Panel and method for producing a panel

Patent metadata

Field	Value
Publication number	US-12024901-B2
Application number	US-202318179692-A
Country	US
Kind code	B2
Filing date	Mar 7, 2023
Priority date	May 26, 2020
Publication date	Jul 2, 2024
Grant date	Jul 2, 2024

Abstract

The invention relates to a panel and a method for producing a panel. The panel is in particular a floor, wall or ceiling panel, and comprises at least one core layer, the core layer comprising an upper core surface and a lower core surface and at least one pair of opposite side edges; wherein the core layer comprises magnesium oxide cement and fibres dispersed in said magnesium oxide cement.

First claim

What is claimed is:

1. A floor, wall or ceiling panel, comprising:
at least one non-foamed core layer comprising an upper core surface and a lower core surface and at least one pair of opposite side edges, said pair of side edges comprising interlocking coupling means;
at least one decorative top layer attached to the upper core surface;
at least one balancing layer attached to the lower core surface;
at least one backing layer attached to the balancing layer, wherein the at least one backing layer is optionally an acoustic backing layer;
wherein the at least one core layer comprises magnesium oxide cement and natural fibres dispersed in said magnesium oxide cement;
wherein the natural fibres, excluding dust and/or powder, have an average length between 2.5 mm and 8 mm and form a reinforcing network within the magnesium oxide cement; and
wherein the at least one core layer has a density in the range of 1350 kg/m 3 to 1550 kg/m3.

2. The panel according to claim 1 , wherein the balancing layer comprises a thermoplastic or thermosetting resin and/or at least one ply of lignocellulose impregnated with a resin.

3. The panel according to claim 1 , wherein the decorative top layer comprises a thermoplastic or thermosetting resin and/or at least one ply of lignocellulose impregnated with a resin.

4. The panel according to claim 1 , wherein the at least one decorative top layer comprises at least one décor layer and at least one base coating layer.

5. The panel according to claim 1 , wherein the décor layer comprises a material selected from a high-pressure laminate, a plurality of impregnated layers, a decorative plastic or vinyl, linoleum, decorative thermoplastic film, stone veneer, wood veneer or ceramic tile.

6. The panel according to claim 1 , wherein the backing layer is a foamed layer.

7. The panel according to claim 1 , wherein the at least backing layer comprise at least one acoustic layer composed of a low density layer of ethylene-vinyl acetate (EVA), irradiation—crosslinked polyethylene (IXPE), expanded polypropylene (XPP) and/or expanded polystyrene (XPS).

8. The panel according to claim 1 , wherein the backing layer comprises a recycled material and/or a recyclable material chosen from the group of: PET, RPET and/or rubber.

9. The panel according to claim 1 , wherein the backing layer comprises nonwoven fibres chosen from the group op: as hemp and/or cork.

10. The panel according to claim 1 , wherein the density of the at least one backing layer is between 65 kg/m 3 and 300 kg/m 3 .

11. The panel according to claim 1 , wherein the natural fibers comprises of wood fibres selected from hardwood fibres and/or softwood fibers.

12. The panel according to claim 1 , wherein at least one upper region of the core layer and/or at least one lower region of the core layer has a density that is less than 15% higher than the average density of the entire core layer.

13. The panel according to claim 12 , wherein the upper region and/or the lower region extends into the core layer for 0.1 mm to 3 mm from the upper core surface and/or the lower core surface.

14. The panel according to claim 1 , wherein the magnesium oxide cement comprises at least 5 wt % of at least one element chosen from the group of: magnesium chloride, magnesium sulphate, magnesium hydroxide and/or magnesium phosphate.

Assignees

• Champion Link Int Corp

Inventors

• Baert Thomas Luc Martine
• Van Poyer Tom
• Boon Sven

Classifications

• B28B1/525

  containing organic fibres, e.g. wood fibres (B28B1/526, B28B1/527 take precedence) · CPC title

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B2419/04

  Tiles for floors or walls · CPC title

• B32B2317/18

  Cellulose, modified cellulose or cellulose derivatives, e.g. viscose (B32B2317/10, B32B2317/12, B32B2317/16 take precedence) · CPC title