CN113202254A

CN113202254A - Panel and method for manufacturing such a panel

Info

Publication number: CN113202254A
Application number: CN202010661690.0A
Authority: CN
Inventors: 托马斯·卢克·马丁·贝尔特; 汤姆·范·波尔; 斯万·伯恩
Original assignee: Chinafloors Timber China Co ltd
Current assignee: Chinafloors Timber China Co ltd
Priority date: 2020-01-31
Filing date: 2020-07-10
Publication date: 2021-08-03
Also published as: WO2021152152A1; EP4097310A1; NL2024806B1

Abstract

The invention relates to a panel, in particular a floor panel, a wall panel or a ceiling panel, the panel comprising: a core layer comprising a mineral or cementitious material; at least one reinforcing layer in the core layer; wherein the panel, in particular the core layer, comprises a first pair of opposite edges, wherein a first edge of the first pair of opposite edges comprises a first coupling part, and wherein a second edge of the first pair of opposite edges comprises a complementary second coupling part, which coupling parts allow a plurality of panels to be coupled to each other; wherein the first coupling part comprises a lateral tongue extending in a direction substantially parallel to a plane defined by the panels, and wherein the second coupling part comprises a groove configured for receiving at least a part of the lateral tongue of another panel, the groove being defined by an upper lip and a lower lip.

Description

Panel and method for manufacturing such a panel

Technical Field

The invention relates to a panel, in particular a floor panel, a wall panel or a ceiling panel.

Background

In the field of floor coverings and wall coverings, panels based on wood materials or derivatives thereof are widely used as material for the main or core layer of the panel. An example is given in us patent 6,688,061. The main drawbacks of such panels are: the moisture absorption of such wood-based materials, which affects the lifetime and durability of such panels; and flammability of wood-based products. Alternatively, several thermoplastic materials may be used, such as polyvinyl chloride, which, although waterproof, suffer from other drawbacks. Polyvinyl chloride (PVC) for panels, for example in patent CN100419019, has the property of flexibility. This requires that the surface of the substrate on which the panel covering is applied is completely smooth and flat. If this is not the case, any unevenness will be visible through the panel when it conforms to the underlying substrate surface, which is aesthetically undesirable to the user. Furthermore, floor panels using PVC as core are susceptible to changes in the temperature of their surroundings, which will result in expansion and contraction of the vinyl floor due to heat and cold fluctuations. PVC panels also typically fail fire ASTM testing.

It is clear that there is a general need in the art to develop floor panels which, although having waterproof and temperature resistant properties, can be produced with a relatively high bending strength resulting in a relatively flat (straight) upper surface. There is also a need in the art to develop such floor panels: the thickness of which can be adjusted relatively easily during production while maintaining sufficient strength of the panel. Furthermore, there is a need to develop a fire retardant panel to allow these panels to be used in a commercial environment.

It is known to use wall panels with mineral-based or glue-based materials to achieve fire protection standards. However, despite the advantages of these materials over wood or thermoplastic materials, the use of reinforcement layers for dimensional stability reasons has an impact on the performance of these materials in various strength tests applicable to flooring.

In particular, floor panels with a core based on mineral or cementitious material (e.g. gypsum or magnesium) may comprise a reinforcement layer of glass fibre, polypropylene, nylon or the like, as described in US7255907 for building boards and in WO2012061300 for stone wood floors.

These mineral panels, when combined with the reinforcing layers described in the prior art, cannot have lockable tongue and groove connections at opposite edges of the panels to be used as part of a floating floor with interlocking coupling components to prevent horizontal and vertical movement. If this type of floor panel is used in combination with a fiberglass reinforcement, it will weaken the structural integrity, causing breakage when engaged with a lock and put into intended use, and will fail when tested in accordance with the ISO4918 resilient fabric laminate floor covering-foot wheelchair test. The prior art therefore tries to solve this problem by a non-locking profile with an insert as in US20170204616, a non-locking tongue and groove on adjacent sides as in US2011058611, or not at all relating to the technical problem presented in the present invention as in EP 2060389.

It is therefore an object of the present invention to provide a panel with a core based on mineral or cementitious material, which obviates at least some of the drawbacks of prior art panels.

Disclosure of Invention

The invention therefore proposes a panel, in particular a floor panel, a wall panel or a ceiling panel, comprising: a core layer comprising a mineral or cementitious material; at least one reinforcing layer in the core layer; wherein a panel, in particular a core layer, comprises a first pair of opposite edges, wherein a first edge of said first pair of opposite edges comprises a first coupling part, and wherein a second edge of said first pair of opposite edges comprises a complementary second coupling part, said coupling parts allowing a plurality of panels to be coupled to each other; wherein the first coupling part comprises a lateral tongue extending in a direction substantially parallel to a plane defined by the panels, and wherein the second coupling part comprises a groove configured for receiving at least a part of a lateral tongue of another panel, the groove being defined by an upper lip and a lower lip, wherein at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panels, such that the reinforcing layer is located at a height of between 30% and 70%, more particularly between 40% and 60%, of the thickness from the top surface of the panel to the highest part of the top surface of the tongue and/or from the bottom surface of the panel to the lowest part of the upper surface of the lower lip, preferably at a height of half of said thickness.

Experiments with different positions of the reinforcement layer within the structure of the tongue and groove provide conclusive evidence that optimal reinforcement of the locking system is achieved while maintaining structural integrity. The panels according to the present application conform to industry standards in terms of structural integrity, while the locking system is durable and not easily broken.

The invention also relates to a (floor) panel comprising: a core layer comprising a mineral or cementitious material; at least one stiffening element in the core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges comprising interlocking coupling parts allowing coupling of a plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue and a groove by locally removing material at the respective edges, and wherein the at least one stiffening element is located in the laminate at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the minimum thickness of the remaining core layer material at the location of the tongue or groove. Interlocking coupling components are coupling components that require elastic deformation, a snap fit, or movement in multiple directions to couple or decouple the components to one another.

It is also conceivable that the panel comprises at least two reinforcing layers extending in a direction substantially parallel to the plane defined by the panel, such that each reinforcing layer is located at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the thickness of the highest part of the top surface of the panel to the top surface of the tongue and/or the lowest part of the bottom surface of the panel to the upper surface of the lower lip, and wherein adjacent reinforcing layers are located at a predetermined distance from each other. Preferably, there is no direct contact between the at least two reinforcing layers.

In one embodiment, the floor panel according to the invention comprises at least two reinforcing layers, wherein a first one of the reinforcing layers is located in the laminate at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the minimum thickness of the remaining material at the location of the tongue; the second one of the reinforcement layers is located in the laminate at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half said minimum thickness, of the minimum thickness of the remaining material at the location of the groove. In this embodiment both the tongue and the groove are further optimized resulting in a more stable panel with a very low risk of damage and wear.

The reinforcing layer may be a separate part inserted into the panel, may be a part of the same material with different properties, such as different density or different material structure, or may be a layer in a laminate. Such a reinforcing layer may be a closed layer or a mesh, sheet or net material, which may be integrated or embedded in the core layer, in particular when the core layer is made of a fluid or semi-fluid material that needs to be cured.

Typically, the core layer has a top surface and a bottom surface, and in one embodiment the remaining material at the location of the tongue or groove extends to the top and bottom surfaces. This means that only one side of the panel needs to be treated when removing the material for forming the tongue or groove.

When the complementary coupling parts are intended to form a click fit, or require bending to couple or snap fit, it is preferred that the flexibility of the at least one reinforcing layer is higher than the flexibility of the core material and/or the core layer. Suitable materials for the reinforcement layer for this purpose are glass fibre, polypropylene, cotton, silica or nylon.

These materials may be bonded to a substrate comprising or consisting of MgO and/or magnesium oxychloride binder and/or magnesium oxysulphate binder and/or MgCl₂And/or MgSO₄And a suitable binder. In a practical embodiment, the core layer may comprise at least 70% by weight of MgO and/or magnesium oxychloride binder and/or magnesium oxysulfate binder and/or MgCl₂And/or MgSO₄And a binder.

The core layer may for example have a thickness of between 3mm and 8mm, in particular between 5mm and 6mm, wherein the minimum thickness of the tongue or groove is between 1mm and 3 mm.

It is contemplated that the complementary coupling members (or interlocking coupling members) are configured to form a click-fit connection.

The (floor) panel according to the invention may comprise a laminate of said core layer and at least one of a decorative top layer, a sound attenuating layer and/or a balancing layer. If a decorative top layer is applied, it may for example comprise at least one cellulose-based layer, preferably paper or kraft paper, and a cured resin. The layer of cellulose-based material may also be a sheet layer adhered to the top surface of the core layer. The veneer layer is preferably selected from wood veneer, cork veneer, bamboo veneer, and the like. Other decorative top layers that may be applied to the present invention include ceramic tiles or tiles, real stone sheets, rubber sheets, decorative plastic or vinyl, linoleum and decorative thermoplastic films or foils. Possibly, the top layer may further be provided with a wear resistant layer and an optional coating. Examples of thermoplastics that can be used in such top layer are PP, PET, PVC, etc. It is also possible to provide an optional primer on the upwardly facing surface of the core and directlyThe visual effect required for printing during the printing process. The decorative top layer may be further finished with a thermosetting varnish or lacquer, such as polyurethane, PUR or melamine based resins. It is also conceivable that the panel comprises (at its back side) at least one balancing layer, which typically consists of at least one layer comprising lignocellulose and a cured resin. The panel may also comprise at least one acoustic layer, which typically consists of a low-density foam layer of Ethylene Vinyl Acetate (EVA), radiation cross-linked polyethylene (IXPE), expanded polypropylene (XPP), expanded polystyrene (XPS), but which may also be a non-woven fibre, for example made of natural fibres (such as hemp or cork) or recycled/recyclable materials (such as PET). The density of the acoustic layer is preferably 65kg/m³To 300kg/m³And most preferably 80kg/m³To 150kg/m³In the meantime.

Tests were carried out using two different panel compositions and reinforcing layers (in the form of layers of a laminate, comprising glass fibres) at different locations. The first panel has a core comprising a magnesium oxychloride adhesive (MOC) and the second panel has a core comprising a magnesium oxysulfate adhesive (MOS).

Table 1 shows the properties of various test panels, in particular floor panels.

Type (B)	Name (R)	Material	Thickness of	Thickness of tongue	Height of glass fiber
						Core	A-tenon-2	MOC	5.4mm	2.2mm	2mm
	B-tenon-0.5	MOS	5.4mm	2.2mm	0.5mm
							B-tongue-1.1	MOS	5.4mm	2.2mm	1.1mm

							B-groove-0.65	MOS	5.4mm	1.3mm	0.65mm
	A-groove-1	MOC	5.4mm	1.3mm	1mm
							B-groove-1.3	MOS	5.4mm	1.3mm	1.3mm

TABLE 1 Properties of various test panels

All (floor) panels were tested according to the standardized tests mentioned in table 2.

Code	Require that	Description of the invention
			EN 310	N/A	Yield strength (breaking point)
ISO 4918	10,000R	Foot wheelchair (for residence)
				25,000R	Foot wheelchair (for business)

TABLE 2 tests carried out

The results of the tests on the panels of table 1 are shown in table 3.

Sample (I)	EN 310	ISO 4918
			A-tenon-2	217N/100mm	8,000R
B-tenon-0.5	221N/100mm	15,000R
			B-tongue-1.1	340N/100mm	25,000R
B-groove-0.65	311N/100mm	25,000R
			A-groove-1	191N/100mm	15,000R
B-groove-1.3	162n/100mm	6,000R

TABLE 3 test results

From the results it can be seen that the at least one stiffening element is preferably located at a height in the laminate of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the minimum thickness of the remaining core material at the location of the tongue or groove.

Drawings

The invention will now be explained in more detail with reference to the following figures:

figure 1 shows a core of a panel according to the invention.

Figure 2 shows a core of a panel according to the invention.

Figure 3 shows a core of a panel according to the invention.

Figure 4 shows a core of a panel according to the invention.

Figure 5 shows a core of a panel according to the invention.

Detailed Description

Fig. 1 shows two sides of a panel 1, in particular a floor panel 1, comprising: a core layer 2, the core layer 2 comprising a mineral or cementitious material; at least one reinforcing layer 6, 7 in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges comprising interlocking coupling parts allowing coupling of a plurality of floor panels to each other, wherein said interlocking coupling parts are formed as a tongue 9 and a groove 3 by locally removing material at the respective edges. Furthermore, the reinforcement layer 6, 7 extends in a direction substantially parallel to the plane defined by the panel such that it is located at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the thickness of the thickness from the top surface of the panel to the highest part of the top surface of the tongue and/or from the bottom surface of the panel to the lowest part of the upper surface of the lower lip. In particular, each reinforcing layer 6, 7 is located in the middle of the minimum thickness 4, 5 of the remaining core material at the location of the tongue or groove. The core layer has a top surface 9 and a bottom surface 8 and the remaining material at the location of the tongue or groove extends to the top or bottom surface.

Fig. 2 shows two sides of a panel 21, in particular a floor panel 21, comprising: a core layer 22, the core layer 22 comprising a mineral or cementitious material; at least one reinforcing

layer

26, 27 in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges comprising interlocking coupling parts allowing coupling of a plurality of floor panels to each other, wherein said interlocking coupling parts are formed as a tongue 290 and a groove 23 by locally removing material at the respective edges. The reinforcement layers 26, 27 are located in the middle of the

minimum thickness

24, 25 of the remaining core material at the location of the tongue or groove. The core layer has a top surface 29 and a bottom surface 28 and the remaining material at the location of the tongue or groove extends to the top or bottom surface.

Fig. 3 shows two sides of a panel 31, in particular a floor panel 31, comprising: a core layer 32, the core layer 32 comprising a mineral or cementitious material; at least one reinforcing layer 36, 37 in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges comprising interlocking coupling parts allowing coupling of a plurality of floor panels to each other, wherein said interlocking coupling parts are formed as a tongue 390 and a groove 33 by locally removing material at the respective edges. The reinforcing layers 36, 37 are located in the middle of the minimum thickness 34, 35 of the remaining core material at the location of the tongue or groove. The core layer has a top surface 39 and a bottom surface 38 and the remaining material at the location of the tongue or groove extends to the top or bottom surface.

Fig. 4 shows two sides of a panel 41, in particular a floor panel 41, comprising: a core layer 42, the core layer 42 comprising a mineral or tacky material; at least one reinforcing

layer

46, 47 in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges comprising interlocking coupling parts allowing coupling of a plurality of floor panels to each other, wherein said interlocking coupling parts are formed as a tongue 490 and a groove 43 by locally removing material at the respective edges. The reinforcing layers 46, 47 are located in the middle of the

minimum thickness

44, 45 of the remaining core material at the location of the tongue or groove. The core layer has a top surface 49 and a bottom surface 48 and the remaining material at the location of the tongue or groove extends to the top or bottom surface.

Fig. 5 shows two sides of a panel 51, in particular a floor panel 51, comprising: a core layer 52, the core layer 52 comprising a mineral or cementitious material; at least one reinforcing

layer

56, 57 in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges comprising interlocking coupling parts allowing to couple a plurality of panels to each other, wherein said interlocking coupling parts are formed as a tongue 590 and a groove 53 by locally removing material at the respective edges. The reinforcement layers 56, 57 are located in the middle of the

minimum thickness

54, 55 of the remaining core material at the location of the tongue or groove. The core layer has a top surface 59 and a bottom surface 58 and the remaining material at the location of the tongue or groove extends to the top or bottom surface.

Although the figures show embodiments comprising two reinforcement layers, it is also conceivable that the panel comprises one reinforcement layer, three reinforcement layers or any other number of reinforcement layers. Preferably, however, for all embodiments, the at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panels, such that said reinforcing layer is located at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half of the thickness from the top surface of the panel to the highest part of the top surface of the tongue and/or from the bottom surface of the panel to the lowest part of the upper surface of the lower lip.

It is obvious that the invention is not limited to the embodiments shown and described herein, but that within the scope of the appended claims many variations are possible which are obvious to a person skilled in the art.

The above inventive concept is illustrated by several exemplary embodiments. It is contemplated that various inventive concepts may be applied without the application of the other details of the described examples. It is not necessary to describe in detail all possible combinations of the above-described inventive concepts, since a person skilled in the art will understand that many inventive concepts may be (re) combined to achieve a specific application.

The verb "to comprise" and its conjugations used in this patent publication is understood to mean not only "comprising" but also the phrases "comprising", "consisting essentially of … …", "formed of … …" and its conjugations. When referring to a reinforcing layer, it may also refer to a reinforcing element and vice versa.

Claims

1. A panel, in particular a floor panel, a wall panel or a ceiling panel, the panel comprising:

-a core layer comprising a mineral or cementitious material;

-at least one reinforcing layer in the core layer;

wherein the panel, in particular the core layer, comprises a first pair of opposing edges, wherein a first edge of the first pair of opposing edges comprises a first coupling part, and wherein a second edge of the first pair of opposing edges comprises a complementary second coupling part, which coupling parts allow a plurality of panels to be coupled to each other;

wherein the first coupling part comprises a lateral tongue extending in a direction substantially parallel to a plane defined by the panels, and wherein the second coupling part comprises a groove configured for receiving at least a part of the lateral tongue of another panel, the groove being defined by an upper lip and a lower lip,

characterized in that at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panel such that the reinforcing layer is located at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the thickness of the highest part of the top surface of the panel to the top surface of the tongue and/or the lowest part of the bottom surface of the panel to the upper surface of the lower lip.

2. Panel according to claim 1, comprising at least two reinforcement layers, wherein a first reinforcement layer extends parallel to the plane of the panel and is located in the core layer at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the thickness of the tongue from the top surface of the core layer to the highest bottom surface of the thickness forming the protrusion of the tongue; and/or a second reinforcement layer extending parallel to the plane of the panel and located in the core layer at a height of between 30% and 70%, more particularly between 40% and 60%, preferably at a height of half the thickness of the thickness from the top surface of the core layer to the lowest top surface of the protrusion forming the groove.

3. Panel according to claim 1 or 2, wherein at least one reinforcement layer forms an integral part of the core layer.

4. Panel according to any one of the preceding claims, wherein the core layer has a top surface and a bottom surface, and wherein the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.

5. Panel according to any one of the preceding claims, wherein at least one reinforcement layer comprises a mesh, sheet or net material.

6. Panel according to any one of the preceding claims, wherein the flexibility of at least one reinforcing layer is higher than the flexibility of the core layer.

7. Panel according to any one of the preceding claims, wherein at least one reinforcement layer comprises glass fibre, polypropylene, cotton, silica and/or nylon.

8. Panel according to any one of the preceding claims, wherein the core layer comprises MgO, magnesium oxychloride, magnesium oxysulfate, MgCl₂、MgSO₄And/or MgCO₃And/or a binder.

9. Panel according to claim 8, wherein the core layer comprises at least 70% by weight of MgO, magnesium oxychloride, magnesium oxysulphate, MgCl₂、MgSO₄And/or MgCO₃And/or a binder.

10. Panel according to any one of the preceding claims, wherein the core layer has a thickness of between 3mm and 8mm, in particular between 5mm and 6 mm.

11. Panel according to any one of the preceding claims, wherein the tongue or groove has a minimum thickness of between 1 and 3 mm.

12. Panel according to one of the foregoing claims, wherein the complementary coupling parts are configured to form a click-fit connection.

13. Panel according to any one of the preceding claims, comprising a laminate of the core layer and at least one of a decorative top layer, a sound attenuating layer and a balancing layer.