CN116802050A

CN116802050A - Decorative panel and decorative floor covering consisting of said panel

Info

Publication number: CN116802050A
Application number: CN202280009161.XA
Authority: CN
Inventors: 艾迪·阿尔贝里克·伯克
Original assignee: I4F Licensing NV
Current assignee: I4F Licensing NV
Priority date: 2021-01-05
Filing date: 2022-01-04
Publication date: 2023-09-22

Abstract

The present 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 covering consisting of a plurality of interconnected panels according to the invention, in particular a floor covering consisting of a plurality of interconnected panels according to the invention.

Description

Decorative panel and decorative floor covering consisting of said panel

Technical Field

Background

In the field of decorative floor coverings, decorative panels having a medium density board (MDF) or high density board (HDF) based core over which a decorative substrate is attached to provide the desired appearance of the panel are known. The main drawback of these known panels is the hygroscopicity of the core layer, which can affect the life and durability of such panels. For this reason, conventional MDF/HDF based panels are increasingly replaced by polyvinyl chloride (PVC) based panels, which are also provided with a decorative substrate on top. These PVC-based panels have the advantage of being relatively waterproof compared to MDF/HDF-based panels. PVC-based panels are often rich in chalk (calcium carbonate) used as an inert filler, wherein the amount of chalk applied increases over time, in particular in order to reduce the cost price of the panel. These panels are also called Stone Plastic Composite (SPC) panels. However, the primary disadvantage of these PVC-based panels is that they are very poor in temperature resistance, and therefore, they are often prone to deformation (bending) in the event that they are exposed to a heat source (e.g. a heating radiator or even a lamp). Furthermore, a common additional important disadvantage of MDF/HDF based panels and PVC based panels is the flammability of these panels. The flammability of furniture is a concern because accidents such as cigarettes and candles can easily cause household fires. Furthermore, the trend to use more chalk in PVC-based panels increases the brittleness of the panels seriously, thereby increasing the risk of breakage of the panels. In particular, in the case of panels shaped to allow interlocking of adjacent panels with each other, the risk of the coupling profile of the panels breaking before and during use has increased considerably, which often makes these panels less suitable or even no longer suitable for constituting a so-called floating floor covering consisting of interlocking panels. Accordingly, there is a general need in the art of decorative floors to further develop decorative panels to counteract at least one of the above-mentioned drawbacks, in particular to develop a relatively fire-resistant decorative panel. There is also a need to develop a decorative panel with improved dimensional stability when subjected to temperature fluctuations during regular use. There is also a need to develop an interlockable panel which can be shaped relatively smoothly, preferably depending on the hardness of the decorative top layer of the panel, and wherein the coupling profile shows a reduced risk of breakage.

Disclosure of Invention

The object of the present invention is to meet at least one of the above-mentioned needs.

The above object of the invention is achieved by providing a decorative panel, in particular a floor panel, a ceiling panel or a wall panel, comprising: a core provided with an upper side and a lower side; a decorative top structure directly or indirectly secured to 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, wherein the second coupling profile is designed to interlockingly engage with the first coupling profile of an adjacent panel in both the horizontal and vertical directions, wherein the core comprises at least one layer of wool formed at least in part from glass fibers bonded together by at least one cured thermoset polymeric binder material.

Typically, the fleece layer comprises (man-made) glass wool, also called mineral wool, consisting of (man-made) glass fibers (MMVF) bonded together. Mineral fiber products of this type are typically made by converting a melt made from suitable raw materials into fibers in a conventional manner, such as by a rotary cup process or a cascade rotor process. The fibers or strands are blown into the forming chamber and sprayed with a binder solution while in air and still hot and randomly deposited as a mat or web on a traveling conveyor. The mat is then transferred to a curing oven where heated air is blown through the mat to cure the binder and rigidly bond the mineral fibers together. Preferably, at least a portion of the man-made glass fibers (MMVF) are made of at least one material selected from mineral wool and/or mineral fibers, including rock wool, mineral wool, slag wool, basalt wool, dolomite wool, diabase wool, volcanic rock wool, ceramic fibers, and glass fibers. The stone or (volcanic) rock based composition may be obtained directly from nature. Slag wool is typically made from recycled waste products of blast furnaces. Glass wool is typically made from a mixture of natural glass and recycled glass, where the recycled glass is obtained, for example, from recycled bottles, automotive windshields and panes. Mineral wool is nonflammable, thermally stable and moisture resistant. It maintains its characteristics even under humid conditions. Furthermore, mineral wool can effectively block sound, which makes mineral wool a relatively good sound dampening material, which is a beneficial property when used in floor panels, wall panels and ceiling panels. Furthermore, it has surprisingly been found that these mineral cottons, which are bonded by means of a cured thermosetting binder, can be shaped in a very smooth manner, which makes the material suitable for integrally forming at least a part of each coupling profile from the material of the core, in particular the material of at least one wool layer of the core. Due to the non-brittle, tough material properties of the fleece layer, the risk of damage to the coupling profile during or after manufacturing can be kept to a minimum, which makes the panel according to the invention ideally suited for composing a floating floor covering consisting of interlocking panels according to the invention in a durable and reliable manner. This is a great advantage over current SPC panels. The core may also be referred to as the substrate of the panel. The layer of (mineral) wool, also known as a (mineral) wool pad or a (mineral) wool mesh, is typically a three-dimensional layer having a thickness of at least 2 mm; preferably, the thickness is between 2mm and 12 mm; more preferably, the thickness is between 3mm and 10 mm. In this layer, the glass fibers may have an at least partially vertical orientation and/or may be stacked on top of each other.

Preferably, the amount (weight percent) of glass fibers in the at least one wool layer exceeds the amount (weight percent) of cured thermosetting polymer binder material. Preferably, the amount (weight percent) of glass fibers in the at least one wool layer is between 75% and 95%, more preferably between 80% and 90%. Preferably, the amount (weight percent) of binder material in the at least one fleece layer is between 5% and 20%, more preferably between 10% and 17%. Mao Liaoceng may contain minor amounts of other materials and/or may contain one or more additives, such as colorants and/or fillers.

The addition of the binder is preferably performed under conditions that allow for a uniform distribution of the binder on the glass fibers. In particular, it is preferable to prevent the formation of fiber bundles in which the binder or binders are dispersed in unbonded fibers that are easily broken to generate dust. This operation aims to hold the fibres bonded together by a sufficiently strong (to ensure good cohesion and to ensure that the product does not tear during use) connection point. However, the cohesion is preferably not so high that the bond remains flexible and the final product remains somewhat deformable. In particular, the connection between the fibres must provide a sufficiently stable and rigid network to withstand the pressures exerted during storage and transport of the product and during its normal use as a (floor) panel. Typically, the binder is supplied in close proximity to the fiber forming device. The reason for applying the binder to the suspended fibres rather than to the mat already formed on the receiving conveyor is that it is difficult for the binder to penetrate into the mineral wool mat, since such mats are compact and the fibres have a fine structure compared to the size of the binder droplets.

Curing of the mineral fibre web (mineral wool) can be carried out in a curing oven by introducing a stream of hot air into the mineral fibre web. However, at the entrance of the curing oven, where the uncured and thus flexible mineral web is introduced into the oven, there is often the problem that: the size of the hot air stream may result in holes or depressions in the mineral fibre web (so-called "hollow blow moulding"), which is undesirable, as these holes or depressions may be visible in the final panel. As curing proceeds along the length of the curing oven, the importance of the problem decreases because the stiffness increases and the mineral fiber web obtains resistance against air pressure. The cure quality can be improved by applying one or more co-binders having, for example, a tstart temperature lower than that of the primary binder (the temperature at which curing begins), rapidly build strength in the mineral fiber web upon introduction into the curing oven, thereby reducing the risk of blow molding in the uncured or partially cured portion, and improving the cure quality and cure rate. Preferably, the core, in particular the at least one fleece layer, comprises a mixture of binder materials, wherein the first binder material has a higher curing temperature and/or curing rate than the at least one second binder material. This enables the use of air pressure which normally results in hollow blow moulding, which in turn increases the capacity. The thermosetting binder materials used in the core, in particular in the (mineral) wool layer, may comprise formaldehyde-containing and formaldehyde-free organic and inorganic binder resins. Suitable formaldehyde-containing resins are, for example, phenolic resins (phenolic resins or urea-modified phenolic resins) and aminoplast resins (melamine-formaldehyde resins or urea-formaldehyde resins), or combinations thereof. Preferred examples of formaldehyde-free binder materials are described below. Preferably, the binder material comprises a (water-soluble) reaction product of an alkanolamine and a carboxylic anhydride, which reaction product may be obtained by reacting at least one alkanolamine with at least one carboxylic anhydride and optionally treating the reaction product with a base. Preferred alkanolamines for preparing such binder materials are alkanolamines having at least two hydroxyl groups. Specific examples of suitable alkanolamines are diethanolamine, triethanolamine, diisopropanolamine, triisopropanolamine, methyldiethanolamine, ethyldiethanolamine, n-butyldiethanolamine, methyldiisopropanolamine, ethylisopropanolamine, ethyldiisopropanolamine, 3-amino-1, 2-propanediol, 2-amino-1, 3-propanediol and tris (hydroxymethyl) aminomethane. Diethanolamine is the presently preferred alkanolamine. The carboxylic anhydride reactant may be selected from saturated or unsaturated aliphatic and cycloaliphatic anhydrides, aromatic anhydrides, and mixtures thereof, with saturated or unsaturated cycloaliphatic anhydrides, aromatic anhydrides, and mixtures thereof being preferred. In a particularly preferred embodiment of the invention, two different anhydrides selected from cycloaliphatic and/or aromatic anhydrides are used. Other suitable examples of binder materials that may be particularly useful as co-binders are acrylics and epoxies. Preferably, the amount (weight percent) of co-binder is 1% to 50% of the total binder, preferably 5% to 35% of the total binder, on a solids basis.

Preferably, the at least one binder material is formed from a sugar component, preferably selected from sucrose, reducing sugars, in particular dextrose, polycarbohydrates and mixtures thereof. Glucose (also known as dextrose) is formed in plants from carbon dioxide absorbed from air using sunlight as an energy source. Part of the glucose is polymerized into long-chain glucose and stored as starch in the granules as a reserve. The viscosity and content of large polymers in syrup generally decrease with increasing DE value. DE is an abbreviation for dextrose equivalent (Dextrose Equivalent), defined as the content of reducing sugars, expressed as grams of anhydrous D-glucose per 100g dry matter in the sample, when determined by the method specified in International Standard ISO 5377-1981 (E). Hydrolytic cleavage of starch can be stopped at different stages of the process, resulting in a carbohydrate mixture (syrup) with different DE values, i.e. with different molecular weight distribution and different reactivity. Only high DE glucose syrups can crystallize easily and give products in powder or granular form. The most popular crystalline product is glucose monohydrate, used in medicine and chewable tablets. Glucose monohydrate is pure glucose (DE 100). For mineral wool binder materials, a large content of polymer should preferably be avoided, since this will provide a more viscous binder, resulting in the tackiness of the formed mineral wool layer (wool mat or binder-containing web) to manufacturing equipment (e.g. forming chamber walls, travelling conveyors, rollers and pendulum bobs). The solubility of the binder solution containing syrup may increase with increasing DE value. The binder solution must be sufficiently water-soluble to allow the binder to be evenly distributed over the mineral fibers that make up the mineral wool mat or web to be cured. Preferably, the binder material comprises an aqueous binder composition comprising a syrup containing reducing sugars having a dextrose equivalent DE of 50 to less than 85. This will generally provide an excellent product meeting the many requirements for binders in mineral wool production lines as well as the requirements for products obtained with binders.

Insufficient curing of the entire batt layer may also occur. This may be the case, for example, when the production line changes from one product type to another and the curing settings need to be changed. For example from a low binder content product to a high binder content product or from a high binder content product to a low binder content product. During the line break-in, the curing settings may not be optimal and under-curing situations may occur. Another problem that may occur during the production of mineral fibre products is an abnormality in the binder distribution, such as aggregation of large amounts of binder material in individual parts of the batt, which affects the performance and is therefore undesirable. The curing process can be monitored more closely by adding at least one fluorescent compound to the core, in particular to the layer of wool, more in particular to the binder material of the layer of wool. Quenching of fluorescence by the binder material is affected by curing. For the purposes of the present invention, the term "cured or partially cured bonding material" refers to a bonding agent that has been cured at least to some extent, such as by heat treatment in a curing apparatus, but not necessarily treated to achieve complete curing in all areas of the product. By visual inspection, the presence of fluorescence and/or fluorescent patterns and/or color changes on the surface of the fleece layer can be detected. In this way, irregularities in curing or anomalies in the binder material can be detected immediately, and the production process can be quickly readjusted, thereby minimizing waste of unacceptable layers of wool. Although in principle any fluorescent compound can be used in any amount in the panel according to the invention, in particular in the core, more in particular in the wool layer, particularly good results are achieved when the liquid mixture comprises a fluorescent compound selected from the group consisting of: one or more xanthines, such as sodium fluorescein salt, 2',7' -dichlorofluorescein, rhodamine B, rhodamine 6G, eosin Y disodium salt (2 ',4',5',7' -tetrabromofluorescein disodium salt), sulforhodamine B; one or more acridines, such as acridine orange (3, 6-bis (dimethylamino) acridine), acridine yellow G (3, 6-diamino-2, 7-dimethylacridine hydrochloride); quinine and/or one or more quinine derivatives, e.g., in the form of tonic water containing quinine; one or more coumarins, such as umbelliferone (7-hydroxycoumarin); one or more aryl sulfonates such as pyran (8-hydroxypyrene-1, 3, 6-trisulfonic acid trisodium salt). Experiments have shown that the well cured areas (brown) and the binder free areas (white) appear "as usual" during the day and do not fluoresce under 365nm uv light. The areas with uncured binder can be easily detected and distinguished from the areas without binder by the presence of pink fluorescence under 365nm uv light and by the presence of pink color during the day: the presence of uncured adhesive, for example due to shot nest (shot nest), can be detected. Even small uncured spots that are invisible to the naked eye during the day can be effectively detected under 365nm ultraviolet light.

Preferably, the core, in particular the at least one fleece layer, comprises aerogel particles. Aerogels are synthetic porous ultralight materials derived from gels in which the liquid component of the gel has been replaced with a gas without significant collapse of the gel structure, thereby forming solids of extremely low density and beneficial vapor permeability. More preferably, the weight of the aerogel particles in the core exceeds the weight of the binder material and/or the weight of the man-made glass fibers in the core. Accordingly, it is preferred to use relatively large weights (and amounts) of aerogel particles, which can significantly reduce the weight and density of the core and thus the panel itself. This results in the use of less binder material, which is advantageous from a cost point of view. The aerogel particles are encased in glass fiber "cages" where the fibers are connected by a binder material at the junctions between the fibers, thereby retaining the aerogel particles within the blanket.

During the production process, the orientation of the fibers in the batt layer can be adjusted. For one of the intended uses of the panel, in particular as a floor panel, it is advantageous if at least one of the fleece layers comprises fibers, the orientation of which is substantially vertical and/or in a vertically cluttered manner. Here, the vertical component of the fiber orientation dominates over the horizontal component of the fiber orientation. This will increase the compressive strength of the batt layer. This does not exclude that it is conceivable to set the fibre orientation in at least one of the wool layers of the core to be substantially horizontal. It is conceivable that the core comprises: at least one base Mao Liaoceng comprising a first mineral wool; and at least one roof Mao Liaoceng comprising a second mineral wool over the base batt layer. The first mineral wool and the second mineral wool may be the same. Preferably, however, the first mineral wool and the second mineral wool have different material compositions and/or different structural properties, such as different fiber orientations.

In general, when terms such as "horizontal" and "vertical" or similar directional references are used in the present invention, these terms should be construed as relative terms; for example, the term "vertical" refers to a direction perpendicular to a plane defined by the panel, while "horizontal" refers to a direction coincident with or parallel to the plane of the panel.

Preferably, the panel, in particular the core, more particularly the at least one fleece layer, comprises at least one reinforcing layer, preferably a non-woven layer or a woven layer, in particular a cloth. The thickness of each reinforcing layer is preferably 0.2mm to 0.4mm. It is conceivable that the core has a multi-layer structure, wherein at least one reinforcing layer is enclosed between two other layers of the panel, in particular between two other layers of the core. Preferably, the density of the reinforcing layer is 1000kg/m ³ To 2000kg/m ³ Preferably between 1400kg/m ³ To 1900kg/m ³ Between, more preferably at 1400kg/m ³ Up to 1700kg/m ³ Between them. The reinforcing layer may comprise natural fibers such as, but not limited to, jute, and/or may comprise: synthetic fibers, such as polymeric fibers, particularly nylon fibers; glass fibers; or carbon fiber. It is conceivable that at least one reinforcing layer is embedded in at least one fleece layer and preferably between two fleece layers that are stacked on top of each other. It is conceivable that the panel comprises a plurality of reinforcement layers, wherein preferably at least one first reinforcement layer is located at the top of the core and at least one second reinforcement layer is located at the bottom of the core.

Preferably, at least one core, in particular at least one fleece layer, has a weight of less than 1200kg/m ³ Is a density of (3). In the case of aerogel particles, about 80kg/m can be obtained ³ To 100kg/m ³ Is relatively low in density. Typically, the density is 130kg/m ³ To 1050kg/m ³ Between them. Preferably, at least one core, in particular at least one fleece layer, has a weight of less than 12kg/m ² Preferably below 10kg/m ² Is a high density of the area of the substrate.

Preferably, the thermal expansion coefficient of the panel, preferably the core, more preferably the at least one layer of wool in at least one direction is below 0.03mm/m/10 ℃, preferably below 0.02mm/m/10 ℃. The coefficient of thermal expansion is preferably applied both in the longitudinal and transverse direction of the panel, preferably the core, more preferably the at least one layer of wool. Preferably, the young's modulus of the at least one fleece layer is between 3500 and 5200MPa, more preferably between 4000 and 4500 MPa. The flexural strength of the at least one wool layer is preferably between 40 and 50MPa, more preferably between 43 and 48 MPa.

Preferably, the decorative top structure is adhered to the core by an adhesive, in particular a waterproof adhesive. This prevents the top structure from easily peeling off the core when wet. An example of a suitable adhesive is a polyurethane adhesive. Alternatively or additionally, it is also conceivable that the decorative top structure is adhered to the core by pressing, in particular hot pressing (e.g. calendaring).

Preferably, an adhesive that loses tackiness at a predetermined temperature is used; more preferably, an adhesive is used which loses tackiness between 80 ℃ and 120 ℃. Such an adhesive would allow the core and the top structure to be separated so that the two parts can be recycled separately. Furthermore, the use of such an adhesive allows for replacement of the damaged top structure by (locally) heating the panels (typically to a temperature between 80 ℃ and 120 ℃) so that the top layer can be replaced without having to remove a plurality of panels. Preferably, the adhesive layer is a flexible layer configured to withstand (linear) expansion and contraction differences between the core and the top structure. Preferably, a hot melt adhesive (thermoplastic adhesive) is used. The invention also relates to the use of an adhesive, in particular a hot melt adhesive, which at least partially loses its tackiness at elevated temperatures, preferably between 80 ℃ and 120 ℃ and/or has a reduced bond strength, for gluing a decorative top structure directly or indirectly to a core for constructing a decorative panel, in particular a decorative panel according to the invention. Such an adhesive facilitates the stripping of the panel for recycling purposes.

Some possible base materials for suitable adhesives include the following:

ethylene Vinyl Acetate (EVA) copolymers, which typically result in low performance, low cost hot melt adhesives. They provide sufficient strength between 15 ℃ and 50 ℃, but are limited to use below 60-80 ℃ and have low creep resistance under load. The vinyl acetate monomer content is preferably about 18% to 29% by weight of the polymer. Large amounts of tackifiers and waxes are often used; one exemplary composition is 30% to 40% EVA copolymer (providing strength and toughness), 30% to 40% tackifier resin (improving wetting and tack), 20% to 30% wax (typically paraffin-based; reducing viscosity, changing set speed, reducing cost), and 0.5% to 1.0% stabilizer. Fillers may be added. Lower molecular weight chains provide lower melt viscosity, better wetting and better adhesion to porous surfaces. Higher molecular weight chains provide better cohesion at high temperatures and better low temperature properties. An increase in the proportion of vinyl acetate reduces the crystallinity of the material, improves optical clarity, flexibility and toughness, and deteriorates the tolerance to solvents. EVA can be crosslinked, for example, by peroxide, to produce a thermoset. EVA may be compounded with an aromatic hydrocarbon resin. Grafting butadiene onto EVA improves its adhesion. Due to the high content of polar groups, the dielectric properties are poor and the dielectric losses are moderately high, which makes this material less preferred in the case of floor panels where good insulation is required. EVA is optically more transparent and has better permeability to gases and water vapor than polyolefin;

Ethylene-acrylate copolymers have lower glass transition temperatures and even higher adhesion to difficult substrates than EVA. These copolymers exhibit better heat resistance, increased adhesion to metals and glass, and are suitable for low temperature use than EVA. Ethylene-vinyl acetate-maleic anhydride and ethylene-acrylate-maleic anhydride terpolymers offer very high properties. Examples are ethylene n-butyl acrylate (EnBA), ethylene Acrylic Acid (EAA) and Ethylene Ethyl Acetate (EEA).

Polyolefin (PO) (polyethylene (usually LDPE, but also HDPE, with higher melting point and better temperature resistance), atactic polypropylene (PP or APP), polybutene-1, oxidized polyethylene, etc.), has low properties for plastics that are difficult to bond. Has very good adhesion to polypropylene, good moisture resistance, and chemical resistance to polar solvents and acid, base and alcohol solutions. Open time is longer compared to EVA and polyamide. Polyolefins have a low surface energy and provide good wettability for most metals and polymers. Metallocene-catalyst synthesized polyolefins have a narrow molecular weight distribution and a correspondingly narrow melting temperature range. Because of the relatively high crystallinity, polyvinyl glues tend to be opaque and, depending on the additives, white or yellowish. The polyethylene hot melt has higher storage period stability, is not easy to burn, and is suitable for a medium temperature range and a porous inflexible substrate. Nitrogen or carbon dioxide may be introduced into the melt to form a foam that increases the spread and open time and reduces heat transfer to the substrate, allowing more heat sensitive substrates to be used; polyethylene based HMA is typically used. PE and APP are typically used alone or with only small amounts of tackifiers (typically hydrocarbons) and waxes (typically paraffin or microcrystalline waxes to reduce cost, improve blocking resistance, and change open time and softening temperature). The molecular weight of the polymer is generally low. Lower molecular weight provides better low temperature performance and higher flexibility, while higher molecular weight increases seal strength, hot tack and melt viscosity.

Polybutene-1 and its copolymers are soft, flexible, partially crystalline, and slowly crystallize with long open time. The low temperature of recrystallization allows stress relief during bond formation. Good adhesion to non-polar surfaces and poor adhesion to polar surfaces. Suitable for use in rubber substrates, and may be formulated to be pressure sensitive.

Amorphous polyolefin (APO/APAO) polymers are compatible with many solvents, tackifiers, waxes, and polymers; they are widely used in many adhesive applications. APO hotmelts have good fuel and acid resistance, moderate heat resistance, are tacky, soft and flexible, have good adhesion, and have a longer open time than crystalline polyolefins. APO tends to have lower melt viscosity, better adhesion, longer open time and slow set time than comparable EVA. Some APOs may be used alone, but are typically compounded with tackifiers, waxes, and plasticizers (e.g., mineral oil, polybutene oil). Examples of APO include amorphous (random) propylene (APP), amorphous propylene/ethylene (APE), amorphous propylene/butene (APB), amorphous propylene/hexene (APH), amorphous propylene/ethylene/butene. APP is harder than APE, APE is harder than APB, APB is harder than APH, which is associated with reduced crystallinity. APO exhibits relatively low cohesion and entangled polymer chains have a relatively high degree of freedom of movement. Under mechanical loading, most of the strain dissipates through elongation and untangling of the polymer chains, and only a small portion of the strain reaches the adhesive-substrate interface. Cohesive failure is therefore the more common failure mode of APO.

Polyamides and polyesters, have high properties.

Polyamide (PA), high performance, suitable for harsh environments; high-temperature glue; typically at temperatures above 200 c, but degrade and char during processing. In the molten state, degradation occurs to some extent due to atmospheric oxygen. The application temperature is high. The use temperature range is high, and generally shows sufficient adhesion in the range of-40 ℃ to 70 ℃; some compositions may be run to 185 c if no load is necessary. Plasticizer resistant and therefore suitable for gluing polyvinyl chloride; however, only polyamides derived from secondary diamines provide satisfactory bonding. Oil and petrol resistant. Has good adhesion to many substrates such as metal, wood, vinyl, ABS and treated polyethylene and polypropylene. Three groups are adopted, and the low molecular weight, the medium molecular weight and the high molecular weight are realized; low molecular weight materials are low temperature melting and easy to apply, but have lower tensile strength, tensile shear strength and elongation than high molecular weight materials. High molecular weight materials require complex extruders and are used as high performance structural adhesives. The presence of hydrogen bonds between the polymer chains gives polyamides with high strength even at low molecular weights compared to other polymers. Hydrogen bonding also provides retention of most of the adhesive strength almost up to the melting point; however, they also make the material more permeable to moisture than polyesters. Can be formulated to be soft and tacky, or can be formulated to be hard and rigid. The addition of polyester to the interest based application represents less than 10% of the total amount of the hot melt adhesive market. The absorption of moisture may lead to foaming during application, as the water evaporates during melting, leaving voids in the adhesive layer, thereby reducing mechanical strength. Polyamide HMA typically consists of dimer acid and typically two or more different diamines. Dimer acid generally comprises 60% to 80% of the total mass of the polyamide and provides amorphous nonpolar character. Linear aliphatic amines such as ethylenediamine and hexamethylenediamine provide hardness and strength. Longer chain amines such as diamines reduce the number of hydrogen bonds per volume of material, resulting in lower hardness. Polyetherdiamines provide good low temperature flexibility. Piperazine and similar diamines also reduce the number of hydrogen bonds. Only polyamides based on piperazine and similar secondary amines can form satisfactory bonds with polyvinyl chloride; primary amines form stronger hydrogen bonds in the binder, secondary amines only act as proton acceptors, do not form hydrogen bonds in the polyamide, and therefore can freely form weaker bonds with vinyl groups, and possibly with hydrogen atoms in the vicinity of chlorine.

Polyesters, similar to polyesters used for synthetic fibers. The application temperature is high. Synthesized from diols and dicarboxylic acids. The length of the glycol chain has a major effect on the properties of the material; as the diol chain length increases, the melting point increases, the crystallization rate increases, and the crystallinity decreases. Both the diol and the acid affect the melting point. Compared to similar polyamides, polyesters are lower in strength and melting point due to the absence of hydrogen bonding, but are more moisture resistant, although still susceptible to moisture. Among other parameters, and in applications where these factors are not of interest, polyesters and polyamides are very similar. Polyesters are suitable for bonding fabrics. They may be used alone or in admixture with a large amount of additives. They are used in applications where high tensile strength and high temperature resistance are required. Most polyester hot melts have a high degree of crystallinity. Polyesters are typically highly crystalline, resulting in a narrow melting temperature range, which facilitates high speed bonding.

Polyurethane

Thermoplastic Polyurethane (TPU) has good adhesion to different surfaces due to the presence of polar groups. Their low glass transition temperature provides flexibility at low temperatures. They are highly elastic and soft, with a broad range of possible crystallization and melting points. Polyurethanes consist of long linear chains with alternating flexible, soft segments (low melting polyester or polyether chains coupled with diisocyanates) and rigid segments (urethane bridges resulting from the reaction of diisocyanates with small molecule ethylene glycol chain extenders). The rigid segments form hydrogen bonds with the rigid segments of other molecules. Higher soft segment-to-hard segment ratios provide better flexibility, elongation and low temperature properties, but also lower hardness, modulus and abrasion resistance. When the adhesive behaves as a soft rubber for use as a pressure sensitive adhesive, the bonding temperature is lower than most other HMAs, only about 50 ℃ to 70 ℃. The surface wettability in this amorphous state is good and the polymer crystallizes upon cooling, forming a strong flexible bond with high cohesion. The polyurethane properties can be tailored by selecting the appropriate combination of diisocyanate and polyol; they may be used alone or blended with plasticizers. Polyurethane is compatible with most common plasticizers and many resins.

Polyurethane (PUR) or reactive urethanes for high temperature and high flexibility. The curing may be rapid or may be prolonged in the range of minutes; the secondary curing is performed with atmospheric moisture or substrate moisture and then continued for several hours, thereby forming crosslinks in the polymer. Excellent solvent resistance and chemical resistance. The application temperature is low, and the method is suitable for heat-sensitive substrates. Heat resistance after curing, use temperatures are typically between-30 ℃ and +150 ℃. Ink resistant solvents. Typically based on prepolymers made from polyols and methylene diphenyl diisocyanate (MDI) or other diisocyanates, with small amounts of free isocyanate groups; these groups react and crosslink when exposed to moisture. The "green" strength of the uncured solidification tends to be lower than the non-reactive HMA, with the mechanical strength developing with curing. The green strength may be increased by blending the prepolymer with other polymers. PUR is well suited for difficult-to-bond substrates because it is highly flexible and has a broad thermoset range.

Styrene Block Copolymers (SBC), also known as styrene copolymer adhesives and rubber-based adhesives, have good low temperature flexibility, high elongation and high heat resistance. Are often used in pressure sensitive adhesive applications where the composition remains tacky even when cured; however, non-pressure sensitive formulations may also be used. High heat resistance and good low-temperature flexibility. The strength is lower than that of polyester. They generally have an ase:Sub>A-B-ase:Sub>A structure with an elastomeric rubber segment between two rigid plastic end blocks. The film forming agent is a high-strength film forming agent when used alone, and the cohesion and viscosity are increased when used as an additive. Water-resistant, soluble in certain organic solvents; crosslinking improves solvent resistance. Resins combined with end blocks (coumarone-indene, alpha-methylstyrene, vinyl toluene, aromatic hydrocarbons, etc.) can improve adhesion and change viscosity. Resins combined with mid-blocks (aliphatic olefins, rosin esters, polyterpenes, terpene phenols) improve adhesion, processing and pressure sensitive properties. The addition of the plasticizer reduces the cost, improves the pressure sensitive viscosity, reduces the melt viscosity, reduces the hardness, and improves the low-temperature flexibility. The ase:Sub>A-B-ase:Sub>A structure promotes phase separation of the polymer, bonding the end blocks together with the central elastic portion acting as ase:Sub>A crosslink; SBCs do not require additional crosslinking.

Styrene-butadiene-styrene (SBS) for high strength PSA (pressure sensitive adhesive) applications.

Styrene-isoprene-styrene (SIS) for low viscosity, high tack PSA applications.

Styrene-ethylene/butylene-styrene (SEBS) for low self-adhesive nonwoven applications.

Styrene-ethylene/propylene (SEP).

Polycaprolactone and soy protein, coconut oil as a plasticizer, a biodegradable hot melt adhesive.

And (3) polycarbonate.

A fluoropolymer comprising a tackifier and an ethylene copolymer having polar groups.

The silicone rubber undergoes crosslinking after curing to form a durable, flexible uv-and weather-resistant silicone sealant.

A thermoplastic elastomer.

Polypyrrole (PPY), a conductive polymer, for use in Intrinsically Conductive Hot Melt Adhesives (ICHMA) for EMI shielding. EVA compounded with 0.1wt.% to 0.5wt.% (weight percent) PPY has a strong absorption capacity for near infrared light and can be used as a near infrared active adhesive.

Various other copolymers.

The binder may be enriched in one or more additives. Examples of such additives include the following:

tackifying resins (e.g., rosins and their derivatives, terpenes and modified terpenes, aliphatic, cycloaliphatic and aromatic resins (C5 aliphatic resins, C9 aromatic resins and C5/C9 aliphatic/aromatic resins), hydrogenated hydrocarbon resins and mixtures thereof, terpene phenolic resins (TPR, often used with EVA)), up to about 40%. Tackifiers tend to have low molecular weights and glass transition and softening temperatures above room temperature, providing them with suitable viscoelasticity. Tackifiers are typically a majority weight percent and cost of hot melt adhesives.

Waxes, such as microcrystalline wax, fatty amide wax, or oxidized fischer-tropsch wax; the cure rate is increased. Wax is one of the key components of the preparation, and can reduce the melt viscosity and improve the bonding strength and the temperature resistance.

Plasticizers (e.g., benzoate esters such as 1, 4-cyclohexanedimethanol dibenzoate, glycerol or pentaerythritol tetrabenzoate, phthalate esters, paraffinic oils, polyisobutylene, chlorinated paraffins, and the like).

Antioxidants and stabilizers (e.g., hindered phenols, BHT, phosphites, phosphates, hindered aromatic amines); small amounts (< 1%) did not affect physical properties. These compounds protect the material from degradation both during the service life and during compounding and in the molten state during application. Stabilizers based on functionalized silicones increase the resistance to extraction and degassing.

The uv stabilizer protects the material from degradation caused by uv irradiation.

Pigments and dyes, sparkling.

Biocides that retard bacterial growth.

A flame retardant.

Antistatic agents.

Fillers for cost reduction, volume increase, cohesive strength (forming aggregate matrix composites) and property change; such as calcium carbonate, barium sulfate, talc, silica, carbon black, clay (e.g., kaolin).

Fugitive glues and pressure sensitive adhesives may be provided in hot melt form. The PSA has a tacky consistency and can be bonded by applying pressure at room temperature. Additives and polymers containing unsaturated bonds are extremely susceptible to autoxidation. Examples include rosin-based additives. Antioxidants may be used to inhibit this aging mechanism. The addition of ferromagnetic particles, hygroscopic water-retaining materials, or other materials can produce a hot melt adhesive that can be activated by microwave heating. Conductive hot melt formulations can be obtained by adding conductive particles.

In another preferred embodiment, the decorative top structure is preferably fused to the core without the use of a separate adhesive. This may be achieved, for example, by using a thermoplastic layer or film as the bottom layer of the decorative top structure, which may be heated and then fused or welded to the core. Alternatively or additionally, this can also be achieved, for example, by applying a core with a softenable upper surface, in particular by applying a core comprising a thermoplastic top layer; and/or by having the top side of the core formed by an at least partially uncured fleece layer, wherein at least a portion of the top structure is applied onto said uncured top side of the core, after which the core is cured by (radiation) irradiation (e.g. thermal radiation and/or UV irradiation). In case the top structure is provided with a curable layer, e.g. a (UV) curable lacquer layer, it is conceivable to apply a single curing step during production to cure both the core and the top structure.

It is (also) conceivable that the underside of the decorative top structure penetrates to the upper side of the core and/or the upper side of the core penetrates to the underside of the decorative top structure, the penetration depth preferably exceeding 0.1mm. In case the decorative top structure penetrates to the upper side of the core, this may be achieved for example by applying the decorative top structure comprising a thermoplastic layer and/or a primer layer and/or an adhesive layer as a bottom layer. In particular in the case of adhesive layers, the adhesive is usually applied in liquid form, a certain penetration and (further) strengthening of the core, in particular of the at least one wool layer and/or of one or more further layers of the decorative top structure, can be achieved. The penetration of the core by the penetrating portion of the decorative roof structure is particularly advantageous at the side edges of the core, in particular at the side edges where grooves or recesses are applied. According to this embodiment, an improved lamination strength between the core and the decorative top structure may also be achieved. In this case, the risk of tearing or splitting between the core and the roof structure can be reduced. The decorative roof structure preferably penetrates the upper side of the core (and/or vice versa) over the entire interface formed between the core and the decorative roof structure or over at least 50% of said interface. The penetration depth achieved is preferably greater than 1% of the thickness of the core. In the case of a multi-layer core, the penetration depth achieved is preferably greater than 10% of the thickness of the upper layer of the core. It has been found that the panels according to this embodiment generally exhibit an (greatly) increased impact resistance of the panels themselves, which is particularly advantageous for the decorative top structure and coupling profile of the panels. Furthermore, with the panel according to this embodiment, the impact resistance of the panel can be improved without the need to add additional rigid or elastic reinforcing elements such as rubber layers, fiberglass layers or metal sheets. In fact, by applying at least two partially overlapping (woven or interwoven) layers of the panel, in particular by allowing at least one layer to penetrate into the other layer, the transmission and dissipation of the impact stresses through the panel can be significantly improved, so that a small portion of said energy is absorbed by the decorative layer, thus improving its impact resistance. The resulting panel can be made lighter and thinner as no stiffening elements need to be added. Furthermore, one layer penetrates into at least another layer, so that propagation of cracks in the core and/or the decorative top structure may be hindered. Furthermore, in the event of surface cracks in the core and/or the decorative top structure, the partially penetrated tie layers, such as adhesive layers, may maintain the consistency of the core and the decorative layer itself, and are preferably compacted, thereby masking the visual appearance of the surface cracks.

The thickness of the decorative top structure is preferably between 0.5mm and 12mm, preferably between 1mm and 6mm, more preferably between 2mm and 4 mm. It has been found experimentally that the core provides adequate support for any top layer when the thickness is between 0.5mm and 12 mm.

The decorative roof structure may have various properties. The top structure may be a single-layer or a multi-layer top structure, wherein at least one (top) layer of the top structure is formed by a flat plate and/or tile and/or other (thinner or thicker) layers, in particular a coating or a finishing layer. In a preferred embodiment, at least one layer of the roof structure and/or the roof structure itself is made at least partly of a glaze and/or a ceramic and/or stone and/or any material selected from polymers, linoleum, ceramics, stone, concrete, mineral porcelain, glass, quartz, soapstone, mosaic, granite, limestone and marble. These materials may be solid, or at least to some extent porous. If a glaze is applied, such a glaze may be transparent or translucent. Typically, the frit is a ceramic frit that is an impermeable layer or coating of vitreous substance fused to the ceramic body by firing. Such glazes may be colored and/or decorative and are generally waterproof. The raw materials for ceramic glazes typically include silica, which is the primary glass former. Various metal oxides, such as sodium, potassium and calcium, may be used as fluxing agents to reduce the melting temperature. Alumina, usually derived from clay, is preferably used to harden the molten glaze to prevent it from falling off. Colorants (e.g., iron oxide, copper carbonate or cobalt carbonate, and sometimes opacifiers such as tin oxide or zirconium oxide) are used to improve the visual appearance of the fired glaze. In case at least one layer of the top structure is at least partly made of a polymer, the polymer may be: soft polymers, such as rubber or any other (soft) thermoplastic or thermosetting polymer; or a harder polymer such as ultra high molecular weight polyethylene (UHMWPE, UHMW) or any other (harder) thermoplastic or thermosetting polymer. Linoleum (commonly referred to simply as lino) is a polymer-based composite material comprising cured linseed oil (oxidized linseed oil) and pine resin, preferably wood chips, such as ground cork dust and/or sawdust, and optionally mineral fillers, such as calcium carbonate. The flat plate and/or tile and/or other (thinner or thicker) layers of the top structure, in particular the coating or finishing layer, may be glued and/or fused to another layer of the top structure and/or the core. Here, it is conceivable to bond the tile, panel, coating, glaze or finishing layer to the core by using a (middle) adhesive layer. The adhesive layer may be considered to be part of a decorative top structure. Alternatively, it is conceivable to fuse tiles, plates, coatings, glazes or finishing layers (directly) to the core, for example by firing and/or heating and/or curing the laminate of the core with the decorative top structure. Thus, it is conceivable that the panel according to the invention consists of two layers: a core (provided with a coupling profile) formed by a single fleece layer; and a single decorative top layer fused to the core.

In the case of decorative top structures composed at least in part of glazes and/or ceramic materials, over time, the top structure may and typically will be stained by scum and films of biological origin (e.g., bacteria, fungi, mold, mildew). The traditional method of removing biological scum and films from the roof structure is to clean the roof structure with a cleaning agent. Preferably, however, and in general, the ornamental roof structure is provided with built-in protection against microbial growth and proliferation. In particular, however, the top structure is at least partially made of a glaze and/or ceramic material, and the high temperatures (typically between 800 ℃ and 1500 ℃) used during the desired ceramic firing process typically preclude the use of organic biocides. In addition to the desired heat resistance, the addition of silver-based biocides alone to ceramic glazes often gives rise to problems such as blushing, cracking, discoloration and other undesirable (physical and/or structural) consequences to the aesthetics of the glaze. Adding zinc oxide alone to the glaze or ceramic frit (prior to firing)The same problem often occurs. The glazing and/or ceramic based top structure (which may be a coating and/or a thin layer) thus preferably has a durable built-in biocidal protection while being aesthetically and optically neutral. In a preferred embodiment of the panel according to the invention, the decorative top structure is at least partly composed of a glaze and/or a ceramic material, wherein at least one antimicrobial composition is dispersed (mixed) in said glaze and/or ceramic material. Preferably, the antimicrobial composition comprises a metal selected from Cu ₂ O、Cu(OH) ₂ 、Cu、CuO ₃ 、Cu ₂ O ₃ And combinations thereof, and at least one non-copper metal or copper-free metal compound. Preferably, the copper-free metal compound is selected from the group consisting of silver-containing compounds, barium-containing compounds, bismuth-containing compounds, tin-containing compounds, titanium-containing compounds (e.g., tiO ₂ ) Zinc-containing compounds, and combinations thereof. Here, the silver-containing compound is preferably selected from AgO, ag ₂ O、Ag ₂ CO ₃ 、AgNO ₃ And combinations thereof. The barium-containing compound may be, for example, ba, baCO ₃ Or a combination thereof. The bismuth-containing compound may be, for example, bi ₂ O ₃ Or a combination thereof. The tin-containing compound may be, for example, snO ₂ . The zinc-containing compound is preferably Zn, znO or a combination thereof. Preferably, the copper-free metal compound is present in the glaze substrate and/or the ceramic substrate in a weight percentage range of at least 0.1%, more preferably 1% to 10%. Preferably, the metallic copper compound or copper-containing metallic compound is present in the glaze substrate or ceramic substrate in a weight percentage range of 1% to 10%. The glaze substrate and/or ceramic substrate is a substrate composition prepared prior to firing. The presence of one or more of these antimicrobial compositions in the glaze and/or ceramic material typically results in a surface that is significantly less green or greenish in color than if copper alone were used in the antimicrobial composition. In some embodiments, a second antimicrobial substance, such as zinc oxide, is used, which almost or completely eliminates green marks that are typically introduced in the fired layer due to the addition of copper. After firing, the fired layer still has durable sterilization Properties such as the ability to kill bacteria and other microorganisms rapidly. The incorporation of the antimicrobial composition into the glaze and/or ceramic material is typically achieved prior to firing: the antimicrobial agent or component is melted into the glass (which constitutes the base composition of the glaze and/or ceramic material), quenched to freeze the amorphous state, and then ground to the desired particle size. The sintered antimicrobial composition is a more homogeneous composition. In case the layer of the top structure based on a glaze and/or ceramic material is directly or indirectly bonded to the core by using an adhesive, the adhesive may be provided with said antimicrobial composition. It is even conceivable that the adhesive is provided with said antimicrobial composition, whereas the glaze and/or the ceramic layer does not contain any antimicrobial composition. The second layer of the adhesive composition may be applied on the dry-sintered glaze and/or the ceramic material. The second adhesive layer preferably employs an adhesive composition comprising one or more antimicrobial agents, such as those described above and below. The glaze and/or ceramic material and the one or more adhesive layers are preferably fired in a conventional manner to mature the surface and produce a substrate with a glaze coating on the surface. As a result of the firing step, all layers are bonded together to form a fired glaze (and/or ceramic) coating on the substrate. The antimicrobial composition is typically present on a glassy surface where it exhibits its antimicrobial properties. In a preferred embodiment, the antimicrobial composition applied comprises a composition selected from the group consisting of Ag ₂ CO ₃ A first antimicrobial agent of composition and selected from Bi ₂ O ₃ 、CuO、SnO ₂ 、TiO ₂ And a second antimicrobial agent of ZnO. Preferably, the first antimicrobial agent is present in the glaze and/or ceramic composition at a concentration of about 2% to 4% by weight of the glaze and/or ceramic composition. The second antimicrobial agent is preferably present in the glaze composition and/or ceramic composition at a concentration of about 2% to 4% by weight of the glaze composition and/or ceramic composition. The combination of a first antimicrobial agent and a second antimicrobial agent as described herein achieves superior antimicrobial activity at lower antimicrobial agent concentrations compared to the antimicrobial ability of either antimicrobial agent alone. This excellent effectBrings about a significant economic advantage and increases the effectiveness of the antimicrobial combination per unit weight. Preferably, the antimicrobial composition is a synergistic antimicrobial composition comprising a first antimicrobial agent and a second antimicrobial agent, the antimicrobial composition being at least one of: 2% Ag ₂ CO ₃ +2% Bi ₂ O ₃ The method comprises the steps of carrying out a first treatment on the surface of the 2% Ag ₂ CO ₃ +2% CuO;2% Ag ₂ CO ₃ +4% SnO ₂ The method comprises the steps of carrying out a first treatment on the surface of the 2% Ag ₂ CO ₃ +2% ZnO;2% Ag ₂ CO ₃ +4% ZnO;2% Bi ₂ O ₃ +2% CuO;2% Bi ₂ O ₃ +4% CuO;2% CuO+4% Ag ₂ CO ₃ The method comprises the steps of carrying out a first treatment on the surface of the 2% CuO+4% SnO ₂ The method comprises the steps of carrying out a first treatment on the surface of the 2% CuO+2% TiO ₂ The method comprises the steps of carrying out a first treatment on the surface of the 2% CuO+4% TiO ₂ The method comprises the steps of carrying out a first treatment on the surface of the 2% cuo+4% ZnO;2% SnO ₂ +4% Ag ₂ CO ₃ The method comprises the steps of carrying out a first treatment on the surface of the 2% SnO ₂ +4% CuO;2% TiO ₂ +4% Ag ₂ CO ₃ The method comprises the steps of carrying out a first treatment on the surface of the 2% TiO ₂ +4% CuO;2% ZnO+4% Ag ₂ CO ₃ The method comprises the steps of carrying out a first treatment on the surface of the And/or 2% zno+4% CuO.

The antimicrobial compositions described above are primarily configured to be mixed with glazes and/or ceramic base materials. Alternatively, however, it is also additionally conceivable to apply one or more of the above-mentioned antimicrobial compositions as a coating onto one or more layers of the panel, preferably onto the top surface of the decorative structure, thereby providing the panel with antimicrobial properties. Thus, in this embodiment, the antimicrobial composition is included in a separate (coating) layer. The coating is typically applied after firing the glaze and/or ceramic material. The coating step is generally considered as a post-treatment, typically achieved before use and before packaging the panels.

Alternative antimicrobial compositions may be used where the antimicrobial composition is applied as a coating and/or does not have to undergo a firing process, such as in the case of alternative decorative top structures (e.g., polymer-based decorative top structures). For example, it is conceivable that at least one panel layer, in particular at least one core layer and/or decorative top structure, comprises and/or is coated with at least one antimicrobial agent, preferably selected from the group consisting of: (i) Organic or organometallic antimicrobial substances, such as halogenated phenyl ethers, halogenated salicylanilines, sesquiterpene alcohols, halogenated carbanilides, bisphenols, general phenols, formaldehyde, quaternary ammonium compounds, pyridine derivatives and hexachlorobenzene; and/or (ii) an inorganic antimicrobial substance comprising silver, zinc or copper in a glass or ceramic matrix, wherein the antimicrobial agent preferably comprises 2,4 '-trichloro-2' -hydroxydiphenyl ether. The antimicrobial agent may also be a chemical selected from the group consisting of: triclosan, o-phenylphenol, diiodomethyl-p-toluenesulfonate, zinc pyrithione, sodium pyrithione, azoles (e.g., propiazoles), poly (hexamethylene biguanide) hydrochloride, 3, 4' -trichlorocarbanilide, barium monohydrate, and silver, copper or zinc in zeolite or amorphous glass powders.

In a preferred embodiment, the decorative top structure comprises graphene and/or at least one derivative of graphene. It has been found that by incorporating graphene and/or at least one graphene derivative in the decorative top structure, the top structure and thus the hardness, the resistance to indentation and the impact resistance of the decorative panel itself can be significantly improved.

Graphene is a two-dimensional layer of carbon atoms arranged in the form of a honeycomb lattice. Such a thin, one-atom thick lattice is relatively strong, flexible, light in weight and easy to process, which makes such a material very suitable for incorporation in the decorative panel according to the invention to increase its impact resistance. In addition, graphene also exhibits excellent heat and electrical conductivity properties, which may also be used to further improve the decorative panel according to the present invention, as will be described in more detail below. In addition, graphene and/or graphene derivatives exhibit excellent oxidation resistance and scratch resistance. Furthermore, it was found that graphene and/or graphene derivatives exhibit excellent antimicrobial properties, which meets the need to improve existing panels still having known benefits, while reducing the risk of bacteria growing on and/or between said panels to expand the applicability of the panels.

The most common graphene derivatives are graphene oxide and reduced graphene oxide. Graphene Oxide (GO) is a monoatomic layered material made by powerful oxidation of graphite, relatively inexpensive and available in large quantities. Graphene oxide is an oxidized (and less expensive) form of graphene containing oxygen-containing groups. Reduced Graphene Oxide (RGO) is a GO morphology that is treated by chemical, thermal, and other methods to reduce oxygen content, while graphene oxide is a material produced by oxidation of graphite that results in increased interlayer spacing and basal plane functionalization of the graphite.

Since it is often necessary to increase the stiffness over the entire upper side of the decorative panel, the graphene and/or graphene derivative preferably covers almost the entire upper side of the core. Such a covering may be achieved, for example, by applying a continuous layer, a discontinuous layer, an overlapping or non-overlapping sheet of particles composed of graphene and/or at least one graphene derivative.

By using graphene and/or graphene derivatives in the panel according to the invention, particularly when applied as part of a porous microstructure, sound absorption properties and thus acoustic damping properties can be significantly enhanced.

Preferably, the decorative top structure comprises at least two layers, wherein at least one layer, preferably a substantially transparent or translucent top layer of the top structure, comprises graphene and/or at least one graphene derivative. The top layer may consist entirely of graphene and/or at least one graphene derivative, but it is also conceivable that the top layer comprises a top coating, for example a (hardened or hardenable) lacquer or resin layer, in which the graphene and/or at least one graphene derivative is dispersed and/or at least partially embedded. It is conceivable that the top surface of the decorative top structure is at least partly made of graphene and/or at least one graphene derivative. It is conceivable that the decorative top structure comprises at least one layer consisting of graphene and/or at least one graphene derivative. The graphene (derivative) layer may be, for example, a continuous layer or a discontinuous layer or lattice, which surrounds or is provided with one or more cracks. The at least one layer consisting of graphene and/or at least one graphene derivative may be at least partially surrounded by and/or between two layers of the panel, preferably between two layers of the decorative top structure, such as between the core and the top coating, and/or between the decorative layer and the top coating, and/or between the core and the decorative layer, and/or between the primer layer and the decorative layer. It is conceivable that the panel, in particular the roof structure and/or the core, comprises a plurality of layers, wherein each layer at least partially consists of graphene and/or at least one graphene derivative.

As mentioned above, it is conceivable that at least one layer consisting of graphene and/or at least one graphene derivative is at least partially embedded in at least one other layer of the decorative top structure. The latter layer, which may also be referred to as a matrix layer, is typically composed of a substance comprising a polymer such as PVC or PU. The matrix layer typically substantially completely surrounds and may penetrate the layer of graphene and/or at least one graphene derivative; in particular, if a crack (crack opening) is applied, the crack (crack opening) is present in a layer consisting of graphene and/or at least one graphene derivative. Preferably, the thickness of the graphene (derivative) intercalating layer is between 0.1nm and 60 μm, more preferably between 0.1nm and 50 μm, for example between 0.1nm and 1 μm, more preferably for example between 0.2nm and 0.4 nm. Such a layer may be prefabricated and adhered to another panel layer during the production of the panel, typically by gluing and/or fusion. If such a layer is produced in-line during the production of the panel, it is conceivable that the layer thickness exceeds 50 μm.

It is conceivable that the decorative top structure comprises particles consisting of graphene and/or at least one graphene derivative, preferably a sheet, such as a nano-sheet, and/or a sheet and/or a nano-tape and/or a fiber. These particles may be randomly distributed in the top structure, but it is generally preferred to embed the particles in at least one layer of the decorative top structure, preferably in at least one polymer layer of the decorative top structure. Preferably, at least a portion of the particles at least partially overlap, at least when viewed from a top view of the panel. Elongated and/or circular particles may preferably be applied, wherein at least a portion of the elongated particles at least partially overlap, wherein more preferably the overlapping particles have a similar orientation. In the case where the particles are incorporated and/or embedded within an extrusion molded polymer-based layer, the elongated or circular particles may be oriented in substantially the same direction during extrusion of the polymer-based layer. During the production of the layer, the particle orientation is generally substantially parallel to the extrusion direction, or at least closer to parallel to the extrusion direction than perpendicular to the extrusion direction. In this way, a tile-like structure of graphene (derivative) based particles can be achieved, which is advantageous for the hardness and impact resistance of the top structure.

The decorative top structure preferably comprises at least one decorative visual print, more preferably a digital decorative print. The print may be applied directly on the core and/or may be applied over a primer layer of the top structure, wherein the primer layer is applied directly or indirectly on the core. Visual prints (also known as decorative images) may be formed from the wood pattern. However, it is well conceivable that the decorative image represents another pattern, for example a customized picture and/or a mosaic pattern or tile pattern. In the case of a mosaic pattern or tile pattern, artificial tiles may be depicted that are aesthetically separated by one or more grout (grout lines).

In a preferred embodiment, the decorative top structure comprises a textured surface, in particular a textured upper surface (which defines the top surface of the panel), also referred to as an embossed structure. Preferably, the textured surface forms part of at least one transparent and/or translucent layer, in particular of at least one wear layer and/or at least one top coating layer. Preferably, the decorative visual printing layer is located below the at least one transparent and/or translucent layer. Such textured surfaces (relief surfaces) generally improve the optical and tactile appearance of the decorative layer. The textured surface comprises a pattern of recesses (depressions or indentations) and/or protrusions, wherein the pattern is preferably at least partly realized by printing, in particular digital printing (i.e. by digital printing techniques). Digital printing is a method of printing a digital-based image directly onto a medium. The digital image may be a decorative image, such as the decorative visual print described above, or an image representing another portion of the top structure, such as at least one wear layer and/or at least one top coating layer. The digital image may be a 2D image or a 3D image. By digital (3D) printing of the top structure, an infinitely free design of the top structure (and the decorative layer) can be obtained, wherein the top structure (and the decorative layer) can also be applied in a precise manner with a high degree of detail, which results in a realistic appearance and a unique, unique decorative panel. This result cannot be achieved by conventional mechanical stamping of the cover structure. As printing apparatus, for example, one or more inkjet printers and/or laser printers may be used. As described above, the substantially transparent or translucent portion of the top structure may be partially or completely digitally printed. The decorative visual printing layer is preferably digitally printed. For this purpose, transparent or translucent, colored or achromatic (transparent) inks may be used. At least one substance, in particular an ink, for realizing at least a part of the decorative top structure may be provided with graphene and/or graphene derivatives and/or other (solid) particles. The latter results in that the graphene and/or graphene derivative may be applied by printing, in particular digital printing, or alternatively by spraying, casting or rolling.

This allows the printed decorative image to remain visible. The printed decorative image of the decorative layer may be based on the CMYK color principle, wherein white is typically provided by the surface of a white base coat (if applied). This is a 4-color arrangement, including cyan, magenta, yellow, and black. Mixing these together results in a relatively small color space/gamut. To increase a specific color or total gamut, spot colors may be added. The spot color may be any color. One or more additional colors may be applied, for example at least one additional color selected from the group consisting of orange, green, blue, red, white, light gray, light magenta and light cyan. These colors may be used alone or in combination. Colors are typically mixed and controlled by a combination of software and hardware (print engine/printhead).

Preferably, at least a portion of the textured surface of the top structure is registered with at least a portion of at least one decorative image formed by the decorative printing layer, in particular with at least one pattern defined by the at least one decorative image formed by the decorative printing layer. By applying registration alignment (also called registration embossing) a very realistic and/or artistic design and appearance of the panel can be achieved. In this way, for example, a realistic wood vein pattern can be achieved, wherein the decorated printed wood veins (2D) are registered (aligned) with the embossed printed wood veins (3D). For example, stone-like designs, animal skin designs, etc. may achieve the same effect. Furthermore, in the case of one or more artificial decorative grout lines printed, the textured surface may comprise one or more recessed channels directly above the decorative grout lines to achieve a realistic appearance of the panel that is virtually equivalent to the surface relief obtained when using real tiles and grout.

At least a part of the embossed structure (textured surface) of the panel is preferably achieved by machining, for example by milling or cutting off the panel and/or by subjecting the panel material to a position-selective deformation, in particular by embossing the panel material. Additionally or alternatively, it is also conceivable and even preferred that at least a part of the embossed structure is realized by digital printing, in particular multi-stage digital printing. The multi-stage digital printing process preferably comprises the sub-steps of: a) Applying a curable liquid substrate layer, such as a substrate ink layer and/or a paint layer, directly or indirectly onto the printed decorative image, preferably covering the entire printed decorative image; b) Selectively applying, preferably printing, liquid relief ink locations onto the liquid base ink layer; c) A polymeric substrate ink, preferably a bump ink; and d) preferably removing at least a portion of the polymerized raised ink, more preferably by machining such as brushing.

The liquid bump ink applied (preferably printed) in a position-selective manner is generally used as a mask, which prevents and/or inhibits polymerization of the base material of the substrate layer upon irradiation, in particular upon irradiation by UV light, which facilitates subsequent removal of the bump ink together with at least partially unhardened parts of the base material (located below and/or mixed with the bump ink). In this way, a high resolution texture can be created. This process is considered a negative pressure patterning process because the substrate level of the substrate (ink) layer is selectively lowered and/or removed. Alternatively or additionally, liquid raised ink is selectively printed directly or indirectly onto the substrate to create an embossed structure from bottom to top (rather than vice versa), which is known as a positive embossing process. The cured (polymeric) ink of the embossed structure is at least partially transparent and/or translucent.

In general, the liquid substrate layer, particularly the substrate ink layer and/or the paint layer, may have various chemical properties. Examples of suitable base materials for the base layer include at least one of the following: polyurethanes, epoxies, acrylates, methacrylates, and/or acrylics. In a preferred embodiment, the bump ink is immiscible or partially miscible in the base material and is mechanically removed from the base material once polymerized. Thus, the main function of the bump ink is to create a three-dimensional structure without changing the chemical-physical properties of the base material. The polymeric raised ink is more brittle and/or liquid than the polymeric base material and thus can be mechanically removed from (the cured portion of) the base material along with the uncured or partially cured portion of the base material without damaging the base material. Thus, if the base material is predominantly non-polar, the raised ink will preferably be polar and vice versa. In a preferred embodiment of the invention, the raised ink comprises at least one photo-crosslinking resin. For application by digital printing (e.g., ink jet printing), the viscosity of the bump ink is preferably 10cps to 15cps at the operating printing temperature, which is typically 40 ℃ to 50 ℃. Thus, similar to other formulations (varnishes and inks) which can be photocrosslinked by inkjet printing, the raised inks will be formed predominantly from (meth) acrylate and/or vinyl monomers. On the other hand, the bump ink may contain acrylate oligomers in addition to monomers in order to control rheology and achieve desired hardness. In order to obtain brittle and easily removable formulations, ingredients featuring low glass transition temperatures, such as isodecyl acrylate, 2- (2-ethoxyethoxy) ethyl acrylate, octyl decyl acrylate, tridecyl acrylate, dodecyl acrylate, diacrylate polyethylene glycol of various molecular weights, may be used. In another preferred embodiment of the invention, the bump ink has a sufficiently high surface tension relative to the base material to maintain shape while penetrating into the base material, thereby forming a detailed structure. Conversely, if the surface tension of the bump ink is too low relative to the surface tension of the base material, sharpness may be lost, with the result that the bump ink wets the surface of the base material. In a preferred embodiment of the invention, the bump ink is capable of rapid penetration and efficient mixing with the base material. In another further preferred embodiment of the invention, the bump ink is capable of rapid penetration, but does not mix with the base material, or partially mix with the base material. In a preferred embodiment of the method according to the invention, the bump ink comprises at least one substance configured to inhibit polymerization of the base material. After polymerization, the areas printed with the raised ink are typically more brittle than the base material. For example, if the base material is composed of a photo-crosslinking resin, the bump ink may contain: polymerization inhibitors, such as UV absorbers, for example 2-hydroxyphenyl-Benzoketone (BP), 2- (2-hydroxyphenyl) -Benzotriazole (BTZ) and 2-hydroxyphenyl-s-triazine (HPT); sterically Hindered Amines (HALS), such as 2, 6-Tetramethylpiperidine (TMP); antioxidants (AO), such as sterically hindered phenols, zhong Liumi, phosphites, stabilizers (in-can stabilizers), such as quinone carboxamides, radical scavengers. In another embodiment of the invention, the raised ink, once polymerized, has a glass transition temperature that is lower than the base material; thus, areas printed with the raised ink will be more easily removed than the polymeric base material. In some embodiments, the raised ink comprises additives for modifying properties (e.g., rheology and/or printability and/or color), and the additives may include photoinitiators, leveling agents, oils, light stabilizers, antioxidants, biocides, pigments, rheology modifiers, humectants, defoamers, and mixtures thereof. Preferably, the bump ink has a higher surface tension than the base material. Similar to the base material, the surface tension of the bump ink can be adjusted by selecting the raw materials and using the same additives as those described above for modifying the base material. In addition to varying the surface tension to obtain a more or less pronounced penetration effect, the addition of the surface tension modifier also helps to improve the printability of the bump ink, especially when using an inkjet printer. The control of the depth of the bump ink in the base material can be adjusted in different ways, for example by applying more or less bump ink, and/or by applying more or less base material (resulting in a thicker or thinner base layer), and/or by leaving more or less time between the application of the bump ink and the subsequent polymerization of the base material and the bump ink, and/or by changing the speed of the droplets of the bump ink using a waveform, wherein faster droplets can penetrate deeper into the base material due to their higher impact force.

The panels according to the invention may preferably be provided with a variety of textures, in particular digitally created embossed structures and mechanically created embossed structures. This provides significantly greater freedom for accurate embossing and/or debossing designs with high levels of detail, not only because mechanically applied textures and digitally applied textures can be combined in various ways, but also because an unlimited number of texture design variations can be achieved by (changing) the digitally applied textures. The multi-texture provides a more pronounced (rough, hilly) embossed structure in which relatively deep embossments can be created, for example, artificial pitch holes (knotholes), grout, grooves, pen-touch structures, plastering techniques (e.g., friction plaster), spatula techniques, natural and organic structures, stone or artificial animal skin (e.g., crocodile skin) can be created, which results in a more realistic appearance of the panel itself. The digitally created first texture and/or the mechanically created second texture may also be used to create one or more bevels and/or one or more grout, preferably at one or more panel edges, but it may also artificially and visually divide the panel into two or more smaller panels (sub-panels). For example, by means of a die such as a platen, a chamfer and/or grout may be mechanically pressed into the core and/or decorative roof structure. In general, mechanically created embossments (which define the second texture) may be used to cost effectively create a basic embossed structure, in particular a basic embossed pattern, which may be a relatively strong (i.e. deep) embossed structure. Digitally created embossments (which define the first texture) are typically used to improve the second texture to achieve an overall texture with more realistic light effects and better depth effects, and thus haptic effects, where the color of the decorative image is typically more perceptible. At least a portion of the first texture and at least a portion of the second texture may be in offset positions. Preferably, at least a portion of the first texture and at least a portion of the second texture may be aligned (registered) with each other to achieve a more exaggerated (intense) embossing; more preferably a more amplified (intense) embossing applied in a position selective manner, in particular in register with the decorative image of the decorative print layer. The digitally created first texture is at least partially implemented by digital printing. In this regard, digital printing may be used to directly or indirectly create depressions (cavities or recesses, such as grooves) and/or ridges (protrusions). The mechanically created second texture is at least partially and often completely achieved by providing the core and/or at least one layer of the decorative top structure with one or more indentations and/or one or more engravings. These indentations (or engravings) are grooves, cavities or recesses pressed into the layer by using a pressing die (e.g. a platen or a press roller).

As mentioned above, the first texture is preferably at least partially defined by at least one at least partially cured substrate layer provided with a plurality of depressions. As with mechanically applied indentations, these depressions constitute cavities and/or recesses, such as grooves and the like, which may have an equivalent appearance and feel. However, during the formation of the indentations, the panel material is typically only deformed, whereas during the formation of the depressions, the panel material is typically chemically and/or mechanically removed from the panel. Different embodiments of these recesses will be described in more detail below. Preferably, a portion of the base layer is provided with the plurality of recesses and another portion of the base layer is free of recesses. Thus, in this embodiment, the substrate layer is only partially embossed. At least a portion of the non-recessed portion of the base layer may be used to create (build up) the ridge, preferably by digital printing.

It is envisioned that the plurality of depressions of the substrate layer form a discontinuous and/or continuous pattern of depressions. It is also conceivable that the plurality of depressions of the substrate layer form a regular pattern of depressions. In general, the pattern of depressions to be achieved depends strongly or even entirely on at least one decorative image of the decorative layer.

Preferably, the substrate layer is a printed substrate layer. This means that the substrate layer, which is initially in a liquid state, is printed directly or indirectly over the decorative layer. Alternatively, the substrate layer may be applied in an initial liquid (uncured) state by a roll coater. One or more depressions may be provided in the substrate layer while the substrate layer is still in a liquid state, and/or one or more depressions may be provided in the substrate layer during and/or after partial or complete curing (solidification) of the substrate layer. Providing one or more depressions in the liquid substrate layer is preferably accomplished by chemical embossing. To this end, preferably (small) reactive droplets of embossing liquid are position-selectively digitally printed or sprayed onto the liquid substrate layer to cause a chemical reaction between the material of the printed droplets and the still liquid substrate layer, wherein the subsequent reaction product optically and/or tactilely alters the structure of the substrate layer at that position. Alternatively, providing one or more depressions in the liquid substrate layer may be achieved by a combination of digital printing and subsequent mechanical action to positionally selectively remove the panel material. For this purpose, droplets of the (alternative) embossing liquid can be deposited, preferably digitally printed, on the (uncured) substrate layer, which is still liquid, in a position-selective manner. This means that the embossing liquid is applied on the portions of the substrate layer where the depressions are to be formed. After application of such an embossing liquid, the substrate layer is preferably at least partially cured, for example by Ultraviolet (UV) irradiation. During this irradiation step, the substrate layer is typically polymerized, but the portions of the substrate layer that are rich in embossing liquid will remain (sufficiently) liquid and/or soft to allow for subsequent and/or simultaneous removal of these soft portions. Such removal of the soft portion may be achieved, for example, by mechanical action, for example, by a rotating brush, but may also be achieved by forcing the soft portion to evaporate, preferably by an Infrared (IR) beam and/or by hot air and/or by means of a suction device (vacuum device) and/or by any other extraction technique. Alternative material removal methods are also conceivable in this connection, for example by removing the material using a laser beam, an electron beam or a water beam. In this embodiment it is preferred that the substrate layer is a hydrophobic substrate layer, which aids in that the water-based embossing liquid droplets ejected by the digital printing device will stay as droplets in a predetermined position during the subsequent curing process step.

The base layer is preferably a curable resin, which is initially applied in a liquid state. The resin may be cured by electromagnetic radiation, such as UV or IR radiation, and/or may be cured by Electron Beam Curing (EBC), wherein electrons are typically ejected at high speeds on the substrate layer to harden (cure) the substrate layer. The substrate layer may for example be at least partially composed of melamine, polyurethane, epoxy and/or any (other) photo-curable resin. The substrate layer may for example (also) consist at least partly of epoxy acrylate, urethane acrylate, polyester acrylate, polyether acrylate, amino acrylate, silicone acrylate, polyisoprene acrylate, polybutadiene acrylate and acrylate monomers, wherein the term acrylate includes both acrylate and methacrylate resins. Vinyl monomers may also be used to at least partially form the substrate layer, wherein in such cases N-vinylcaprolactam (NVC), acryloylmorpholine (ACMO), diethylene glycol divinyl ether (DVE-2), triethylene glycol divinyl ether (DVE-3) and/or mixtures thereof are preferably used. The substrate layer may comprise solid particles in an amount of at least 20% (weight percent) relative to the weight of the substrate layer.

In the case of using an embossing liquid to achieve the depressions in the substrate layer, the embossing liquid preferably comprises at least one component selected from the group consisting of water, water-based substances, silicone polyethers, silicone acrylates and silicone polyether acrylates. The presence of silicone generally improves the embossability of the substrate layer and provides a natural appearance to the treated coating, which is particularly appreciated from an aesthetic point of view.

Providing one or more depressions in the substrate layer during or after curing may be accomplished by chemical embossing (as previously described) and/or by mechanical embossing. In this respect, it should be noted that the substrate layer may (additionally or alternatively) be subjected to a laser beam or a particle beam, such as a water beam or an electron beam, to cure the substrate layer.

Preferably, the recesses provided in the substrate layer have a depth of between 2 μm and 100 μm, preferably between 3 μm and 50 μm. Preferably, the height of the ridges of the ridge pattern layer is between 2 μm and 500 μm, preferably between 3 μm and 300 μm. The total embossing depth is determined by the sum of the maximum depression depth and the maximum ridge height. In case of applying a plurality of substrate layers and/or a plurality of raised pattern layers, an increase in the total embossing depth may be achieved. Typically, the raised pattern layer is realized by digital printing, in particular 3D digital printing. Preferably, a digital printing apparatus is used for applying at least one layer of a panel according to the invention and comprises one or more digitally controllable apertures, each configured to eject droplets of a hardenable liquid to create a raised pattern layer and/or another panel layer, such as a (uniform or non-uniform (textured)) intermediate layer or top coating. The layer thickness generally corresponds to the liquid sprayed on the surface. In a preferred embodiment, the hardenable drops are ejected such that at least two layer parts are formed of different hardenable liquids, wherein the layer parts are typically arranged side by side and adjacent to each other and/or at a distance from each other. More preferably, one liquid hardens into an opaque layer and the other liquid hardens into a light transmissive layer. This provides opaque and transparent portions in the raised pattern layer, thereby providing more design freedom of the decorative top structure and thus of the panel itself. This enables, for example, the transparent layer portion to at least partially interface with the opaque layer portion. The two different hardenable liquids used in this process step may be miscible or immiscible with each other.

In a preferred embodiment, at least a portion of the depression of the base layer is aligned in registration with at least a portion of the at least one decorative image formed by the decorative print layer.

In a preferred embodiment, at least a portion of the depression of the base layer is aligned in registration with at least a portion of the at least one decorative image formed by the decorative print layer, in particular with at least one pattern defined by the at least one decorative image formed by the decorative print layer. Preferably, at least a portion of the protuberances pattern layer are registered with at least a portion of at least one decorative image formed by the decorative printing layer. By applying registration alignment (also called registration embossing) a very realistic and/or artistic design and appearance of the panel can be achieved. The decorative image may be formed of a wood pattern. However, it is well conceivable that the decorative image represents another pattern, for example a customized picture and/or a mosaic pattern or tile pattern. In the case of a mosaic pattern or tile pattern, an artificial tile may be depicted that is aesthetically separated by one or more grout. Here, the applied embossed structure may comprise a substrate layer having thicker layer portions covering the artificial tile and thinner layer portions covering one or more grout. Here, it is also conceivable that the protuberances of the protuberance pattern cover mainly or only the artificial tile and less or not at all. In this way, a realistic surface relief can be achieved, which is practically equal to the surface relief obtained when using real tiles and grout.

In a preferred embodiment, the first texture is at least partially defined by at least one at least partially cured raised pattern layer formed from a plurality of printed raised bumps. In this respect, the raised pattern layer is preferably realized by printing, in particular digital printing, and defines a (printed) positive embossing layer. The protuberances (protrusions) are preferably provided above the negative pressure flower layer formed by the depressions (recesses) applied in the above-mentioned substrate layer. This means that the raised pattern layer is preferably printed over the substrate layer. Typically, the upper side of the substrate layer defines an embossed substrate level and the depressions and at least a portion and/or at least a plurality of ridges are located on opposite sides of said embossed substrate level. It is also conceivable that the depression and at least a part and/or at least a plurality of elevations are located on the same side of the base level.

As mentioned above, at least a portion and/or at least a plurality of protuberances are preferably printed on the non-recessed portion of the substrate layer, which results in an increased depth effect of the embossed structure itself.

Typically, the upper side of the substrate layer defines an embossed substrate level and the depressions and at least a portion and/or at least a plurality of ridges are located on opposite sides of said embossed substrate level. It is also conceivable that the depression and at least a part and/or at least a plurality of elevations are located on the same side of the base level.

Preferably, the height of the ridges of the ridge pattern layer is between 2 μm and 500 μm, preferably between 3 μm and 300 μm. Preferably, at least one indentation of the second texture has a depth of at least 0.4 μm. The total embossing depth is determined by the sum of the maximum depression and/or indentation depth and the maximum ridge height. In the case of applying multiple base layers and/or multiple raised pattern layers to define the first texture, the first texture and the total embossing depth of the texture may be significantly increased, resulting in more realistically experienced artificial visual and tactile effects. Here, the total embossing depth measured from the top surface of the panel may be greater than 700 μm, even greater than 800 μm, even greater than 900 μm. In case the second texture is at least partly applied to the upper side of the core, the total embossing depth may be further increased depending on the thickness of the core.

Preferably, at least a portion of the protuberances of the raised pattern layer are aligned in registration with at least a portion of at least one decorative image formed by the decorative print layer, in particular with at least one pattern defined by at least one decorative image formed by the decorative print layer. To this end, it is conceivable to use at least one 3D camera for determining (analyzing) the relief pattern of the physical sample. After determining the pattern, the image may be converted into a three-dimensional model of the sample using specialized software. The 3D printer may be configured to print the depressions and/or elevations registered with the three-dimensional model. Thus, the depression pattern and/or the ridge pattern layer may be obtained substantially without manually setting or positioning the depressions and/or the ridges. For example, the sample may be a piece of natural wood, natural stone, or the like, such that the 3D camera may provide the most natural looking surface.

The indentations are preferably obtained by at least one die, such as a platen and/or an embossing roller. Typically, the stamper is provided with a selected inverse impression of the second texture. In achieving the second texture, the stamper will be pressed against the panel surface to be textured, wherein heat is typically also applied. The latter may be achieved, for example, by using a heated die. Here, it is for example conceivable to press the press mould onto the (unfinished) panel with a pressure of 25-30 bar. The temperature applied may vary but is typically between 150 ℃ and 200 ℃. The press mould is typically pressed against the (unfinished) panel for a period of 0.5 to 50 seconds. Alternatively or additionally, the second texture may be applied by any other type of mechanical action, such as brushing, drilling, milling, engraving and/or scraping, but such other type of mechanical action typically results in a more randomly shaped second texture than the predetermined second texture obtained by using a stamper. It is conceivable that not only the core is provided with a second texture, but also one or more layers of the decorative top structure. The second texture may be achieved in a single pressing step. In this case, the decorative printing layer may also be (slightly) deformed. Since the deformation of the decorative printing layer is predefined and known in advance, it is conceivable that the initial printed image of the decorative printing layer is pre-adjusted to compensate for the deformation of the printing layer during embossing. This will result in an image that appears to be completely free of distortion.

Preferably, at least a portion of the indentations of the second texture are aligned in registration with at least a portion of the at least one decorative image formed by the decorative print layer, in particular with at least one pattern defined by the at least one decorative image formed by the decorative print layer. One or more indentations may consist of continuous short indentations and/or longer, uninterrupted, possibly curved indentations. Other designs are obviously not excluded. In the case where the image of the decorative print layer represents a wood (vein) pattern, it is generally desirable that the position and/or shape of the indentations is functionally at least a part of the wood pattern, which means that these indentations are initially realized in accordance with the function of the wood veins and possibly also in accordance with the function of the wood pores. In the case of short impressions, the wood venues may be guided in their length according to the printing and/or may be guided in their longitudinal direction and preferably also follow.

In an alternative embodiment of the panel according to the invention, at least one second texture is created by means of a coating roll, wherein a material layer is initially applied to the coating roll and subsequently transferred onto the surface of the (unfinished) panel, wherein the material layer is textured by means of the coating roll and/or by means of a plurality of digitally controlled gas nozzles configured to blow gas, in particular air, onto the material layer carried by the coating roll in order to transform (texture) the material layer before transferring the material onto the surface of the (unfinished) panel. Depending on the gas nozzle control, this may result in the material layer having a random second texture or having a predetermined second texture.

Preferably, the depth of the at least one indentation exceeds the nominal thickness of the decorative top structure. This means that the at least one indentation causes the core to deform. As mentioned above, it is conceivable that only at least one indentation is provided in the core and that the superlocated decorative top structure follows the second texture achieved in this way.

It is conceivable and generally effective that the maximum depth of the second texture exceeds the maximum depth of the first texture relative to the top surface of the panel. However, it is also conceivable that the maximum depth of the first texture exceeds the maximum depth of the second texture with respect to the top surface of the panel.

In a preferred embodiment, at least one cover layer, preferably at least one wear layer, of the decorative top structure comprises a first texture. The first texture will typically leave the decorative print layer intact (unaffected/undeformed). It is conceivable that at least one cover layer, preferably at least one wear layer, of the decorative top structure comprises a second texture. The second texture may be such that the second texture deforms the decorative print layer. However, the second texture may also be such that the second texture does not deform the decorative print layer and leaves the decorative print layer intact.

Preferably, the at least one first cover layer, more preferably the at least one first wear layer, of the decorative top structure comprises a first texture, and wherein the at least one second cover layer, preferably the at least one second wear layer, of the decorative top structure comprises a second texture. It is conceivable that the second texture is also at least partly present in the first cover layer. Vice versa, it is conceivable that the second texture is also at least partly present in the first cover layer, but this is generally not possible due to the different application methods of the first texture.

In a preferred embodiment, the decorative top structure comprises at least one wear layer and at least one top coating, preferably a UV-cured top coating, covering said wear layer. Typically, the top coating defines the upper surface of the panel. The top coat is typically a layer of paint that is at least partially hardened (cured) by (UV) irradiation. In this respect, it is generally preferred that the first texture is first at least partially hardened (cured) before hardening (curing) the top coating, in particular the lacquer layer. The paint layer may comprise any suitable known wear resistant material, such as a wear resistant macromolecular material coated on the layer underneath it, or a known ceramic bead coating. If the top coat is provided in liquid form, it may be adhered to the layer below it by curing the top coat. The top coat may also comprise a layer of organic polymer and/or inorganic material, such as a uv-curable or hardenable coating or a combination of another organic polymer layer and a uv-curable or hardenable coating. The top coating may be provided with at least one antimicrobial substance, thereby increasing the antimicrobial properties of the panel itself. In an embodiment of the panel according to the invention, at least a part of the (first and/or second) texture of the panel is not covered by the top coating. In this way, a further embossing effect (relief effect) can be achieved, and/or glossy and matt areas can be created in this way, which can further contribute to the desired aesthetic appearance of the panel itself. In this regard, for example, it is conceivable that the decorative image of the decorative print layer is formed of artificial tiles separated by a grout, wherein the artificial tiles may be covered by a paint layer to provide a glossy effect to the tiles, while the grout is substantially uncovered by the paint layer to maintain a more matt appearance.

Preferably, at least a portion of the decorative layer is located below the first texture and the second texture. It is conceivable that the decorative printed layer is deformed at least partly by the second texture, but it is also conceivable that the decorative printed layer is not deformed by the second texture and remains intact. In the event that deformation of the decorative print layer due to the second texture is foreseeable, the image is preferably printed in a slightly modified format during printing to compensate for subsequent deformation during application of the second texture. However, it is also conceivable that from an aesthetic point of view, it is preferable to purposefully create a deformed decorative printing layer, for example by printing the decorative printing layer onto a textured surface and/or by deforming the decorative printing layer after application. This may improve the visual depth effect.

It is conceivable that at least a portion of the decorative print layer is located between the first texture and the second texture. In this case, it is conceivable that the decorative printing layer is positioned above the first texture, and that the second texture is positioned above the decorative printing layer. It is also conceivable that the decorative printing layer is positioned above the second texture, while the first texture is positioned above the decorative printing layer.

It is conceivable that the at least one first texture is positioned below the at least one second texture and/or that the at least one first texture is positioned above the at least one second texture. Various configurations are conceivable in this regard.

Preferably, the panel comprises a top surface, wherein the first texture and/or the second texture at least partially define a relief (texture) of the top surface. It is conceivable here that the at least one texture present in the panel is substantially no longer present or hardly present at the top surface anymore, as the applied texture is usually eliminated by the at least one super-positioning layer. The latter may be advantageous to create a visible textured decorative printed layer, for example creating an improved depth effect, wherein the texture is no longer required, or at least a complete initial roughness, at the top surface of the panel itself.

In a preferred embodiment, the top surface of the panel according to the invention has an average roughness (Ra) of more than 15 μm, preferably more than 17 μm, most preferably more than 20 μm. The average roughness Ra, also referred to as surface roughness, is preferably less than 500 μm, more preferably less than 400 μm, most preferably less than 350 μm, in particular less than 300 μm. The maximum roughness (Rm) may obviously be greater than the above-mentioned values and may exceed 500 μm, which is desirable in certain designs, for example in designs with one or more artificial (wooden) pitch holes. The average roughness (Ra) is an arithmetic average of absolute values of roughness curve coordinates (vertical coordinates with respect to roughness average line), also called Arithmetic Average (AA), centerline average (CLA). The average roughness is the area between the roughness curve (which defines the texture) and its average line, or the integral of the absolute value of the roughness curve height over the evaluation length.

It is conceivable and possibly preferred that at least one visible panel layer of the decorative top structure, such as the top coating or any other layer, has a varying gloss in at least one direction extending parallel to the plane defined by the panels. In this way, glossy and matt areas can be created, which is advantageous from an aesthetic point of view. Such varying gloss may be at least partially consistent with and/or adjusted in accordance with the decorative image of the decorative print layer. Preferably, during production, the initially hardenable top coating is irradiated with short wave UV light, typically having a wavelength of less than 200 μm, and/or an electron beam, to harden (cure or polymerize) the top coating such that micro-wrinkling occurs, which results in an extremely matt optical structure. Preferably, at least one UV irradiation step is performed under inert conditions. The latter is preferably achieved by applying an atmosphere consisting of one or more of the following gases: helium, neon, xenon, krypton, nitrogen, and/or carbon dioxide. Depending on the composition of the substance to be cured, UV curing of the substance may lead to oxygen inhibition. Oxygen inhibition typically occurs in free radical UV systems. Oxygen inhibition means that after the reaction between oxygen (a very reactive gas) and the radicals formed from the acrylate double bond system has stopped the polymerization process of the coating or printing ink surface, oxygen also reacts very rapidly with these radicals. Thus, the coating or printing ink will remain tacky at the surface, while the deeper layers have been properly cured. The properties of scratch resistance and chemical resistance will be significantly reduced by this undesired effect, which can be prevented by applying the inert atmosphere.

The height of the micro-wrinkles is typically of the order of 100 nm. More preferably, the top coat is additionally deep structured, forming structured recesses to provide additional texture to the top coat, which may be a second texture. It is conceivable that the top coating has or is provided with at least one glossy lacquer layer.

It is conceivable that the panel comprises a plurality of decorative printed layers. It is envisioned and generally preferred that at least one of the decorative printed layers is a continuous (uninterrupted) layer. It may also be preferred that the at least one decorative printed layer is a discontinuous (intermittent) layer covering only a portion of the underlying layer.

Preferably, the decorative roof structure comprises: a decorative visual printing layer; at least one substantially transparent or translucent wear layer applied over the print layer; and preferably at least one substantially transparent or translucent top coating applied over the at least one wear layer, wherein the at least one wear layer and/or the at least one top coating comprises graphene and/or at least one graphene derivative. The visual printing layer may consist of only a decorative ink layer, but it is also conceivable that the visual printing layer comprises a substrate layer, for example a polymer film or a paper film, on which the decorative ink is printed or otherwise applied. The visually printed layer may be attached directly to the core, for example by fusing the visually printed layer to the core or by gluing the visually printed layer to the core, wherein for example a polyurethane adhesive may be used. Optionally, the upper surface of the core is covered by at least one primer layer prior to attaching the visual printed layer to the core, wherein the visual printed layer will actually be attached to the (upper) primer layer applied to the core. This preferred embodiment means that (at least a part of) the graphene (derivative) is applied over the decorative printed layer and can thus help to protect the decorative printed layer. As described above, the decorative top structure may be implemented partially or completely by digital printing. Optionally, the substance, in particular the ink, used to achieve at least a portion of the wear layer and/or the top coat layer may be enriched (mixed) with particles of graphene and/or graphene derivatives. It is conceivable that the decorative top structure comprises a decorative visual printed layer and a single (only one) transparent or translucent wear layer over said visual printed layer, without applying a separate top coating. At least one, and preferably each, of the wear layers in the case of the application of a plurality of wear layers, is preferably made of transparent or translucent polyurethane, or alternatively of polyvinyl chloride, polypropylene or any other suitable transparent or translucent polymer, or alternatively of translucent, in particular transparent, glazing.

Preferably, the decorative top structure comprises at least one composite layer comprising graphene and/or graphene derivatives in an amount (weight percent) of between 0.01% and 1.5%, preferably between 0.5% and 1.0% of the composite layer. This amount of graphene and/or graphene derivatives is typically sufficient to significantly increase the stiffness and impact resistance of the panel, while keeping the increase in cost price as limited as possible and/or while keeping the top structure sufficiently transparent and/or translucent to ensure sufficient visibility of the decorative printed layer of the top structure.

The decorative top structure may comprise at least one layer consisting of graphene paper. Graphene paper is typically composed of graphene and/or one or more derivatives thereof, such as graphene oxide. The graphene paper is preferably at least partially composed of graphene nanoplatelets assembled in a layer-by-layer manner. Because of the limited size of the graphene sheets, in-plane tensile loads are difficult to continuously transfer through the intra-layer bonds of the distributed graphene sheets, and thus inter-layer crosslinking preferably facilitates tensile load transfer between adjacent layers. For graphene nanocomposites, intra-layer covalent bonds are typically much stronger than inter-layer crosslinks. Typically, for graphene paper, the starting material used is water-dispersed graphene oxide flakes, which are vacuum filtered to produce individual foils. The thickness of these foils is generally in the range of 0.1 μm to 150 μm, preferably 5 μm to 120 μm. Like graphene, graphene paper is an electrical conductor; like graphene oxide, graphene oxide paper is an electrical insulator. For graphene-graphene oxide papers, the paper is composed partly of graphene, partly of graphene oxide, optionally also reduced graphene oxide. By adjusting the ratio between graphene and graphene oxide, the conductivity of the paper can be fine-tuned. This may be used to optimize the electrical conductivity properties for the target application of the decorative panel according to the invention. It is conceivable that the decorative top structure comprises at least one decorative printed layer above the graphene (graphene oxide) -containing paper, and wherein the graphene (graphene oxide) -containing paper preferably carries the decorative printed layer. Preferably, the young's modulus of the decorative top structure is between 9Gpa and 181Gpa, preferably between 9Gpa and 50Gpa, more particularly about 10Gpa. The actual young's modulus depends to a large extent on the amount of graphene and/or graphene oxide used and the form of application of the graphene and/or graphene oxide. In general, the graphene sheet itself may have a young's modulus of 1000 Gpa. When graphene is used as part of the composite in the layers of the top structure (this is typically the case), the young's modulus typically drops below 181Gpa and is typically around 10Gpa.

Preferably, at least one substantially transparent or translucent layer of the decorative top structure is a printed layer. The layer may or may not comprise graphene and/or graphene derivatives. It is conceivable that the entire top structure is applied by means of digital printing. It is also conceivable that a part of the top structure, including at least one decorative layer and at least one wear layer, is applied by means of digital printing.

Preferably, the antimicrobial composition is on the surface of the panelThe application level is preferably 0.5g/m ² To 5.0g/m ² More preferably within the range of 1.0g/m ² To 3.0g/m ² Within a range of (2).

It is conceivable that the footprint of the core exceeds the footprint of the decorative top structure. It is envisaged that a portion of the upper side of the core preferably extends along one or more edges relative to the decorative roof structure. This exposed portion of the upper side of the core may be used to facilitate coupling of the panels and/or to form grout lines, optionally filled with grout after panel installation (interlocking).

The decorative top structure may also be a multi-layer structure. Preferably, the decorative top structure comprises at least one decorative layer and at least one transparent wear layer covering said decorative layer. Preferably, the decorative top structure comprises from bottom to top:

i. Optionally, at least one substrate layer, in particular a primer layer and/or an adhesive layer;

at least one decorative layer, in particular a thermoplastic film or paper film provided with decorative (digitally or mechanically applied) prints;

at least one transparent wear layer covering the decorative layer; and

optionally, at least one paint layer, preferably a UV cured paint layer, covering the wear layer.

The paint layer or other protective layer may be applied over the wear layer to protect the top structure and thus the panel itself. The finishing layer may be applied between the decorative layer and the wear layer. The decorative layer will be visible and will serve to provide an attractive appearance to the panel. For this purpose, the decorative layer may have a design pattern, which may be, for example, a wood grain pattern, a mineral particle pattern resembling marble, granite or any other natural stone particle, an image, a photograph or color pattern, a color mixture or a single color, to name a few design possibilities. A customized appearance is also conceivable, which is usually achieved by digital printing during the production of the panels. In an alternative embodiment, the decorative top structure is omitted and is therefore not applied in the panel according to the invention. In the latter embodiment, the decorative panel, in particular the floor panel, the ceiling panel or the wall panel, comprises: a core provided with an upper side and a lower side; a first panel edge comprising a first coupling profile; and a second panel edge comprising a second coupling profile, wherein the second coupling profile is designed to interlockingly engage with the first coupling profile of an adjacent panel in both the horizontal and vertical directions, wherein the core comprises at least one fleece layer formed at least in part from synthetic glass fibers bonded together by at least one cured thermosetting polymer binder material.

Preferably, the first coupling profile comprises:

an upward tongue;

at least one upward flank located at a distance from the upward tongue;

an upward groove formed between the upward tongue and the upward flank, wherein the upward groove is adapted to receive at least a portion of a downward tongue of a second coupling profile of an adjacent panel; and

at least one first locking element, preferably arranged distally of the upward tongue facing away from the upward flank;

and preferably the (complementary) second coupling profile comprises:

a first downward tongue;

at least one first downward flank located at a distance from the downward tongue;

a first downward groove formed between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a portion of an upward tongue of a first coupling profile of an adjacent panel; and

at least one second locking element adapted to co-act with the first locking element of an adjacent panel, and preferably arranged at the downward flank.

Preferably, the first locking element comprises a protrusion and/or a recess and the second locking element comprises a protrusion and/or a recess. The protrusions are generally adapted to be at least partly received in recesses of adjacent coupling panels in order to achieve a locked coupling, preferably a coupling locked in a vertical direction. It is also conceivable that the first locking element and the second locking element are not formed by a projection-recess combination, but by another combination of co-acting profiled surfaces and/or high friction contact surfaces. In this latter embodiment, at least one of the first and second locking elements may be formed by a (flat or otherwise shaped) contact surface, which is composed of an optionally separate plastic material configured to generate friction with the other locking element of the other panel in the joined (coupled) state. Examples of plastics suitable for friction generation include:

Acetal (POM), which is rigid, strong, has good creep resistance. The friction coefficient is low, the stability is kept at high temperature, and the water resistance is good;

nylon (PA), which absorbs more moisture than most polymers, wherein impact strength and general energy absorption quality actually improve as it absorbs moisture. Nylon also has a low coefficient of friction, good electrical properties and good chemical resistance;

polyphthalamide (PPA). The high performance nylon has improved temperature resistance and lower moisture absorption. It also has good chemical resistance;

polyetheretherketone (PEEK), which is a high temperature thermoplastic, has good chemical and flame resistance, and high strength. PEEK is the favorite of the aerospace industry;

polyphenylene Sulfide (PPS), which balances characteristics including chemical and high temperature resistance, flame retardancy, flowability, dimensional stability, and good electrical properties;

polybutylene terephthalate (PBT), which is dimensionally stable, has high heat resistance and chemical resistance, and has good electrical properties;

thermoplastic Polyimides (TPIs), which are inherently flame retardant, with good physical, chemical and abrasion resistance properties;

Polycarbonate (PC) having good impact strength, high heat resistance and good dimensional stability. PC also has good electrical properties and is stable in water and mineral or organic acids; and

polyetherimide (PEI), which retains strength and stiffness at high temperatures. It also has good long-term heat resistance, dimensional stability, inherent flame retardancy, and resistance to hydrocarbons, alcohols, and halogenated solvents.

It is conceivable that the first coupling profile and the second coupling profile are configured such that in the coupled state there is a pretension that urges the coupled panels at the respective edges towards each other, wherein this is preferably performed by applying an overlapping profile of the first coupling profile and the second coupling profile, in particular an overlapping profile of the downward tongue and the upward groove and/or an overlapping profile of the upward tongue and the downward groove, and wherein the first coupling profile and the second coupling profile are configured such that two such panels can be coupled to each other by a folding down movement and/or a vertical movement, wherein in the coupled state at least a part of the downward tongue of the second coupling profile is inserted in the upward groove of the first coupling profile such that the downward tongue is clamped by the first coupling profile and/or the upward tongue is clamped by the second coupling profile.

In a preferred embodiment, the panel comprises at least one third coupling profile and at least one fourth coupling profile at a third panel edge and a fourth panel edge, respectively, wherein the third coupling profile comprises:

a lateral tongue extending in a direction substantially parallel to the upper side of the core;

at least one second downward flank located at a distance from the lateral tongue; and

a second downward groove formed between the lateral tongue and the second downward flank;

wherein the fourth coupling profile comprises:

a third groove configured for receiving at least a portion of a lateral tongue of a third coupling profile of an adjacent panel, and defined by an upper lip and a lower lip, wherein the 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 a rotational movement, wherein in the coupled state at least a part of a lateral tongue of a first panel is inserted into a third groove of an adjacent second panel, and wherein at least a part of an upward locking element of the second panel is inserted into a second downward groove of the first panel.

The panel, typically the core, in particular at least one core, preferably comprises recycled material. Recycling the material typically involves reusing the remaining material produced in the previous (panel) production process.

The thickness of the core is preferably at least 3mm, preferably at least 4mm, more preferably at least 5mm. The panel thickness is typically between 3mm and 12mm, preferably between 4mm and 10 mm.

In a preferred embodiment, at least one batt layer has a varying density in the thickness direction of the batt layer. Preferably, the ratio of mineral fibres and binder material varies in the thickness direction. In this way, depending on the desired properties of the panel, a denser or less dense sub-layer may be formed on the top and/or bottom side of the fleece layer. It is conceivable that at least one fleece layer has a varying density in the width direction and/or in the length direction of the Mao Liaoceng. For example, this may result in a denser region of the fleece layer being formed at the edges of two or more panels, which may be advantageous in forming a coupling profile at these edges.

It is conceivable that at least one fleece layer is at least partially filled with at least one filler, in particular an inert filler. Such fillers may be, for example, colorants, chalk, talc, antimicrobial substances, fluorescent dyes, etc.

In a preferred embodiment, the panel comprises at least one backing layer, which is directly or indirectly fixed to the underside of the core. The at least one backing layer is preferably made at least partially of a flexible material, preferably at least one material selected from the group consisting of elastomers, thermoplastic materials, ethylene vinyl acetate, polyurethane, cork, wood, paper and cardboard. The thickness of the backing layer typically varies between about 0.1mm and 2.5 mm. The backing layer generally provides additional robustness, dimensional stability and improved impact resistance of the panel itself, which increases the durability of the panel and prevents damage to the panel. Furthermore, the (flexible) backing layer may increase the acoustic (sound damping) properties of the panel.

The invention also relates to a core for use in a decorative panel according to one of the preceding claims, wherein a first core edge comprises at least a part of a first coupling profile and a second core edge comprises at least a part of a second coupling profile, wherein the second coupling profile is designed to interlockingly engage with the first coupling profile of an adjacent panel or an adjacent core in both the horizontal and vertical direction, wherein the core comprises at least one fleece layer formed at least partly of synthetic glass fibers bonded together by at least one cured thermosetting polymer binder material.

The invention also relates to a decorative covering, in particular a decorative floor covering, a decorative ceiling covering or a decorative wall covering, comprising a plurality of interconnected decorative panels according to the invention.

Preferred embodiments of the present invention will be set forth in a set of non-limiting clauses given below.

1. Decorative panel, in particular floor panel, ceiling panel or wall panel, comprising:

a core provided with an upper side and a lower side;

a decorative top structure directly or indirectly secured to the upper side of the core;

a first panel edge comprising a first coupling profile and a second panel edge comprising a second coupling profile, wherein the second coupling profile is designed to interlockingly engage with the first coupling profile of an adjacent panel in both the horizontal and vertical directions;

wherein the core comprises at least one wool layer formed at least in part from synthetic glass fibers bonded together by at least one cured thermosetting polymeric binder material.

2. The decorative panel of clause 1, wherein at least a portion of the artificial glass fibers are made of at least one material selected from the group consisting of rock wool, mineral wool, slag wool, basalt wool, and glass fibers.

3. The decorative panel of clause 1 or 2, wherein the at least one binder material is a material selected from urea-modified phenolic resins and alkanolamine/carboxylic anhydride reaction products.

4. The decorative panel of one of the preceding clauses, wherein at least one binder material is a material selected from the group consisting of acrylic and epoxy.

5. The decorative panel according to one of the preceding clauses, wherein at least one binder material is formed from a sugar component, preferably selected from: sucrose, reducing sugars, in particular dextrose, carbohydrates, and mixtures thereof.

6. The decorative panel of one of the preceding clauses, wherein the core comprises at least one primary binder material, the primary binder material being a material selected from urea-modified phenolic resins and alkanolamines/carboxylic anhydrides, and wherein the core comprises at least one co-binder material selected from acrylic resins and epoxy resins.

7. The decorative panel of clause 6, wherein the amount of the solid-based co-binder is 1 to 50 weight percent of the total binder, preferably 5 to 35 weight percent of the total binder.

8. The decorative panel of one of the preceding clauses, wherein the core comprises a mixture of binder materials, wherein the first binder material has a higher curing temperature and/or curing rate than the at least one second binder material.

9. The decorative panel of any one of the preceding clauses, wherein the core comprises at least one fluorescent compound, preferably selected from: xanthine, acridine, quinine derivatives, coumarin, and arylsulfonates.

10. The decorative panel of one of the preceding clauses, wherein the core comprises aerogel particles.

11. The decorative panel of clause 10, wherein the weight of aerogel particles in the core exceeds the weight of the binder material and/or the weight of the man-made glass fibers in the core.

12. The decorative panel of one of the preceding clauses, wherein the fiber orientation in the at least one layer of wool of the core is substantially vertical.

13. The decorative panel of one of the preceding clauses, wherein the core comprises: at least one base Mao Liaoceng comprising a first mineral wool; and at least one roof Mao Liaoceng comprising a second mineral wool over the base batt, wherein the first mineral wool and the second mineral wool have different material compositions and/or different structural properties.

14. The decorative panel according to one of the preceding clauses, wherein the panel, in particular the core, comprises at least one reinforcing layer, preferably a non-woven layer or a woven layer, in particular a cloth.

15. The decorative panel of clause 14, wherein the reinforcing layer comprises fiberglass.

16. The decorative panel of one of the preceding clauses 14-15, wherein the reinforcing layer comprises: natural fibers such as jute; and/or synthetic fibers, in particular polymeric fibers.

17. The decorative panel according to one of the preceding clauses 14 to 16, wherein the at least one reinforcing layer is embedded in the core and is preferably surrounded by two fleece layers.

18. The decorative panel according to one of the preceding clauses, wherein the panel comprises a plurality of reinforcing layers, wherein preferably at least one first reinforcing layer is located in the top of the core, and wherein at least one second reinforcing layer is located in the bottom of the core.

19. The decorative panel according to one of the preceding clauses, wherein the density of at least one core is below 1kg/m ³ 。

20. The decorative panel of one of the preceding clauses, wherein the decorative top structure is adhered to the core by a waterproof adhesive.

21. The decorative panel according to one of the preceding clauses, wherein the decorative top structure is preferably fused to the core without the use of a separate adhesive.

22. The decorative panel according to one of the preceding clauses, wherein the underside of the decorative top structure penetrates into the upper side of the core, preferably to a depth exceeding 0.1 mm.

23. The decorative panel of one of the preceding clauses, wherein the decorative top structure comprises: at least one decorative layer, preferably a digitally printed decorative layer; and at least one transparent wear layer covering the decorative layer.

24. The decorative panel of one of the preceding clauses, wherein the decorative top structure comprises, from bottom to top:

i. optionally, at least one substrate layer, in particular a primer layer;

at least one decorative layer, in particular a digitally printed decorative layer provided with decorative (digital) prints and/or a thermoplastic film or paper film;

at least one transparent wear layer covering the decorative layer; and

25. The decorative panel of one of the preceding clauses, wherein the first coupling profile comprises:

an upward tongue;

at least one upward flank located at a distance from the upward tongue;

and wherein the second coupling profile comprises:

a first downward tongue;

26. The decorative panel of any one of the preceding clauses, wherein the panel comprises at least one third coupling profile and at least one fourth coupling profile at a third panel edge and a fourth panel edge, respectively, wherein the third coupling profile comprises:

wherein the fourth coupling profile comprises:

wherein the third coupling profile and the fourth coupling profile are configured such that two of the panels can be coupled to each other by a rotational movement, wherein in the coupled state at least a part of a lateral tongue of a first panel is inserted into a third groove of an adjacent second panel, and wherein at least a part of an upward locking element of the second panel is inserted into a second downward groove of the first panel.

27. The decorative panel according to any one of the preceding clauses, wherein at least a portion of at least one coupling profile and preferably at least a portion of each coupling profile is integrally made of the material of the core.

28. The decorative panel of any one of the preceding clauses, wherein at least one fleece layer has a varying density in the thickness direction of the fleece layer.

29. The decorative panel of any one of the preceding clauses, wherein at least one fleece layer has a varying density in the width and/or length direction of the Mao Liaoceng.

30. The decorative panel of one of the preceding clauses, wherein at least one of the fleece layers is at least partially filled with an inert filler.

31. The decorative panel according to one of the preceding clauses, wherein the thickness of the panel is between 2mm and 10mm, preferably between 3mm and 10 mm.

32. The panel according to one of the preceding clauses, wherein at least one panel layer comprises and/or is coated with at least one antimicrobial composition.

33. The panel of clause 32, wherein the antimicrobial composition comprises a metal selected from Cu ₂ O、Cu(OH) ₂ 、Cu、CuO ₃ 、Cu ₂ O ₃ And combinations thereof, and at least one non-copper metal or copper-free metal compound.

34. The panel of clause 32 or 33, wherein the antimicrobial composition is selected from the group consisting of: (i) Organic or organometallic antimicrobial substances, such as halogenated phenyl ethers, halogenated salicylanilines, sesquiterpene alcohols, halogenated carbanilides, bisphenols, general phenols, formaldehyde, quaternary ammonium compounds, pyridine derivatives and hexachlorobenzene; and/or (ii) an inorganic antimicrobial substance comprising silver, zinc or copper in a glass or ceramic matrix, wherein the antimicrobial agent preferably comprises 2,4 '-trichloro-2' -hydroxydiphenyl ether.

35. The decorative panel according to one of the preceding clauses, wherein the top structure comprises at least one layer of enamel, in particular a layer of decorative enamel.

36. The decorative panel of clause 35, wherein the top structure comprises at least one translucent, particularly transparent, glaze layer, wherein the wear layer is formed from the glaze layer.

37. The decorative panel of one of the preceding clauses, wherein the top structure comprises at least one layer composed at least in part of a material selected from the group consisting of glaze, ceramic, stone, linoleum, ceramic, stone, concrete, mineral porcelain, glass, quartz, soapstone, mosaic, granite, limestone, and marble.

38. The decorative panel of one of the preceding clauses, wherein the top structure comprises a textured upper surface.

39. The decorative panel of one of the preceding clauses, wherein the textured upper surface is a digitally printed textured surface comprising digitally printed depressions and/or digitally printed ridges.

40. The decorative panel of clause 28 or 29, wherein at least a portion of the textured surface of the decorative top structure is aligned in registration with at least a portion of at least one decorative image of the decorative printed layer of the decorative top structure, particularly with at least one pattern defined by at least one decorative image formed by the decorative printed layer of the top structure.

41. The decorative panel according to one of the preceding clauses, wherein the panel and preferably at least one panel edge is provided with at least one chamfer or grout.

42. The decorative panel of clause 31, wherein at least one chamfer or grout is a digitally printed chamfer or grout.

43. The decorative panel of clause 31 or 32, wherein at least one chamfer or grout is a mechanically pressed chamfer or grout.

44. The decorative panel of one of clauses 31-33, wherein the panel is provided with at least one grout that artificially and visually divides the panel into a plurality of smaller panels.

45. A core for use in a decorative panel according to one of the preceding clauses, wherein a first core edge comprises at least a portion of a first coupling profile and a second core edge comprises at least a portion of a second coupling profile, wherein the second coupling profile is designed to interlockingly engage with the first coupling profile of an adjacent panel or an adjacent core in both a horizontal direction and a vertical direction, wherein the core comprises at least one fleece layer formed at least in part from artificial glass fibers bonded together by at least one cured thermosetting polymer binder material.

46. A decorative covering, in particular a decorative floor covering, a decorative ceiling covering or a decorative wall covering, comprising a plurality of interconnected decorative panels according to any one of clauses 1 to 44.

Drawings

The invention will be elucidated on the basis of non-limiting exemplary embodiments shown in the following figures, in which:

FIG. 1 shows a rectangular floor panel according to the invention;

FIG. 2 shows a transverse cross-section along line A-A in FIG. 1 of the respective side edges;

FIG. 3 illustrates a method of joining the side edges shown in FIG. 2;

FIG. 4 shows the side edges of FIG. 2 in a coupled state in a transverse cross-sectional view;

FIG. 5 shows a longitudinal cross-sectional view of each side edge along line B-B in FIG. 1;

FIG. 6 illustrates a method of joining the side edges shown in FIG. 5;

fig. 7 shows further details of the respective side edges in the coupled state in a longitudinal section;

FIG. 8 illustrates an alternative embodiment of the side edges of FIG. 2, which allows for another coupling method;

fig. 9 shows another alternative embodiment of the side edges of fig. 2.

Detailed Description

Fig. 1 shows a decorative panel 1 provided with a decorative top structure 12 on an upper side 2 (see also fig. 2). The panel is rectangular in shape having a length extending longitudinally along the B-B line and a width extending transversely along the A-A line. The plane of the panel is thus determined by the combination of the A-A and B-B lines. At the opposite side edges 3 and 4, a first coupling part in the form of a contour 5 and a second coupling part in the form of a contour 6 are provided, respectively. At the opposite side edges 9 and 10, a third coupling part in the form of a contour 7 and a fourth coupling part in the form of a contour 8 are provided, respectively.

Fig. 2 shows a transverse cross-section of the first coupling part 5 at the side edge 3. The first coupling part 5 comprises a lateral tongue 20, the lateral tongue 20 comprising a front area 21 and a rear area 22, wherein a bottom surface 23 and/or a side surface 23 of the front area 21 is at least partly rounded, wherein a top surface 24 of the front area 21 is at least partly inclined downwards in a direction away from the rear area 22, and wherein a bottom surface 26 and/or a side surface 26 of the rear area 22 of the lateral tongue 20 defines a first contact part 26, and wherein the lateral tongue 20 comprises a passive bottom surface 27 adjacent to the first contact part 26, wherein the passive bottom surface 27 is defined by a cut-out at the underside of the lateral tongue 20. The passive bottom surface 27 here extends over an intermediate region 28 between the rear region 22 and the front region 21 and is substantially planar. The passive bottom surface 27 slopes downwardly in a direction towards the front area 21 such that the sloping top surface 24 of the lateral tongue and the sloping passive bottom surface 27 converge in a direction away from the rear area of the lateral tongue. Furthermore, the second coupling part 6 comprises a recess 30, which recess 30 is intended to receive at least a part of a lateral tongue 20 of another panel; the recess 30 is defined by an upper lip 31 and a lower lip 32, wherein the lower lip 32 extends beyond the upper lip 31, and wherein the lower lip 32 is provided with an upwardly protruding shoulder 33, the shoulder 33 defining a second contact portion 34, the second contact portion 34 being configured to actively co-act with the first contact portion 26 of another panel in a coupled state of the panels as will be discussed with reference to fig. 4. The top surface 35 of the lower lip 32 is at least partly smoothly curved and is configured as a sliding surface for the at least partly rounded bottom surface 23 and/or side surface 23 of the front area 21 of the lateral tongue 20 of the other panel during coupling of the first coupling part and the second coupling part. The upper surface 35 of the lower lip is provided with staggered cut-out portions 35s, the cut-out portions 35s being at least partially located below the upper lip 31 and being configured to receive an end portion of a lateral tongue 20 of another panel.

The panel 1 comprises a core 1a and a decorative top structure 12 fixed directly or indirectly above said core. An optional backing layer 105 is attached to the underside of the core 1 a. The core 1a comprises at least one (mineral) Mao Liaoceng, the fleece layer being formed at least partially and optionally entirely of synthetic glass fibers bonded together by at least one cured thermosetting polymer binder material, typically a resin. Preferably, at least a portion of the artificial glass fiber is made of at least one material selected from the group consisting of rock wool, mineral wool, slag wool, basalt wool, and glass fiber. It is conceivable that the core 1a comprises a plurality of different wool layers and/or at least one non-wool layer, such as a glass fiber layer, a thermoplastic layer and/or a cement layer. The top structure 12 may have various properties, two of which embodiments 12a, 12b are shown in fig. 2. In the first embodiment 12a, the top structure has a laminated structure, and includes: a decorative layer, in particular a thermoplastic film or a paper film, carrying a decorative image, preferably digitally printed; and at least one protective layer, such as a finishing layer and/or a wear layer and/or a paint layer, located over the decorative layer. Further embodiments have been given in the above description. Alternatively or additionally, the roof structure 12b may comprise tiles, in particular mineral tiles, wherein the tiles are preferably made at least partly of ceramics and/or stone and/or any material selected from ceramics, stone, concrete, mineral porcelain, glass, quartz, soapstone, mosaic, granite, limestone and marble. Often, these tiles are difficult or even impossible to form, so the forming core provides a solution for manufacturing interlockable mineral tiles. The top structure 12 may be glued to the core 1a by means of an adhesive and/or may be fused to the core 1 a.

The backing layer 105 is attached directly or indirectly to the rear side of the core 1 a. The at least one backing layer is preferably made at least partially of a flexible material, preferably an elastomer. The thickness of the backing layer typically varies between about 0.1mm and 2.5 mm. Non-limiting examples of backing layer materials may be polyethylene, cork, polyurethane, and ethylene-vinyl acetate. The polyethylene backing layer 105 typically has a thickness of, for example, 2mm or less. The backing layer 105 generally provides additional robustness, dimensional stability, and/or impact resistance to the panel itself, which increases the durability of the panel. Furthermore, the (flexible) backing layer 105 may increase the acoustic (sound damping) properties of the panel 1.

In the following figures, the backing layer 105 and the top structure 12 are not shown separately for clarity, but they may be incorporated in each of the figures shown.

Fig. 3 shows a coupling method of two panels 1 and 1', wherein each panel is provided with a first coupling part 5 and a second coupling part 6 as shown in fig. 2. The two panels are coupled to each other by a tilting movement on arrow MA. As is evident from fig. 3, the curvature of the top surface 35 of the lower lip 32 serves as a sliding surface for the at least partially circular bottom surface 23 and/or the side surface 23 of the tongue 20.

Fig. 4 shows the coupling parts 5 and 6 of the two panels 1 and 1' once the coupling shown in fig. 3 has been completed by a tilting movement. In the coupled state shown, the respective contact portions 26 and 34 together create a tension force (T1), which tension force (T1) forces the side edges 3 and 4 towards each other. Furthermore, in the coupled state shown, the at least partially curved top surface 35 of the lower lip 32 and the passive bottom surface 27 of the lateral tongue 20 are mutually positioned such that there is an intermediate space S adjacent to the actively co-acting first and second contact portions 26, 34. The passive bottom surface 27 is depicted as a substantially flat surface, but may alternatively have a concave or convex surface, as long as a certain amount of intermediate space S is maintained between the tongue and the recess in the coupled state. The lower surface 36 of the upper lip 31 is at least partially inclined and is configured to abut at least a portion of the top surface 24 of the front region of the lateral tongue 20. The top surface 35 of the lower lip defines a deepest point 38 of the recess, wherein the shoulder 33 of the lower lip defines a highest point 39 of the lower lip, wherein the deepest point and the highest point define a Lower Lip Depth (LLD). On the upper side of the panels 1 and 1' pressed together by the tension from the contact portions 26 and 34, there is a joint 40, the joint 40 defining a vertical plane VP subdividing the lower lip 32 into an inner lower lip portion 32i and an outer lower lip portion 32o. Here, the top surface of the shoulder 33 is located at a distance from the first coupling part 5, so that there is also an intermediate space at this part.

Fig. 5 shows a longitudinal section along line B-B of the panel 1 shown in fig. 1. At the side edges 9 and 10, a third coupling part in the form of a profile 7 and a fourth coupling profile in the form of a profile 8 are provided, respectively. The third coupling part 7 comprises an upward tongue 71, an upward flank 72 located at a distance from the upward tongue, and an upward groove 73 formed between the upward tongue 71 and the upward flank 72, wherein the upward groove is adapted to receive at least a part of the downward tongue 81 of the fourth coupling part 8 of another panel. The side of the upward tongue 71 facing the upward flank 72 is the inner side 77 of the upward tongue, while the side of the upward tongue 71 facing away from the upward flank 72 is the outer side 76 of the upward tongue. The first locking element 75 is arranged on the outer side of the upward tongue 71 facing away from the upward flank 72. The fourth coupling part 8 comprises a downward tongue 81, a downward flank 82 located at a distance from the downward tongue, and a downward groove 83 formed between the downward tongue 81 and the downward flank 82, wherein the downward groove 83 is adapted to receive at least a part of the upward tongue 71 of the third coupling part 7 of another panel. The side of the downward tongue 81 facing the downward flank 82 is the inner side 87 of the downward tongue, while the side of the downward tongue 81 facing away from the downward flank 82 is the outer side 86 of the downward tongue 81. A second locking element 85 adapted to co-act with the first locking element 75 of the other panel is provided at the downward flank 82.

Fig. 6 shows how the third coupling profile 7 and the fourth coupling profile 8 in fig. 5 can be coupled to each other when connecting the panels 1 and 1' to each other. Here, the panel 1' is moved vertically downwards along the arrow, wherein the profiles 7 and 8 are engaged with each other by receiving the upward tongue 71 in the downward groove 83 and the downward tongue 81 in the upward groove 73.

Fig. 7 shows in more detail the side edges 7 and 8 in the coupled state after the vertical movement coupling as shown in fig. 6 is completed. It is noted that the side edges 7 and 8 of the embodiment of fig. 7 contain some slight modifications compared to the embodiments shown in fig. 5 and 6, which modifications can be seen directly from the figures and will be explained further below. To the extent that fig. 5-7 have the same common features, these features are denoted by the same reference numerals. The inner side 77 of the upward tongue 71 is in contact with the inner side 87 of the downward tongue 81 of another panel such that these panels create a tension force (T2) which urges the side edges 7 and 8 towards each other. A portion of the inner side 77 of the upper tongue is inclined towards the upper flank 72 and a portion of the inner side 87 of the lower tongue 81 is inclined towards the lower flank 82, so that the two coupled panels interlock in a direction perpendicular to the panel plane (i.e. in the vertical direction). Furthermore, the first locking element 75 and the second locking element 85 interlock with each other, thereby further facilitating the vertical interlocking of the coupled panels. The first locking element is a protrusion 75 and the second locking element is a recess 85. The protrusion 75 has an upper portion 90 and an adjoining lower portion 88, wherein the lower portion 88 comprises an inclined locking surface and the upper portion 90 comprises a preferably curved guiding surface. Recess 85 includes an upper portion 94 and an adjoining lower portion 92, wherein lower portion 92 includes an angled locking surface. The respective upper portions 90 and 94 are at a distance from each other, allowing an intermediate space. On the upper side of the coupled side edges 7 and 8, the upper contact surfaces 95 and 96 are forced together due to the interaction of the inner sides 77 and 87. Further, the respective upper contact surfaces 95 and 96 are provided with a protrusion 98 and a recess 97, the protrusion 98 and the recess 97 interlocking with each other in the coupled state. Above the projection 98 and the recess 97, mutually engaging inclined contact surfaces 99a and 99b are provided, respectively.

Fig. 8 shows an alternative embodiment according to the side edges 3 and 4 of fig. 2, wherein the upper surface 24 of the front region 21 of the lateral tongue and the side surface 23 of the front region 21 of the lateral tongue are connected by a transitional convexity 100, and the lower surface 36 of the upper lip 31 and the side surface 102 of the upper lip 31 are connected by a transitional convexity 104. All other features of the side edges 3 and 4 are similar to those of fig. 2. The embodiment shown allows for a coupling movement by moving the panels towards each other in a planar direction as indicated by the arrow "snap in".

Fig. 9 shows an alternative embodiment according to the side edges 3 and 4 of fig. 2, wherein the upper surface 35 of the lower lip 32 has staggered cut-out portions 35s, the cut-out portions 35s being complementary in size to the end portion 23 of the tongue 20, such that the cut-out portions 35s enclose the end portion 23 in a clamping manner. All other features of the side edges 3 and 4 are similar to those of fig. 2.

The above inventive concept has been illustrated by several exemplary embodiments. It is conceivable that the various inventive concepts may also be applied without applying further details of the described examples. All conceivable examples of the above-described inventive concepts need not be elaborated on, as it will be appreciated by one skilled in the art that many inventive concepts can be (re) combined to realize a specific application.

It is obvious that the invention is not limited to the working examples shown and described herein, but that within the scope of the appended claims there may be many variations obvious to a person skilled in the art.

The verb "comprise" and its conjugations used in this patent should be understood to mean not only "comprising", but also the phrases "comprising", "consisting essentially of … …", "formed of … …" and its variants.

Claims

a core provided with an upper side and a lower side;

wherein the core comprises at least one wool layer formed at least in part from synthetic glass fibers bonded together by at least one cured thermoset polymeric binder material, wherein the decorative top structure comprises: at least one glaze layer; and optionally at least one digitally printed decorative layer covered by the glaze layer.

2. The decorative panel of claim 1, wherein at least a portion of the artificial glass fibers are made of at least one material selected from the group consisting of rock wool, mineral wool, slag wool, basalt wool, and glass fibers.

3. The decorative panel of claim 1 or 2, wherein at least one binder material is a material selected from urea-modified phenolic resins and alkanolamine/carboxylic anhydride reaction products.

4. Decorative panel according to one of the preceding claims, wherein at least one binder material is a material selected from the group consisting of acrylic and epoxy.

5. Decorative panel according to one of the preceding claims, wherein at least one binder material is formed from a sugar component, preferably selected from: sucrose, reducing sugars, in particular dextrose, carbohydrates, and mixtures thereof.

6. The decorative panel according to one of the preceding claims, wherein the core comprises at least one primary binder material, which is a material selected from urea-modified phenolic resins and alkanolamine/carboxylic anhydrides, and wherein the core comprises at least one co-binder material selected from acrylic resins and epoxy resins.

7. The decorative panel according to claim 6, wherein the amount of the solid-based co-binder is 1 to 50% by weight of the total binder, preferably 5 to 35% of the total binder.

8. The decorative panel according to one of the preceding claims, wherein the core comprises a mixture of binder materials, wherein a first binder material has a higher curing temperature and/or curing rate than at least one second binder material.

9. The decorative panel according to any one of the preceding claims, wherein the core comprises at least one fluorescent compound, preferably selected from: xanthine, acridine, quinine derivatives, coumarin, and arylsulfonates.

10. The decorative panel of one of the preceding claims, wherein the core comprises aerogel particles.

11. The decorative panel of claim 10, wherein the weight of aerogel particles in the core exceeds the weight of the binder material and/or the weight of the man-made glass fibers in the core.

12. Decorative panel according to one of the preceding claims, wherein the fibre orientation in at least one layer of wool of the core is substantially vertical.

13. The decorative panel according to one of the preceding claims, wherein the core comprises: at least one base Mao Liaoceng comprising a first mineral wool; and at least one roof Mao Liaoceng comprising a second mineral wool over the base batt, wherein the first mineral wool and the second mineral wool have different material compositions and/or different structural properties.

14. Decorative panel according to one of the preceding claims, wherein the panel, in particular the core, comprises at least one reinforcing layer, preferably a non-woven layer or a woven layer, in particular a cloth.

15. The decorative panel of claim 14, wherein the reinforcing layer comprises fiberglass.

16. The decorative panel according to one of the preceding claims 14 to 15, wherein the reinforcing layer comprises: natural fibers such as jute; and/or synthetic fibers, in particular polymeric fibers.

17. The decorative panel according to one of the preceding claims 14 to 16, wherein the at least one reinforcing layer is embedded in the core and is preferably surrounded by two fleece layers.

18. Decorative panel according to one of the preceding claims, wherein the panel comprises a plurality of reinforcement layers, wherein preferably at least one first reinforcement layer is located in the top of the core and wherein at least one second reinforcement layer is located in the bottom of the core.

19. Decorative panel according to one of the preceding claims, wherein the density of at least one core is below 1kg/m ³ 。

20. The decorative panel according to one of the preceding claims, wherein the decorative top structure is adhered to the core by a waterproof adhesive.

21. Decorative panel according to one of the preceding claims, wherein the decorative top structure is preferably fused to the core without the use of a separate adhesive.

22. The decorative panel according to one of the preceding claims, wherein the underside of the decorative top structure penetrates into the upper side of the core, preferably to a depth exceeding 0.1 mm.

23. The decorative panel according to one of the preceding claims, wherein the decorative top structure comprises: at least one digitally printed decorative layer; and at least one transparent wear layer covering the digitally printed decorative layer.

24. Decorative panel according to one of the preceding claims, wherein the top structure comprises at least one layer of enamel, in particular a decorative enamel layer.

25. Decorative panel according to claim 23 and 24, wherein the top structure comprises at least one translucent, in particular transparent, glaze layer, wherein the wear layer is formed by the glaze layer.

26. The decorative panel according to one of the preceding claims, wherein the decorative top structure comprises from bottom to top:

i. optionally, at least one substrate layer, in particular a primer layer;

at least one decorative layer, in particular a digitally printed decorative layer provided with decorative printing and/or a thermoplastic film or paper film;

at least one transparent wear layer covering the decorative layer; and

27. The decorative panel of one of the preceding claims, wherein the top structure comprises at least one layer at least partially composed of a material selected from the group consisting of glaze, ceramic, stone, linoleum, ceramic, stone, concrete, mineral porcelain, glass, quartz, soapstone, mosaic, granite, limestone, and marble.

28. The decorative panel of one of the preceding claims, wherein the top structure comprises a textured upper surface.

29. Decorative panel according to one of the preceding claims, wherein the textured upper surface is a digitally printed textured surface comprising digitally printed depressions and/or digitally printed ridges.

30. The decorative panel of claim 28 or 29, wherein at least a portion of the textured surface of the decorative top structure is aligned in registration with at least a portion of at least one decorative image of the decorative printed layer of the decorative top structure, in particular with at least one pattern defined by at least one decorative image formed by the decorative printed layer of the top structure.

31. Decorative panel according to one of the preceding claims, wherein the panel and preferably at least one panel edge is provided with at least one chamfer or grout.

32. The decorative panel of claim 31, wherein at least one chamfer or grout is a digitally printed chamfer or grout.

33. The decorative panel of claim 31 or 32, wherein at least one chamfer or grout is a mechanically pressed chamfer or grout.

34. Decorative panel according to one of the claims 31 to 33, wherein the panel is provided with at least one grout which artificially and visually divides the panel into a plurality of smaller panels.

35. The decorative panel of one of the preceding claims, wherein the first coupling profile comprises:

An upward tongue;

at least one upward flank located at a distance from the upward tongue;

and wherein the second coupling profile comprises:

a first downward tongue;

36. The decorative panel of any one of the preceding claims, wherein the panel comprises at least one third coupling profile and at least one fourth coupling profile at a third panel edge and a fourth panel edge, respectively, wherein the third coupling profile comprises:

wherein the fourth coupling profile comprises:

37. The decorative panel of any one of the preceding claims, wherein at least a portion of at least one coupling profile and preferably at least a portion of each coupling profile is integrally made of the material of the core.

38. The decorative panel of any one of the preceding claims, wherein at least one fleece layer has a varying density in the thickness direction of the fleece layer.

39. The decorative panel of any one of the preceding claims, wherein at least one fleece layer has a varying density in the width and/or length direction of the Mao Liaoceng.

40. Decorative panel according to one of the preceding claims, wherein at least one fleece layer is at least partially filled with an inert filler.

41. Decorative panel according to one of the preceding claims, wherein the thickness of the panel is between 2mm and 10mm, preferably between 3mm and 10 mm.

42. Panel according to one of the preceding claims, wherein at least one panel layer comprises and/or is coated with at least one antimicrobial composition.

43. The panel according to claim 42, wherein the antimicrobial composition comprises a material selected from Cu ₂ O、Cu(OH) ₂ 、Cu、CuO ₃ 、Cu ₂ O ₃ And combinations thereof, and at least one non-copper metal or copper-free metal compound.

44. The panel according to claim 42 or 43, wherein the antimicrobial composition is selected from the group consisting of: (i) Organic or organometallic antimicrobial substances, such as halogenated phenyl ethers, halogenated salicylanilines, sesquiterpene alcohols, halogenated carbanilides, bisphenols, general phenols, formaldehyde, quaternary ammonium compounds, pyridine derivatives and hexachlorobenzene; and/or (ii) an inorganic antimicrobial substance comprising silver, zinc or copper in a glass or ceramic matrix, wherein the antimicrobial agent preferably comprises 2,4 '-trichloro-2' -hydroxydiphenyl ether.

45. Panel according to one of the preceding claims, wherein the decorative top structure has a thickness between 0.5mm and 12mm, preferably between 1mm and 6mm, more preferably between 2mm and 4 mm.

46. Core for use in a decorative panel according to one of the preceding claims, wherein a first core edge comprises at least a part of the first coupling profile and a second core edge comprises at least a part of the second coupling profile, wherein the second coupling profile is designed to interlockingly engage with the first coupling profile of an adjacent panel or an adjacent core in both the horizontal and vertical direction, wherein the core comprises at least one fleece layer formed at least partly of synthetic glass fibers bonded together by at least one cured thermosetting polymer binder material.

47. A decorative covering, in particular a decorative floor covering, a decorative ceiling covering or a decorative wall covering, comprising a plurality of mutually coupled decorative panels according to any one of claims 1 to 45.