EA040976B1 - FLOOR ELEMENT FOR FORMING FLOOR COVERING, FLOOR COVERING AND METHOD FOR MANUFACTURING FLOOR ELEMENT - Google Patents

Description

Cross-reference to related applications

This application claims priority over U.S. Patent Application No. 16/028745 filed July 6, 2018, the contents of which are incorporated herein by reference in their entirety.

The technical field to which the invention belongs

The present invention relates to a floor element for forming a floor covering, to a floor covering and to a method for manufacturing a floor element.

More specifically, the invention relates to a floor element for forming a floor covering, the floor element comprising a decorative layer made of a brittle material such as natural stone, glass or sintered ceramic material such as porcelain, earthenware, and the like. The decorative layer can be, for example, a ceramic tile.

Prerequisites for the invention

Traditionally, ceramic tiles are laid by placing them side by side on a surface such as a floor or wall. Usually, an adhesive is used to attach the tiles to the surface. Seams between tiles are filled with grout. Thus, the tiles are bonded to a hard surface, such as a concrete subfloor, thereby improving their impact resistance. The connection with the subfloor, and thus with the structure of the dwelling, also leads to a strong attenuation of walking sounds, both in the room where the floor is laid and in the rooms below the respective room. The tiled surface is waterproof and hygienic, as it can be cleaned very wet. However, the step of laying tiles using adhesive is a very laborious step, which takes up a significant part of the labor costs when laying a typical floor covering. In addition, this laying technique requires a lot of professional experience to ensure a well-leveled floor covering. Thus, due to the labor and time required for installation, professional tiling is usually quite expensive.

To replace an existing tile floor, it is often necessary to break the tiles, repair the surface by removing adhesive residue, and then lay the new floor. Thus, the destruction of a floor covering made of tiles is a laborious and time-consuming operation. If the purpose of the restoration is to replace only one or a few damaged tiles, this operation is also more complicated, since when replacing one tile, it is preferable not to damage adjacent tiles.

In recent years, manufacturers have been trying to develop simpler DIY tiling solutions. Some examples of such attempts are described in patent documents WO 2004/097141 and WO 2008/097860. The floor elements described in these documents can be laid on the surface and mechanically connected to each other to form a floor covering without the use of adhesives, which reduces installation labor and time. This type of flooring is known as floating flooring. Specifically, in these documents, a ceramic tile or natural stone slab is attached to a support layer which contains connectors configured to connect to the connectors of an adjacent floor element, thereby forming a floor covering.

On the other hand, since such floor elements are not connected to a common rigid surface, the impact strength and hence the fatigue strength are significantly reduced. Floating stacking can also increase the noise generated when walking. Joints between tiles, as described in WO 2008/097860, may be susceptible to water penetration, especially when wet cleaning. According to some embodiments of patent document WO 2004/097141, joints between adjacent floor elements may be grouted, which may result in water tightness of the respective joint.

To increase the impact strength of ceramic tiles, US 2014/349,084 proposes a tile with a composite structure. In such a composite tile, a reinforcing layer is located between two ceramic layers or between a ceramic layer and a polymer laminate. As an example of the reinforcing layer, a glass fiber layer is mentioned. However, tile installation is still complicated. Bonding to the underlying subfloor is required, for example through a bottom layer with a pressure sensitive adhesive or fast adhesive loop material, so that the tile is substantially integral with the subfloor to improve impact resistance. In addition, precise positioning of tiles is difficult.

WO 2010/072704 proposes another type of reinforcement layer, namely a steel plate. This steel plate is glued to the back surface of the ceramic tile or slab. However, laying in this case is also difficult. Laying is done by simply placing the tiles on the subfloor, so precise positioning of the tiles is difficult, resulting in poorly leveled flooring and noisy and permeable flooring.

The purpose of the present invention is, first of all, to develop an alternative floor

- 1 040976 th element, which, in accordance with some preferred embodiments, is directed to solving one or more problems arising in the art.

The essence of the invention

In one aspect of the present invention, a floor element for flooring is provided, the floor element comprising a decorative layer made of a ceramic material and a support layer positioned under this decorative layer, the support layer comprising edges which are provided with connecting elements configured to making a mechanical connection with the connecting elements of an adjacent floor element, and in which the floor element comprises an intermediate layer having a polymeric material that penetrates into the lower surface of the decorative layer.

In another aspect of the present invention, a method for manufacturing a floor element is provided, comprising the steps of: (i) providing a decorative layer made from a ceramic material; (ii) providing a support layer; (iii) providing a polymeric material for bonding the decorative layer to the support layer; (iv) co-pressing the layers to form a floor element so that the polymeric material penetrates into the ceramic layer.

In another aspect of the invention, the use of a polymeric material is provided for bonding a decorative layer made of ceramic material to a support layer to form a floor element, the polymeric material having a viscosity at 20°C of less than 1000 Pa-s.

In another aspect of the invention, a floor element is provided, comprising a decorative layer made of ceramic material, and a support layer located under the decorative layer, the support layer comprising at least two pairs of opposite edges, the opposite edges comprising connecting elements capable of mechanically connections with connecting elements of adjacent floor elements, wherein the first connecting elements on the first pair of opposite edges are configured to be connected to the connecting elements of adjacent floor elements by means of angular displacement around a horizontal axis parallel to the respective edges, and wherein the second connecting elements on the second pair of edges are configured to connection with connecting elements of adjacent floor elements by translational movement in the downward direction of the respective edges towards each other.

In another aspect of the invention, a floor element is provided, comprising a decorative layer having a density, expressed as a surface density, of at least 10 kg/cm ² ; and a support layer located under the decorative layer, wherein the support layer comprises at least two pairs of opposite edges, the opposite edges comprising connecting elements configured to be mechanically connected to the connecting elements of adjacent floor elements, the first connecting elements on the first pair of opposite edges made with the possibility of connection with the connecting elements of adjacent floor elements by means of angular movement around a horizontal axis parallel to the respective edges, and moreover, the second connecting elements on the second pair of edges are made with the possibility of connection with the connecting elements of adjacent floor elements by means of translational movement in the downward direction of the respective edges towards each other friend.

These and other objects, features and advantages of the present invention are apparent from the following specifications, given with reference to the description, claims and drawings.

Brief description of the drawings

Below are non-limiting and illustrative drawings to illustrate some of the possible forms of embodiments in accordance with the disclosure.

In FIG. 1 is a plan view of an embodiment of a floor element of the present invention;

in fig. 2 is an enlarged cross-sectional view taken along line II-II in FIG. 1;

in fig. 3 is an enlarged view of the region F3 marked in FIG. 2;

in fig. 4 is an enlarged cross-sectional view taken along line IV-IV in FIG. 1;

in fig. 5 is a scaled-down plan view of a floor covering comprising a plurality of the floor elements of FIG. 1;

in fig. 6 is an enlarged cross-sectional view taken along line VI-VI in FIG. 5;

in fig. 7 is an enlarged view of the area F7 marked in FIG. 6;

in fig. 8 is an enlarged cross-sectional view taken along the line VIII-VIII of FIG. 5;

in fig. 9 is an enlarged view of the region F9 marked in FIG. 8;

in fig. 10 shows some of the steps in the manufacturing process for the floor element.

Detailed description

To facilitate understanding of the principles and features of various embodiments, below

- 2 040976 provides various illustrative options for implementation. Although illustrative embodiments of the invention are explained in detail, it should be understood that other embodiments are possible. Accordingly, the scope of the invention is not intended to be limited by the details of construction and arrangement of components described in the following description or examples. The invention may have other embodiments and may be practiced or carried out in various ways. In addition, when describing illustrative embodiments, specific terminology is used for clarity.

It should also be noted that the singular forms used in the description and in the appended claims include plural references, unless the context clearly dictates otherwise. For example, a component reference also includes a composition of a plurality of components. References to a composition including a singular form component are intended to include other components in addition to the one named.

As used herein, and/or can mean and, can mean or, can mean exclusive - or, can mean one, can mean some but not all, can mean none, and/or can mean both. The term or is intended to mean exclusively or.

In addition, when describing illustrative embodiments, terminology is used to provide greater clarity. Each term is intended to have its broadest meaning as understood by those skilled in the art and to include technical equivalents that work in a similar way to achieve a similar purpose. It should be understood that embodiments of the disclosed technology may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure this description. References to one embodiment, an embodiment, an illustrative embodiment, some embodiments, specific embodiments, various embodiments, and so on indicate that the technology variant(s) of the disclosed technology thus described may include a specific feature, structure or feature, but not every embodiment necessarily includes a particular feature, structure, or feature. In addition, the reuse of a phrase in one embodiment does not necessarily refer to the same embodiment, although it may.

Ranges herein may be expressed as from about, or approximately, or substantially one specific value, and/or to about, or approximately, or substantially another specific value. When such a range is indicated, other illustrative embodiments include from one specific value and/or to another specific value. In addition, the term roughly means within an acceptable error range for a particular quantity, as determined by one of ordinary skill in the art, which will depend in part on how the quantity is measured or determined, i.e. from the limitations of the measuring system.

By containing or containing or including, it is meant that at least the specified chemical compound, element, particle or method step is present in the chemical compound, article or method, but does not exclude the presence of other chemical compounds, materials, particles, steps method, even if other such chemical compounds, materials, particles, method steps have the same function as those named.

It should also be understood that the mention of one or more method steps does not exclude the presence of additional method steps or intermediate method steps between these explicitly designated steps. Similarly, it should be understood that the mention of one or more components in the composition does not exclude the presence of additional components other than those explicitly indicated.

The materials described below as the materials from which the various elements of the present invention are made are intended to be illustrative and not limiting. It is intended that many suitable materials that could perform the same or similar function as the materials described herein are within the scope of the invention. Such other materials not described herein may include, without limitation, materials that have been developed, for example, since the development of the invention. Any dimensions listed in the various drawings are for illustrative purposes only and are not intended to be limiting. It is assumed that other dimensions and proportions are included in the scope of the invention.

Embodiments of the invention

Thus, the present invention according to its first independent aspect relates to a floor element for forming a floor covering, this floor element comprising a decorative layer made of ceramic material and a support layer located under this decorative layer, the support layer comprising edges, in which connecting elements are provided, made with the possibility of mechanical connection with the connecting elements of an adjacent floor element, and moreover, the floor element contains an intermediate layer having a polymeric material that penetrates into the lower surface of the

- 3 040976 corative layer. The inventors have found that, thanks to this solution, the impact strength of the floor element, in particular of the decorative layer made of ceramic, is significantly increased, so that even with mechanical interlocking of such floor covering elements, the impact strength reaches or even exceeds the impact strength of traditional elements laid with using glue. In addition, the claimed solution makes it possible to increase the impact strength of the floor element without the need to add additional rigid or elastic reinforcing elements, such as a layer of rubber, fiberglass or metal plates.

In fact, the resin penetrating the pores of the decorative layer significantly improves the transmission and dissipation of impact stress through the floor element, so that less of said energy is absorbed by the decorative layer, improving its impact resistance. Since there is no need to add rigid reinforcing elements, the resulting floor element is lighter and thinner. Moreover, the resin prevents the propagation of cracks in the decorative layer itself. Furthermore, in the case of surface cracks in the decorative layer, the intermediate layer keeps the decorative layer bound and preferably sealed, thereby masking the appearance of the surface cracks.

The impact strength of a floor covering can be determined using a steel ball impact test. According to this test, the impact resistance is measured by dropping a steel ball on the floor element from a certain height, and if the floor element does not break, the height is increased until the height at which the steel ball breaks the floor element is reached. The steel ball has a weight of 225.5 g and a diameter of 38.1 mm (1.5 inches). The impact strength is expressed in terms of the maximum height from which a steel ball, when dropped onto a floor element, does not destroy the floor element. The higher the fall height, the greater the impact strength. Impact strength can be expressed in joules (J), i.e. in the energy of a steel ball when it hits the surface of the floor element. The inventors have found that conventional floor coverings, such as floor coverings made of porcelain floor elements with a thickness of approximately 10 mm, directly bonded to a subfloor, typically exhibit an impact strength in the range of 1.68 to 2.25 J (corresponding to ball drop from a height ranging from 762 mm to 1016 mm), with known floating floors exhibiting an impact strength typically less than 1.12 J (corresponding to a ball drop below 508 mm). The inventors have found that with this solution, an impact strength of more than 5.62 J (corresponding to a steel ball falling from a height of more than 2540 mm) can be achieved.

The fatigue strength of a floor covering is determined using the so-called Robinson test in accordance with ASTM standard C627. In accordance with this test, a three-wheeled trolley is rotated around its center on top of a sample taken from a section of a tile floor. Above each wheel is a rod on which weights are strung. The power motor sets the unit in motion, and the trolley rotates at a speed of 15 rpm. The test is carried out in accordance with the load schedule for 14 different cycles. For each cycle, the graph determines the type of wheel used (soft rubber, hard rubber, or steel), the amount of weight to be placed on each wheel, and the total number of cart revolutions to be completed. After the completion of each cycle, a sample taken from the tile floor area is examined visually. Based on the results of the test, the floor is qualified according to the number of cycles that have passed without destruction, and the appropriate class of use for which the floor is intended is determined.

Samples that complete cycles 1-3 without failure are classified as Habitable;

samples that complete cycles 1-6 without failure are classified as Light class for commercial use;

samples that complete cycles 1-10 without failure are classified as Medium class for commercial use;

samples that complete cycles 1-12 without failure are classified as Heavy class for commercial use;

samples that complete all 14 cycles without failure are classified as Extra Heavy for commercial use.

The inventors have found that by using the intermediate layer according to the invention, the Robertson test can result in at least 6 cycles (Light Commercial Grade).

According to a preferred embodiment of the invention, the decorative layer comprises a ceramic body, for example made from porcelain, red clay ceramic, stoneware, earthenware or other sinterable ceramic powders. Preferably the decorative layer is a ceramic tile or board. By ceramic tile is meant an element with a substantially flat body, consisting of heat-treatable minerals such as clay, and

- 4 040976 preferably with a fired decorative top surface, preferably, but not necessarily based on a glaze. The glaze also prevents resin from entering the top surface of the decorative layer when penetrating into the decorative layer, thus affecting the appearance of the floor element.

However, it should be noted that this first aspect can advantageously be applied to decorative layers made from any material of any type exhibiting open porosity, at least in accordance with its lower surface. Examples of said material may be brittle materials such as natural stone, concrete, glass or glass-ceramic. By brittle material is meant a material that fails without significant plastic deformation. In particular, with respect to the scope of the invention of the said patent application, the term brittle material means a material which by itself (when it is not associated with a support layer and does not have any reinforcing element) has an impact strength of less than 1.68 J (corresponding to ball dropped from a height of less than 762 mm) according to the drop ball test.

In accordance with a preferred aspect of the invention, the decorative layer may contain, at least in accordance with its lower surface, an open porosity, which allows the resin to penetrate into the decorative layer itself. In fact, as mentioned above, the inventors have unexpectedly found that by allowing the resin of the intermediate layer to penetrate into the pores of the decorative layer, the transmission of impact energy can be significantly improved. Thus, in accordance with a preferred embodiment of the invention, the decorative layer has an apparent porosity in the range of 0.1 to 10% as determined in accordance with ASTM C373, more preferably 2 to 8%, such as 6%. . The above ranges and values of apparent porosity provide an optimal balance between the intrinsic mechanical properties of the decorative layer and its resin permeability, thereby optimizing impact strength. In fact, the pores of the material, in particular the closed pores which cannot be permeable to the resin, may represent weak points in the material itself, so it is preferable that the decorative layer contains an apparent porosity of less than 15%, preferably less than 10%, measured according to ASTM C373. In addition, the decorative layer may preferably have an open pore volume in the range of 0.01 to 1 cm ³ , more preferably 0.10 to 0.90 cm ³ , such as 0.60 cm ³ . Thus, the pores are large enough to be filled with resin, but at the same time they are small enough not to impair the mechanical properties of the decorative layer. This result is particularly impressive as this range of apparent porosity is not only characteristic of ceramic tiles used for residential wall or flooring, but also for high traffic industrial flooring where high mechanical strength is required. properties, and it is preferable to use ceramic tiles having apparent porosity.

Thus, according to the first preferred possibility, the decorative layer is made of porcelain. Porcelain is a ceramic material obtained by firing at a high temperature of, for example, about 1200°C, a mixture of relatively pure raw materials containing clays, kaolin, quartz, feldspar, calcium carbonate and/or other mineral raw materials. Porcelain has a very low apparent porosity, preferably less than 1%, such as 0.3%, measured according to ASTM C373. The open pore volume of porcelain is in the range of 0.01 to 0.1 cm ³ , more preferably 0.1 to 0.6 cm ³ . The porosity values mentioned are such that the porcelain material exhibits relatively high mechanical properties, which can be further improved by the resin penetrating the decorative layer. In fact, porcelain tiles as such, i.e. not bonded to the backing layer and having no resin penetrating the decorative layer exhibits an impact strength of 0.73 J, while a floor element containing a decorative layer made of porcelain bonded over the backing layer via an intermediate layer containing resin , which penetrates the lower surface of the decorative layer, can reach an impact strength of up to 3.37 J.

Therefore, according to a second preferred possibility, the decorative layer is made of red clay ceramic tiles. Red clay pottery is a ceramic material obtained by firing at a high temperature of, for example, about 1150° C., a mixture of raw materials containing clays, kaolin, quartz, feldspar, calcium carbonate, and/or other mineral raw materials. Red clay pottery can be fired at a lower temperature than porcelain, thus providing a higher porosity and water absorption rate. In addition, red clay ceramics can be obtained from a mixture of raw materials that is cheaper than a mixture of raw materials required to produce porcelain. For example, ceramics based on red clay can

- 5 040976 have an apparent porosity of less than 10%, preferably 2 to 8%, for example 6% measured according to ASTM C373. The red clay ceramic may have an open pore volume ranging from 0.10 to 0.90 cm ³ , for example, it may be 0.60 cm ³ . Usually red clay ceramic tiles as such, i.e. not bonded to the support layer and having no resin penetrating the decorative layer, has an impact strength of 0.67 J, while a floor element containing a decorative layer made of red clay ceramic, glued over the support layer by means of an intermediate layer containing resin that penetrates the lower surface of the decorative layer can have an impact strength as high as 5.62 J. an element according to the invention containing red clay ceramic exhibits significantly greater impact resistance than a floor element containing porcelain.

The inventors have found that the interaction between the resin and the decorative layer is improved if the decorative layer has a bottom surface that is a substantially flat surface. The bottom surface is an invisible surface (in use) that is opposite the top decorative surface of the decorative layer. Typically, the bottom surface of a ceramic tile contains a back structure, typically formed by ribs and notches, which can be as thick as 1 mm, but the inventors have found that it is preferable to use a decorative layer that is free of said back structure to apply resin to the bottom surface itself. , for example from the mentioned edges. In addition, according to a preferred embodiment of the invention, the lower surface of the decorative layer, in particular of the ceramic tile, is free from the undercoat. The undercoat is a thin coating mainly containing engobe, which is applied, often irregularly, to the bottom surface of the ceramic tile, and which has the function of preventing the unfired ceramic tile material from sticking to the kiln rollers. Since the undercoat contains engobe, which is at least partly composed of a glass mixture and which, during the firing of the ceramic tile, melts into the pores of the ceramic tile that are open on its lower surface, the lower surface itself becomes impermeable. Thus, the inventors have found that a decorative layer made of a ceramic tile having a bottom surface free of a backing coating provides a better permeability of the bottom surface of the ceramic tile. It is also possible for the undercoat to cover a part of the lower surface of the decorative layer which is less than 20%, preferably 10% of said lower surface. Thus, the undercoat does not completely seal off the bottom surface, allowing the resin to penetrate into said porosity of the decorative layer while assisting in the production of a decorative layer that prevents the green ceramic tile material from sticking to the kiln rollers.

The decorative layer has a top surface containing the decor. Decor can have many textures, ornaments and colors. In a preferred embodiment, the decor imitates a natural product such as natural stone or wood. Preferably, if the decor is at least partially made by printing. Printing is preferably carried out by digital printing such as inkjet printing, although screen printing, rotogravure printing, flexographic printing or offset printing is not excluded. According to one embodiment, the décor is at least partially formed by a uniformly dyed base material or a mixture of dyed base materials.

The decorative layer may comprise a base coat at least partially covering its top surface and configured to receive a decor on its top, for example, configured to receive a print on its top. The base coat can be white, beige, brown, or any other color suitable for receiving decor on its top. In the case where the decorative layer is made of a ceramic material, the base layer preferably comprises at least a glaze covering the upper surface of the ceramic body.

The decorative layer may also comprise a protective coating at least partially covering its top surface and configured to be positioned over the decor. The protective coating may be transparent or translucent. Obviously, a protective coating can be used in combination with a base coat. In the case where the decorative layer is made of a ceramic material, the protective layer is preferably a glaze.

Preferably, the decorative layer has a thickness in the range of 4 to 15 mm, preferably 6 to 12 mm, more preferably more than 7 mm, such as 8 mm or 10 mm. The inventors have found that by adding an intermediate layer, satisfactory fatigue performance can be achieved for a relatively thin decorative layer. In addition, it should be noted that the mentioned preferred thicknesses provide good

- 6 040976 balance between the weight and cost of the material, on the one hand, and mechanical resistance, on the other hand. Generally speaking, more thickness corresponds to more weight, more cost, but also more mechanical resistance. Due to the reinforcing effect provided by the resin penetrating the lower surface of the decorative layer, it is possible to reduce the thickness of the decorative layer itself. In any case, it should also be noted that the stiffness of the decorative layer inhibits the thermal expansion of the support layer, and that this constraining effect increases as the thickness of the decorative layer increases.

It should be noted that the decorative layer may have a density in terms of surface density of at least 10 kg/m ² , preferably 15 kg/m ² , for example more than 19 kg/m ² . The high density of the decorative layer can facilitate the laying of the floor covering and in particular the interlocking of the floor elements in the vertical direction, as will be described in more detail below. Also preferably, the decorative layer has a density, expressed as a basis weight, of less than 35 kg/m ² , preferably less than 30 kg/m ² , for example less than 25 kg/m ² . In fact, an excessively heavy decorative layer can interfere with the maneuverability of the floor element, as well as complicate its packaging and transport.

The decorative layer may be of any shape, such as square, rectangular or hexagonal. In a preferred embodiment, the floor elements are rectangular and oblong in shape and preferably have a wood grain pattern showing lines of wood fibers extending throughout the longitudinal direction of the rectangular decorative layer. The cover may also be of any size, although it is preferred that it has a surface area of less than 1.5 m ² , preferably less than 1 m ² , more preferably less than 0.4 m ² .

According to a preferred aspect of the invention, the intermediate layer comprises a resin, such as a thermoset resin or a thermoplastic resin. Examples of thermosetting resin are epoxy, polyurethane, cyanoacrylate or acrylic resin. Examples of the thermoplastic resin are hot melt adhesive, thermoplastic polyester, vinyl, and so on. Preferably the resin is a rigid resin. In fact, the inventors have found that a rigid resin, as opposed to an elastic resin, improves the transfer of impact energy between layers. In particular, according to a preferred embodiment of the invention, the intermediate layer comprises an epoxy resin. It is also preferred that the epoxy resin is a two-component resin, i.e. a thermoset resin obtained by curing at low temperature (for example, at room temperature) a mixture of two components, namely resin and hardener. When the two resin components are mixed with each other, the curing reaction starts, so there is no need to activate the curing by external energy such as heat, UV or electron beam radiation. Said external energy may optionally be provided to speed up the curing process. According to a preferred aspect of the invention, the resin has a viscosity at 20°C of less than 1000 Pa-s, preferably less than 800 Pa-s, more preferably less than 600 Pa-s, for example about 400 Pa-s. Within the scope of the invention, viscosity means the viscosity of the uncured resin, for example the viscosity of a mixture of two components before curing, i.e. during the so-called pot life. In fact, the inventors have found that if the resin is fluid enough during application to the back of the decorative layer, it can penetrate into its pores, greatly improving the bonding of the intermediate layer to the decorative layer. In practice, when the resin penetrates the pores of the decorative layer, it essentially forms a polymer-ceramic composite layer, which significantly improves the impact resistance of the floor element. It should be noted that, according to the preferred solution, the resin is essentially in a liquid state during the manufacturing process of the floor element. In any case, the possibility of the resin being in a pasty or gel-like state during the manufacturing process, such as a resin exhibiting thixotropic behavior to achieve sufficient fluidity to penetrate into the pores of the decorative layer under given manufacturing process conditions, such as during the pressing step, is not ruled out. In accordance with an embodiment of the invention, the intermediate layer may contain two or more different resins. For example, the intermediate layer may comprise a first resin to impregnate the pores of the decorative layer and a second resin to bond the decorative layer to the backing layer. According to the above embodiment, the first resin may be a hard resin for reinforcing the decorative layer, and the second resin may be, for example, a soft or elastomer resin which provides a cushioning effect upon impact.

The inventors have also found that the resin can preferably be free of fillers such as mineral fillers. In fact, the inventors have found that the presence of fillers, on the one hand, improves the mechanical properties of the resin itself, and on the other hand, increases the viscosity of the resin, thus creating an obstacle to penetration into the decorative layer.

The resin preferably has a tensile strength in the range of 50

- 7 040976 up to 90 MPa, more preferably from 60 to 80 MPa, for example 75 MPa. It should be noted that the resin preferably has a compressive strength in the range of 90 to 130 MPa, more preferably 100 to 120 MPa, such as 110 MPa. The inventors have found that this strength is sufficient to provide a rigid matrix for the polymer-ceramic composite layer to dissipate energy upon impact. It should also be noted that the resin may preferably have a hardness value of at least 50, measured on the D scale of Shore hardness.

Preferably, the resin covers at least part of the lower surface of the decorative layer, for example most of, ie. at least 50% of the bottom surface of said decorative layer. More preferably, the resin covers 80% or more of the lower surface of the decorative layer, for example, it covers 100% of the lower surface of the decorative layer, to provide the effect of distributing and dissipating energy upon impact occurring at any point of the decorative layer.

The resin is preferably applied to the lower surface of the decorative layer in an amount of more than 150 g/m ² , more preferably more than 200 g/m ² , for example 220 g/m ² , so that the amount of resin is sufficient to completely penetrate into the open pores of the lower surface of the decorative layer. layer.

It is also preferred that the resin is applied in an amount sufficient to overflow from the exposed porosity of the decorative layer in order to act as an adhesive for the support layer. In other words, it is preferable that the resin partially penetrates the open porosity of the decorative layer and partially covers its lower surface to form an intermediate layer and improve energy transfer. Said energy transfer effect is further improved if the support layer is directly bonded to the intermediate layer and in particular to said resin part which covers the lower surface of the decorative layer so that the intermediate layer acts as an adhesive layer which bonds the decorative layer to the support layer.

In addition, the intermediate layer may have a reinforcing element. The reinforcing element may be embedded in the intermediate layer, for example embedded in the polymeric material, or the reinforcement layer may be a reinforcement layer located between the intermediate layer and the support layer. The reinforcing element may comprise fibers such as glass fibers, carbon fibers, polymeric fibers such as aramid or polyamide fibers, or ceramic fibers such as boron or silicate fibers. The fibers may be woven or non-woven fibers, for example in various orientations, and may be in the form of a mat, fleece or fabric. Said reinforcing element can be used to further improve the impact strength of the floor elements, especially in the case of special or specific installations such as raised floors.

According to an alternative embodiment, the reinforcement may have a metal plate, such as a steel or aluminum plate. Preferably, the metal plate is capable of creating a compressed state in the decorative layer. Since the decorative layer is in a compressed state, the impact resistance is greatly improved because the compression inhibits the propagation of cracks and helps hide visible surface cracks. To achieve this, the metal plates are first stretched, for example by mechanical or thermal stretching, and then bonded to the decorative layer while the metal plate is in the stretched state. The stretch is then released by interrupting the mechanical stretch or by cooling the metal plate itself, thereby creating a compressed state in the decorative layer. For example, in an embodiment, the metal plate has a coefficient of thermal expansion greater than that of the decorative layer. With this solution, the reinforcing element is heated to the stretched state and then bonded to the decorative layer while it is still in the stretched state, and then cooled to return to its original state and bring the decorative layer into a compressed state.

According to a preferred embodiment of the invention, the support layer is made of a material which is different from that of the decorative layer. In particular, the support layer is preferably made of a material capable of providing connecting elements and/or made of a waterproof material and/or made of a compressible material.

The support layer is preferably made of a polymeric material. Polymeric materials have good mechanical properties in combination with relatively low cost and low weight, and in addition they provide an impermeable and sound-absorbing backing layer. It should be noted that the expression "preferably made of a polymeric material" does not necessarily mean that the support layer is made exclusively of a polymeric material. In particular, it is not excluded that the support layer may contain fillers such as fibres, threads, whiskers or particles made of polymeric or non-polymeric material. In addition, this does not necessarily mean that the polymeric material is the majority of the material in the support layer, for example more than 50

- 8 040976 wt%. In any case, said expression generally means that the polymeric material is a matrix surrounded by and bound to said filler.

Preferably, the support layer is made from a thermoplastic polymeric material. Preferably, examples of the thermoplastic material are polyvinyl chloride (PVC), polypropylene (PP) or polyurethane, in particular thermoplastic polyurethane. Preferably, said thermoplastic polymeric material has a glass transition temperature (Tg) of less than 100°C. Forming the support layer from a material with a relatively low glass transition temperature results in a support layer that compresses easily at room temperature. Compression is desirable in many ways. For example, the possible thermal expansion of the support layer can be partially or completely suppressed by a more rigid or inelastic decorative layer and/or a reinforcement element that holds the support layer material in its original size. Compression is also of interest to the design of the connectors and allows for some adaptation to subfloor irregularities, which in turn prevents air pockets from forming between the base layer and the subfloor, which can amplify walking noises.

Among thermoplastic materials, PVC is the preferred choice for the backing layer due to the balance between processability, physical, mechanical properties and cost. In addition, the inventors have found that PVC shows good affinity with resin, in particular epoxy resins, so that it is possible to form a very good bond and interface between the support layer and the intermediate layer. This interface improves the transfer of impact energy between the layers of the floor element, thereby improving its impact resistance. In addition, the inventors have found that due to the interaction of PVC and resin, in particular epoxy resin, it is possible to reduce or eliminate the effect of delamination between the support layer and the intermediate layer, which leads to an increase in the fatigue strength of the floor element. In fact, since said good interaction prevents delamination between the decorative layer and the support layer, the mechanical properties of the floor member do not substantially change even after long-term use, thus showing good fatigue strength.

In a preferred embodiment, the support layer is made of either rigid or flexible PVC, wherein the rigid PVC contains less than 15 parts by weight of plasticizer and the flexible PVC contains 15 parts by weight of plasticizer. or more, preferably more than 20 or more than 25 wt.h. In the context of the present description, rigid means that the support layer, taken alone, flexes under its own weight by less than 10 cm per 1 m, and even better less than 5 cm per 1 m, while elastic means that the support layer, taken separately , bends under its own weight by more than 10 cm per 1 m. The support layer may also contain fillers such as mineral particles such as chalk or calcium carbonate. Said fillers may be present in the support layer in a relatively large amount, for example in an amount of more than 30% by weight or more than 60% by weight of such fillers. The fillers add weight to the support layer and make the support layer very effective in dampening the transmission of walking sounds to the spaces below. Rigid PVC containing fillers is also known as Rigid Polymer Composite (HRC). In any case, the amount of filler should preferably be limited to 70% by weight, for example to less than 50% by weight, in order not to unduly increase the brittleness of the support layer. Rigid PVC provides a backing layer that has good dimensional stability with temperature changes. In other words, the expansion of the support layer at high temperature is thus limited, which ensures good stability of the floor. Preferably, the rigid PVC has a thermal expansion coefficient of less than 85 µm/m/°C, preferably less than 60 µm/m/°C, eg 50 µm/m/°C. For example, the coefficient of thermal expansion of the support layer, especially when made of rigid PVC, is in the range of 20 to 85 µm/m per °C, preferably 40 to 60 µm/m per °C. The support layer made of flexible PVC has less dimensional stability, but it compresses more easily and therefore its tendency to expand is suppressed at least to some extent by the decorative layer and/or the intermediate layer.

The inventors have found that the best results in terms of impact strength are achieved with a support layer made from a rigid polymeric material, preferably PVC. Therefore, according to a preferred embodiment, the support layer is made of a rigid polymeric material, preferably PVC, which may have a flexural modulus ranging from 1.5 to 3.5 GPa, for example about 2.6 GPa. The support layer may also have a flexural strength ranging from 60 to 90 MPa, for example about 76 MPa. In addition, the support layer may have a compressive strength ranging from 40 to 70 MPa, for example about 56 MPa. In fact, the inventors have found that the stiffness of the support layer helps absorb energy on impact, thereby improving impact strength.

In accordance with other embodiments, the support layer, made of flexible PVC or some other material, thermoplastic or not, can be configured to compensate for changes in size due to temperature. For example, the reference layer could be you

- 9 040976 is made up of a plurality of individual elements, such as strips, or may contain grooves separating adjacent parts of the support layer, thereby allowing the expansion of said parts without affecting the overall stability of the floor. Said grooves are preferably open towards the lower surface of the support layer.

In addition, the support layer preferably has a thickness in the range of 2 to 7 mm, preferably less than 6 mm, more preferably about 4 mm or less. The thinner support layer provides limited costs and higher thermal stability, in particular because the thermal expansion of the thinner support layer can be more effectively suppressed by the rigidity of the support layer. For example, a preferred embodiment of the invention provides a support layer made of rigid PVC and having a thickness of 4 mm, thus providing a good solution in terms of thermal stability, noise reduction, low weight and low cost. As also stated above, the inventors have found that the stiffness of the decorative layer helps to suppress thermal expansion of the support layer, and that the stiffness of said layers depends on their thickness. Therefore, according to a preferred embodiment, the decorative layer has a thickness that is equal to or greater than the thickness of the support layer, preferably the thickness of the decorative layer is at least equal to, preferably 1.5 times greater, more preferably 2 times the thickness of the support layer. .

The thickness of the floor element is less than 20 mm, preferably 18 mm or less, more preferably 13 mm or less. In this way, the thickness of the resulting floor element is relatively small, so that the environmental impact of the floor is reduced, in particular in the case of restoration of an existing floor covering. In this way, the surface load of the floor element is limited, so that packing, transport and installation are simplified. For example, the surface load of the floor element is at least 18 kg/m ² , preferably at least 21 kg/m ² . For example, in a preferred embodiment in which the decorative layer is made of porcelain and has a thickness of 8.5 mm, and in which the support layer is made of PVC and has a thickness of 4 mm, the surface load of the floor element is about 24 kg/m ² . As a result, a good balance has been struck between cost-effective transport and packaging and ease of installation. In fact, a weight in excess of the above limits may assist in the bonding of the two flooring elements, in particular by improving their mutual vertical interlocking.

According to a preferred embodiment of the invention, the floor element comprises a ceramic decorative layer, preferably made of porcelain or red clay ceramic, a support layer made of rigid PVC, and an intermediate layer containing resin penetrating the bottom surface of the decorative layer. Preferably, the ceramic decorative layer has a thickness in the range of 6 to 12 mm, more preferably 8 mm. Preferably, the support layer has a thickness of less than 6 mm, more preferably 4 mm. This embodiment provides a floor element having a particularly effective thermal stability, so that the floor covering is not affected by changes in room temperature. Furthermore, this effect is achieved by a floor element having a thickness of less than 13 mm. This value is a relatively small value, and this provides advantages in terms of packaging, cost and maneuverability.

As mentioned above, the support layer contains edges with connecting elements made with the possibility of mechanical connection with the connecting elements of an adjacent flooring element. A mechanical connection is to be understood as a connection which allows adjacent flooring elements to be connected to each other without the need for an adhesive or the like. The mechanical connection can be realized by means of profiled edges containing connecting elements, usually a male and a female part, which insert one into the other. It should be noted that preferably the connecting elements are configured in such a way that said mechanical connection leads to mutual blocking of said edges in the vertical direction and/or one or more horizontal directions.

The connecting elements preferably comprise at least a male part and at least a female part, such a male part and a female part in the connected state of two such floor elements engaging with each other. The male part and the female part are preferably at least partially formed in the support layer. For example, the male portion and/or the female portion may be entirely formed in said support layer. Said male part and female part in the connected state of two identical floor elements are engaged with each other to create a mechanical connection of the respective edges, preferably leading to mutual blocking of said edges in the vertical direction and in one or more horizontal directions, or resulting in mutual blocking in the vertical direction or in one or more horizontal directions

- 10 040976 n.

As used in this document, the terms horizontal and vertical generally refer to flooring laid on a surface that is considered horizontal in its general meaning. Thus, when used in relation to a single floor element that is a substantially flat element having a base plane, the terms horizontal and vertical should be considered as terms respectively equivalent to the terms parallel to the base plane of the floor element/laid floor elements and perpendicular to the main plane of the floor element / the laid floor elements.

In addition, in the connected state of the two said adjacent floor elements, the connecting elements interact and preferably form blocking surfaces that limit the mutual movement of said floor elements in the vertical and/or in one or more horizontal directions. Preferably, in the connected state of two adjacent floor elements, first blocking surfaces are formed, which limit the mutual movement of said floor elements in a direction perpendicular to the connected edges and in a substantially horizontal plane. In addition, in said connected state, second blocking surfaces are formed to limit the mutual movement of said floor elements in a substantially vertical direction. Thanks to this solution, the floor elements can be easily installed without the risk of impermissible height differences between adjacent floor elements. In addition, the floor elements are firmly bonded to each other to improve the fatigue performance of the floor covering. In addition, by limiting the relative movement of the floor element, it is possible to reduce the walking noise, i. e. reduce the noise that occurs with each step.

In accordance with a preferred embodiment of the invention, the male part and the female part can be located essentially along the entire length of the respective edge, for example, essentially defining the edge. For example, according to this embodiment, the male and female portions may generally be formed as a tongue and groove that substantially extend along the entire length of the respective mutually opposed edges. Preferably, the male part is located on the first edge of the floor element, and at least the female part is located on the second opposite edge of the floor element.

Alternatively, the male part and the female part may extend for a limited length of the respective edge, such limited length being less than the entire length of the corresponding edge itself, preferably less than half the length of the corresponding edge. According to this possibility, the edges preferably comprise areas free from said male part and said female part. The geometries of the parts to be joined in accordance with this alternative embodiment include an interacting male and female that are dovetail-shaped in plan view, or a male and female that look like jigsaw puzzle pieces in plan view.

In some embodiments, the implementation of the connecting elements are configured to create a state of prestressing between the connecting elements in their connected state. In other words, the connecting elements are configured to create an elastic deformation in the connected state, thereby causing a reaction against each other. Thanks to this solution, the connection between the floor elements is strengthened, and the connection itself contributes to the waterproofing of the floor covering.

In accordance with a preferred embodiment of the invention, the connecting elements are designed in such a way that, in the connected state, the connection is free from pretension, so that the connection process is simplified and less effort is required for the operator. That is, in the connected state, the connecting elements are in an undeformed state. In addition, the connecting movement of the connecting element, i. e. the relative movement between the connecting elements, which provides a mechanical connection, occurs without deformation of the connecting elements. For example, in some embodiments, in the connected state, play is provided between the connecting elements to allow slight movement between the connecting elements in the vertical and/or horizontal direction. For example, the size of the male part on a plane orthogonal to the corresponding edge is equal to or slightly smaller than the size of the female part on the same plane.

The connecting elements are made with the possibility of connection by moving one floor element relative to another adjacent floor element. Such movement may be translational movement downwards, for example in a vertical direction, translational movement in a horizontal direction, for example perpendicular to the edges, or angular movement about a horizontal axis parallel to the edges. Obviously, a corresponding movement preferably results in the aforementioned male part and the female parts of adjacent floor elements engaging with each other.

- 11 040976

To this end, the connecting elements can be designed according to several different possibilities, two of which are briefly described below.

According to the first possibility, said connecting elements are designed to be connected to each other by means of an angular movement around a horizontal axis parallel to the edges. According to this first possibility, it is also preferable that the connecting elements are operable to be connected by translational movement in a horizontal direction, for example perpendicular to the edge. According to the first possibility, the male part and the female part are respectively made in the form of a tongue and a groove, the tongue protruding outwardly beyond its respective edge in the horizontal direction and the groove protruding inward relative to the corresponding edge in the horizontal direction. As noted above, the tongue and groove are configured such that, in the connected state of said tongue and groove, first and second blocking surfaces are formed to limit relative movements of the floor element in the vertical and horizontal directions, said horizontal direction being perpendicular to the edge. In accordance with a preferred embodiment, the tongue comprises a horizontally extending lip extending in the horizontal direction and a protrusion protruding downwards. As a consequence, in this embodiment, the groove has a horizontal recess for receiving the tongue jaw, and an upwardly oriented hollow portion for receiving the tongue protrusion to accommodate the tongue in the groove. Also preferably, in the connected state, the tongue is placed in the groove in such a way that a non-working space is formed between the tip of the tongue, in particular its jaw, and the lower part of the groove, in particular its recess. Also preferably, in the connected state, the tongue is placed in the groove in such a way that a vertical non-working space is formed between the lower surface of the tongue, in particular its jaw, and the groove, in particular its recess. Thanks to this solution, the tongue has a narrower jaw than the groove, so that the angular movement for connecting the floor elements is definitely improved. Also preferably, in the connected state, the downward protrusion of the tongue comes into contact with the hollow part of the groove, and the upper surface of the tongue comes into contact with the groove. In particular, preferably the lower surface of the tongue comes into contact with the groove only in accordance with the protrusion. As a result, said second contact surfaces are provided, and at the same time, the connection by means of angular movement is simplified due to the lower contact surface, which is formed only in correspondence with the protrusion of the tongue, and not in accordance with its jaw. In other words, the sponge has more space inside the tongue to perform angular movement.

In addition, in accordance with a preferred embodiment of this first possibility, in the connected state, the tongue and the groove form a play. Said play allows small movements in the vertical and/or horizontal direction, preferably in the horizontal direction. The play is such that the tongue and groove can be connected to each other without deformation.

As a result, the operator's efforts to lay the floor elements are significantly reduced, and this is especially important, since the weight of the decorative layer, on the one hand, complicates the laying operations, and on the other hand, contributes to the mutual blocking of the floor elements. Therefore, a slight loosening of the connection due to play is allowed, which contributes to ease of laying. Preferably said play is more than 0.01 mm, preferably more than 0.03 mm. Moreover, said play is preferably less than 0.10 mm, for example less than 0.08 mm.

In accordance with the second possibility, said connecting elements are made with the possibility of connection by translational movement in a downward direction, for example, in a vertical direction. According to this second possibility, the connecting elements comprise an upwardly directed lower hook part which is located on one edge and also a downwardly directed upper hook part which is located on the opposite edge. The lower hook portion defines an upwardly directed cavity forming the female portion, while the upper hook portion defines a downwardly directed lip forming the male portion. While in the connected state, the downwardly directed jaw and the upwardly directed cavity form a first blocking surface for limiting mutual movement in a horizontal direction, for example perpendicular to the edge. Preferably, the upper hook part and the lower hook part, more preferably the lip and the cavity respectively, are configured to form, in the connected state, a second blocking surface to limit mutual movement of the floor elements in the vertical direction. In particular, the upper hook portion and the lower hook portion are configured to form two sets of said second blocking surfaces, for example, on opposite male portions and female portions. Preferably, both the upper hook portion and the lower hook portion comprise notched portions to form, in the connected state, a first and/or second interlocking surface for limiting mutual floor movement.

- 12 040976th element. In addition, the connecting elements in accordance with the mentioned second possibility are made with the possibility of deformation during the connecting movement. Preferably, the lower hook part comprises a flexible shoulder part deformable by being connected to the upper hook part of the lower hook part, so that by said deformation the notched parts are connected.

It should be noted that the floor element may contain the same connecting elements, i.e. elements according to the first or second possibility, on all their edges. According to a preferred embodiment of the invention, the floor element may comprise connecting elements having different shapes or different sizes at different edges. For example, the floor element may comprise connectors according to a first possibility on a first pair of opposite edges, such as in the case of a rectangular floor element, on long edges, and connectors according to a second possibility on a second feather of opposite edges, such as on short edges. In other words, the rectangular floor element may include connectors that can be connected by angular movement on long edges, and the connectors can be connected by translational movement in a downward direction at short edges. Thanks to this solution, the connection of floor elements is greatly simplified.

In fact, thanks to the angular movement, for example, provided by the tongue and groove, it is easy to align the long edges of the floor element, thereby simplifying positioning and ensuring a strong connection of long edges in both the vertical and horizontal direction, while short edges can be easily joined by translational movement downwards, as a direct consequence of joining the long edges. This is particularly advantageous in the case of heavy decorative layers, in fact, when connecting the connecting elements according to the first possibility, for example the tongue and the groove on the long sides, it is sufficient to let the floor element lie in a horizontal position in order to mechanically connect the connecting elements according to the second possibility. , for example on short edges, without the need to hammer or hit the floor element itself. This also occurs in the case where the connecting elements according to the second possibility deform during connection, since the weight of the decorative layer may be sufficient to cause said deformation.

Preferably, the support layer has a shape substantially corresponding to the decorative layer, but preferably with one or more portions extending beyond the decorative layer. The support layer may also include one or more recesses extending under the decorative layer. The support layer is preferably a coherent element, with the support layer preferably covering the majority, ie. at least 50% of the bottom surface of said decorative layer. For example, the support layer covers 80% or more of the lower surface of the decorative layer. More preferably, the support layer completely covers at least the bottom surface of the decorative layer (ie covers 100% of the bottom surface), and in some embodiments may extend beyond the bottom surface of the decorative layer. Also, the decorative layer may at least partially cover the upper surface of the support layer, preferably the majority of it, for example more than 50%, preferably more than 80%, for example 90% or more. According to one embodiment, the support layer comprises a plurality of separate adjacent support layer portions, in which case said plurality of support layer portions preferably covers at least 50% of the bottom surface, or even 80% or more.

Preferably, the support layer is attached to the decorative layer in such a way that it extends beyond at least one edge of the decorative layer, for example at least two edges of the decorative layer, preferably consecutive edges of the decorative layer, more preferably beyond all edges of the decorative layer. In particular, in accordance with a preferred embodiment, the decorative layer is placed on the support layer in such a way that it is aligned centrally with the upper surface of the support layer, for example, each upper edge of the support layer extends the same distance from the edge of the decorative layer. It is also not excluded that the decorative layer is placed on the support layer in an offset state relative to the upper surface of the support layer, so that the predetermined distance between the upper edge of the support layer and the edge of the decorative layer varies from edge to edge of the decorative layer. Said predetermined distance is at least 0.5 mm, more preferably 0.75 mm, such as 1 mm or 1.5 mm.

The floor element may be of any size, although it is preferred that it has a surface area of less than 1.5 m ² , preferably less than 1 m ² , more preferably less than 0.4 m ² . For example, the floor element, and in particular the decorative layer, comprises an edge having a maximum length of less than 1.5 m, preferably less than 0.9 m.

- 13 040976 for depressions or bulges that can affect the laying of the floor covering, the impact resistance and also the fatigue strength of the floor element. For floor elements with a reduced area, the influence of said irregularities, as well as the likelihood of said irregularities occurring, is reduced. In addition, the decorative layer, especially when made of ceramic material, can be slightly curved, so that the same issues can arise due to irregularities in the subfloor. The larger the side of the decorative layer, the greater said bending, so that it is preferable that the floor element and the decorative layer have a reduced surface area.

In accordance with a preferred embodiment of the invention, in the connected state of the two said floor elements, it is preferable to provide an intermediate distance between the respective upper edges of adjacent floor elements. Preferably, the decorative layer is placed on the support layer in such a way that when the floor elements are in the connected state, there is said intermediate distance between the edges of adjacent decorative layers, while the edges of the underlying support layer are connected to each other by means of the connecting elements present. Thanks to this solution, slight changes in the dimensions of the decorative layer of adjacent tiles can be tolerated. In the case where the decorative layer is formed from one or more ceramic tiles, both rectified and non-rectified tiles can be selected, with non-rectified tiles being preferred as they are less expensive than rectified tiles. Even if rectified tiles are chosen, an intermediate spacing of at least 1.5 mm, such as about 3 mm or more, is preferred in the case of non-rectified tiles. In general, with fragile decorative layers, it is best to prevent direct contact between the edges of the decorative layer of adjacent floor elements in order to minimize the risk of breaking off parts of the edges when laying or using the floor covering. Avoiding direct contact between the edges of the decorative layers also prevents squeaks from walking on the floor. In addition, some decorative layers and/or support layers may expand and contract due to temperature changes. The existing intermediate distance prevents expansion and contraction from affecting the stability of the floor. For example, the predetermined distance between the edges of the decorative layer and the upper edge of the supporting layers is the same on all edges of the decorative layer and is preferably half the intermediate distance between the respective upper edges of adjacent floor elements in the connected state. This solution is particularly advantageous in the case of non-rectified tiles because it facilitates the positioning of tiles of the same size, which may have slightly different dimensions on the support layers.

An intermediate distance or gap between decorative layers of adjacent flooring elements can be finished in several possible ways.

According to a first possibility, said intermediate distance between the floor elements can be filled with grout, thus providing an impervious floor covering. Preferably, a polymeric grout and/or a cement-based grout is used. The grout can be elastic or hard grout. A flexible grout may, for example, be a silicone-based grout, while a hard grout may be, for example, an epoxy-based grout or a cement-based grout. Epoxy grout and silicone grout are examples of polymer grout, other examples of polymer grout are polyurethane grout or acrylic grout.

According to a second possibility, the decorative layer can be at least partially, preferably completely, surrounded by a gasket, so that in the connected state of two adjacent floor elements, said gasket is compressed under the influence of the decorative layer of the adjacent floor element to create a substantially watertight connection of the floor elements. .

It should be noted that the characteristic that the floor element comprises an intermediate layer having a polymeric material that penetrates the lower surface of the decorative layer constitutes the inventive idea, irrespective of the presence of a support layer, and in particular a support layer containing edges with connecting elements made with the possibility of mechanical connection with the connecting elements of the adjacent element of the floor covering. Therefore, the present invention, according to a second independent aspect, relates to a floor element for forming a floor covering, the floor element comprising a first decorative layer made of a ceramic material and a second layer located under this decorative layer, the second layer comprising a polymeric material, which penetrates the lower surface of the decorative layer. According to this second independent aspect of the invention, the floor element may optionally comprise a third support layer located below the second layer. In addition, optionally, the third support layer may comprise one or more of the additional support layers described above with respect to the first independent aspect. Obviously, the decorative layer and the intermediate layer may also contain one or more

- 14 040976 features described above with respect to the first independent aspect.

As an example, the floor element according to said second independent aspect can be laid on the subfloor by means of a pressure-sensitive adhesive layer of a fast-adhesive looped fabric (eg Velcro® fabric). The floor element, for example, may comprise a pressure-sensitive adhesive layer located under a second layer, for example a two-adhesive layer, covered with a cover sheet, which must be removed before laying the floor element on the subfloor. Alternatively, the floor element can also be laid on a pressure-sensitive adhesive substrate. As a further example, a floor element according to said second independent aspect may be laid on a subfloor by means of a layer of fast adhesive looped fabric (eg Velcro® fabric). In this case, the floor element may comprise a third support layer comprising a fabric in the form of a Velcro fastener adapted to adhere to the subfloor substrate. In addition, for example, the floor element according to said second independent aspect can be laid on the subfloor by magnetic means. In this case, the floor element may comprise a third support layer containing a magnetic and/or ferromagnetic material suitable for interacting with a magnetic and/or ferromagnetic subfloor.

It should be noted that the fact that a polymeric material can be used to form a floor covering containing a decorative layer, for example, made of ceramic material, and the polymeric material penetrates the lower surface of the decorative layer, constitutes the inventive idea, regardless of the additional features of the floor element. such as, for example, the nature of the decorative layer and the presence of the support layer. Therefore, according to a third independent aspect, the invention relates to the use of a polymeric material for bonding a decorative layer made of ceramic material to a support layer to form a floor element. In this case, the polymeric material may have one or more of the features of the support layer described above with respect to the first independent aspect. In addition, the decorative layer and the support layer may have one or more of the features described above with respect to the first independent aspect.

According to a fourth independent aspect of the invention, there is provided a floor covering comprising a plurality of adjacent floor elements, each floor element comprising a decorative layer of ceramic material and a support layer located under the decorative layer, the floor covering comprising a combination of the following features: at least one floor element contains an intermediate layer having a polymeric material that penetrates the lower surface of the decorative layer; floor elements contain connecting elements, made with the possibility of connection with the connecting elements of adjacent floor elements; the floor covering contains a grout that fills the intermediate distance separating the decorative layers of the floor elements. Preferably, the floor elements are separated from the lower surface, for example from the subfloor, i. e. they are not bonded to the bottom surface by adhesive or mechanical means. This solution offers a floor covering consisting of floor elements installed without the use of adhesives, which exhibits a high satisfactory impact and fatigue resistance and is completely impermeable. Through the second aspect, the inventors eventually came up with a solution to a long overdue need in the art for ceramic flooring. They offered an easy-to-install ceramic tile floor with good impact resistance and water resistance. The floor elements of the first aspect and preferred embodiments thereof can be used to form a floor covering in accordance with the present third aspect.

In accordance with a preferred embodiment of the invention, the floor covering comprises an underlay layer located under the floor elements, which is configured to act as a moisture barrier. Thanks to this solution, it is possible to prevent the formation of mold under the floor elements. In combination with or as an alternative to such a solution, the underlayment can be configured to act as a noise barrier, thereby reducing floor footstep noise.

The invention also relates to a method for manufacturing a floor element, such as the floor element of the present invention. Therefore, according to a fifth independent aspect of the invention, there is provided a method for manufacturing a floor element comprising the steps of providing a decorative layer made of a ceramic material; providing a support layer; providing a polymeric material for bonding the decorative layer to the support layer; joint pressing of the layers to form a floor element with penetration of the polymeric material into the ceramic layer. Thus, a method is provided which enables the production of floor elements to be laid on a subfloor without the use of an adhesive or binder and which exhibits the required impact and fatigue resistance. In addition, I will mention

- 15 040976 This method provides a simple and efficient production of high resistance floor elements. In fact, since it is not necessary to use a rigid reinforcing element, the method contains a reduced number of steps so that it is a relatively fast method and can be carried out using relatively simple equipment. Obviously, the resulting floor element preferably exhibits the characteristic features of the floor elements of the invention described above.

The step of providing the decorative layer may include the step of brushing and/or roughening the bottom surface of the decorative layer. Said brushing and/or roughening step aims to prepare the lower surface of the decorative layer for penetration of the resin material. For example, in the case where the decorative layer is made of a ceramic material, said brushing and/or roughening step aims to remove the underlying coating and/or structure of the lower surface of the decorative layer. Thus, any decorative layer can be used to make a floor element without having to make a specific decorative layer for the floor element, for example without having to make ceramic tiles without undercoating and without structure on the bottom surface.

As already described, the support layer may contain edges with connecting elements. Therefore, according to a preferred embodiment of the invention, the step of providing a support layer may comprise the step of providing a support layer comprising edges in which connecting elements are provided, i.e. the connecting elements are provided in the support layer during a separate process. Alternatively, the method for manufacturing the floor element may comprise the step of providing connecting elements at the edges of the support layer. Said step of providing the connecting elements may comprise milling, molding or other methods. In addition, said step of providing the connectors may be performed either before or after the step of placing the decorative layer over the support layer, for example either before said step of providing the resin or after said step of pressing.

The step of providing the resin comprises the step of applying the uncured resin to at least the surface of the decorative layer and/or the support layer. The polymeric material may be applied by rolling, spraying, pouring or other methods. In accordance with one embodiment of the invention, the polymeric material is applied to the upper surface of the support layer. According to an alternative embodiment, the resin material is applied during multiple intermediate steps, for example a first amount of resin is applied to the top surface of the support layer in a first intermediate step and a second amount of resin is applied to the bottom surface of the decorative layer in a second intermediate step. This solution is particularly advantageous for the production of floor elements in which the intermediate layer contains a reinforcing element, such as fibre. In fact, more resin may be required in this case, and multiple resin delivery steps may be ideal to ensure proper bonding of the layers, embedding of the reinforcement, and permeability of the decorative layer.

The step of providing the resin may include the step of mixing its components in case the resin is a two-component resin, such as a two-component epoxy resin. Said mixing step may be carried out at the time, i.e. simultaneously with the step of applying the uncured resin, or shortly before the step of applying the uncured resin. In fact, the curing of a resin is often activated by mixing its components, whereby the viscosity of the resin increases. Thus, it is preferable to delay the start of the curing reaction as long as possible in order to facilitate the distribution of the resin on the surfaces of the layers and improve the permeability of the decorative layer. For example, in accordance with a preferred embodiment of the invention, the resin is applied by spraying, and the components are mixed, for example, during spraying, essentially in accordance with the nozzle of the spray equipment.

Preferably, during the pressing step, the layers are subjected to a pressure of at least 350 kg/m ² , more preferably at least 370 kg/m ² . The mentioned values have been found to be optimal to ensure the penetration of the resin into the decorative layer. In addition, these values have been found to be optimal to ensure 100% resin coverage of the bottom surface of the decorative layer, since in some embodiments the resin is applied according to the pattern and then distributed during said pressing step. Moreover, the inventors found that by maintaining the pressure for a long pressing time, it is possible to improve the permeability of the decorative layer, for example, it is possible to achieve a greater penetration depth. Therefore, according to a preferred aspect of the invention, during the pressing step, the pressure is maintained for a pressing time of more than 1 s, preferably more than 10 s, for example 30 s. This pressing time has been found to be optimal to ensure satisfactory resin coverage of the bottom surface of the decorative layer, preferably 100% coverage of said bottom surface, when the resin is applied according to the pattern. Moreover, especially in the case of a resin based on epoxy

- 16 040976 resin, said pressing time is sufficient to cover until the resin begins to cure, so that the decorative layer and the support layer at least partially adhere to each other and slide between them during transport of the floor elements after pressing is prevented.

It should be noted that while 100% resin coverage of said bottom surface of the decorative layer is a desirable achievement, it may also be important to prevent or minimize resin overflow beyond the edges of the decorative layer itself, more preferably to prevent or minimize resin overflow. for connecting elements. In fact, in the event that resin is spilled onto the connection element, the connection between the floor elements can be adversely affected. Several steps can be taken to prevent this unwanted transfusion. According to a preferred measure, the decorative layer and/or the support layer may comprise one or more grooves respectively open on the bottom surface or on the top surface, configured to collect a portion of the resin. If said grooves are provided on the decorative layer, they are made directly close to the very edge of the decorative layer. In case said grooves are provided on the decorative layer, they are provided in the part of the upper surface intended to be covered with the decorative layer, for example near the edges of the decorative layer, when the decorative layer is placed on the support layer. In this case, it is preferable that the grooves are parallel to said edges of the decorative layer. Alternatively or additionally, this may be implemented in the portion of the top surface that extends beyond the edges of the decorative layer. In any case, it is preferred that the grooves are parallel to said edges of the decorative layer. Preferably, said grooves extend continuously along said edges.

The pressing step may be performed by any suitable method for applying pressure to the decorative layer and/or to the support layer to promote resin penetration into the decorative layer. Therefore, according to an embodiment of the invention, the pressing step may be a static pressing step, in which the layers are fed into the static press mold in order to be subjected to a predetermined pressure by the press punch. Thus, it is possible to maintain the pressure for a given pressing time to improve the permeability of the decorative layer. According to an alternative embodiment, the pressing step may be a laminating step in which the layers are fed into laminating equipment, eg under one laminating roller or web, or between a pair of laminating rollers to be subjected to a predetermined pressure. Because lamination is a continuous process, it is possible to speed up the entire manufacturing process while applying sufficient pressure to the layers to allow penetration into the decorative layer. During lamination, the pressing time depends on the advance speed of the layers, therefore the advance speed can be adjusted in order to speed up the process and at the same time ensure sufficient pressing time.

Preferably, the method comprises the step of storing the floor elements during the storage time to allow at least partial curing of the resin prior to its packaging, shipping and/or use in the floor covering. Preferably, the storage time ensures that the resin is at least 70% cured, preferably 85%, more preferably the resin is fully cured. For example, said storage time is at least 0.5 hour, preferably more than 1 hour, such as 2 hours.

It should also be noted that the characteristic that the floor element may comprise connecting elements according to the first possibility on the first pair of opposite edges, and connecting elements according to the second possibility on the second pair of opposite edges, forms an independent idea of the invention, regardless from other features of the floor element. Therefore, according to a sixth independent aspect, the invention relates to a floor element comprising a decorative layer made of ceramic material and a support layer located under the decorative layer, the support layer comprising at least two pairs of opposite edges, each of which contains connecting elements , made with the possibility of mechanical connection with the connecting elements of adjacent floor elements, and the first connecting elements on the first pair of edges are made with the possibility of connection with the connecting elements of adjacent floor elements by means of angular movement around a horizontal axis parallel to the respective edges, and moreover, the second connecting elements on the second a pair of edges are made with the possibility of connection with the connecting elements of adjacent floor elements by translational movement in the downward direction of the respective edges towards each other. Such a combination of different types of connecting elements is particularly advantageous in the case of heavy decorative layers such as ceramic stones or the like, and in fact, after connecting the first connecting elements, it is sufficient to allow the floor element to lie in a horizontal position in order to effect the mechanical connection of the second connecting elements.

- 17 040976 without having to hammer or hit the floor element itself. This is also the case when the second connecting elements deform during connection, since the weight of the decorative layer may be sufficient to cause such deformation. After connecting the first connecting elements, the user will have the impression of simply dropping the floor elements to complete the connection, since no more effort is needed. It should be noted that the floor elements according to the sixth independent aspect may contain one or more of the features described in relation to the first independent aspect.

It should be noted that within this sixth independent aspect, the preferred embodiment comprises a decorative layer made from ceramic, however, it should be noted that this sixth aspect can advantageously be used with decorative layers made from any kind of relatively heavy material such as natural stone, quartz , artificial stone, concrete, glass or glass-ceramic. It should also be noted that this sixth aspect can advantageously be applied with decorative layers having a basis weight of at least 10 kg/m ² , preferably more than 15 kg/m ² , for example more than 19 kg/m ² , regardless from the material forming the decorative layer.

The inventors have also found that the connection of the floor elements according to the sixth independent aspect is further simplified if, in the connected state, the first connecting elements are connected to form a play, such as a horizontal play. In fact, if, on the one hand, the weight of the decorative layer facilitates the connection of the second connecting elements after the connection of the first connecting elements, on the other hand, this complicates the said connection of the first connecting elements, and, in particular, this complicates the maneuverability of the floor element. Therefore, play contributes to said connection on the first pair of edges. This effect is further enhanced if the play is more than 0.01 mm, preferably more than 0.03 mm. Moreover, said play is preferably less than 0.10 mm, for example less than 0.08 mm. In particular, this effect is further enhanced if the play ensures that the first connecting elements are connected to each other without deformation.

It should also be noted that the idea that the floor element contains a support layer made of rigid PVC to improve the thermal stability of the floor element constitutes an independent idea of the invention, regardless of the presence of other features of the floor element itself, in particular the presence of an intermediate layer penetrating on the underside of the decorative layer. According to a seventh independent aspect, the invention relates to a floor element comprising a decorative layer made of ceramic material and a support layer located under this decorative layer, with the characteristic that said support layer is made of rigid PVC. It should be noted that the floor element according to the seventh independent aspect may comprise one or more of the features described in relation to the first independent aspect.

It should be noted that said resin collection grooves may constitute the inventive concept, irrespective of the presence of other features of the floor element. Therefore, according to an eighth independent aspect, the invention relates to a floor element comprising a decorative layer, a support layer and an intermediate layer located between the decorative layer and the support layer, said intermediate layer containing a resin, with the characteristic that the decorative layer and/or the support layer contains one or more grooves configured to collect a portion of the resin. It should be noted that the floor element according to this eighth independent aspect may comprise one or more of the features described in relation to any aspect of the invention.

In order to better illustrate the features of the invention, several preferred forms of the embodiments are described below, by way of example without any limitation, with reference to the accompanying drawings, in which: FIG. 1 is a plan view of an embodiment of a floor element of the present invention;

in fig. 2 is an enlarged cross-sectional view taken along line II-II in FIG. 1;

in fig. 3 is an enlarged view of the region F3 marked in FIG. 2;

in fig. 4 is an enlarged cross-sectional view taken along line IV-IV in FIG. 1;

in fig. 5 shows a reduced scale plan view of a floor covering containing a plurality of floor elements 1 of FIG. 1;

in fig. 6 is an enlarged cross-sectional view taken along line VI-VI in FIG. 5;

in fig. 7 is an enlarged view of the area F7 marked in FIG. 6;

in fig. 8 is an enlarged cross-sectional view taken along the line VIII-VIII of FIG. 5;

in fig. 9 is an enlarged view of the region F9 marked in FIG. 8;

in fig. 10 shows some of the steps in the manufacturing process for the floor element.

In FIG. 1 shows a plan view of an embodiment of floor element 1 in accordance with Fig.

- 18 040976 shaving. The floor element 1 contains a decorative layer 2 located above the support layer 3.

As shown, the floor element 1 has a rectangular oblong shape. Preferably, the floor element 1 has a surface area of less than 1.5 m ² , preferably less than 1 m ² , more preferably less than 0.4 m ² . For example, the decorative layer 2 has edges having a maximum length L of less than 1.5 m, preferably less than 0.9 m.

The decorative layer 1 has a top surface 4 containing the decor 5. The decor 5 may have a variety of textures, patterns and shades. In the example shown, the decor imitates a wood structure containing veins and stratifications. Preferably, the decor 5 is at least partially formed by the printed image 6. The printed image 6 is preferably made by digital printing, such as ink jet printing, although the use of screen printing, rotogravure printing, flexographic printing or offset printing is not excluded.

In FIG. 2 shows on a larger scale a cross section taken along line II-II in FIG. 1. In accordance with the illustrated example, the decorative layer 2 comprises a body 7 made of a ceramic material, such as red clay or porcelain.

The decorative layer 2 comprises a base coat 8 at least partially covering the upper surface of the body 7, containing, for example, at least glaze. The base coat 8 is adapted to receive the decor 5 on its upper surface, for example adapted to receive the printed image 6 on its upper surface. The base coat 8 may be white, beige, brown or any other color suitable for receiving the decor 7 on its top surface.

The decorative layer 2 further comprises a protective coating 9 at least partially covering the upper surface of the body 7, for example containing at least glaze. The protective coating 9 is designed to be applied over the decor 5 and is a transparent or translucent coating.

In FIG. 2 also shows that the decorative layer 2 has a thickness T1 ranging from 4 to 15 mm, for example 6 mm, preferably more than 7 mm, for example from 8 to 10 mm.

The support layer 3 according to the example is made of a polymeric material, preferably a thermoplastic material like polyvinyl chloride (PVC). In a preferred embodiment, the support layer is made of rigid PVC. In the context of the present description, rigid means that the support layer, taken alone, bends under its own weight by less than 10 cm per 1 m, and even more preferably less than 5 cm per 1 m. The support layer 3 can also contain a large number of fillers, such as calcium carbonate, for example more than 30% by weight or more than 60% by weight of such fillers.

Furthermore, according to a preferred embodiment, the support layer 3 is made of rigid PVC, which may have a flexural modulus ranging from 1.5 to 3.5 GPa, for example about 2.6 GPa. Moreover, the support layer 3 may have a flexural strength ranging from 60 to 90 MPa, for example about 76 MPa. In addition, the support layer 3 may have a compressive strength ranging from 40 to 70 MPa, for example about 56 MPa. Preferably, the support layer 3 has a coefficient of thermal expansion in the range of 20 to 85 µm/m per °C, preferably 40 to 60 µm/m per °C.

In addition, the support layer 3 preferably has a thickness T2 ranging from 2 to 7 mm, preferably less than 6 mm, more preferably about 4 mm or less.

In FIG. 2 also shows that the support layer 3 comprises longitudinal edges 10 in which first connecting elements 11, 12 are provided which are capable of being mechanically connected to the connecting elements 11, 12 of the adjacent floor element 1. In the examples shown, the connecting elements 11, 12 comprise a male and female parts located on opposite longitudinal edges 10.

The first connecting elements 11, 12 of the longitudinal edges 10 are made with the possibility of connecting with each other by means of angular movement around a horizontal axis parallel to the longitudinal edges 10. The male and female parts are respectively made in the form of a tongue 11 and a groove 12, with the tongue 11 extending outwardly beyond its the corresponding longitudinal edge 10 in the horizontal direction X, and the groove 12 extends inward relative to the corresponding longitudinal edge 10 in said horizontal direction.

The support layer 3 extends beyond the longitudinal edges 26 of the decorative layer 2. In the example, the support layer 3 comprises upper longitudinal edges 27 which extend beyond the longitudinal edge 26 of the decorative layer 2 by a distance D1. Said distance D1 is the same on both opposite longitudinal edges 26 of the decorative layer 2.

In FIG. 2 also shows that the floor element 1 comprises an intermediate layer 13 located between the decorative layer 2 and the support layer 3. The intermediate layer 13 comprises a polymeric material such as a thermosetting resin or a thermoplastic resin. Examples of thermosetting resin are epoxy, polyurethane, cyanoacrylate or acrylic resin. Examples of the thermoplastic resin are hot melt adhesive, thermoplastic polyester, vinyl, and so on. Prefer

- 19 040976 The resin is essentially a hard resin. In particular, according to a preferred embodiment of the invention, the intermediate layer comprises an epoxy resin. Also preferably, the epoxy resin is a two-component resin, i.e. a thermosetting resin formed by curing at a low temperature (eg, at room temperature) a mixture of two components, namely a resin and a hardener.

The resin preferably has a tensile strength in the range of 50 to 90 MPa, more preferably 60 to 80 MPa, such as 75 MPa. In addition, the resin preferably has a compressive strength in the range of 90 to 130 MPa, more preferably 100 to 120 MPa, such as 110 MPa. Also preferably, the resin has a hardness value of at least 50, measured on the D scale of Shore hardness.

As shown, the intermediate layer 13 covers 100% of the lower surface of the decorative layer 2. The resin is preferably applied to the lower surface of the decorative layer 2 in an amount of more than 150 g/m ² , more preferably more than 200 g/m ² , for example 220 g/m ² .

In the preferred example shown in FIG. 2, the intermediate layer 13 is in direct contact with the upper surface of the support layer 3 in order to act as an adhesive between the decorative layer 2 and the support layer 3.

In the embodiment of FIG. 2, the support layer 3 comprises grooves 50 configured to collect a portion of the resin of the intermediate layer 13 in case it spills over the edges 26 of the decorative layer 2, to prevent said resin from spilling onto the connecting elements 11, 12. In this embodiment, said groove 50 is provided in part of the support layer 3 extending beyond the edges 26 of the decorative layer 2. In addition, said grooves 50 run continuously and parallel to the edges 26 of the decorative layer 2. of the embodiments, for example, they can also be present in accordance with the short edges of the floor element 1.

In FIG. 3 is an enlarged view of the region F3 marked in FIG. 2. As shown in FIG. 3, the decorative layer 2, more specifically its body 7, has, at least in accordance with its lower surface, an open porosity 14 allowing the resin to penetrate into the decorative layer 2 itself.

Thus, in accordance with a preferred embodiment of the invention, the decorative layer 2 has an apparent porosity in the range of 0.1 to 10%, determined in accordance with ASTM C373, more preferably in the range of 2 to 8%, for example 6%. In addition, the decorative layer may preferably have an open pore volume 14 ranging from 0.01 to 1 cm ³ , more preferably from 0.10 to 0.90 cm ³ , for example 0.60 cm ³ .

Therefore, in order to properly flow into said open pores 14, the resin has a viscosity at 20°C of less than 1000 Pa-s, preferably less than 800 Pa-s, more preferably less than 600 Pa-s, for example about 400 Pa-s. In the scope of the invention, the viscosity means the viscosity of the uncured resin, for example the viscosity of the mixture of the two components before the completion of curing, i.e. during the so-called pot life.

In FIG. 4 is an enlarged cross-sectional view taken along line IV-IV in FIG. 1. In accordance with an embodiment, the support layer 3 comprises transverse edges 15, in which second connecting elements 16, 17 are provided, made with the possibility of mechanical connection with the second connecting elements 16, 17 of the adjacent floor element 1.

In the examples shown, the second connecting elements 16, 17 differ from the first connecting elements 11, 12 of the longitudinal edges 10. The second connecting elements 16, 17 of the transverse edges 15 are configured to be connected to each other by translational movement along an essentially vertical direction. In the examples shown, said second connecting elements 16, 17 are designed to be connected by translational movement in a downward direction, for example in the vertical Y direction.

The support layer 3 extends beyond the transverse edges 28 of the decorative layer 2. In the example, the support layer 3 comprises upper transverse edges 29 which extend beyond the transverse edges 28 of the decorative layer 2 by a distance D2. Said distance D2 is the same on both opposite edges 28 of the decorative layer 2. In addition, in the said preferred example, said distance D2 is equal to the distance D1. For example, said distances D1 and D2 are more than 0.5 mm, preferably more than 0.75 mm, for example 1.5 mm.

Fig. 5 is a plan view of a floor covering 18 comprising a plurality of floor elements 1 connected by first connecting elements 11, 12 along the longitudinal edges 10 and by second connecting elements 16, 17 along the transverse edges 15.

In FIG. 6 is an enlarged cross-sectional view taken along line VI-VI in FIG.

- 20 040976

5. The floor covering 18 comprises a grout 19 filling the intermediate distance I separating the decorative layers 2 of the floor elements 1. According to the example shown, the intermediate distance I is twice the distance D1 between the top edge of the support layer 3 and the edge of the decorative layer 3.

The grout 19 is preferably made of a polymeric material. The grout 19 may be a resilient or rigid grout. The flexible grout 19 may be, for example, a silicone-based grout, while the rigid grout may be, for example, an epoxy-based or cement-based grout. Other examples of polymeric grouts are polyurethane-based and acrylic-based grouts.

In FIG. 6 also shows a section of the mechanical connection between the first connecting elements 11, 12 along a plane transverse to the longitudinal edges 10. Said mechanical connection between the first connecting elements 11, 12 is described in detail with the aid of FIG. 7.

In FIG. 7 is an enlarged view of the region F7 shown in FIG. 6. According to the preferred example shown in FIG. 7, the tongue 11 includes a horizontally extending jaw 20 and a downwardly projecting protrusion 21. The groove 12 includes a horizontal recess 22 for receiving the jaw 20 of the tongue 11, and an upward hollow portion 23 for receiving the protrusion 21 of the tongue 11 in order to allow insertion. tongue 11 into groove 12.

In the connected state shown in FIG. 7, the upper edges 27 of the support layers 3 come into contact with each other, thereby forming the first set of first blocking surfaces 24, limiting the mutual movement of said floor elements 1 in the horizontal direction X, perpendicular to the connected longitudinal edges 10.

In FIG. 7 also shows that, in said connected state, the lip 20 is inserted into the recess 22. The upper surface of the lip 20 comes into contact with the upper wall of the recess 22, thereby forming a first set of second blocking surfaces 25, limiting the relative movement of said floor elements 1, essentially in the vertical Y direction. It should be noted that between the tip of the jaw 20 and the bottom of the recess 22, a horizontal non-working space S1 is formed. In addition, a vertical non-working space S2 is formed between the bottom surface of the jaw 20 and the recess 22.

The downward protruding protrusion 21 of the tongue 11 is inserted into the hollow part 23 of the groove 12. The lower surface of the downward protruding protrusion 21 comes into contact with said hollow part 23 to form a second set of second blocking surfaces 25. In other words, the bottom surface of the tongue 16 comes into contact with the groove 12 exclusively in accordance with the projection 21 protruding downwards.

As seen in FIG. 7, in the connected state between the protrusion 21 and the hollow part 23, a horizontal play P is formed, which provides a slight horizontal movement of the tongue 11 in the groove 12. Said play P and said small horizontal movements are limited by a set of first contact surfaces that can be formed between the protrusion 21 and hollow part 23.

Preferably said play P is more than 0.01 mm, preferably more than 0.03 mm. Furthermore, said play P is preferably less than 0.10 mm, for example less than 0.08 mm.

It should be noted that in the connected state, the tongue 11 and the groove 12 are in an undeformed state. In addition, all the angular movement that the connection between the tongue 11 and the groove 12 provides takes place without deformation of the first connecting elements 11, 12. In fact, due to the play P and the non-working spaces S1, S2, the connection between the tongue 11 and the groove 12 is greatly simplified.

In FIG. 8 is an enlarged cross-sectional view taken along line VIII-VIII in FIG. 5. In FIG. 8 shows a section of the mechanical connection between the second connecting elements 16, 17 along a plane transverse to the transverse edges 15. Said mechanical connection between the second connecting elements 16, 17 is described in detail with the aid of FIG. 9.

In FIG. 9 is an enlarged view of the region F9 marked in FIG. 8.

The second connectors 16, 17 comprise a downwardly directed upper hook portion 16 located on one transverse edge 15 and an upwardly directed lower hook portion 17 located on the opposite edge 15. The lower hook portion 17 defines an upwardly directed cavity forming the female portion, wherein the upper hook portion 16 defines a downwardly directed lip forming the male portion.

In the connected state, the downwardly directed jaw and the upwardly directed cavity form a first blocking surface 24 for limiting mutual movement of the floor element 1 in the horizontal Z direction perpendicular to the transverse edge 15.

In addition, both the upper hook portion 16 and the lower hook portion 17 comprise undercut portions 30 so that, in the connected state, second blocking surfaces 25 are formed to limit the relative movement of the floor elements 1 in the vertical Y direction. In particular, for example, on opposite sides of the male part and

-

Claims (8)

The female part is formed by two sets of said second blocking surfaces 25. Preferably, the lower hook portion 17 comprises an elastic shoulder portion 31 configured to deform when the upper hook portion 16 is connected to the lower hook portion 17, such that the undercut portions 30 are connected by said deformation. In FIG. 10 shows some of the steps in the manufacturing process for the floor element. The method comprises a first step S1 of providing the decorative layer 2. In step S1, the decorative layer 2 is applied to the resin application area 40, in which the uncured resin material R is applied to the lower surface of the decorative layer 2, for example, according to the sample. The uncured resin R preferably has a viscosity at 20°C of less than 1000 Pa-s, preferably less than 800 Pa-s, more preferably less than 600 Pa-s, for example about 400 Pa-s. It should be noted that, in the resin application portion 40, the decorative layer is placed so that the top surface containing the decor 6 faces down. Then, in step S2, the decorative layer 2 is transferred to the placement area 41 in which the support layer 3 is located. and the support layer 2 is suitably centered relative to each other. Thereafter, in step S3, the semi-finished layer structure 42 is transferred to a pressing station 43, where the layers are pressed together to form the floor element 1, allowing the resin material to penetrate the pores of the ceramic material of the decorative layer 2 and form the intermediate layer 13. Preferably, the pressure during the pressing time is maintained for at least 1 s, preferably 30 s, so that the uncured resin R can spread covering at least 80%, preferably 100% of the lower surface of the decorative layer 2. In addition, said pressing time is necessary in order to ensure penetration uncured resin R into the decorative layer 2. Preferably, during step S4, the pressure acting on the layers is at least 350 kg/m ² . Then, in step S4, the pressed floor element 1 is transferred to the storage area 44 for a predetermined time to allow the resin R to continue curing before being packaged, transported and/or used in the floor covering. Preferably, the storage time is such that the resin R is at least 70%, preferably 85%, more preferably fully cured. For example, said storage time is at least 0.5 hours, preferably more than 1 hour, such as 2 hours. The present invention is in no way limited to the above embodiments, and such floor elements can be made according to various embodiments without departing from the scope of the present invention. CLAIM 1. Floor element (1) for forming a floor covering, moreover, the floor element contains a decorative layer (2) made of ceramic material, and a support layer (3) located under the decorative layer (2), moreover, the support layer (3) contains edges (10, 15), in which connecting elements (11, 12, 16, 17) are provided, made with the possibility of mechanical connection with connecting elements (11, 12, 16, 17) of an adjacent floor element (1), and moreover, the floor the element (1) contains an intermediate layer (13) having a polymeric material that penetrates into the lower surface of the decorative layer, and said polymeric material does not contain fillers. 2. The floor element (1) according to claim 1, wherein the polymeric material contains an epoxy resin. 3. A floor element (1) according to any one of the preceding claims, wherein the polymeric material has a viscosity at 20°C of less than 1000 Pa-s. 4. Floor element (1) according to any one of the preceding claims, wherein the intermediate layer (13) covers 80% or more of the lower surface of the decorative layer (2). 5. Floor element (1) according to any of the preceding claims, wherein the intermediate layer (13) contains resin in an amount of at least 150 g/m ² . 6. Floor element (1) according to any one of the preceding claims, in which the intermediate layer (13) contains an adhesive layer that bonds the decorative layer (2) to the support layer (3). 7. A floor element (1) according to any one of the preceding claims, wherein the decorative layer (2) has an apparent porosity ranging from 0.1 to 10%, measured in accordance with ASTM C373. 8. Floor element (1) according to any one of the preceding claims, wherein the decorative layer (2) has an open pore volume (14) in the range of 0.01 to 1 cm ³ measured in accordance with the American Society for Testing Standard C373 materials. -