Abstract
The invention relates to an area covering element including at least one sheet-like carrier core, at least one protective layer and a decorative layer arranged between the sheet-like carrier core and the at least one protective layer. The sheet-like carrier core consists in this case of a strong, load-bearing carrier material and has at least an upper side and an underside arranged opposite from the upper side and also at least a first and second side face, arranged opposite from one another and respectively joining the upper side and underside. The decorative layer is formed by a printed film, which is firmly connected to the carrier core, the printed film at least partially covering at least the upper side and the first and second side faces of the sheet-like carrier core and the protective layer covering the full surface area at least of the printed film connected to the carrier core.
Claims
1. An area covering element comprising at least one carrier core, at least one protective layer and a decorative layer arranged between the carrier core and the at least one protective layer, the carrier core consisting of a strong, load-bearing carrier material and having at least an upper side and an underside arranged opposite from the upper side and also at least a first and second side face, arranged opposite from one another and respectively joining the upper side and underside, wherein the decorative layer is formed by a printed film, which is firmly connected to the carrier core, the printed film at least partially covering at least the upper side and the first and second side faces of the carrier core, towards the underside of the carrier core, and in that the at least one protective layer is covering the full surface area of the printed film connected to the carrier core, wherein the printed film is visible through the at least one protective layer and the underside of the carrier core is provided with at least one primer layer and the printed film at least partially covers at least the upper side and the underside and also the first and second side faces of the carrier core.
2. The area covering element according to claim 1, wherein the printed film completely covers the upper side and the underside and also the first and second side faces of the carrier core.
3. The area covering element according to claim 1, wherein the printed film furthermore extends at least partially over oppositely arranged third and fourth side faces of the carrier core.
4. The area covering element according to claim 1, wherein the protective layer is formed by a surface coating.
5. The area covering element according to claim 1, wherein the protective layer is formed by a transparent protective film.
6. The area covering element according to claim 1, wherein the carrier material of the carrier core comprises a wood, a wood material, a plastic, a plastic composite material, a mineral plastic composite material or a mineral material.
7. The area covering element according to claim 1, wherein the printed film is a film printed by means of digital printing.
8. The area covering element according to claim 1, wherein the printed film is produced from a plastic.
9. The area covering element according to claim 1, in which the carrier core has a thickness of between 2 and 25 mm.
10. The area covering element according to claim 1, in which the area covering element is provided with at least one first coupling profile configured to co-act with a second coupling profile of an adjacent said area covering element.
11. The area covering element according to claim 10, in which the at least one first coupling profile is located at a first side face and/or a second side face of the area covering element.
12. The area covering element according to claim 10, in which the at least one first coupling profile is located at a third side face and/or a fourth side face of the area covering element.
13. The area covering element according to claim 12, in which the first side face and the second side face of the area covering element are free of the first and second coupling profiles.
14. The area covering element according to claim 10, in which the at least one first coupling profile and a complementary said second coupling profile are located at opposite side faces of the area covering element.
15. The area covering element according to claim 10, wherein the at least one first coupling profile is at least partially formed by a tongue or pin.
16. The area covering element according to claim 10, wherein the second coupling profile is at least partially formed by a groove or recess.
17. The area covering element according to claim 10, wherein at least one pair of complementary said first and second coupling profiles is configured to interlock at least two adjacent said area covering elements, such that the area covering elements are locked in a horizontal direction, parallel to a plane defined by the area covering elements, and a vertical direction, perpendicular to said plane defined by the area covering elements.
18. A method for producing an area covering element, in which at least one decorative layer that is formed by a printed film is applied to a carrier core of a strong, load-bearing carrier material, for this purpose the printed film being arranged on the carrier core in such a way that an upper side and at least a first and second side face of the carrier core are at least partially covered by the printed film and the printed film being firmly connected to the carrier core and subsequently at least one protective layer being applied in such a way that at least the printed film connected to the carrier core is covered over its full surface area by the at least one protective layer, and wherein the printed film is visible through the at least one protective layer and an underside of the carrier core is provided with at least one primer layer, wherein the carrier core is enclosed with the printed film, for this purpose the printed film being arranged on the carrier core in such a way that not only the upper side and the first and second side faces but also an underside of the carrier core are completely covered by the printed film.
19. The method according to claim 18, wherein the printed film is adhesively attached at least on the upper side and the first and second side faces of the carrier core, for this purpose a layer of adhesive being applied at least to the upper side and the first and second side faces of the carrier core before the application of the printed film.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention is described below for example on the basis of the schematic drawing, in which:
(2) FIG. 1 shows in a basic schematically represented manner a lateral view of an embodiment of the area covering element according to the invention,
(3) FIG. 2 shows in a basic schematically represented manner a lateral view of an alternative embodiment of the area covering element according to the invention,
(4) FIG. 3 shows in a schematic sectional representation a detail of a preferred embodiment of the area covering element,
(5) FIG. 4 shows in a schematic sectional representation a detail of a further preferred embodiment of the area covering element and
(6) FIG. 5 shows in a schematic sectional representation a detail of yet another preferred embodiment of the area covering element.
(7) FIG. 6a-6d show in a schematic perspective representation different embodiments of area covering elements provided with one or more coupling profiles according to the invention.
(8) FIG. 7 shows a perspective view of a rectangular floor panel according to the present invention.
(9) FIG. 8 shows a cross-sectional view indicated by section A-A in FIG. 7.
(10) FIG. 9 is a cross-sectional view indicated by section B-B in FIG. 7.
DESCRIPTION OF THE INVENTION
(11) FIG. 1 shows in a lateral view a substantially cuboidal or sheet-like area covering element 1, which can be assembled with further area covering elements 1 over a surface area to form a floor covering, ceiling covering and/or wall covering indoors or outdoors, in particular outdoors. In particular, the area covering element 1 may be laid in an interlocking formation to form a decking.
(12) The area covering element 1 comprises a sheet-like carrier core 2, which is formed substantially in a cuboidal manner and consists of a strong, load-bearing carrier material, for example of wood or of a wood-plastic composite material. The sheet-like carrier core 2 has at least an upper side 5, an underside 6 arranged opposite from the upper side 5 and also four side faces, respectively adjoining one another at right angles and joining the upper side and underside. In FIG. 1, only the first and second side faces 7, 8, which are arranged opposite from one another, are provided with designations. In the example shown, the sheet-like carrier core 2 has a thickness of around 20 mm.
(13) The upper side 5 and the first and second side faces 7, 8 of the sheet-like carrier core 2 are covered by a decorative layer 3, which is formed by a printed film. The printed film 3 has a lower side, which is facing the sheet-like carrier core 2, and an upper side, which is opposite from the lower side and may also be referred to as the visible side. The printed film 3, which in the example shown is around 80 μm thick, is firmly connected by way of its lower side to the corresponding surface areas of the upper side 5 and of the first and second side faces 7, 8 of the sheet-like carrier core 2.
(14) Also arranged on the upper side or visible side of the printed film 3 is a protective layer 4, which in the example shown is formed by a surface coating in the form of a transparent lacquer, it being possible for the lacquer to be applied to the upper side or visible side of the printed film 3 in a viscous or liquid form and subsequently cured. The protective layer 4 covers the full surface area of the printed film 3 connected to the carrier core 2. The visible side of the printed film 3 also remains visible through the lacquer. The region of the upper side 5 may also be understood as a visible surface or as an upper surface area of the area covering element 1, which in an assembled floor covering also corresponds to the tread area.
(15) In the case of the example of FIG. 1, consequently three sides of the sheet-like carrier core 2 are covered by the printed film 3, and consequently along with it also by the protective layer 4, so that the sheet-like carrier core 2 in the present concept is covered or coated on three sides by the printed film 3 and the protective layer 4.
(16) FIG. 2 shows—likewise in a lateral view—a further embodiment of the sheet-like area covering element 1 according to the invention. The exemplary embodiment of FIG. 2 differs from that of FIG. 1 substantially in that, in addition to the upper side 5 and the first and second side faces 7, 8, the underside 6 of the sheet-like carrier core 2 is also completely covered by the printed film 3 and the protective layer 4. The carrier core 2 is consequently enveloped or enclosed all around by the printed film 3 and the protective layer 4.
(17) Not shown in the figures, but possible as an alternative variant of the embodiment, the protective layer 4 may furthermore also be partially or completely applied on surface areas of the carrier core 2 that are not covered by printed film 3.
(18) FIGS. 3 to 5 show enlarged in a respective sectional representation a detail of different variants of the embodiment of the present area covering element 1, each of the variants shown being able to be realized both in the embodiment of FIG. 1 and in that of FIG. 2. In the case of all the variants shown according to FIGS. 3 to 5, the printed film 3 is adhesively bonded to the carrier core 2 by way of its lower side that is facing the carrier core 2. For the adhesive bonding, in each case a full-surface-area layer of adhesive 9 is arranged for this purpose between the carrier core 2 and the printed film 3. For an additionally improved bonding of the layer of adhesive 9 on the carrier material of the carrier core 2, provided directly on its surface is a layer of bonding agent 10, which is likewise applied over its full surface area and is consequently arranged between the surface of the carrier core 2 and the layer of adhesive 9.
(19) In the case of the examples according to FIGS. 3 and 5, the layer of adhesive 9 is in this case chosen such that the attachment or bonding between the layer of adhesive 9 and the plastic material of the printed film 3 takes place optimally without any further precautions, so that the printed film 3 is connected by its lower side directly to the layer of adhesive 9. According to FIG. 4, as a difference from this, also arranged between the layer of adhesive 9 and the printed film 3 is a further layer of bonding agent 10 for improving the bonding.
(20) In the case of the examples of FIGS. 3 and 4, the protective layer 4 is formed by a surface coating, to be specific by a transparent lacquer, which is applied directly to the visible side of the printed film 3 that is facing away from the carrier core 2 and is cured. By contrast, in the case of the example of FIG. 5, the protective layer 4 is formed by a transparent protective film, which is adhesively bonded to the visible side of the printed film 3 by way of a layer of adhesive substance 11.
(21) FIG. 6a-6d show in a schematic perspective representation different embodiments of area covering elements provided with one or more coupling profiles according to the invention. More in particular, these figures show different imaginable shapes of area covering elements according to the invention, wherein the depicted are covering elements are each provided with one or more coupling profiles allowing the area covering elements to be connected to one or more other area covering elements. Here, FIG. 6 shows a rectangular element 12 having at a first side face 12a a first coupling profile 13a, and having at an opposite second side face 12b a second coupling profile 13b. The first coupling profile 13a is configured to co-act with the second coupling profile 13b (of another (similar) area covering element). In this example, the first coupling profile 13a is formed by a groove extending along the first side face 12a and extending in a direction parallel to the plane defined by the area covering element 12, and the second coupling profile 13b is formed by a tongue extending along the second side face 12b of the area covering element 12 in a direction parallel to the plane defined by the area covering element 12. The tongue 12b could be clamped into the groove 12a to realize a vertical locking effect and—to some extent—a horizontal locking effect. A printed film, as for example shown in the previous figures, may cover the combination of the first face side 12a and the second face side 12b and/or the combination of a remaining third face side 12c and opposite fourth face side 12d. The printed film normally covers the complete upper side 12e of the covering element 12, and may also cover at least a part of the underside 12f of the covering element 12.
(22) In FIG. 6b two different area covering elements 14, 15 (type A and type B) are shown, wherein each area covering elements 14, 15 is provided with a single coupling profile 14a, 15a, wherein the coupling profiles 14a, 15a of different covering elements 14, 15 are configured to co-act with each other.
(23) In FIG. 6c an area covering element 16 is shown which is provided with alternative complementary coupling profiles 16a, 16b. Here, a first coupling profile 16a comprises a pin or a tongue 16aa, and two holes 16ab, 16ac, and a second coupling profile 16b comprises a hole 16ba and two pins or tongues 16bb, 16bc. Since the coupling profiles 16a, 16b are configured to co-act with each other, different covering elements 16 can be connected (mechanically) with each other. In FIG. 6d an alternative embodiment is shown, wherein in fact two different area covering elements 17, 18 (type A and type B) are shown, wherein each area covering elements 17, 18 is provided with a single coupling profile 17a, 18a, wherein the coupling profiles 17a, 18a of different covering elements 17, 18 are configured to co-act with each other. It may be clear that instead of the shown configuration(s) other configurations of one or more holes and/or one or more tongues (or pins) can be applied at one or more side faces of the area covering element 16.
(24) FIG. 7 shows a rectangular floor panel 101 according to the present invention. The panel 101 is interconnectable with similar panels for forming a covering, as will be shown in further figures. The floor panel 101 can be made of any material, though typical materials are wood, in particular HDF, MDF, and LDF, mineral and/or plastic, in particular thermoplastic, more in particular PVC. Commonly, the floor panel 101 is made of a laminate comprising a central layer (core layer) enclosed by a backing structure and a top structure (not shown). The top structure comprises a decorative layer which is typically formed by a printed film, on top of which a protective layer is applied. The panel 101 comprises a centrally located core 102 provided with an upper side 103 and a lower side 104. The core 102 is integrally connected with a first pair of opposite edges, in particular a first edge 105 and a complementary second edge 106, located at the long lateral sides of the panel 101. The core is also integrally connected with a second pair of opposite edges, in particular a third edge 107 and a complementary fourth edge 108, located at the short sides of the panel 101 in this exemplary embodiment. The decorative layer covers the upper side 103, and one or more side edges 105, 106, 107, 108, of the core 102 at least partially.
(25) FIG. 8 is a cross-sectional view indicated by section A-A in FIG. 7. In this cross-section, the shape of the complementary first edge 105 and second 106 edge are shown in detail. The first edge 105 comprises a sideward tongue 109 which is integrally connected to the core 102. By means of the vertical dashed line the border between the sideward tongue 109 and the core 102 is visualised. A front region 109a of the sideward tongue 109 is provided with a rounded bottom surface 110. An outer end of the rounded bottom surface 110 adjoins an inclined locking surface 111. An opposite end of the rounded bottom surface 110 adjoins a bearing surface 112 making part of a back region 109b of the sideward tongue 109. The second edge 106 of the panel 101 comprises an upper lip 113 and a lower lip 114 defining a recess 115. Both lips 113, 114 are integrally connected to the core 102. By means of the vertical dashed line the border between the lips 113, 114 and the core is visualised. As shown in FIG. 8, the width of the upper lip 113 is substantially smaller than the width of the lower lip 114. The recess 115 has a shape which is complementary to the shape of the sideward tongue 109. More in particular, a top surface 116 of a back region 114a of the lower lip 114 has a (complementary) rounded shape, configured to co-act with the rounded front region 109a of the sideward tongue 109, while a front region 114b of the lower lip 114 is provided with a upwardly protruding shoulder 117, configured to co-act with the bearing surface 112 of the sideward tongue 109. A lower surface 118 of the upper lip 113 is inclined and corresponds to the locking surface 111 of the sideward tongue 109. Locking at the first edge 105 and the second edge 106 of adjacent panels 101 by insertion of the sideward tongue 109 of a panel 101 to be coupled into the recess 115, wherein said panel 101 is initially held in an inclined position. After insertion of the sideward tongue 109 into the recess, the panel 101 to be coupled will be pivoted (angled) in downward direction about an axis parallel to the first edge 105 until both panels 101 are positioned in the same—commonly horizontal—plane, wherein the locking surface 111 of the sideward tongue 9 will engage the locking surface of the upper lip 118, and wherein at least a bottom front part is accommodated substantially form-fittingly in the recess 115, and wherein the bearing surface 112 is supported by the shoulder 117. Locking at the first edge 105 and the second edge 106 leads to locking of the connected panels 101 in both horizontal direction and vertical direction. The angling down locking principle of the first and second edges 105, 106 is a relatively easy locking principle which facilitates mutual coupling of panels at these edges 105, 106 tremendously.
(26) FIG. 9 is a cross-sectional view indicated by section B-B in FIG. 7. In this cross-section, the shape of the complementary third edge 107 and second 108 edge are shown in detail. The third edge 107 comprises an upward tongue 119, an upward flank 120 and an upward groove 121 formed between upward tongue 119 and upward flank 120. The upward tongue 119 is connected to the core 102 by means of a bridge 122, which is preferably resilient to some extent. A side 119a of upward tongue 119 facing toward upward flank 120 extends in the direction of the normal N.sub.1 of the upper side 103 of the core 102. The tangent R.sub.1 and the normal N.sub.1 of the upper side 103 of the core 102 are thus directed toward each other (converging orientation), wherein the angle enclosed by R.sub.1 and N.sub.1 is preferably between 0 and 10 degrees in this exemplary embodiment. Due to the converging orientation of the upward flank 120 and the side 119a of the upward tongue 119 facing toward to the upward flank 120, the upward groove 122 is a closed groove, which is only accessible to a complementary counterpart by deformation of the upward tongue 119 and/or bridge 122. Another side 119b of upward tongue 119 facing toward upward flank 120 forms or may form an aligning edge enabling facilitated realization of a coupling to an adjacent floor panel 101. As shown, this side 119b functioning as aligning edge is directed away from the normal N.sub.1 of upper side 103 of the core 102. An upper side 119d of upward tongue 119 does however extend in the direction of the normal N.sub.1 of the upper side 103 of the core 102, and runs inclining downward in the direction of the side 119e of upward tongue 119 facing away from upward flank 120. This chamfering provides the option of giving the complementary fourth edge 108 a more robust and therefore stronger form. A part of the side 119e of upward tongue 119 facing away from upward flank 120 is oriented substantially vertically and is moreover provided with an outward bulge 123. A lower part 120a of upward flank 120 is oriented diagonally, while an upper part 120b of upward flank 120 is shown to be substantially vertical and forms a stop surface for fourth edge 108. In between the inclined part 120a and the substantially vertical part 120b of the upward flank an additional coupling element, in particular an additional bulge 124, is provided. A lower wall part 121a of upward groove 121 is oriented substantially horizontally in this exemplary embodiment. The fourth edge 108 is substantially complementary to third edge 107. The fourth edge 108 comprises a downward tongue 125, a downward flank 126 and a downward groove 127 formed between downward tongue 125 and downward flank 126. The downward tongue 125 is connected to the core 102 by means of a bridge 128, which is preferably resilient to some extent. A side 125a of downward tongue 125 facing toward downward flank 126 lies in the direction of the normal N.sub.2 of the lower side 104 of the core 102. This means that a tangent R.sub.2 of side 125a of downward tongue 125 and the normal of the lower side 104 of the core 102 are mutually converging, wherein the angle enclosed by R.sub.2 and N.sub.2 is preferably between 0 and 10 degrees in this exemplary embodiment. More preferably, the inclination of R.sub.1 is identical to the inclination of R.sub.2; hence, R.sub.1 and R.sub.2 are preferably parallel. Due to the converging orientation of the downward flank 126 and the side 125a of the downward tongue 125 facing toward to the downward flank 126, the downward groove 127 is a closed groove, which is only accessible for the upward tongue 119 of an adjacent panel 101 by deformation of the downward tongue 125 and/or bridge 128, as a result of which the entrance of the downward groove can be widened (temporary). A side 125b of the downward tongue 125 facing away from downward flank 126 is diagonally oriented, but has a flatter orientation than the complementary side 120a of upward flank 120, whereby a gap (air space) will be formed in the coupled position, which will generally facilitate coupling between two floor panels 101. The inclining side 125b of downward tongue 125 also functions as aligning edge for the purpose of further facilitating coupling between two floor panels 101. Another side 125c facing away from downward flank 126 takes a substantially vertical form, though is provided with a small cavity 129 configured to co-act with the additional bulge 124 of another panel 101. A top part of the side 125c facing away from downward flank 126 forms a complementary stop surface for stop surface 120b of upward flank 120 (of an adjacent floor panel). Downward flank 126 is oriented substantially vertically and is provided with a recess 130 adapted to receive the outward bulge 123 of the upward tongue 119 (of an adjacent floor panel).
(27) 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.
(28) 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.
(29) 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.
LIST OF DESIGNATIONS
(30) 1 area covering element
(31) 2 sheet-like carrier core
(32) 3 decorative layer—printed film
(33) 4 protective layer
(34) 5 upper side
(35) 6 underside
(36) 7 first side face
(37) 8 second side face
(38) 9 layer of adhesive
(39) 10 layer of bonding agent
(40) 11 layer of adhesive substance
