar references correspond to similar or equivalent components and/or technical features.

[0100] FIG. 1a-1e show shows schematic representations of possible embodiments of panels 100 according to the present invention. The figures show a schematic representation of a side view of the panel 100. Each panel 100a, 100b, 100c, 100d, 100e can for example be a floor panel 100, a wall panel 100, or a ceiling panel 100. Each panel comprises a core layer 101, which core layer 101 comprises an upper core layer 101a and a lower core layer 101b. The upper core layer 101a comprises a first composite material whereas the lower core layer 101b comprises a second composite material. The Vicat softening temperature of the upper core layer 101a differs from the Vicat softening temperature of the lower core layer 101b. Part of the bottom surface of the core layer 101, in particular the lower core layer 101b, of each panel 100a, 100b, 100c, 100d, 100e is provided with a plurality of impressed cavities 102 which extend towards the top surface of the core layer 101. FIG. 1a shows that the panel 100 can optionally be provided with interconnecting coupling parts 103a, 103b. Interconnecting coupling parts 103a, 103b could be applied to any of the embodiments covered by the present invention.

[0101] FIG. 1a shows a panel 100a comprising a plurality of cavities 102 which are positioned at predetermined distance from another. The panel 100a further comprises a top layer 106. In the shown embodiment the top layer 106 is a ceramic panel 106 attached to the top surface of the core layer 101. The coupling parts 103a, 103b extend through both the upper core layer 101a and the lower core layer 101b. FIG. 1b shows a panel 100b wherein the depth the cavities 102 differs per cavity 102. The cavities 102 are substantially trapezium shaped in cross section. Optionally, the panel 100b may comprise a decorative top layer. FIG. 1c shows an embodiment wherein the cavities 102 have a cross section which is semicircular. The cavities 102 are filled with sound absorbing material 107. The panel 100c further comprises a backing layer 108 which is attached to the bottom surface of the lower core layer 101b. FIG. 1d shows that the height, or depth, h of the cavities 102 is higher than the thickness of the lower core layer 101b. Hence the cavities 102 extend into the upper core layer 101a. FIG. 1e shows a side view of a panel 100e wherein it can be seen that the cavity 102 extends over substantially the entire length of the panel 100e but that the cavity 102 starts and ends at a predetermined distance from the outer ends of the panel 100e. The panel 100e further comprises a backing layer 108, in particular a balancing layer 108. the cavity 102 is free of filling material, such as a sound absorbing material.

[0102] FIGS. 2a-2d shows schematic representations of possible embodiments of panels 200 according to the present invention. The figures show a bottom view of the panel 200. Each panel 200a, 200b, 200c, 200d can for example be a floor panel 200, a wall panel 200, or a ceiling panel 200. Each panel 200 comprises a core layer 201 which core layer 201 comprises an upper core layer and a lower core layer. The figures show the bottom surface of the lower core layer. Part of the bottom surface of the core layer 201 of each panel 200a, 200b, 200c, 200d is provided with the (impressed) cavities 202 which extend towards the top surface of the core layer 201. In the shown embodiments, the panels 200a, 200b, 200c, 200d are not provided with (interlocking) coupling means. However, it is conceivable that said coupling means are applied.

[0103] FIG. 2a shows a panel 200a comprises a plurality of substantially parallel cavities 202. Each cavity 202 is positioned at a predetermined distance from the peripheral edges of the panel 200a. It can also be seen that each cavity 202 extends in longitudinal direction of the panel 200a. FIG. 2b shows a panel 200b wherein the cavities 202 form a network of interconnected cavities 202. It is experimentally found that such embodiment may strengthen the sound dampening effect of the panel 200b. FIG. 2c shows a panel 200c with a plurality of individual cavities 202 which extend substantially in the longitudinal direction of the panel 200c. The cavities 202 are locally widened. At least the locally widened areas may for example be filled with sound absorbing material. FIG. 2d shows a panel 200d having series of substantially V-shaped cavities 202. the cavities 202 are positioned at a predetermined distance from another and do not interfere with an adjacent cavity 202.

[0104] FIG. 3a shows a schematic representations of possible embodiment of a panel 300 according to the present invention. The figure shows a bottom view of the panel 300. The panel comprises a core layer 301 which core layer 301 comprises an upper core layer and a lower core layer. The figures show the bottom surface of the lower core layer. Part of the bottom surface of the core layer 301 is provided with a plurality of cavities 302. The cavities 302 extends towards the top surface of the core layer 301. The cavities 302 are integrally formed cavities 302. In the shown embodiment, the cavities 302 define a cell pattern, in particular a polygon cell pattern. The figure show that the cavities 302 are separated via partitions 303, wherein at least part of the partitions 303 between the cavities 302 have a thickness which is smaller than the length and/or width of the cavities 302. In the shown embodiment, the cavities 302 are thermoformed into the bottom surface of core layer 301.

[0105] FIG. 3b shows a roller 330 which could be applied to manufacture a panel 300 according to the present invention, in particular as shown in FIG. 3a. The plurality of cavities can be provided by subjecting at least part of the bottom surface of a core layer to a (rotary) imprinting process. This can be done substantially directly after co-extrusion of the core layer, if this technique is applied. It is for example conceivable that the core layer is led trough at least two rollers 330, wherein at least one of the rollers is provided with a surface structure 331 configured to provide a plurality of cavities in at least part of the bottom surface of the core layer.

[0106] FIGS. 3c-3h show a bottom view of various further possible embodiments of a panel according to the present invention. The figures are in line with FIG. 3a, and show a bottom view of part of a panel according to the present invention. The figures show for each embodiment a plurality of impressed cavities 302, in particular in a repeated pattern. The cavities 302 are separated via partitions 303, wherein at least part of the partitions 303 between the cavities 302 have a thickness which is smaller than the length and/or width of the cavities 302.

[0107] FIGS. 4a-4i show cross sectional views of various possible embodiments of impressed cavities 402 according to the present invention. It can be seen that the cavities 402 have rather clear boundaries, wherefore the cavities 402 could also function as attenuation chambers.

[0108] 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.

[0109] 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.

[0110] 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. When it is referred to reinforcing layer also a reinforcing element can be meant, or vice versa. Within the scope of this invention, where the term impressed cavity is used, also the term cavity could be applied, or vice versa. Where the terms impressed or impressing are applied, also the terms depressed or depressing could be used. The upper core layer and the lower core layer can be integrated core layers. The upper core layer could also be referred to as core layer and the lower core layer as bottom layer.