Abstract
The invention relates to a decorative surface covering element, in particular a floor panel, ceiling panel or wall panel. The invention also relates to a panel covering, such as a floor covering, ceiling covering or wall covering, comprising a plurality of panels according to the invention. The invention further relates to a method of producing a decorative surface covering element according to the invention.
Claims
1. A decorative surface covering element, comprising: a core provided with an upper side and a lower side, a decorative top structure affixed, directly or indirectly, on said upper side of the core, said decorative top structure comprising: at least one decorative layer forming at least one décor image, a substantially transparent or translucent printed covering structure at least partially covering said decorative layer, wherein the printed covering structure comprises: a printed center portion covering a center portion of the decorative layer, and at least one printed peripheral portion adjacent to said center portion, and extending along a length of a side of the center portion, wherein said at least one peripheral portion covers at least one peripheral portion of the decorative layer, wherein the peripheral portion of the covering structure is recessed with respect to the center portion of the covering structure, and wherein the printed peripheral portion of the covering structure represents a peripheral bevel and/or a peripheral grout line, and wherein at least one peripheral portion of the decorative layer is provided with a different print compared to the print of the center portion of the decorative layer.
2. The surface covering element according to claim 1, wherein the height of at least a part of the printed peripheral portion of the covering structure decreases in a direction away from the printed center portion of the covering structure.
3. The surface covering element according to claim 1, wherein at least a part of the peripheral portion of the covering structure has a chamfered top surface.
4. The surface covering element according to claim 1, wherein at least a part of the peripheral portion of the covering structure has a substantially flat top surface.
5. The surface covering element according to claim 1, wherein at least a part of the peripheral portion of the covering structure has a curved top surface.
6. The surface covering element according to claim 1, wherein at least a part of the peripheral portion of the covering structure has a top surface which is substantially parallel to a plane defined by the core.
7. The surface covering element according to claim 1, wherein the peripheral portion of the covering structure forms an at least partially concave channel.
8. The surface covering element according to claim 1, wherein the maximum height difference between a lowest region of the peripheral portion of the covering structure and an highest region of the center portion of the covering structure is situated between 200 and 800 micron.
9. The surface covering element according to claim 1, wherein the printed peripheral portion of the covering structure is formed by: at least one, at least partially cured layer provided with at least one indented zone, extending in longitudinal direction of the peripheral portion, and/or at least one at least partially cured elevated pattern layer formed by at least one elevated zone extending in longitudinal direction of the peripheral portion.
10. The surface covering element according to claim 1, wherein the printed center portion of the covering structure comprises at least one recessed channel representing an internal grout line.
11. The surface covering element according to claim 1, wherein at least one peripheral portion of the decorative layer is provided with a different print compared to the print of the center portion of the decorative layer.
12. The surface covering element according to claim 1, wherein the printed center portion of the covering structure is an embossed center portion, which is formed by: at least one, at least partially cured base layer provided with a plurality of indentations, and/or at least one at least partially cured elevated pattern layer formed by a plurality of elevations, preferably printed on top of said base layer.
13. The surface covering element according to claim 1, wherein a first edge of the surface covering element comprises a first coupling profile, and a second edge of the surface covering element, preferably opposite to the first edge, comprising a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent surface covering element, both in horizontal direction and in vertical direction, wherein the first coupling profile and the second coupling profile are preferably configured such that two of such surface covering elements can be coupled to each other by means of a lowering movement.
14. The surface covering element according to claim 1, wherein the surface covering element comprises at least one third coupling profile and at least one fourth coupling profile located respectively at a third edge and a fourth edge, 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 surface covering element, 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 surface covering elements 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 surface covering element is inserted into the third groove of an adjacent, second surface covering element, and wherein at least a part of the upward locking element of said second surface covering element is inserted into the second downward groove of said first surface covering element.
15. The surface covering element according to claim 1, wherein the print of at least one peripheral portion of the decorative layer has a different color compared to the print of the center portion of the decorative layer.
16. The surface covering element according to claim 1, wherein at least one peripheral portion of the decorative layer is provided with a darker print compared to the print of the center portion of the decorative layer.
17. The surface covering element according to claim 1, wherein the at least one peripheral portion of the decorative layer has a more matt appearance compared to the print of the center portion of the decorative layer.
18. A method of producing a decorative surface covering element according to claim 1, comprising the steps of: A) forming at least one decorative layer onto the upper side of the core by means of printing, wherein at least one peripheral portion of the decorative layer is provided with a different print compared to the print of the center portion of the decorative layer, B) applying a liquid base layer on at least a part of at least one décor image formed during step A) to form a center portion and at least one peripheral portion of the covering structure, position-selectively printing of a plurality of embossing droplets on the still liquid base layer in a manner, that the thickness of the base layer changes on the positions where the embossing droplets are spayed on, such that at these positions indentations are formed in the liquid base layer, and such that the average height of the center portion of the covering structure exceeds the average height of the peripheral portion of the covering structure, wherein the printed peripheral portion of the covering structure is formed as peripheral bevel and/or a peripheral grout line, C) at least partially curing said base layer provided with said indentations.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures:
(2) FIG. 1a shows a schematic representation of a cross section of a decorative panel as an example of a surface covering element according to the invention;
(3) FIG. 1b shows that a liquid base layer is applied on the décor image formed at the upper side of the panel;
(4) FIG. 1c show that a plurality of embossing droplets is position-selectively printed on the still liquid base layer;
(5) FIG. 1d shows indentations formed in the liquid base layer at the positions where the embossing droplets are sprayed on;
(6) FIG. 1e shows a plurality of elevations printed on top of said base layer; Figure if shows the embossing structure mechanically treated by means of a plurality of successively oriented rotating cylindrical brush rollers;
(7) FIG. 1g shows a roughened texture of the embossing structure;
(8) FIG. 2a shows a schematic representation of a side view of another example of a decorative panel according to the present invention;
(9) FIG. 2b shows a top view of the panel shown in FIG. 2a;
(10) FIG. 3 shows a schematic representation of a further example of a decorative panel according to the present invention;
(11) FIGS. 4a and 4b show non-limiting examples of coupling profiles used in panels according to the present invention, having an embossing structure with a mechanically roughened upper surface;
(12) FIGS. 5a and 5b show two different embodiments (partial view) of a floor covering comprising (at least) two interconnected decorative panels according to the invention;
(13) FIG. 6a shows a first different embodiment of a large panel or slab to be cut in smaller panels;
(14) FIG. 6b shows a second different embodiment of a large panel or slab to be cut in smaller panels.
DESCRIPTION OF THE INVENTION
(15) FIGS. 1a-1g show subsequent steps of a method according to the present invention. FIG. 1a shows a schematic representation of a cross section of a decorative panel (110) as an example of a surface covering element according to the invention. The figure shows the core (100) of the panel (110). The core (100) is typically substantially rigid, and may possibly comprises at least one polymer and/or at least one wood-based material. A decorative layer (107), in particular a décor image, is formed, preferably by means of digital printing, onto the upper side (100A) of the core (100) by means of printing, in particular digital printing. FIG. 1b show that a liquid base layer (101) is applied on the décor image formed at the upper side (100A) of the panel (110). The liquid forming the liquid base layer (101) is for example a UV sealer. The liquid base layer (101) generally has a relatively high surface tension in order to allow precise embossing in the liquid base layer (101). FIG. 1c show that a plurality of embossing droplets (102) is position-selectively printed on the still liquid base layer (101). This is done such that the thickness of the base layer (101) changes on the positions where the embossing droplets (102) are spayed on. FIG. 1d shows that this results in that positions indentations (103) are formed in the liquid base layer (101) at the positions where the embossing droplets (102) are sprayed on. The base layer (101) is at least partially cured after the base layer (101) is provided with said indentations (103). Subsequently an elevated pattern layer is formed by position-selectively printing of a plurality elevations on the base layer (101). The elevation droplets (104) applied onto the panel (110) are shown in FIG. 1d. The pattern layer obtained via the position-selectively printing of the elevations (105) is subsequently at least partially cured. Preferably, the embossing droplets (102) and/or the elevation droplets (104) have a surface tension which is higher than the surface tension of the liquid base layer (101). Optionally, one or more finishing layers (not shown) can be applied to the panel (110). Via the steps shown in FIGS. 1a-1e, a decorative panel (110) is obtained, comprising a core (100) and a decorative top structure affixed on the upper side (100A) of the core (100). The decorative top structure comprises a decorative print layer forming at least one décor image and a substantially transparent or translucent three-dimensional embossing structure at least partially covering said print layer. The embossing structure is a multi-layer embossing structure which comprises a base layer (101) provided with a plurality of indentations (103) and an elevated pattern layer formed by a plurality of elevations (105) printed on top of said base layer (101). It can be seen that the indentations (103) and the elevations (105) can overlap, such that a panel (110) having an irregular height structure is obtained. The plurality of indentations (103) of the base layer (101) forms a discontinuous indentation pattern. At least one side edge of the panel (110) the base layer is provided with an inclined smooth or textured surface, which forms a bevel (106). Hence, the bevel (106) is formed by the printed base layer (101), wherein the decorative layer (107) extends underneath said bevel (106) and thus remains intact. The panel (110) may possibly comprise multiple coupling profiles for coupling multiple panels (110). The panel (110) may also comprise a backing layer (not shown) affixed to a lower side of the core (100). In figure if it is shown that the embossing structure is mechanically treated by means of a plurality of successively oriented rotating cylindrical brush rollers (120a, 120b, 120c), wherein adjacent brush rollers (120a, 120b, 120c) axially rotate in opposite directions. The brush rollers (120a, 120b, 120c) typically have relatively sturdy and/or rigid brush wires, preferably at least partially made of metal, more preferably of steel and/or a composite of steel and carbon. The diameter of the brush rollers (120a, 120b, 120c) in this exemplary embodiment is substantially 30 centimeter. The rotation speed of the brush rollers (120a, 120b, 120c) is typically between 550 and 650 revolutions per minute (rpm), and is preferably substantially equal to 600 rpm. The brush rollers (120a, 120b, 120c) are used to transform the (complete) initially smooth texture of the upper surface of the panel (110) into a more roughened texture of the upper surface of the panel (110). This roughened texture of the embossing structure has typically more sharp edges, and has a look and feel appearance which comes close(r) to natural wood nerves, as shown in more detail in FIG. 1g. This is in particular advantageous in case the décor image also constitutes a wood nerve pattern, preferably a wood nerve pattern, wherein the decorated wood nerves are in register (in line) with the embossed wood nerves. During this mechanical action, material will be removed from the embossing structure, and optionally also from an intermediate transparent layer (if applied) situation in between the embossing structure and the décor image, which material will be released as dust particles. To evacuate at least a part of the dust particles created during this mechanical brushing action (roughening action), each brush roller (120a, 120b, 120c) is enclosed by a cover (140a, 140b, 140c), also referred to as housing or cage, which cover (140a, 140b, 140c) is connected to a vacuum system (not shown). It can be chosen that brush rollers (120a, 120b, 120c) also brush the bevel(s) (106) or that the brush rollers substantially keep distance from the bevel(s) (106) in order to leave the bevel(s) (106) untouched. During further displacement of the panel (110) in a transport direction T, the panel (110) will pass an axially rotating cylindrical cleaning brush roller having more soft wires, such as textile and/or nylon wires, to remove further dust particles from the panel (110). Typically after roughening and cleaning, the panel (110) will be cut into smaller panels, and will be profiled at two or four panel edges (not shown), wherein the one or more bevels (106) may or may not be shortened (i.e. reduced in width and/or length).
(16) FIG. 2a shows a schematic representation of a side view of another example of a decorative panel (220) according to the present invention. The panel (220) comprises a core (200) provided with an upper side and a lower side, and a decorative top structure (201) affixed, directly or indirectly, on said upper side of the core (200). The decorative top structure (201) comprises a decorative print layer forming at least one décor image. The panel (220) also comprises a substantially transparent or translucent three-dimensional embossing structure (202) covering said print layer (201). In the shown embodiment comprises the embossing structure (202) a continuous printed base layer (204) provided with one or more internal grouts (203) with a concave shape, and an elevated pattern layer formed by a plurality of (discontinuous) elevations (205) printed on top of said continuous base layer (204). Two side edges of the panel (220), as also shown in FIG. 2b, are provided with an external grout (210), also referred to as peripheral grout line (210), wherein a lower rectangular part of the grout (210) is formed by the base layer (204), and wherein an upper part of the grout (210) is provided with a bevel (211) formed by one of the printed elevations (205). The elevations form part of a lacquer layer (205). A carrier layer (206), and in particular a primer layer (206) is present enclosed between the top structure (201) and the embossing structure (202). In the shown embodiment, the primer layer (206) comprises a pattern of mat primer (206A) and glossy primer (206B). The indentations (203) are present where the primer layer (206) is provided with mat primer (206A). The structured elevations (205) cover the glossy primer (206B) of the primer layer (206). Due to the embossing structure (202) being substantially transparent, the differences within the primer layer (206) are visible. It is also conceivable that the primer layer (206) is attached onto the upper side of the core (200), and that the decorative top structure (201) is attached onto the primer layer (206). FIG. 2b shows a top view of the panel (220) shown in FIG. 2a. It can be seen that due to a part of the base layer being provided with said plurality of indentations (203) and part of the base layer being free of indentations a visually observable pattern is obtained. This effect is further reinforced by the primer layer (206) comprising both mat and glossy primer (206A, 206B) in a pattern which is in line with the embossing structure (202).
(17) FIG. 3 shows a schematic representation of a further example of a decorative panel (330) according to the present invention. The figure show a cross section of a decorative panel (330), in particular a floor panel (330). The panel (330) comprises a rigid, flexible, or semiflexible core (300) provided with an upper side and a lower side. A decorative print layer (301) is indirectly affixed on the upper side of the core (300). A carrier layer (302) formed by a primer (302) is present in between the core (300) and the decorative layer (301) in order to provide better adhesion of the decorative layer (301). An intermediate layer (303) is present on top of the printed decorative top layer (301). The intermediate layer (303) is formed by a transparent or translucent, light-reflective thermoplastic layer (303). The light-reflective thermoplastic layer (303) is glued onto the printed decorative layer (301) by means of a hot melt glue layer (304). A substantially transparent or translucent three-dimensional embossing structure (305) is positioned on top op of aforementioned layers (300, 301, 302, 303, 304). The embossing structure (305) is a multi-layer embossing structure (305) which comprises two at least partially cured base layers (306A, 306B) provided with a plurality of indentations. A part of each base layer (306A, 306B) is free of indentations, although the upper base layer (306b) is provided at opposite edges (310a, 310b) of the panel (330) with a chamfering, meaning an inclined upper surface, to form a bevel (311a, 311b). The embossing structure (305) also comprises an elevated pattern layer (307) formed by a plurality of elevations printed on top of the upper base layer (306B). The elevations are both printed on parts of the base layer (306B) that respectively provided with indentations and parts that are free of indentations. Despite not shown, it is also conceivable that an embossing layer is present on top of the lower base layer (306A). A secondary printed decorated layer (308) is affixed to the lower base layer (306A). This printed decorative layer (308) is affixed to the parts of the base layer (306A) which is free of indentations. The entire panel (330) is covered with a finishing layer (309), in particular a lacquer layer (309), which follows the shape of the bevels (311a, 311b). The panel (330) benefits of the presence of two printed decorative layers (301, 308), resulting in that a unique visual pattern can be obtained. The indentations provided in the base layer (306A, 306B) typically have a depth situated in between 2 micron and 100 micron, preferably situated in between 3 micron and 50 micron. The elevations of the elevated pattern layer (307) typically have a height situated in between 2 micron and 500 micron, preferably situated in between 3 micron and 300 micron. The embossing structure, in particular one or both base layers (306A, 306B) and/or the pattern layer (307) and/or the finishing layer (309) is provided with a roughened texture by mechanically brushing these one or more layers (directly) after application. Here, it is conceivable that a layer is mechanically roughened (and optionally cleaned) prior to applying one or more further layers on top of said roughened layer. The core (300) which may be solid of foamed is provided at opposite edges with complementary coupling profiles (312, 313) schematically shown as a simple tongue and complementary groove, intended to interlock adjacent panels (300).
(18) FIGS. 4a and 4b show non-limiting examples of coupling profiles (401A, 401B, 402A, 402B) used in panels (400A, 400B) according to the present invention, having an embossing structure with a mechanically roughened upper surface, e.g. as discussed and shown in the previous figures, and having printed bevels (410A, 410B) at two or four opposite edges. A first panel edge (440A) comprises a first coupling profile (401A), and a second panel edge (440B) opposite to the first panel edge (440A), comprising a second coupling profile (401B) being designed to engage interlockingly with said first coupling profile (401A) of an adjacent panel, both in horizontal direction and in vertical direction, wherein the first coupling profile (401A) and the second coupling profile (401B) are configured such that two of such panels can be coupled to each other by means of a lowering movement. This is shown in FIG. 4a. FIG. 4b show the panel comprising a third coupling profile (402A) and a coupling profile (402B) located respectively at a third panel edge (441A) and a fourth panel edge (441B). The third coupling profile (402A) and the fourth coupling profile (402B) are configured such that two of such panels (440A, 440B) 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 an upward locking element of said second panel is inserted into the second downward groove of said first panel.
(19) FIGS. 5a and 5b show two different embodiments of a floor covering comprising (at least) two interconnected decorative panels (500) according to the invention. In this figure, the panels are merely partially shown. Each decorative panel (500) comprises a rectangular, preferably oblong, core (501) which core (501) is provided at at least one pair of opposite sides with a tongue (502) and a complementary groove (503), which are configured to co-act with each other in such as way that the panels (500) are locked with respect to each other, both in horizontal direction (parallel to a plane defined by the panels (500)) and in vertical direction (perpendicular to said plane defined by the panels (500)). The tongue (502) is configured to be coupled into the groove (503) by means of an angling down movement (turning movement). The tongue (502) and the groove (503) are integrally formed with the core (501). On top of the core (501) a decorative layer (504) is applied, which may be formed by a decorative film or a decorative print directly printed on the core. On top of the decorative layer (504) a substantially transparent or translucent printed covering structure (505) entirely covering said decorative layer (504) is applied. In FIG. 5a it is shown that a seam between the panels (500) is defining a vertical plane V.sub.1. In this figure it is also shown that the covering structure (505) is provided with a zone (506A, 506B) with a reduced thickness, both above the tongue (502) and above the groove (503), such that said zones (506A, 506B) of reduced thickness of adjacent panels (500) are connecting to each other to form a single grout line (507). Here, the grout line (507) is positioned partially at one side of the vertical plane V.sub.1 and position partially at an opposite side of the vertical plane V.sub.1. The grout line (507) has a substantially rectangular cross-section and is provided, near the top surface, with a bevel (508A, 508B). In FIG. 5b a slightly different embodiment is shown, wherein a seam between the panels (500) is defining a vertical plane V.sub.2, and wherein the covering structure (505) is provided with a zone (510) with a reduced thickness, only above the tongue (502) and not above the groove (503). In an interconnected state of two panels (500), as shown, adjacent covering structures (505) together form a grout line (511), wherein one edge of the grout line (511) coincides with the vertical plane V.sub.2.
(20) FIG. 6A shows a first different embodiment of a large panel or slab (601) to be cut in smaller panels according to the cutting lines (A) in order to form a plurality—here six—surface covering elements (602) according to the invention. The shaded areas indicate a flat or textured center portion (603) of a printed covering structure of each surface covering element (602), covering a center portion of an underlying decorative layer, and wherein a peripheral portion (604) of said printed covering structure is recessed with respect to the center portion (603) of the covering structure, and wherein the printed peripheral portion of the covering structure represents a peripheral bevel and/or a peripheral grout line, in particular a peripheral faux grout line. The peripheral portion covers at least one peripheral portion of the decorative layer. As shown, the peripheral portion extends to all four edges of the surface covering element (602). After cutting the slab (601) into surface covering elements (602), the edges of the surface covering elements (602), including the peripheral portion of the decorative layer and the peripheral portion of the covering structure will be machined, in particular profiled, typically by way of milling, in order to create interlockable surface covering elements (602). This construction may for example lead to the embodiment shown in FIG. 5A.
(21) FIG. 6B shows a second different embodiment of a large panel or slab (611) to be cut in smaller panels according to the cutting lines (B) in order to form a plurality—here six—surface covering elements (612) according to the invention. This embodiment looks quite similar to the embodiment shown in FIG. 6A, but differs in that a recessed peripheral portion (613) of a printed covering structure extends only over two adjacent edges (a long edge and an adjacent short edge) of each surface covering element (612). This embodiment may for example lead to the embodiment shown in FIG. 5B.
(22) Hence, 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.
(23) 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.
(24) 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.
