Panel, in particular a floor, ceiling, or wall panel; a covering constructed by a multitude of such panels; and a method for the recycling of such a panel

Abstract

A panel, in particular a floor, ceiling, or wall panel, of a planar design having a top side, a bottom side and multiple side edges, which panel has a laminated structure of layers that are adhered to each other. The layers extend parallel to the plane of the panel, and include a core layer having a lower side and an upper side, and a top layer which is provided on the upper side of the core layer either directly or indirectly. At least two layers of the panel, in particular the top layer and the core layer, are directly or indirectly adhered to each other by an intermediate adhesive layer. The intermediate adhesive layer is composed of adjacent intermediate zones which include non-adhesive intermediate zones and adhesive intermediate zones, which intermediate adhesive layer establishes an adhesive strength between the two layers, such that a durable adhesion between the two layers is obtained, and a clean delamination of the two layers is allowed for when the two layers are subjected to a sufficient delamination force.

Claims

1. A decorative panel of a planar design having a top side, a bottom side and multiple side edges, the panel having a laminated structure of layers that are adhered to each other, wherein the layers extend parallel to the plane of the panel, and comprises: a core layer having a lower side and an upper side, and a top layer is provided on the upper side of the core layer either directly or indirectly, wherein the top layer comprises: a decorative visual print layer, and at least one substantially transparent or translucent wear layer applied on top of said print layer, wherein at least two layers of the panel, the top layer and the core layer, are directly or indirectly adhered to each other by an intermediate adhesive layer, wherein the intermediate adhesive layer is composed of adjacent intermediate zones comprise one or more non-adhesive intermediate zones and one or more adhesive intermediate zones, wherein the one or more adhesive intermediate zones define a pattern.

2. The panel according to claim 1, wherein the adhesive intermediate zones comprise an adhesive material based on polyurethane or a polymeric mixture comprising polyurethane.

3. The panel according to claim 1, wherein the adhesive intermediate zones comprise discrete adhesive intermediate zones that are separated from each other.

4. The panel according to claim 1, wherein at least two sets of two adjacent layers of the panel, are directly or indirectly adhered to each other by an intermediate adhesive layer, wherein each intermediate adhesive layer is composed of adjacent intermediate zones that comprise one or more non-adhesive intermediate zones and one or more adhesive intermediate zones, wherein the one or more adhesive intermediate zones define a pattern.

5. The panel according to claim 1, wherein the adhesive intermediate zones comprise adhesive intermediate zones that are interconnected to each other to form a grid pattern.

6. The panel according to claim 1, wherein the non-adhesive intermediate zones comprise void spaces and/or are free of any adhesive.

7. The panel according to claim 1, wherein the non-adhesive intermediate zones comprise an inactivated adhesive material that establishes no adhesive strength between the layers.

8. The panel according to claim 1, wherein the non-adhesive intermediate zones comprise an adhesive material that is covered at an upper side and/or a bottom side thereof, with a masking layer of a material that has no adhesive properties with respect to the layer the masking layer is in contact with.

9. The panel according to claim 1, wherein the value of the adhesive strength of the intermediate adhesive layer is 60% or less of the adhesive strength of an intermediate adhesive layer of the same thickness that is entirely composed of adhesive intermediate zones that are adjacent to each other and thus form a continuous layer.

10. The panel according to claim 1, wherein the surface area covered by said one or more adhesive intermediate zones and the surface area covered by said one or more non-adhesive intermediate zones define a ratio, wherein said ratio is situated between 0.4 and 9.

11. The panel according to claim 1, wherein the panel has a length in the range of 0.40 to 2.0 m, a width in the range of 70 to 180 mm, and an overall thickness of 2 to 20 mm.

12. The panel according to claim 1, wherein the top layer comprises a wear layer that is of transparent quality and/or comprises a polymeric material.

13. The panel according to claim 1, wherein at least one substantially transparent or translucent top coating layer applied on top of said at least one wear layer.

14. The panel according to claim 1, wherein the layers of the panel further comprise a backing layer that is directly or indirectly adhered to the lower side of the core layer by the intermediate adhesive layer, wherein the back layer and the core layer, are directly or indirectly adhered to each other by an intermediate adhesive layer, wherein the intermediate adhesive layer is composed of adjacent intermediate zones that comprise one or more non-adhesive intermediate zones and one or more adhesive intermediate zones.

15. The panel according to claim 1, wherein the core layer comprises polyurethane or a polymeric mixture comprising polyurethane.

16. The panel according to claim 1, wherein the core layer comprises a polymeric material that is a mixture of recycled polymeric material and virgin polymeric material.

17. The panel according to claim 1, wherein the panel comprises at least one pair of two opposite side edges that are provided with respective interconnecting profiles that are complementary to each other.

18. The floor, ceiling, or wall covering constructed by a multitude of adjacent panels according to claim 1.

19. A method for recycling of a panel, wherein the method comprises consecutive steps of: i. collecting a multitude of panels wherein each panel is defined according to claim 1, and ii. delaminating each collected panel that involves applying a sufficient delamination force such that two layers that are adhered to each other by the intermediate adhesive layer are delaminated.

20. The method according to claim 19, further comprising a subsequent step of: separately processing of the two delaminated layers that are obtained in step ii., in respective separated streams.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be further elucidated by examples of preferred, non-limitative embodiments of the invention which are shown in the appended figures, wherein:

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

(3) FIG. 2 shows a cross-sectional view of two panels and their coupling profiles according to the invention;

(4) FIG. 3 shows a top view of a part of the panel of FIG. 2;

(5) FIG. 4 shows a top view of a part of an alternative embodiment of the invention;

(6) FIG. 5 shows a cross-sectional view of a part of the panel of FIG. 3;

(7) FIG. 6 shows a top view of a part of an alternative embodiment of the invention;

(8) FIG. 7 shows a cross-sectional view of a part of the panel of FIG. 6.

DESCRIPTION OF THE INVENTION

(9) FIG. 1 shows a panel 1 suitable as a floor, ceiling or wall panel, which panel is of a planar design having an top side 7, a bottom side and side edges 3a-d which comprise a first side edge 3a provided with a first profile 10 and a second side edge 3c provided with a second profile 11. A top layer 30 is present at the top side 7 of the panel.

(10) FIG. 2 shows a cross-section of the panel 1 of FIG. 1, perpendicular to the first and second side edges 3a and 3c, which are provided with a first profile 10 and a second profile 11. The bottom side 9 of the panel 1, is laid on a substrate layer for instance a floor surface S.

(11) The panel 1 has a laminated structure of layers 28, 30 and 32 that are adhered to each other, which layers extend parallel to the plane of the panel 1, and comprise: a core layer 28 having a lower side and an upper side, a top layer 30 which is adhered on the upper side of the core layer by an intermediate adhesive layer 27 according to the invention, and a backing layer 32 which is adhered on the lower side of the core layer by an intermediate adhesive layer 29 according to the invention.

(12) Further in FIG. 2, another identical panel 1 is shown in part, of which the second side edge 3c is to be coupled to the panel 1, by a downward vertical movement indicated by vector D.

(13) The first profile 10 and the second profile 11 of both panels 1 and 1 are mutually interacting profiles that can be coupled to each other and are complementary to each other. During coupling, the second profile 11 of panel 1 is vertically inserted in the first profile 10 of panel 1, which involves the downward tongue 22 of panel 1 being inserted in the first groove 23 of panel 1, and the upward tongue 21 of panel 1 being inserted in the second groove 24 of panel 1. When coupled, the panels 1 and 1 lie in a common plane which is parallel to the floor surface S.

(14) FIG. 3 shows a top view of a part of the panel according to FIG. 2, wherein the top layer is not depicted for illustrative purposes, and hence shows the structure underneath the top layer which comprises a top surface of the core layer 28 on which an intermediate adhesive layer is present. The intermediate adhesive layer comprises adhesive intermediate zones in the form of discrete dots 40 and discrete lines 42 of equal thickness which are both made from an adhesive material. A further part of the intermediate adhesive layer comprises non-adhesive intermediate zones 43 in the form of void spaces 43 that are present between the discrete dots 40 and discrete lines 42.

(15) FIG. 4 shows analogously to FIG. 3, a top view of a part of an alternative embodiment of the invention, wherein the top layer is not depicted for illustrative purposes. The shown part of the alternative panel comprises a top surface of the core layer 28 on which an intermediate adhesive layer is present. The intermediate adhesive layer comprises adhesive intermediate zones in the form of intersecting lines 44 of adhesive material, which together form a grid structure. A further part of the intermediate adhesive layer comprises non-adhesive intermediate zones 43 in the form of void spaces 43 that are present outside the grid structure of lines 44.

(16) FIG. 5 shows a cross-sectional view of a part of the panel along lines A-A indicated in FIG. 3, wherein the top layer 30 is included. The top layer 30 is adhered onto the upper side of the core layer 28 by the intermediate adhesive layer 27. The intermediate adhesive layer 27 is composed of adjacent intermediate zones that comprise adhesive intermediate zones in the form of dots 40 and lines 42 of adhesive material, and non-adhesive intermediate zones in the form of void spaces 43.

(17) FIG. 6 shows analogously to FIG. 3, a top view of a part of an alternative embodiment of the invention, wherein the top layer is not depicted for illustrative purposes. In the shown embodiment, the top surface of the core layer is not visible, as the top surface is entirely covered by an intermediate adhesive layer 27, which contains non-adhesive intermediate zones of cured adhesive 46 (indicated by the hatched lines) and adhesive intermediate zones in the form of dots 44 and lines 42 of adhesive material.

(18) FIG. 7 shows a cross-sectional view of a part of the panel along lines A-A indicated in FIG. 6, wherein the top layer 30 is included. The top layer 30 is adhered onto the upper side of the core layer 28 by the intermediate adhesive layer 27. The intermediate adhesive layer 27 comprises adhesive intermediate zones in the form of dots 40 and lines 42 of adhesive material, and non-adhesive intermediate zones of cured adhesive material 46 (indicated by the hatched lines).

(19) The hereby presented invention has been illustrated by several illustrative embodiments. It is noted that any features of the invention described herein are disclosed not only in their explicit combination, but also as a group of features wherein each feature should be construed as disclosed independent from another, and as such is an individual, preferred feature of the invention.

(20) In the present application, the non-limited verb comprise and conjugations thereof, is used in a broader sense by which also the limited verb contain, substantially consist of, formed by are included.