Abstract
The invention relates to a decorative surface covering element, in particular a floor panel, ceiling panel or wall panel. The invention also relates to a panel covering, such as a floor covering, ceiling covering or wall covering, including a plurality of panels. The invention further relates to a method of producing a decorative surface covering element.
Claims
1. A decorative surface covering element, in particular a decorative panel, such as 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 décor image,
a substantially transparent or translucent three-dimensional embossing structure at least partially covering said print layer, wherein the embossing structure is a multi-layer embossing structure which comprises: at least one, at least partially cured base layer provided with a plurality of indentations, and at least one at least partially cured elevated pattern layer formed by a plurality of elevations digitally printed on top of said base layer, wherein at least a part of an upper surface of the embossing structure is provided with a roughened texture, and preferably at least one finishing layer at least partially covering the roughened embossing structure.
2. The surface covering element according to claim 1, wherein an upper side of the base layer defines an embossing base level, and wherein the indentations and at least a part of the elevations are situated at opposite sides of said embossing base level.
3. The surface covering element according to claim 1, wherein an upper side of the base layer defines a base level, and wherein the indentations and at least a part of the elevations are situated at the same side of said base level.
4. The surface covering element according to claim 1, wherein a part of the base layer is provided with said plurality of indentations, and wherein another part of the base layer is free of indentations.
5. The surface covering element according to claim 4, wherein at least a part of the elevations are printed on the part of the base layer which is free of indentations.
6. The surface covering element according to claim 1, wherein the plurality of indentations of the base layer forms a discontinuous indentation pattern.
7. The surface covering element according to claim 1, wherein the base layer is a printed base layer.
8. (canceled)
9. (canceled)
10. The surface covering element according to claim 1, 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 decor image formed by the decorative print layer.
11. (canceled)
12. (canceled)
13. The surface covering element according to claim 1, wherein a coloured coating is provided in the indentations and onto the base layer.
14. (canceled)
15. (canceled)
16. The surface covering element according to claim 1, wherein the base layer comprises acrylic resin.
17-20. (canceled)
21. The surface covering element according to claim 1, wherein the elevated pattern layer comprises acrylic resin.
22. (canceled)
23. The surface covering element according to claim 1, wherein at least one finishing layer is applied, and wherein the upper surface of the embossing structure is entirely covered by a finishing layer, in particular a lacquer layer.
24. The surface covering element according to claim 1, wherein at least one finishing layer is applied, and wherein at least at least one finishing layer is free of any roughened texture.
25. The surface covering element according to claim 1, wherein at least a part of the decorative layer is printed directly onto the upper side of the core.
26. The surface covering element according to claim 1, wherein the upper side of the core is provided with a carrier layer, preferably formed by a primer or a film, wherein at least a part of the decorative layer is printed directly onto the carrier layer.
27. The surface covering element according to claim 1, wherein in between the printed decorative layer and the embossing structure at least one intermediate layer is situated, wherein at least one intermediate layer is formed by a transparent or translucent, light-reflective thermoplastic layer, preferably a polyester layer, more preferably a polyethylene terephthalate layer, wherein said light-reflective thermoplastic layer is glued onto the printed decorative layer.
28-31. (canceled)
32. The surfacecovering element 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, 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 the first coupling profile and the second coupling profile are preferably configured such that two of such surface covering elements can be coupled to each other by means of a lowering movement.
33. (canceled)
34. (canceled)
35. The surface covering element according to wherein the core is at least partially foamed.
36. (canceled)
37. (canceled)
38. The surface covering element according to claim 1, wherein the core comprises at least one composite material of at least one polymeric material and at least one non-polymeric material.
39. (canceled)
40. (canceled)
41. The surface covering element according to wherein the embossing structure comprises a plurality of base layers and/or a plurality of elevated pattern layers.
42. (canceled)
43. The surface covering element according to wherein the roughened texture is wherein the roughned texture is a brushed roughened texture.
44. (canceled)
45. (canceled)
46. The surface covering element according to wherein the base layer and/or the pattern layer is composed of a water based ink composition.
47. (canceled)
48. (canceled)
49. The surface covering element according to wherein the roughened texture is provided both to at least a part of the base layer and to at least a part of the pattern layer.
50. (canceled)
51. (canceled)
52. The surface covering element according to wherein the embossing structure is a printed embossing structure, and wherein at least a part of an upper surface of the printed embossing structure is provided with a mechanically roughened texture.
53. (canceled)
54. (canceled)
55. The surface covering element covering, in particular floor covering, ceiling covering, or wall covering, consisting of mutually coupled surface covering elements according to claim 1.
56-72. (canceled)
Description
DETAILED DESCRIPTION OF THE INVENTION
[0127] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures.
[0128] FIGS. 1a-1g show 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) as an example of a surface covering element according to the invention. The figure shows the core (100) of the panel (110). The core (100) is typically substantially rigid, and may possibly comprises at least one polymer and/or at least one wood-based material. A decor image is formed onto the upper side (100A) of the core (100) by means of printing, in particular digital printing. FIG. 1b show that a liquid base layer (101) is applied on the decor image formed at the upper side (100A) of the panel (110). The liquid forming the liquid base layer (101) is for example a UV sealer. The liquid base layer (101) generally has a relatively high surface tension in order to allow precise embossing in the liquid base layer (101). FIG. 1c show that a plurality of embossing droplets (102) is position-selectively printed on the still 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. 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. The base layer (101) is at least partially cured after the base layer (101) is provided with said indentations (103).
[0129] 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. Preferably, the embossing droplets (102) and/or the elevation droplets (104) have a surface tension which is higher than the surface tension of the liquid base layer (101). Optionally, one or more finishing layers (not shown) can be applied to the panel (110). 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 decor image and a substantially transparent or translucent three-dimensional embossing structure at least partially covering said print layer. The embossing structure 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). In FIG. 1f it is shown that the embossing structure is mechanically treated by means of a plurality of successively oriented rotating cylindrical brush rollers (120a, 120b, 120c), wherein adjacent brush rollers (120a, 120b, 120c) axially rotate in opposite directions. The brush rollers (120a, 120b, 120c) typically have relatively sturdy and/or rigid brush wires, preferably at least partially made of metal, more preferably of steel and/or a composite of steel and carbon. The diameter of the brush rollers (120a, 120b, 120c) in this exemplary embodiment is substantially 30 centimetre. The rotation speed of the brush rollers (120a, 120b, 120c) is typically between 550 and 650 revolutions per minute (rpm), and is preferably substantially equal to 600 rpm. The brush rollers (120a, 120b, 120c) are used to transform the (complete) initially smooth texture of the upper surface of the panel (110)into a more roughened texture of the upper surface of the panel (110). This roughened texture of the embossing structure has typically more sharp edges, and has a look and feel appearance which comes close(r) to natural wood nerves, as shown in more detail in FIG. 1g. This is in particular advantageous in case the decor image also constitutes a wood nerve pattern, preferably a wood nerve pattern, wherein the decorated wood nerves are in register (in line) with the embossed wood nerves. During this mechanical action, material will be removed from the embossing structure, and optionally also from an intermediate transparent layer (if applied) situation in between the embossing structure and the decor image, which material will be released as dust particles. To evacuate at least a part of the dust particles created during this mechanical brushing action (roughening action), each brush roller (120a, 120b, 120c, 130) is enclosed by a cover (140a, 140b, 140c, 140d), also referred to as housing or cage, which cover (140a, 140b, 140c, 140d) is connected to a vacuum system (not shown). During further displacement of the panel (110) in a transport direction T, the panel (110) will pass an axially rotating cylindrical cleaning brush roller (130) having more soft wires, such as textile and/or nylon wires, to remove further dust particles from the panel (110). Typically after roughening and cleaning, the panel (110) will be cut into smaller panels, and will be profiled at two or four panel edges (not shown).
[0130] FIG. 2a shows a schematic representation of another example of a decorative panel (220) according to the present invention. The panel (220) comprises a core (200) provided with an upper side and a lower side, and a decorative top structure (201) affixed, directly or indirectly, on said upper side of the core (200). The decorative top structure (201) comprises a decorative print layer forming at least one decor image. The panel (220) also comprises a substantially transparent or translucent three-dimensional embossing structure (202) covering said print layer (201). In the shown embodiment comprises the embossing structure (202) a base layer (204) provided with a plurality of indentations (203), and an elevated pattern layer formed by a plurality of elevations (205) printed on top of said base layer (204). The elevations form part of a lacquer layer (205). A carrier layer (206), and in particular a primer layer (206) is present enclosed between the top structure (201) and the embossing structure (202). In the shown embodiment, the primer layer (206) comprises a pattern of mat primer (206A) and glossy primer (206B). The indentations (203) are present where the primer layer (206) is provided with mat primer (206A). The structured elevations (205) cover the glossy primer (206B) of the primer layer (206). Due to the embossing structure (202) being substantially transparent, the differences within the primer layer (206) are visible. It is also conceivable that the primer layer (206) is attached onto the upper side of the core (200), and that the decorative top structure (201) is attached onto the primer layer (206).
[0131] FIG. 2b shows a top view of the panel (220) shown in FIG. 2a. It can be seen that due to a part of the base layer being provided with said plurality of indentations (203) and part of the base layer being free of indentations a visually observable pattern is obtained. This effect is further reinforced by the primer layer (206) comprising both mat and glossy primer (206A, 206B) in a pattern which is in line with the embossing structure (202).
[0132] 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). An intermediate layer (303) is present on top of the printed decorative top layer (301). The intermediate layer (303) is formed by a transparent or translucent, light-reflective thermoplastic layer (303). The light-reflective thermoplastic layer (303) is glued onto the printed decorative layer (301) by means of a hot melt glue layer (304). A substantially transparent or translucent three-dimensional embossing structure (305) is positioned on top op of aforementioned layers (300, 301, 302, 303, 304). 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. 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 finishing layer (309), in particular a lacquer layer (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) typically have a depth situated in between 2 micron and 100 micron, preferably situated in between 3 micron and 50 micron. The elevations of the elevated pattern layer (307) typically have a height situated in between 2 micron and 500 micron, preferably situated in between 3 micron and 300 micron. The embossing structure, in particular one or both base layers (306A, 306B) and/or the pattern layer (307) and/or the finishing layer (309) is provided with a roughened texture by mechanically brushing these one or more layers (directly) after application. Here, it is conceivable that a layer is mechanically roughened (and optionally cleaned) prior to applying one or more further layers on top of said roughened layer.
[0133] 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, having an embossing structure with a mechanically roughened upper surface, e.g. as discussed and shown in the previous figures. 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.
DESCRIPTION OF THE INVENTION
[0134] 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.
[0135] 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.
[0136] 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.
