Panel, Covering, and Method for Manufacturing Such a Panel

Abstract

The present invention relates to a panel, such as a floor panel, a wall panel or a ceiling panel, in particular a decorative floor panel. The invention also relates to a covering, in particular a floor covering, including multiple interconnected panels according to the invention. The invention also relates to a method of manufacturing a panel according to the invention.

Claims

1-58. (canceled)

59. A decorative panel, in particular a decorative floor panel, comprising: a core which comprises at least three material layers; at least one first edge and at least one opposite second edge; wherein said first edge comprises a first upper edge portion, wherein said second edge comprises a second upper edge portion; at least one first coupling part arranged on said first edge, and at least one second coupling part arranged on said opposite second edge, wherein the first coupling part of said panel and the second coupling part of another panel are arranged to be coupled to provide a locking of two coupled panels, such that a least a part of the first upper edge portion faces, in particular co-acts or is configured to co-act with, at least a part of the second upper edge portion to form a top seam in between the panels; wherein at least one material layer of the core comprises at least one expandable material layer which comprises at least one material configured to expand or swell upon contact with moisture, to create or improve a seal between panels in a coupled condition, wherein the expandable material layer is at least partially exposed at the interface in between at least two panels in coupled condition; and at least one decorative top section, directly or indirectly affixed to an upper side of said core layer, wherein said decorative top section comprises: i. at least one decorative layer affixed, either directly or indirectly, to an upper surface of the core layer, and at least one transparent and/or translucent protective layer covering said decorative layer.

60. The panel according to claim 59, wherein the said at least one expandable material layer is positioned such that during expanding or swelling of said expandable material layer upon contact with moisture, the top seam is tightened.

61. The panel according to claim 59, wherein at least one expandable material layer is partially covered by at least one protective layer, at least at one of the edges of the panel, wherein the protective layer may be a removable layer.

62. The panel according to claim 59, wherein the at least one expandable material layer defines at least a part of the first upper edge portion and at least a part of the second upper edge portion.

63. The panel according to claim 59, wherein, in coupled condition of two adjacent panels, at least one expandable material layer of one panel is at least partially covered by an opposing upper edge portion and/or the expandable material layer of the adjacent panel.

64. The panel according to claim 59, wherein, in coupled condition of two adjacent panels, the at least one expandable material layer, at least in unexpanded state, of one panel is at least partially and/or initially left uncovered by an opposing upper edge portion and/or opposing expandable material layer of the adjacent panel.

65. The panel according to claim 59, wherein the thickness of the expandable layer varies along its length.

66. The panel according to claim 59, wherein the upper layer (A) comprises a moisture proof material.

67. The panel according to claim 59, wherein at least one upper edge portion is provided with a plurality of expandable material layers, wherein each expandable material layer comprises at least one material configured to expand or swell upon contact with moisture.

68. The panel according to claim 59, wherein each upper edge portion is provided with at least one expandable material layer, wherein, in coupled condition of adjacent panels, expendable material layers of opposing upper edge portions are configured to co-act with each other.

69. The panel according to claim 59, wherein the lower layer (C, A) comprises a moisture sensitive material like wood or MDF or HDF.

70. The panel according to claim 59, wherein the material composition of the upper layer (A) is identical to the material composition of the lower layer (A).

71. The panel according to claim 59, wherein the material composition of the upper layer (A) differs from to the material composition of the lower layer (C).

72. The panel according to claim 59, wherein the thickness of at least one expandable material layer varies in lateral direction.

73. The panel according to claim 59, wherein the thickness of the expandable material layer is between 10 and 1000 micron, in particular between 20 and 500 micron.

74. The panel according to claim 59, wherein at least one upper edge portion is provided with a channel-shaped recessed portion extending along the length of one said upper edge portion, wherein the recessed portion is configured to adjoin an upper edge portion of an adjacent panel, in coupled condition of two panels, wherein, in coupled condition of two panels, the adjoining upper edges enclose a groove, such as a U-shaped groove or a V-shaped groove, representing a grout line, wherein a bottom portion of the recessed portion, connecting to a side wall of the upper edge portion, is provided with at least one expandable material layer.

75. The panel according to claim 59, wherein the material layer comprises at least one hydrogel-forming water-swellable polymer.

76. The panel according to claim 59, wherein the expandable material layer is coloured, wherein the colour of the expandable layer is representative for at least one panel characteristic.

77. The panel according to claim 59, wherein at least one first edge, in particular said first upper edge portion, and at least one opposite second edge, are impregnated with an impregnation agent, in particular a hydrophobic impregnation agent.

78. A covering, comprising multiple interconnected panels according to claim 59.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0140] The terms Fig., Figs., Figure, and Figures are used interchangeably in the specification to refer to the corresponding figures in the drawings.

[0141] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures, wherein:

[0142] FIG. 1 schematically shows two coupled panels according to the invention;

[0143] FIG. 2 shows the panels as shown in FIG. 1, with the addition of a grout or bevel on top; and

[0144] FIG. 3 schematically shows a cross section of (a part of) two panels according to the invention, in coupled condition.

DESCRIPTION OF THE INVENTION

[0145] FIG. 1 schematically shows two panels (1) in coupled condition, comprising a centrally located core (2), wherein the core comprises at least three layered material layers (3, 4, 5), with an upper layer (3), a middle layer (4) and a lower layer (5). FIG. 1 shows a first edge (6) of a panel (1) on the left and a second edge (7) of another panel (1) on the right, wherein said first edge (6) comprises a first upper edge portion (8), wherein said second edge (7) comprises a second upper edge portion (9). The panels (1) also shown a first coupling part (10) arranged on said first edge (6), and a second coupling part (11) arranged on said opposite second edge (7), wherein the first coupling part (10) of said panel and the second coupling part (11) of another panel (1) are arranged to be coupled to provide a locking of two coupled panels (1), such that a least a part of the first upper edge portion (8) faces, in particular co-acts or is configured to co-act with, at least a part of the second upper edge portion (9) to form a top seam in between the panels (1). At least a part of the material layers (3, 4, 5) of the core (2), preferably the middle layer (4) of the core (2), comprises at least one expandable material layer (4) which comprises at least one material configured to expand or swell upon contact with moisture, to create or improve a seal between panels in a coupled condition, wherein the expandable material layer is at least partially exposed at the interface of at least two panels in coupled condition.

[0146] FIG. 1 further shows that the first coupling part (10) and the second coupling part (11) of another panel are arranged to be coupled by means of a downward motion; wherein the first coupling part (10) comprises an upward tongue (15), at least one upward flank (16) lying at a distance from the upward tongue and an upward groove (17) formed in between the upward tongue and the upward flank. The second coupling part (11) comprises a downward tongue (18), at least one downward flank lying (19) at a distance from the downward tongue, and a downward groove (20) 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 part of another panel.

[0147] The outside of the upward tongue (15) comprises a first locking element in the form of an outward bulge (21) and the downward flank (19) is provided with a second locking element, in the form of a recess (22), wherein at least a part of the first and at least a part of second locking element are arranged to be in contact, in coupled condition of the panels and form a locking element surface (23).

[0148] FIG. 2 shows the panels (1) as shown in FIG. 1, with the addition of a grout (12) or bevel on top. The grout (12) is formed by a recess in the upper layer (3). The grout (12) can also be deeper, such that it's bottom (13) is arranged in the middle layer (4), instead of in the upper layer (3).

[0149] The upright sidewalls (14) of the grout (12) yield a rectangular recess in cross section, as shown in FIG. 2. Turning the sidewalls (14) outward at an angle changes the shape of the recess and creates a bevel (not-shown).

[0150] FIG. 3 schematically shows a cross section of (a part of) two panels (30) according to the invention, in coupled condition. More in particular, this cross section shows a third edge (31) and a fourth edge (32) of the panel according to the invention. These edges (31, 32) may be combined with any of the first and second edges as shown in FIG. 1 or 2. Alternatively, these edges (31, 32) may also be applied at remaining edges of the panel (30), wherein a panel (30) in this case would typically have two third edges and two fourth edges. The third edge (31) comprises a third upper edge portion (31a), wherein said fourth edge (32) comprises a fourth upper edge portion (32a). At least one third coupling part (33) arranged on said third edge (31), and at least one fourth coupling part (34) arranged on said opposite fourth edge (32), wherein the third coupling part (33) of the panel (30) and the fourth coupling part (34) of another panel (30) are arranged to be coupled to provide a locking of two coupled panels, such that a least a part of the third upper edge portion (31a) faces, in particular co-acts or is configured to co-act with, at least a part of the fourth upper edge portion (32a) to form a top seam (35) in between the panels; wherein the third upper edge portion (31a) and/or the fourth upper edge portion (32a) is provided with at least one expandable material layer (36) which comprises at least one material configured to expand or swell upon contact with moisture. The third coupling part (33) and the fourth coupling part (34) of another panel (30) are arranged to be coupled by means of an angling down motion, also referred to as turning or rotary movement. As shown in this figure, the third coupling part (30) comprises: a sideward tongue (37) extending in a direction substantially parallel to the upper side of the core, at least one second downward flank (37a) lying at a distance from the sideward tongue, and a second downward groove (37b) formed between the sideward tongue (37) and the second downward flank (37a), and wherein the fourth coupling part (34) comprises: a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile (33) of an adjacent panel (30), said third groove being defined by an upper lip (38) and a lower lip (39), wherein said lower lip (39) is provided with an upward locking element (40), wherein the third coupling part (33) and the fourth coupling part (34) are configured such that two of such panels (30) can be coupled to each other by means of a turning movement, wherein, as shown in FIG. 9, in the coupled condition at least a part of the sideward tongue (37) of a first panel (30) is inserted into the third groove of an adjacent, second panel, and wherein at least a part of the upward locking element (40) of said second panel is inserted into the second downward groove (37b) of said first panel (40). The panels (30) shown typically have a thickness situated in between and including 8 and 12 mm. A lower side of the upward sideward tongue (37) may comprise a flat portion, which is in particular advantageous in case thinner panels, typically having a thickness of 5 mm or less, are applied.

[0151] 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.

[0152] 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.