Decorative panel, and decorative floor covering consisting of said panels

Patent metadata

Field	Value
Publication number	US-11624193-B2
Application number	US-201917299126-A
Country	US
Kind code	B2
Filing date	Sep 30, 2019
Priority date	Dec 3, 2018
Publication date	Apr 11, 2023
Grant date	Apr 11, 2023

Abstract

In the field of decorative floor coverings, decorative panels are known having a MDF (Medium Density Board) or HDF (High Density Board) based core layer on top of which a decorative substrate is attached to provide the panels a desired appearance. The invention relates to a panel, in particular a decorative panel, a floor panel, a ceiling panel or a wall panel. The invention also relates to a floor covering consisting of a plurality of mutually coupled panels.

First claim

The invention claimed is:

1. A decorative panel, comprising:
a core provided with an upper side and a lower side,
a decorative top structure affixed on said upper side of the core,
a first panel edge comprising a first coupling profile, and a second panel edge comprising a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, both in horizontal direction and in vertical direction,
wherein said core comprises:
at least one composite layer comprising:
at least one magnesia cement,
cellulose based particles dispersed in said at least one magnesia cement; and
at least one reinforcement layer embedded in said at least one composite layer,

 wherein the at least one magnesia cement comprises 5Mg(OH) 2 .MgSO 4 .3H 2 O (513-phase) and/or 3Mg(OH) 2 .MgSO 4 .8H 2 O (318-phase).

2. The panel according to claim 1 , wherein the at least one magnesia cement comprises magnesium chloride.

3. The panel according to claim 1 , wherein the at least one magnesia cement comprises magnesium oxychloride.

4. The panel according to claim 1 , wherein the at least one magnesia cement comprises 5Mg(OH) 2 .MgCl 2 .8H 2 O and/or Mg 2 (OH)ClCO 3 .3H 2 O.

5. The panel according to claim 1 , wherein the at least one magnesia cement comprises magnesite.

6. The panel according to claim 1 , wherein the at least one magnesia cement comprises at least 10% of the 5Mg(OH) 2 .MgSO 4 .3H 2 O (513-phase).

7. The panel according to claim 1 , wherein the at least one magnesia cement comprises 5Mg(OH) 2 .MgSO 4 .5H 2 O (515-phase) and/or Mg(OH) 2 .MgSO 4 .7H 2 O (517-phase).

8. The panel according to claim 1 , wherein the at least one composite layer comprises at least one mineralizer selected from the group consisting of: sodium hydroxide (NaOH), calcium chloride (CaCl 2 ), aluminium sulphate (Al 2 (SO 4 ) 3 ), and calcium hydroxide Ca(OH) 2 .

9. The panel according to claim 1 , wherein the cellulose based particles comprise lignocellulose.

10. The panel according to claim 1 , wherein the cellulose based particles comprise wood and/or hemp fibres.

11. The panel according to claim 1 , wherein at least a part of the cellulose based particles is formed by wood chips.

12. The panel according to claim 1 , wherein the core comprises dispersed particles being made of another material than cellulose.

13. The panel according to claim 1 , wherein the at least one composite layer comprises at least one additional filler selected from the group consisting of: steel, glass, polypropylene, wood, acrylic, alumina, curaua, carbon, cellulose, coconut, kevlar, nylon, perlon, polyethylene, PVA, rock wool, sisal, and fique.

14. The panel according to claim 1 , wherein the at least one composite layer comprises at least one of additive selected from the group consisting of: sodium carboxymethyl cellulose, fly ash, silica fume, iron oxide, fatty acids, and alkali metal sulphates.

15. The panel according to claim 1 , wherein the at least one composite layer comprises at least one polymer.

16. The panel according to claim 1 , wherein the at least one composite layer is free of polymers.

17. The panel according to claim 1 , wherein the at least one composite layer is at least partially foamed.

18. The panel according to claim 1 , wherein the at least one composite layer is free of plasticizer.

19. The panel according to claim 1 , wherein the at least one reinforcement layer is a non-woven layer or woven layer.

20. The panel according to claim 1 , wherein the at least one composite layer comprises at least 50% by weight of the at least one magnesia cement.

21. The panel according to claim 1 , wherein the at least one composite layer comprises a plurality of reinforcement layers.

22. The panel according to claim 1 , wherein the at least one reinforcement layer extends in only one coupling profile of the first and second coupling profile.

23. The panel according to claim 1 , 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.

24. The panel according to claim 1 , wherein the panel comprises at least one third coupling profile and at least one fourth coupling profile located respectively at a third panel edge and a fourth panel 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 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.

25. A decorative covering, comprising a plurality of mutually coupled decorative panels according to claim 1 .

Assignees

• I4F Licensing Nv

Inventors

• Boucké Eddy Alberic

Classifications

• B32B2307/3065

  Flame resistant or retardant, fire resistant or retardant · CPC title

• B32B2262/101

  Glass fibres · CPC title

• C04B28/34

  containing cold phosphate binders · CPC title

• B32B2264/067

  Wood particles · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title