Tile Panel, and a Surface Covering Constructed by a Multitude of Neighbouring Tile Panels

Abstract

The invention relates to a tile panel which includes a support panel which is essentially flat and has a top side onto which one or more tiles are adhered by an adhesive, wherein the support panel is made from a material which is different than the material from which the one or more tiles are made, and the top side of the support panel includes a recessed structure in which the adhesive is present. The invention also relates to a surface covering, in particular for a floor, ceiling or wall surface, which is constructed by a multitude of neighbouring tile panels.

Claims

1-31. (canceled)

32. A tile panel, in particular decorative tile panel, which comprises a support panel which is essentially flat and has a top side onto which one or more ceramic tiles, in particular one or more decorative tiles, are adhered by an adhesive, wherein the support panel is made from a material which is different than the material from which the one or more tiles are made, wherein at least the top side of the support panel, preferably the support panel as a whole, comprises an essentially mineral material or a mineral composite material, such as magnesium oxide material or calcium carbonate, wherein the adhesive is provided in the form of a continuous adhesive layer that covers the substantially entire contact surface between the support panel and the at least one tile positioned on top of said support panel, wherein the adhesive penetrates the top side of the support panel, wherein the support panel comprises a recessed structure at least partially defined by pores present in the top side of the support panel, wherein said pores are at least partially filled with adhesive, wherein the adhesive penetrates a bottom side of the at least one tile, wherein at least one tile comprises a recessed structure partially defined by pores present in the bottom side of said at least one tile, wherein said pores are at least partially filled with adhesive and wherein the porosity of the top side of the support panel is at least 4 times, preferably less than 12 times, the porosity of the bottom side of the at least one tile.

33. The tile panel according to claim 32, wherein the adhesive has a viscosity at 20° C. below 950 Pas.

34. The tile panel according to claim 32, wherein the area density of the adhesive is at least 150 g/m2.

35. The tile panel according to claim 32, wherein the one or more tiles are made of an essentially mineral material or a mineral composite material.

36. The tile panel according to claim 32, wherein the one or more tiles have a Mohs hardness greater than 3, and preferably has a breaking modulus greater than 10 N/mm2, more preferably greater than 30 N/mm2.

37. The tile panel according to claim 32, wherein the top side of the support panel comprises pores having an average pore size which gradually decreases in the direction from the top side of the support panel towards an opposed bottom side of the support panel.

38. The tile panel according to claim 32, wherein the support panel comprises a recessed structure which at least partially defines a relief structure which is at least partially filled with adhesive.

39. The tile panel according to claim 38, wherein the relief structure is formed by extrusion, piercing, punching, pressing, printing, etching, embossing, milling and/or cutting.

40. The tile panel according to claim 32, wherein the top side of the support panel, and preferably the support panel as a whole, is made from an extruded material.

41. The tile panel according to claim 32, wherein at least the top side of the support panel, and preferably the support panel as a whole, is made from water-repellent material.

42. The tile panel according to claim 32, wherein at least the top side of the support panel, and preferably the support panel as a whole, comprises a composite material of wood fibres and a resin, in particular MDF or HDF composite material.

43. The tile panel according to claim 42, wherein at least the top side of the support panel, and preferably the support panel as a whole, comprises at least 50 wt. % of the composite material.

44. The tile panel according to claim 42, wherein the composite material comprises wood fibres which are coated by a water repellent coating.

45. The tile panel according to claim 32, wherein at least the top side of the support panel, and preferably the support panel as a whole, comprises at least 50 wt. % of the essentially mineral material or mineral composite material.

46. The tile panel according to claim 32, wherein at least two opposite side edges of the support panel are provided with complementary coupling profiles, which are preferably made from a resilient material which is preferably water-repellent and which are designed to interlink two neighbouring tile panels with each other.

47. The tile panel according to claim 46, wherein the support panel has linear side edges, and a first pair of opposing side edges of the support panel is provided with respectively a first and second coupling profile, which are designed to interlink two neighbouring tile panels with each other.

48. A decorative panel according to claim 47, wherein the first coupling profile comprises: an upward tongue, at least one upward flank lying at a distance from the upward tongue, an upward groove formed in between the upward tongue and the upward flank wherein the upward groove is adapted to receive at least a part of a downward tongue of a second coupling profile of an adjacent panel, and at least one first locking element, preferably provided at a distant side of the upward tongue facing away from the upward flank, and wherein the second coupling profile comprises: a first downward tongue, at least one first downward flank lying at a distance from the downward tongue, a first downward groove 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 profile of an adjacent panel, and at least one second locking element adapted for co-action with a first locking element of an adjacent panel, said second locking element preferably being provided at the downward flank.

49. The tile panel according to claim 46, wherein a second pair of opposing side edges of the support panel is provided with respectively a third and fourth coupling profile, which are designed to interlink two neighbouring tile panels with each other.

50. The decorative panel according to claim 49, wherein the third coupling profile comprises: a sideward tongue extending in a direction substantially parallel to the upper side of the core, at least one second downward flank lying at a distance from the sideward tongue, and a second downward groove formed between the sideward tongue and the second downward flank, wherein the fourth coupling profile comprises: a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile of an adjacent panel, said third groove being defined by an upper lip and a lower lip, wherein said lower lip is provided with an upward locking element, wherein the third coupling profile and the fourth coupling profile are configured such that two of such panels 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 the upward locking element of said second panel is inserted into the second downward groove of said first panel.

51. The decorative panel according to claim 46, wherein at least a part of at least one coupling profile, preferably each coupling profile, is integrally made from material of the support panel.

52. The tile panel according to claim 32, wherein the one or more tiles are positioned within a surface area of the top side of the support panel which surface area is defined by a margin line which runs parallel to the side edges of the support panel, and wherein the one or more tiles are positioned at a margin distance from the side edges.

53. The tile panel according to claim 52, which comprises multiple tiles adhered onto the top side of the support panel, which tiles are spaced apart by, preferably linear, interspatial gaps having a substantially constant gap width which is substantially twice the margin distance between a tile and a nearest side edge.

54. The tile panel according to claim 32, wherein the density of the support panel is between 600 and 900 kg/m.sup.3.

55. The tile panel according to claim 32, wherein the one or more tiles have a thickness of 2-12 mm, preferably 4-8 mm, more preferably 4-6 mm.

56. The tile panel according to claim 32, wherein the support panel has a thickness of 2-10 mm, preferably of 2-6 mm.

57. A surface covering, in particular for a floor, ceiling or wall surface covering, which is constructed by a multitude of neighbouring, preferably interlocked, tile panels according to claim 32.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0130] The invention will be further elucidated by several examples and with reference to the appended figures, wherein:

[0131] FIG. 1 is a top view of a tile panel according to a preferred embodiment of the invention;

[0132] FIG. 2 is a cross-sectional view of the tile panel of FIG. 1;

[0133] FIG. 3 is a top view of the support panel of the tile panel of FIG. 1;

[0134] FIG. 4 is a top view of a tile panel according to another preferred embodiment of the invention;

[0135] FIG. 5 is a cross-sectional view of a detail of the side edges of two neighbouring panels that are interlinked to each other by a preferred type of coupling profiles;

[0136] FIG. 6 is a cross-sectional view of two neighbouring panels that are interlinked to each other by another preferred type of coupling profiles;

[0137] FIG. 7 is a (partial) cross section of another preferred embodiment of a tile panel according to the invention; and

[0138] FIG. 8 shows on a larger scale a view on the area F3 shown in FIG. 7.

DESCRIPTION OF THE INVENTION

[0139] FIG. 1 shows a tile panel 1, which comprises a support panel 5 which is essentially flat and has a top side onto which one tile 3 is adhered by an adhesive layer (not visible). The support panel 5 is made from a composite material of wood fibres and a resin, and has a top side which is provided with pores 6 which are indicated by the small dots. The tile 3 is made from a ceramic material. One side edge 10 of the support panel is provided with a tongue 7 as a coupling profile. The dimension of the tile 3 is such, that its outer circumference is at a margin distance d from the side edges of the support panel 5.

[0140] Dotted line A-A′ indicates a cross-section of the panel which is depicted in FIG. 2.

[0141] FIG. 2 shows a cross-section of the same tile panel 1 as in FIG. 1, along line A-A′ in FIG. 1. Identical parts in both figures have the same reference numerals as in FIG. 1.

[0142] Opposed to the side edge 10 provided with tongue 7, is a side edge 12 which is provided with a groove 28 as coupling profile, so that the side edges 10 and 12 of neighbouring panels can be interlinked by inserting the tongue profile into the groove profile.

[0143] The tile 3 is glued onto the top side of the support panel 5, by an adhesive layer 20 which is present as a thin intermediate layer between the tile 3 and the top side of the support panel 5. The top side of the support panel 5 is provided with a recessed structure 22, which is formed by parallel grooves in the support panel 5. The adhesive layer 20 extends into the grooves 22, so that adhesive is present in the recessed structure 22. The adhesive layer also extends into the pores 6 which are present at the top side of the support panel, which may be considered to make part of the recessed structure 22. The glue penetrates the recessed structure 22, in particular the pores of the support panel 5, at least partially

[0144] FIG. 3 shows a top view of the support panel 5 of tile panel of FIG. 1, without the adhesive layer and tile. Identical parts in both figures have the same reference numerals as in FIG. 1.

[0145] The support panel 5 is made from a composite material of wood fibres and a resin, and has a top side which is provided with pores 6 which are indicated by the small dots. The top side of the support panel 5, has a recessed structure formed by parallel grooves 22.

[0146] The dotted line 30 is a margin line which runs parallel to the side edges of the support panel 5, at a margin distance d from the side edges of the support panel. The margin line 30 defines the area 32 within which the one or more tiles according to the invention are adhered onto the top side of the support panel 5.

[0147] FIG. 4 shows a rectangular tile panel 1 having one single support panel 5 onto which eight tiles 3 are adhered by an adhesive. The configuration of the tiles 3 is they are spaced apart by linear interspatial gaps 40 having a constant gap width which is about 3.0 mm. At the opposed side edges 42 the gap distance to the respective side edges of the support panel is also about 3.0 mm. At the other pair of opposed side edges 44 the gap distance is about 1.5 mm.

[0148] FIG. 5 shows two side edges of two neighbouring tile panels 1 and 1′, which are interlinked by a coupling profile 5 and 6 which contain a tongue 51 and a groove 61. The coupling profiles 5 and 6 are configured such that an angling or turning movement (depicted by arrow T) allows for coupling the two profiles together, which results in an interlocked coupling in the horizontal plane.

[0149] FIG. 6 shows two side edges of two neighbouring tile panels 1 and 1′, which are interlinked by a coupling profile 7 and 8 which contain a respective tongue 71 and groove 73, and a respective tongue 81 and groove 83. The coupling profiles 7 and 8 are configured such that a drop down movement of panel 1′ (depicted by the arrow) allows for coupling of the two profiles together, which results in an interlocked coupling in the horizontal plane.

[0150] FIG. 7 shows a cross-sectional view of a tile panel 101 having a rectangular elongated shape. Preferably, the floor element 101 comprises a superficial area of less than 1.6 m2, preferably less than 1.2 m2, more preferably less than 0.6 m2. The tile panel 101 comprises a tile 102 glued on top of a support panel 103 by using an adhesive 113. The tile 102 is preferably at least partially made from a composition 107 chosen from the group consisting of: ceramic, clay, and magnesium oxide, cement, and concrete. The tile 102 has a top side 104 with a decorative appearance 5, which may at least partially be formed by a decorative print 106. The decorative print 106 can be provided with a variety of textures, designs and colours, and may e.g. simulate a wood pattern comprising wood nerves and flakes. The print 106 may be realized by means of digital printing, such as inkjet printing, although screen printing, rotogravure, flexography or off-set printing is not excluded. Optionally, a, typically white, background coating 108 is situated in between the tile 102 and the print 106. Preferably, a transparent or translucent protective coating 109 may be applied to cover the print 106 at least partially, and preferably entirely. In this figure, it is also shown that the tile 102 has a thickness T1, which is preferably between 4 and 15 mm, for example 6 mm, preferably above 7 mm, for example 8 or 10 mm. The support panel 103 preferably has a thickness T2 between 2 and 8 mm, preferably below 6 mm, more preferably about 4 mm or less. The footprint of the top side of the support panel 103 is larger than the footprint of the tile 102 in order to realize a circumferential grout line. More in particular, the support panel 103 extends beyond longitudinal edges 105 of the tile 102. In the example, the support layer 103 comprises upper longitudinal edges 115 that extend beyond the longitudinal edge 105 of the tile 102 of a distance D1. Said distance D1 is equal on both the opposite longitudinal edges 105 of the tile 102. It is also shown that the support panel 103 comprises longitudinal edges 10 provided with first coupling profiles 111, 112 configured to realize a mechanical coupling with coupling profiles 111 , 112 of an adjacent tile panel 101. In the illustrated examples the coupling elements 111,112 comprise a male and female parts disposed on opposite longitudinal edges 110.

[0151] The first coupling profiles 111,112 of the longitudinal edges 110 are configured for being coupled each other by means of an angling motion around a horizontal axis parallel to the longitudinal edges 110. The male and female parts are respectively shaped in form of a tongue 111 and a groove 112 wherein the tongue 111 projects outwardly beyond its respective longitudinal edge 110 in a horizontal direction X and the groove 112 projects inwardly with respect to the respective longitudinal edge 110 in said horizontal direction.

[0152] The adhesive 113 used preferably comprises a resin material, in particular a thermosetting resin or thermoplastic resin. Examples of thermosetting resin are epoxy, polyurethane, cyanoacrylate or acrylic resin. Examples of thermoplastic resin are hot melt, polyester thermoplastic, vinyl etc. Preferably the resin is a rigid resin. The adhesive is preferably provided onto the bottom side of the tile 102 in an amount above 175 g/m2. Optionally, and as shown in FIG. 7, the support panel 103 may comprise grooves 116 or gutters adapted to collect a portion of the adhesive 113 in case of overflow beyond the edges 105 of the tile 102, in order to prevent said adhesive to overflow onto the coupling profiles 111,112. In this embodiment said grooves 116 are provided in the portion of the support panel 103 extending beyond the edges 105 of the tile 102. Moreover, said grooves 116 extend parallel and continuously to the edges 105 of the tile 102. For a reason of simplicity, the grooves 116 are not illustrated in other figures of the present application, but the grooves can be present in any of the embodiments described herein.

[0153] FIG. 8 shows a detailed view on the area F3 identified in FIG. 7. As illustrated in FIG. 8, the top side of the support panel 103 is provided with pores into which the adhesive 113 penetrates, and the bottom side of the tile 102 is also provided with pores into which the adhesive 113 penetrates. The penetrations of the adhesive leads to a tentacled connection 114 between the support panel 103 and the tile 102, which increases the contact surface area of the adhesive 113, and hence which increases the bonding strength between the support panel 103 and the tile 102. In practice, the porosity of the top side of the support panel 103 is greater than the porosity of the bottom side of the tile 102, as a result of which the amount of adhesive penetrating the support panel 103 normally exceeds the amount of adhesive penetrating the tile 102. This adhesive absorption volume ratio can be at least 4. In order to allow the (initially liquid) adhesive to properly flow into the pores, which can be forced by exerting an external pressure and/or by way of capillary action, the adhesive preferably has a viscosity at 20° C. below 950 Pas, preferably below 750 Pas, more preferably below 550 Pas

[0154] 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.

[0155] 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.

[0156] 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.