Panel suitable for assembling a waterproof floor or wall covering, method of producing a panel

Abstract

Panel suitable for assembling a waterproof floor or wall covering from a plurality of said panels, wherein the panel has a substantially planar top surface, and a substantially planar bottom surface, the panel having a laminated structure of layers which comprises: a flexible core layer which basically is composed of a material which is relatively low in density and is provided with voids in the form of air pockets, and a rigid top layer which comprises a support layer that is basically composed of a material that is relatively high in density and which is virtually devoid of air pockets, wherein the thickness of the core layer is smaller than the thickness of the support layer, preferably in a ratio of 0.5 or less, more preferably in a ratio between 0.5 and 0.10.

Claims

1. A panel suitable for assembling a waterproof floor or wall covering from a plurality of said panels, wherein the panel has a substantially planar top surface, and a substantially planar bottom surface, the panel having a laminated structure of layers which comprises: a flexible core layer which is substantially composed of a material which is provided with voids in the form of air pockets and hence is relatively low in density, a rigid top layer which comprises a support layer that is substantially composed of a material that is devoid of air pockets and hence is relatively high in density, wherein the rigid top layer further comprises a wear layer and a décor layer on top of the support layer, and a rigid backing layer which is provided directly or indirectly to the bottom side of the core layer, wherein the core layer has a lower density than the top layer and the backing layer, wherein the core layer has a density of 100-300 kg/m3, wherein the material of the core layer comprises a foam material from polyethylene, ethylene-vinyl acetate, polystyrene, polypropylene, polyurethane, or melamine, or alternatively cork, wherein the support layer has a density of at least 1200 kg/m3, wherein a pore volume of the voids in the core layer is in a range of 20 to 50%, and wherein the pore size of the voids in the core layer is in a range of 0.01 to 0.5 mm.

2. The panel according to claim 1, wherein the material of the backing layer is a thermoplastic material, wood, paper or paper impregnated with melamine.

3. The panel according to claim 1, wherein the backing layer is made of a flexible vinyl compound with a plasticizer content of at least 5 wt. %.

4. The panel according to claim 1, wherein the backing layer is made of polyvinyl chloride (PVC).

5. The panel according to claim 4, wherein the backing layer is made of extruded polyvinyl chloride (PVC) material that is free from plasticizer.

6. The panel according to claim 1, wherein the backing layer has a thickness of 0.5 to 5.0 mm.

7. The panel according to claim 1, wherein the backing layer has a density of at least 1600 kg/m3.

8. The panel according to claim 1, wherein the voids in the material of the core layer have a closed cell and/or open cell structure.

9. The panel according to claim 1, wherein the support layer is directly or indirectly provided onto the top side of the core layer.

10. The panel according to claim 1, wherein the core layer has a thickness in the range of 0.5 to 3.0 mm.

11. The panel according to claim 1, wherein the support layer contains a reinforcing material.

12. The panel according to claim 1, wherein the material of the support layer comprises a thermoplastic material, wherein the material of the support layer is polyvinyl chloride (PVC) that is virtually free from plasticizer and contains CaCO3 as filler material.

13. The panel according to claim 1, wherein the top layer comprises the wear layer on top of the décor layer.

14. The panel according to claim 1, the panel having at least four substantially linear side edges having a rectangular design, wherein the linear side edges comprise at least one pair of opposite side edges which are provided with interconnecting coupling means for interconnecting one panel within another.

15. The panel according to claim 14, wherein the interconnecting coupling means are provided as an integral part of the support layer.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The invention will be further explained with reference to the appended figures wherein:

(2) FIG. 1 shows in perspective a preferred embodiment of the panel according to the invention;

(3) FIG. 2 shows a cross-section of the preferred embodiment of the panel according to the invention;

(4) FIGS. 3a, 3b, 3c, and 3d show a cross-section of several variants of the panel according to the invention;

(5) FIG. 4 shows a cross-section of a panel as proposed in relevant prior art.

(6) FIG. 1 shows a panel 1 suitable for assembling a waterproof floor or wall covering by interconnecting a plurality of said panels with each other, wherein the panel has a substantially planar top surface 3, and a substantially planar bottom surface 5, at least four substantially linear side edges 6a,6b,6c,6d comprising at least one pair of opposite side edges 6a,6c which are provided with interconnecting coupling means 7,8 for interconnecting one panel within another, the panel having a sandwich structure which comprises a core layer 10 basically composed of a foam material, a rigid top layer 12 and a backing layer 14.

(7) FIG. 2 shows the same embodiment as FIG. 1 in cross-section, wherein the interconnecting coupling means 7,8 comprise a tongue 7 and a groove 8, each having an interlocking feature 20a (a projection) and 20b (a recess) which avoids free movement of interconnected panels when the tongue of one panel is inserted in the groove of another neighbouring panel.

(8) The core layer 10 is composed of a foam structure based on EVA, which has soft and flexible properties. The foam structure of the core layer 10 contains voids in the form of air pockets which are schematically depicted by small circles 10a.

(9) The rigid top layer 12 comprises a support layer 12a, a décor layer 12b, a wear layer 12c, and a coating 12d. The support layer 12a is a rigid, high density PVC material that is free from plasticizer.

(10) The backing layer 14 is composed of an extruded PVC material that is free from plasticizer, and consequently is rigid.

(11) The shown thicknesses are roughly indicative for the actual thicknesses that are used in the panel of the invention. The overall thickness of the shown panel is approximately 6 mm.

(12) FIG. 3 shows several variants of the panel in regard of the design of the side edges 6a and 6c. The laminated structure of the layers in FIGS. 3A-3D are the same as that of layers 10, 12 and 14 as depicted in FIG. 2.

(13) FIG. 3a shows a design of side edges 6a and 6c as depicted in FIG. 2 which allows for an interlocking of two complementary side edges by an angling-in movement;

(14) FIG. 3b shows a design of side edges 6a and 6c being simply a flat surface, wherein the side edges may be interlocked by applying an adhesive material on the contacting side edges of neighbouring panels;

(15) FIG. 3c shows a design of side edges 6a and 6c being provided with a classic groove 8 and tongue 7 design, which requires a horizontal shifting movement to interconnect two panels.

(16) FIG. 3d shows a design of side edges 6a and 6c being provided with another classic groove 8 and tongue 7 design, that allows for interconnection by a vertical or drop-down movement.

(17) Importantly, in all the above tongue and groove designs shown, both types of interconnecting coupling means form an integral part of the support layer 12a.

(18) FIG. 4 shows a cross-section of a panel as proposed in relevant prior art, for comparative reasons and in connection to the comparative example given below.

COMPARATIVE EXAMPLE

(19) The advantageous technical effect of the invention will be further substantiated with reference to the following comparative example:

Example I

(20) WPC Flooring Product (Prior Art)

(21) A so-called WPC flooring panel was produced in line with the disclosure of U.S. Pat. No. 9,212,494, and attached FIG. 4.

(22) Essentially, the core layer of foam material forms the main layer of the panel for constituting more than half the total thickness of the panel (in line with FIG. 4). Furthermore, the tongue and groove profiles are an integral part of the core layer. The density of the core layer is approx. 750 kg/m3.

(23) The top layer provided on the core layer of foam material, is more dense and has a density of 1600 to 1800 kg/m3 which is above the value of the core layer.

(24) The backing layers consisted of an EVA and PE cushion layer with a density of approx. 200 kg/m3.

Example II

(25) Panel According to the Invention

(26) A specimen panel according to the invention and as depicted in FIG. 2, was produced having the following properties:

(27) Support layer: Made from PVC that is virtually free from plasticizer and contains CaCO3 as filler material, wherein CaCO3 is present in a wt. % content of 60. thickness of 2.5 to 3.0 mm. density of 1800 to 2000 kg/m3 rigid, solid properties

(28) Core layer: Made from EVA, PE or PS foam Thickness of 0.8 to 1.5 mm Density of 100 to 300 kg/m3 Soft, flexible properties

(29) Backing layer: Made from PVC that is virtually free from plasticizer and contains CaCO3 as filler material, wherein CaCO3 is present in a wt. % content of 60. thickness of 0.8 to 2.0 mm. density of at least 1600 kg/m3 rigid, solid properties
Common Features

(30) Both panel I and II, were provided with similar finishing layers on its top surface, i.e. a coating, a wear layer, and a décor layer. The materials used were also similar and are commonly used in the art.

(31) Comparative Tests

(32) Both panels were subjected to the following tests: acoustic tests; in accordance with the following standards: ISO 10140-1, ISO 717-2, ASTME2179-03, ASTME989-06. indentation tests; in accordance with the following standards: ASTM 1914. Rigidity tests; in accordance with the following standards: EN 310.

(33) The below table shows the results that were obtained by the above tests.

(34) TABLE-US-00001 Acoustic performance Indentation Improvement performance Rigidity of impact Reducing of Residual Modulus of Test name sound impact sound indentation elasticity Test norms ISO 10140-1, ASTME2179-03, ASTM 1914 EN 310 ISO 717-2 ASTME989-06 Test results ΔLw ΔIIC MOE value Example II 21 dB-22 dB 25 dB-26 dB l%-5% 3000- (Invention) 6000 N/mm2 Example I 21-22 dB 25 dB-27 dB  8%-25% 800- (prior art) 2000 N/mm2

(35) From the above table, one derives directly that the panel according to the invention achieves not only adequate acoustic properties, but in addition also has satisfactorily values in terms of both indentation resistance and rigidity.

(36) For combining all these three properties to an adequate extent, the invention is arguably an improvement over the prior art, which in contrast shows inadequate values both in terms of indentation resistance and rigidity.