EA045113B1 - FLOOR ELEMENT FOR FORMING FLOOR COVERING, FLOOR COVERING AND METHOD FOR MANUFACTURING FLOOR ELEMENT - Google Patents

Description

Cross reference to related applications

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

Field of technology to which the invention relates

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

More particularly, 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, ceramic tiles.

Prerequisites for creating an invention

Traditionally, ceramic tiles are installed by placing them next to each other on a surface such as a floor or wall. Typically, an adhesive is used to attach tiles to the surface. The seams between the tiles are filled with grout. This bonds the tiles to a rigid surface, such as a concrete subfloor, thereby improving their impact resistance. The connection to the subfloor and thus to the structure of the home also leads to a strong attenuation of the sounds generated by walking, both in the room where the floor is installed and in the rooms below the corresponding room. The tiled surface is waterproof and hygienic, as it can be cleaned with very wet conditions. However, the step of laying tiles using adhesive is a very labor-intensive step, which takes up a significant portion of the labor costs when laying a typical floor covering. In addition, this installation technology requires extensive professional experience to ensure a well-leveled floor covering. Thus, due to the labor and time required for installation, professional tile installation is usually quite expensive.

To replace an existing tile floor, it is often necessary to break up the tiles, restore the surface by removing any remaining adhesive, and then install the new floor. Thus, the destruction of a floor covering made of tiles is a labor-intensive and time-consuming operation. If the purpose of the restoration is to replace only one or more damaged tiles, this operation also becomes more complicated, since when replacing one tile it is preferable not to damage adjacent tiles.

In recent years, manufacturers have attempted to develop easier DIY tile installation solutions. Some examples of such attempts are described in patent documents WO 2004/097141 and WO 2008/097860. The flooring elements described in these documents can be laid on a surface and mechanically joined together to form a floor covering without the use of adhesives, reducing labor and installation time. This type of flooring is known as floating flooring. In particular, in these documents, a ceramic tile or a natural stone slab is attached to a support layer that contains connecting elements configured to provide connection to the connecting elements of an adjacent floor element, thereby forming a floor covering.

On the other hand, since such floor elements are not connected to an overall rigid surface, impact strength and therefore fatigue resistance are significantly reduced. Floating installation may also increase walking noise. Joints between tiles, as described in patent document WO 2008/097860, can be susceptible to water penetration, especially when wet cleaning. According to some embodiments of WO 2004/097141, grout may be applied to joints between adjacent floor elements, which may result in the joint being watertight.

To increase the impact resistance of ceramic tiles, US Patent Document 2014/349084 proposes tiles with a composite structure. In such composite tiles, a reinforcing layer is located between two ceramic layers or between a ceramic layer and a polymer laminate. As an example of a reinforcing layer, a glass fiber layer is mentioned. However, installing tiles is still complicated. Bonding to the underlying subfloor is required, such as through a backing layer, a pressure-sensitive adhesive, or a quick-adhesive loop material, so that the tile is substantially integral with the subfloor to improve impact resistance. In addition, precise positioning of the tile is difficult.

Patent document WO 2010/072704 proposes another type of reinforcing layer, namely a steel plate. This steel plate is glued to the back surface of the ceramic tile or slab. However, installation in this case is also difficult. Installation is accomplished by simply placing tiles on the subfloor, so precise positioning of tiles is difficult, resulting in poorly leveled flooring and noisy, leaky flooring.

The purpose of the present invention is primarily to develop an alternative floor

- 1045113 element, which, in accordance with some preferred embodiments, is aimed at solving one or more problems arising in the art.

The essence of the invention

In one aspect of the present invention, there is provided a floor element for a floor covering, wherein the floor element comprises a decorative layer made of a ceramic material and a support layer disposed underneath the decorative layer, wherein the support layer comprises edges which are provided with connecting elements configured to making a mechanical connection to the connecting elements of an adjacent floor element, and wherein the floor element comprises an intermediate layer having a polymeric material that penetrates the lower surface of the decorative layer.

In another aspect of the present invention, there is provided a method for manufacturing a floor element, comprising the steps of (i) providing a decorative layer made of a ceramic material; (ii) providing a support layer; (iii) providing a polymeric material for bonding the decorative layer to the support layer; (iv) pressing the layers together to form a floor element, allowing the polymer material to penetrate into the ceramic layer.

Another aspect of the invention provides the use of a polymeric material for bonding a decorative layer made of a ceramic material to a support layer to form a floor element, the polymeric material having a viscosity at 20° C. of less than 1000 Pas.

Another aspect of the invention provides a floor element comprising a decorative layer made of a ceramic material and a support layer located below the decorative layer, wherein the support layer includes at least two pairs of opposing edges, wherein the opposing edges include connecting elements configured to perform mechanical connections to the connecting elements of adjacent floor elements, wherein the first connecting elements on the first pair of opposite edges are configured to connect to the connecting elements of adjacent floor elements through angular movement about a horizontal axis parallel to the respective edges, and wherein the second connecting elements on the second pair of edges are configured connecting to the connecting elements of adjacent floor elements by progressive downward movement of the respective edges towards each other.

In another aspect of the invention, there is provided a floor element comprising: a decorative layer having a density, expressed by a surface density, of at least 10 kg/cm ² ; and a support layer located below the decorative layer, wherein the support layer comprises at least two pairs of opposing edges, wherein the opposing edges comprise connecting elements configured to be mechanically coupled to connecting elements of adjacent floor elements, the first connecting elements on the first pair of opposing edges configured to be connected to the connecting elements of adjacent floor elements by angular movement about a horizontal axis parallel to the respective edges, and wherein the second connecting elements on the second pair of edges are configured to be connected to the connecting elements of adjacent floor elements by translational downward movement of the respective edges to each other to a friend.

These and other objects, features and advantages of the present invention will be apparent from the following specifications when taken with reference to the description, claims and drawings.

Brief description of drawings

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

In fig. 1 is a top view of an embodiment of a floor member 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 area 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 top view of a floor covering comprising the plurality of 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 line VIII-VIII of FIG. 5;

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

- 2 045113 in Fig. 10 shows some steps of the method for manufacturing a floor element.

Detailed description

To facilitate understanding of the principles and features of the various embodiments, various illustrative embodiments are set forth below. 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 to the design details 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. Additionally, specific terminology is used in the description of the illustrative embodiments for clarity.

It should also be noted that as used in the specification and in the accompanying claims, the singular number "a" and "a" include plural references unless the context clearly dictates otherwise. For example, reference to a component also includes a composition of multiple components. References to a composition including a singular component are intended to include other components in addition to the one named. In other words, the singular terms do not denote a limitation in quantity, but rather denote the presence of at least one of the components mentioned.

As used herein, the term and/or may mean and, may mean or, may mean exclusive - or, may mean one, may mean some but not all, may mean neither, and/or may mean both. The term or is intended to refer exclusively to or.

Additionally, terminology has been used in describing the exemplary embodiments 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 operate in a similar manner to achieve a similar purpose. It should be understood that embodiments of the disclosed technology may be practiced without these specific details. In other cases, well-known methods, structures and technologies have not been shown in detail so as not to obscure the understanding of this description. References to one embodiment, an embodiment, an example embodiment, some embodiments, specific embodiments, various embodiments, etc. indicate that the embodiment(s) of the disclosed technology so described may include a particular feature, structure or characteristic, but not every embodiment necessarily includes a particular feature, structure or characteristic. Additionally, repeated use 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 particular value and/or to about, or approximately, or substantially another specific value. When such a range is indicated, other exemplary embodiments include from one specific value and/or to another specific value. In addition, the term approximately means within the acceptable range of errors for a particular quantity, as determined by one skilled 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 is meant that at least the specified chemical compound, element, particle or method step is present in the chemical compound, product 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 reference to one or more method steps does not preclude the presence of additional method steps or intermediate method steps between those explicitly identified steps. Likewise, it should be understood that mention of one or more components in a composition does not preclude the presence of additional components other than those expressly identified.

The materials described below as the materials from which 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 were developed, for example, after 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 intended that other dimensions and proportions be included within the scope of the invention.

Embodiments of the Invention

Thus, the present invention, in accordance with its first independent aspect, relates to a floor element for forming a floor covering, the floor element

- 3 045113 contains a decorative layer made of ceramic material, and a support layer located under this decorative layer, wherein the support layer contains edges in which connecting elements are provided, made with the possibility of mechanical connection with the connecting elements of an adjacent floor element, and wherein the floor element the element contains an intermediate layer having a polymeric material that penetrates the lower surface of the decorative layer. The inventors have discovered that, thanks to this solution, the impact strength of a floor element, in particular a decorative layer made of ceramics, is significantly increased, so that even with mechanical interlocking of such floor elements, the impact strength reaches or even exceeds the impact strength of traditional elements laid using adhesive . 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 into 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. Additionally, in the case of surface cracks in the decorative layer, the intermediate layer keeps the decorative layer bound and preferably compacted, 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, impact strength is measured by throwing a steel ball onto a 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). Impact strength is expressed in terms of the maximum height from which a steel ball, when dropped onto a floor element, will not destroy the floor element. The higher the drop 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 a floor element. The inventors have discovered that traditional floor coverings, such as floor coverings made from approximately 10 mm thick porcelain floor elements directly bonded to the subfloor, typically exhibit impact strengths in the range of 1.68 to 2.25 J (corresponding to ball drop from a height ranging from 762 to 1016 mm), with known floating floors exhibiting an impact strength typically less than 1.12 J (corresponding to a ball drop from a height below 508 mm). The inventors have discovered 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 American Society for Testing and Materials Standard C627. In this test, a three-wheeled cart is rotated around its center on top of a sample taken from a section of tile floor. Above each wheel there is a rod on which weights are strung. The power motor drives the unit and the trolley rotates at a speed of 15 rpm. The test is carried out in accordance with the loading schedule for 14 different cycles. For each cycle, the schedule identifies the type of wheel used (soft rubber, hard rubber or steel), the amount of weight placed on each wheel, and the total number of cart revolutions to be completed. After completion of each cycle, a sample taken from a section of the tile floor is examined visually. Based on the test results, the floor is qualified in accordance with the number of cycles passed without destruction and the corresponding class of application for which the floor is intended is determined:

samples that completed cycles 1-3 without destruction are classified as Intended for residential class;

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

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

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

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

The inventors have discovered that by using the interlayer according to the invention, the Robertson test can result in a minimum of six cycles (Light Commercial Grade).

According to a preferred embodiment of the invention, the decorative layer is

- 4 045113 holds a ceramic body, for example made from porcelain, red clay pottery, stoneware, earthenware or their other sintered ceramic powders. Preferably, the decorative layer is a ceramic tile or slab. By ceramic tile is meant an element with a substantially flat body consisting of heat-treatable minerals such as clay, and preferably with a fired decorative top surface, preferably but not necessarily based on a glaze. The glaze also prevents the resin from penetrating the top surface of the decorative layer as it penetrates the decorative layer, thereby affecting the appearance of the floor element.

However, it should be noted that this first aspect can advantageously be applied to decorative layers made of any material of any type exhibiting open porosity at least in accordance with its lower surface. Examples of the material mentioned could be brittle materials such as natural stone, concrete, glass or glass ceramics. A brittle material means a material that fails without significant plastic deformation. In particular, with respect to the scope of the said patent application, by the term brittle material is meant a material which by itself (unless associated with a support layer and without any reinforcement) has an impact strength of less than 1.68 J ( corresponding to a ball falling from a height of less than 762 mm) according to the falling ball test.

According to a preferred aspect of the invention, the decorative layer may comprise, at least along its lower surface, open porosity which allows resin to penetrate into the decorative layer itself. In fact, as mentioned above, the inventors have unexpectedly discovered that by allowing the resin of the intermediate layer to penetrate into the pores of the decorative layer, the energy transfer upon impact can be significantly improved. Thus, in accordance with a preferred embodiment of the invention, the decorative layer contains an apparent porosity ranging from 0.1 to 10%, determined in accordance with American Society for Testing and Testing Materials standard C373, more preferably from 2 to 8%, for example 6% . The above ranges and apparent porosity values provide an optimal balance between the intrinsic mechanical properties of the decorative layer and its resin permeability, thereby optimizing impact resistance. In fact, the pores of the material, especially closed pores that cannot be permeable to the resin, may represent weak points of the material itself, so it is preferable that the decorative layer contains an apparent porosity of less than 15%, preferably less than 10%, measured in accordance with American Society for Testing and Materials standard C373. In addition, the decorative layer may preferably have an open pore volume ranging from 0.01 to 1 cm ³ , more preferably from 0.10 to 0.90 cm ³ , for example 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 since this range of apparent porosity is characteristic not only of ceramic tiles used for wall coverings or flooring in residential areas, but also for flooring in high-traffic industrial areas where increased 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 produced by firing at a high temperature, 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, that is, not associated with a backing layer and without resin penetrating the decorative layer, exhibit an impact strength of 0.73 J, while a floor element containing a decorative layer made of porcelain glued on top of the support layer by means of an intermediate layer containing a resin that penetrates the lower surface of the decorative layer, can achieve an impact strength of up to 3.37 J.

Therefore, according to the second preferred option, the decorative layer is made of red clay ceramic tiles. Red clay pottery is a ceramic material produced by firing at a high temperature of, for example, about 1150°C, a mixture of raw materials containing clays, kaolin, quartz, field

- 5 045113 spar, calcium carbonate and/or other mineral raw materials. Red clay pottery can be fired at a lower temperature than porcelain, thereby providing higher porosity and water absorption rates. In addition, red clay ceramics can be produced from a raw material mixture that is cheaper than the raw material mixture required to produce porcelain. For example, red clay ceramics may have an apparent porosity of less than 10%, preferably 2 to 8%, such as 6%, measured according to ASTM C373. Red clay ceramics may have an open pore volume ranging from 0.10 to 0.90 cm ³ , for example, 0.60 cm ³ . Typically, ceramic tiles are made from red clay as such, i.e. not associated with the support layer and without 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 ceramics glued on top of the support layer by means of an intermediate layer , containing a resin that penetrates the lower surface of the decorative layer, can have an impact strength as high as 5.62 J. It should be noted that red clay ceramic tiles as such have an impact strength of less than porcelain tiles as such, while floor an element according to the invention containing red clay ceramic exhibits significantly greater impact resistance than a floor element containing porcelain.

The inventors have discovered that the interaction between the resin and the decorative layer is improved if the decorative layer contains a bottom surface that is a substantially flat surface. The bottom surface is an invisible surface (in use) that is opposite to the top decorative surface of the decorative layer. Typically, the bottom surface of a ceramic tile contains a back structure, typically formed by ridges and grooves, which can be up to 1 mm thick, but the inventors have found that for applying resin to the bottom surface itself, it is preferable to use a decorative layer that is free of said back structure , for example from the mentioned ribs. Moreover, according to a preferred embodiment of the invention, the lower surface of the decorative layer, in particular of the ceramic tile, is free of the underlying coating. The undercoat is a thin coating containing primarily engobé that is applied, often unevenly, to the undersurface of the ceramic tile and has the function of preventing the unfired ceramic tile material from sticking to the kiln rollers. Since the bottom coating contains an 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 impervious. Thus, the inventors have discovered that a decorative layer made from ceramic tiles having a bottom surface free of the underlying coating provides better permeability to the bottom surface of the ceramic tiles. It is also possible for the bottom coating to cover a portion of the bottom surface of the decorative layer which constitutes less than 20%, preferably 10% of said bottom surface. Thus, the undercoat does not completely impervious the undersurface, allowing the resin to penetrate into said porosity of the decorative layer, while simultaneously facilitating the production of a decorative layer that prevents the green tile material from adhering to the kiln rollers.

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

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

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

- 6 045113

Preferably, the decorative layer has a thickness in the range of 4 to 15 mm, preferably 6 to 12 mm, more preferably greater than 7 mm, for example 8 or 10 mm. The inventors have discovered 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 preferred thickness values mentioned provide a good balance between the weight and cost of the material, on the one hand, and the mechanical resistance, on the other hand. Generally speaking, greater thickness equals greater weight, greater cost, but also greater mechanical resistance. Thanks 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 rigidity of the decorative layer restrains the thermal expansion of the support layer and that this restraining effect increases as the thickness of the decorative layer increases.

It should be noted that the decorative layer may have a density, expressed as a basis density, of at least 10 kg/ ^m2 , preferably 15 kg/ ^m2 , for example more than 19 kg/ ^m2 . 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 by a surface density, of less than 35 kg/ ^m2 , preferably less than 30 kg/ ^m2 , for example less than 25 kg/ ^m2 . In fact, an overly heavy decorative layer can affect the maneuverability of the floor element, as well as complicate its packaging and transportation.

The decorative layer can 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 depicting wood grain lines extending throughout the longitudinal direction of the rectangular decorative layer. The cover element can 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, for example a thermosetting resin or a thermoplastic resin. Examples of thermoset resin are epoxy resin, polyurethane, cyanoacrylate or acrylic resin. Examples of thermoplastic resin are hot melt adhesive, polyester thermoplastic, vinyl, etc. Preferably the resin is a rigid resin. In fact, the inventors discovered that rigid resin, as opposed to flexible 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 preferable that the epoxy resin is a two-component resin, i.e. A thermosetting resin produced by low temperature (eg, room temperature) curing of a mixture of two components, namely a resin and a hardener. When the two resin components are mixed together, the curing reaction begins so there is no need to activate curing through external energy such as heat, UV or electron beam radiation. Said external energy may be optionally provided to speed up the curing process. In accordance with 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 is performed, i.e. during the so-called pot life. In fact, the inventors have discovered that if the resin is sufficiently fluid when applied to the back of the decorative layer, it can penetrate into its pores, significantly 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 composite polymer-ceramic layer, which significantly improves the impact resistance of the floor element. It should be noted that, in a preferred solution, the resin is essentially in a liquid state during the manufacturing process of the floor element. In any case, the possibility cannot be ruled out that the resin is in a paste or gel state during the manufacturing process, for example, the resin exhibiting thixotropic behavior to achieve sufficient fluidity to penetrate the pores of the decorative layer under given conditions of the manufacturing process, for example, during the pressing step. According to an embodiment of the invention, the intermediate layer may comprise two or more different resins. For example, the intermediate layer may comprise a first resin for impregnating the pores of the decorative layer and a second resin for bonding the decorative layer to the support layer. According to said 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 elastomeric resin that provides a shock absorbing effect upon impact.

- 7 045113

The inventors have also discovered that the resin may preferably be free of fillers such as mineral fillers. In fact, the inventors have discovered that the presence of fillers, on the one hand, improves the mechanical properties of the resin as such, 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 to 90 MPa, more preferably 60 to 80 MPa, for example 75 MPa. It should be noted that the resin preferably has a compressive strength ranging from 90 to 130 MPa, more preferably from 100 to 120 MPa, for example 110 MPa. The inventors have discovered 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 Shore Hardness D scale.

Preferably, the resin covers at least part of the lower surface of the decorative layer, for example a large part, i.e. at least 50% of the lower 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 an energy distribution and dissipation effect upon impact occurring at any point of the decorative layer.

The resin is preferably applied to the bottom surface of the decorative layer in an amount of more than 150 g/ ^m2 , more preferably more than 200 g/ ^m2 , for example, 220 g/ ^m2 , so that the amount of resin is sufficient to completely penetrate the open pores of the bottom surface of the decorative layer. layer.

It is also preferable that the resin be applied in an amount sufficient to overflow from the open porosity of the decorative layer to act as an adhesive for the backing 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 portion of the resin that covers the lower surface of the decorative layer so that the intermediate layer acts as an adhesive layer that 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 a polymeric material, or the reinforcing layer may be a reinforcing layer located between the intermediate layer and the support layer. The reinforcing element may comprise fibers such as glass fibers, carbon fibers, polymer 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, arranged 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 resistance of floor elements, especially in the case of special or special installations such as raised floors.

According to an alternative embodiment, the reinforcing element may have a metal plate, for example a steel or aluminum plate. It is preferable if the metal plate is configured to create a compressed state in the decorative layer. Since the decorative layer is in a compressed state, impact strength is significantly improved because the compression inhibits crack propagation and helps hide visible surface cracks. To achieve this purpose, 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 tension 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 thermal expansion coefficient greater than the thermal expansion coefficient of the decorative layer. With this solution, the reinforcing element is heated to a stretched state and then bonded to the decorative layer while it is still in a 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 that is different from the material 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. Polymer materials have good mechanical properties in combination with relatively low cost and low weight, and in addition they provide an impermeable and sound-absorbing support 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 possible that the support layer may contain fillers such as fibers, threads, whiskers or particles made of polymeric or non-polymeric material. In addition, this does not necessarily mean that the polymeric material represents the majority of the material in the support layer, for example, more than 50% by weight. In any case, said expression generally means that the polymeric material is a matrix surrounded and associated with said filler.

Preferably, the support layer is made of a thermoplastic polymer material. Preferably, examples of the thermoplastic material are polyvinyl chloride (PVC), polypropylene (PP) or polyurethane, in particular thermoplastic polyurethane. Preferably, said thermoplastic polymer 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 is easily compressed at room temperature. Compression is desirable in many ways. For example, possible thermal expansion of the support layer can be partially or completely suppressed by a stiffer or inelastic decorative layer and/or reinforcing element that holds the support layer material at its original size. Compression is also of interest in the design of the connecting elements and provides some adaptation to subfloor unevenness, which in turn prevents the formation of air pockets between the support layer and the subfloor, which can increase walking noise.

Among thermoplastic materials, PVC is the preferred choice for backing layer due to the balance between processability, physical, mechanical properties and cost. In addition, the inventors have discovered that PVC exhibits good affinity for 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 discovered that through the interaction of PVC and a resin, in particular an epoxy resin, it is possible to reduce or eliminate the delamination effect between the support layer and the intermediate layer, resulting in 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 element are substantially unchanged even after long-term use, thereby demonstrating good fatigue resistance.

In a preferred embodiment, the support layer is made of either rigid or flexible PVC, wherein the rigid PVC contains an amount of plasticizer of less than 15 parts by weight. (parts by weight), and elastic PVC contains an amount of plasticizer of 15 parts by weight. or more preferably more than 20 or more than 25 parts by weight. 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/m and even better by less than 5 cm/m, while elastic means that the support layer, taken separately, bends under its own weight by more than 10 cm/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. Fillers add weight to the support layer and make the support layer very effective in suppressing the transmission of walking sounds to the rooms below. Rigid PVC containing fillers is also known as rigid polymer composite (RPC). In any case, the amount of filler should preferably be limited to 70% by weight, for example to less than 50% by weight, so as not to unduly increase the brittleness of the support layer. Rigid PVC provides a support layer that has good dimensional stability with temperature changes. In other words, the expansion of the support layer at high temperatures is thereby limited, which ensures good stability of the floor. Preferably, the rigid PVC has a coefficient of thermal expansion of less than 85 µm/m per 1°C, preferably less than 60 µm/m per 1°C, for example 50 µm/m per 1°C. For example, the coefficient of thermal expansion of the support layer, especially when it is made of rigid PVC, is in the range from 20 to 85 µm/m per 1°C, preferably from 40 to 60 µm/m per 1°C. A support layer made of flexible polyvinyl chloride has less dimensional stability, but it is more easily compressed 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 discovered that better results in terms of impact resistance are achieved by using a support layer made of 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

MPa, for example approximately 56 MPa. In fact, the inventors discovered that the stiffness of the support layer helps absorb energy upon impact, thereby improving impact resistance.

According to other embodiments, the support layer, made of elastic PVC or some other material, thermoplastic or not, can be configured to accommodate changes in size due to temperature. For example, the support layer may be made of a plurality of individual elements, such as strips, or may include grooves separating adjacent portions of the support layer, thereby allowing said portions to expand without affecting the overall stability of the floor. Said grooves are preferably open to the lower surface of the support layer.

Moreover, the support layer preferably has a thickness ranging from 2 to 7 mm, preferably less than 6 mm, more preferably about 4 mm or less. A thinner support layer provides limited costs and higher thermal stability, in particular because thermal expansion of a thinner support layer can be more effectively suppressed by the stiffness 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 discovered that the rigidity of the decorative layer helps suppress thermal expansion of the support layer and that the rigidity 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, 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, especially in the case of restoration of an existing floor covering. In this way, the surface load of the floor element is limited, so that packaging, 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 approximately 24 kg/m ² . This achieves a good balance between cost-effectiveness of transport and packaging and ease of installation. In fact, weights exceeding the mentioned limits can help to connect 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 a resin that penetrates the lower surface of the decorative layer. Preferably, the ceramic decorative layer has a thickness ranging from 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 particularly effective thermal stability so that the floor covering is not affected by changes in room temperature. In addition, this effect is achieved by means of a floor element having a thickness of less than 13 mm. This value is a relatively small value and provides advantages in packaging, cost and maneuverability.

As mentioned above, the support layer includes edges with connecting elements configured to be mechanically connected to the connecting elements of an adjacent floor covering element. By mechanical connection is meant a connection that allows adjacent floor covering elements to be connected to each other without the need for adhesives 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 results in mutual interlocking of said edges in the vertical direction and/or one or more horizontal directions.

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

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

Moreover, in the connected state of the two adjacent floor elements, the connecting elements interact and preferably form interlocking surfaces limiting the mutual movement of the said floor elements in vertical and/or in one or more horizontal directions. Preferably, in the connected state of two adjacent floor elements, first blocking surfaces are formed that 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 which limit the mutual movement of said floor elements in a substantially vertical direction. Thanks to this solution, floor elements can be easily laid without the risk of creating unacceptable differences in height between adjacent floor elements. In addition, the floor elements are firmly connected 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 noise generated when walking, i.e. reducing the noise that occurs with each step.

According to a preferred embodiment of the invention, the male portion and the female portion may be located substantially along the entire length of the respective edge, for example substantially defining the edge. For example, according to this embodiment, the male and female portions may be substantially configured as a tongue and groove that substantially extend along the entire length of their respective mutually opposing 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 portion and the female portion may extend over a limited length of the respective edge, such limited length being less than the entire length of the respective edge itself, preferably less than half the length of the respective edge. According to this possibility, the edges preferably comprise areas free from said male part and said female part. Joint geometries in accordance with this alternative embodiment include cooperating male and female portions that are dovetail-shaped in plan view, or male and female portions that resemble puzzle joints in plan view.

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

According to 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 connecting process is simplified and less effort is required by 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

- 11 045113 edge, equal to or slightly less than the size of the female part on the same plane.

The connecting elements are configured to make a connection by moving one floor element relative to another adjacent floor element. Such movement may be a downward translational movement, for example, in a vertical direction, a horizontal translational movement, for example, perpendicular to the edges, or an angular movement about a horizontal axis parallel to the edges. It is apparent that the corresponding movement preferably causes the aforementioned male portion and the female portions of the adjacent floor members to engage with each other.

For this purpose, 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 angular movement around a horizontal axis parallel to the edges. According to this first possibility, it is also preferable that the connecting elements are designed to be connected by translational movement in a horizontal direction, for example perpendicular to the edge. According to the above-mentioned first possibility, the male part and the female part are respectively configured as a tongue and a groove, the tongue protruding outwardly beyond its respective edge in a horizontal direction, and the groove protruding inwardly relative to the corresponding edge in a 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 locking surfaces are formed to limit relative movements of the floor element in a vertical and horizontal direction, said horizontal direction being perpendicular to the edge. According to a preferred embodiment, the tongue includes a horizontally extending jaw extending in a horizontal direction and a downwardly extending protrusion. 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 projection 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 jaw that is narrower than the groove, so that the angular movement for connecting the floor elements is definitely improved. Also preferably, in the connected state, the downwardly projecting protrusion of the tongue is in contact with the hollow part of the groove, and the upper surface of the tongue is in contact with the groove. In particular, preferably the lower surface of the tongue comes into contact with the groove only in accordance with the projection. Due to this, the said second contact surfaces are provided, and at the same time the connection by angular movement is simplified due to the lower contact surface, which is formed only in accordance with the protrusion of the tongue and not in accordance with its jaw. In other words, the jaw has more space inside the tongue to perform angular movement.

Moreover, according to a preferred embodiment of this first possibility, the tongue and groove form a play in the connected state. Said play allows for 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 effort in laying the floor elements is significantly reduced, and this is especially important since the weight of the decorative layer, on the one hand, complicates the installation operations, and on the other hand, contributes to the mutual blocking of the floor elements. Consequently, slight weakening of the connection due to play is allowed, which contributes to ease of installation. Preferably, said play is greater than 0.01 mm, preferably greater than 0.03 mm. Moreover, said play is preferably less than 0.10 mm, for example less than 0.08 mm.

According to the second possibility, said connecting elements are designed to be connected 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 portion which is located on one edge, as well as a downwardly directed upper hook portion which is located on the opposite edge. The lower hook portion defines an upwardly directed cavity defining the female portion, while the upper hook portion defines a downwardly directed jaw defining the male portion. When in a connected state, the downwardly directed jaw and the upwardly directed cavity form a first locking surface for limiting mutual movement in a horizontal direction, for example perpendicular to the edge. Preferably top

- 12 045113 the hook-shaped part and the lower hook-shaped part, more preferably the jaw and the cavity respectively, are configured to form, in the connected state, a second locking surface to limit the 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 locking surfaces, for example, opposite the male portion and the female portion. 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 locking surface to limit mutual movement of the floor element. In addition, the connecting elements in accordance with the mentioned second possibility are designed to be deformable during the connecting movement. Preferably, the lower hook portion comprises a flexible shoulder portion that is deformable by coupling with the upper hook portion of the lower hook portion, such that the notched portions are connected by said deformation.

It should be noted that the floor element may contain identical connecting elements, i.e. elements in accordance with 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 connecting elements according to a first possibility at a first pair of opposite edges, for example, in the case of a rectangular floor element, at the long edges, and connecting elements according to a second possibility at a second pair of opposite edges, for example at the short edges. In other words, the rectangular floor element may include connecting elements configured to be connected by angular movement at the long edges, and connecting elements configured to be connected by translational downward movement at the 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 tongue and groove, it is easy to align the long edges of the floor element, thereby simplifying positioning and ensuring a strong connection of the long edges in both vertical and horizontal directions, while the short edges can be easily connected by translational movement in a downward direction, as a direct consequence of the connection of the long edges. This is particularly advantageous in the case of heavy decorative layers, in fact, when connecting the connecting elements in accordance with the first possibility, for example tongue and groove on the long sides, it is sufficient to allow the floor element to lie in a horizontal position to perform a mechanical connection of the connecting elements in accordance with the second possibility eg on short edges, without having to hammer or hit the floor element itself. This also occurs in the case where the connecting elements according to the second possibility are deformed during connection, since the weight of the decorative layer may be sufficient to cause said deformation.

Preferably, the support layer has a shape generally corresponding to the decorative layer, but preferably with one or more parts extending beyond the decorative layer. The support layer may also include one or more recesses extending underneath the decorative layer. The support layer is preferably a coherent element, with the support layer preferably covering a large portion, i.e. at least 50% of the lower 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 top surface of the support layer, preferably a large portion thereof, eg more than 50%, preferably more than 80%, eg 90% or more. According to one embodiment, the support layer comprises a plurality of separate adjacent support layer portions, and in such a 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 successive edges of the decorative layer, more preferably beyond all edges of the decorative layer. In particular, according to a preferred embodiment, the decorative layer is placed on the support layer such that it is centered with the top surface of the support layer, for example, each top edge of the support layer extends beyond the edge of the decorative layer by the same distance. It is also possible 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, for example 1 mm or

1.5 mm.

The floor element can be of any size, although preferably 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. In fact, the floor elements are intended to be laid over a subfloor which may have irregularities such as indentations or protrusions, which can affect the installation of the floor covering, the impact strength, and the fatigue resistance of the floor element. For floor elements with a reduced area, the influence of the mentioned irregularities, as well as the likelihood of the occurrence of the mentioned irregularities, is reduced. In addition, the decorative layer, especially if it is made of ceramic material, may be slightly curved, so the same issues may arise due to irregularities in the subfloor. The larger the side of the decorative layer, the greater the said bending, so that it is preferable that the floor element and the decorative layer have a reduced surface area.

According to a preferred embodiment of the invention, in the connected state of the two floor elements mentioned, it is preferable to provide an intermediate distance between the respective upper edges of the adjacent floor elements. Preferably, the decorative layer is placed on the support layer in such a way that, when the floor elements are in a connected state, there is said intermediate distance between the edges of adjacent decorative layers, the edges of the underlying support layer being connected to each other by means of existing connecting elements. Thanks to this solution, small changes in the size 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, non-rectified tiles being preferred because they are less expensive than rectified tiles. Even if rectified tiles are selected, an intermediate distance of at least 1.5 mm, for example 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 the edges of the decorative layer from directly touching adjacent flooring elements in order to minimize the risk of parts of the edges breaking off during installation or use of the floor covering. Preventing direct contact between the edges of the decorative layers also prevents squeaks caused by walking on the floor. Additionally, 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 top edge of the support layers is the same at all edges of the decorative layer and is preferably half the intermediate distance between the corresponding top edges of adjacent floor elements in the connected state. This solution is particularly advantageous when using non-rectified tiles because it simplifies the positioning of tiles of the same size, which may have slightly different dimensions on the support layers.

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

According to the first possibility, said intermediate distance between the floor elements can be filled with grout, thus providing an impermeable floor covering. Preferably, polymer grout and/or cement-based grout is used. The grout can be flexible or rigid grout. The flexible grout may, for example, be a silicone-based grout, while the rigid 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 may be at least partially, preferably completely, surrounded by a spacer such that, in the connected state of two adjacent floor elements, said spacer is compressed by the decorative layer of the adjacent floor element to create a substantially watertight connection between the floor elements.

It should be noted that the characteristic feature that the floor element contains an intermediate layer having a polymeric material which penetrates the lower surface of the decorative layer constitutes the idea of the invention, regardless of the presence of a support layer and, in particular, a support layer containing edges with connecting elements configured to provide mechanical connection with connecting elements of an adjacent floor covering element. 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 disposed underneath the decorative layer, wherein the second layer contains a polymer material that penetrates into 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 underneath the second layer. Additionally, optionally, the third support layer may comprise one or more additional support layers described above with respect to the first independent aspect. It will be appreciated that the decorative layer and the intermediate layer may also comprise one or more of the features described above with respect to the first independent aspect.

As an example, the floor element in accordance with said second independent aspect may be laid on the subfloor by means of a pressure sensitive adhesive layer, a layer of fast adhesive loop fabric (eg Velcro® fabric). The floor element, for example, may comprise a pressure sensitive adhesive layer located underneath a second layer, such as a dual adhesive layer covered by a cover sheet, which must be removed before installing the floor element on the subfloor. Alternatively, the floor element can also be laid on a pressure-sensitive adhesive backing. As a further example, the floor element in accordance with said second independent aspect may be laid on the subfloor by means of a layer of quick-adhesive loop fabric (eg, Velcro® fabric). In this case, the floor element may include a third support layer comprising Velcro fabric configured to adhere to the subfloor underlayment. Moreover, for example, the floor element in accordance with said second independent aspect can be laid on the subfloor by magnetic means. In this case, the floor element may include a third support layer containing magnetic and/or ferromagnetic material suitable for interaction with the magnetic and/or ferromagnetic subfloor.

It should be noted that the fact that a polymeric material can be used to form a floor covering comprising a decorative layer, for example made of a ceramic material, and the polymeric material penetrates the lower surface of the decorative layer constitutes the idea of the invention, regardless of additional characteristics of the floor element , such as, for example, the nature of the decorative layer and the presence of a 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 a 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, wherein each floor element comprises a decorative layer of ceramic material and a support layer disposed beneath the decorative layer, wherein the floor covering comprises 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; the floor elements contain connecting elements configured to be connected to the connecting elements of adjacent floor elements; the floor covering contains grout that fills the intermediate space 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 laid without the use of adhesive, which exhibits high satisfactory impact and fatigue resistance and is completely impermeable. Through the second aspect, the inventors have ultimately provided a solution to a long-standing need in the art related to ceramic flooring. They offered an easy-to-install ceramic tile floor with good impact resistance and water resistance. Floor elements of the first aspect and preferred embodiments thereof may be used to form a floor covering in accordance with the present third aspect.

According to a preferred embodiment of the invention, the floor covering comprises an underlayment layer located below 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 floor elements. In combination or as an alternative to this solution, the underlayment may be configured to act as a noise barrier, thereby reducing noise generated by footsteps on the floor.

The invention also relates to a method for manufacturing a floor element, such as the floor element of the present invention. Therefore, in accordance with the fifth independent aspect of iso

- 15 045113 webbing proposes 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, ensuring penetration of the polymer material into the ceramic layer. Thus, a method is provided that provides floor elements that can be laid on a subfloor without the use of an adhesive or adhesive and that exhibits the required impact and fatigue resistance. In addition, the said method allows for simple and efficient production of high-resistance floor elements. In fact, since there is no need to use a rigid reinforcing element, the method contains a reduced number of steps, so that it is a relatively fast method and it can be performed using relatively simple equipment. It will be appreciated that the resulting floor element preferably exhibits the characteristic features of the above-described floor elements of the invention.

The step of providing the decorative layer may comprise 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 polymeric material. For example, in the case where the decorative layer is made of a ceramic material, said brushing and/or roughening step is aimed at removing the underlying coating and/or structure of the lower surface of the decorative layer. Thus, any decorative layer can be used to produce a floor element without the need to produce a special decorative layer for the floor element, for example, without the need to produce ceramic tiles without a bottom cover and without a 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. connecting elements are provided in the support layer during a separate process. Alternatively, the method of producing a floor element may comprise the step of providing connecting elements at the edges of the support layer. Said step of providing connecting elements may comprise milling, molding or other methods. Moreover, said step of providing connecting elements may be performed either before or after the step of placing a decorative layer on top of the support layer, for example, either before said step of providing resin or after said pressing step.

The step of providing the resin comprises the step of applying an uncured resin to at least the surface of the decorative layer and/or the support layer. The polymer material can be applied by rolling, spraying, pouring or other methods. In accordance with one embodiment of the invention, a polymeric material is applied to the top 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 upper surface of the support layer in a first intermediate step, and a second amount of resin is applied to the lower 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, for example fibre. In fact, more resin may be required in this case, and multiple stages of resin provision may be ideal to ensure proper layer adhesion, reinforcement sealing, and decorative layer permeability.

The step of providing the resin may include the step of mixing its components if the resin is a two-component resin, for example, a two-component epoxy resin. Said mixing step can be performed at a time, i.e. simultaneously with the uncured resin application step, or shortly before the uncured resin application step. In fact, the curing of a resin is often activated by mixing its components, causing the viscosity of the resin to increase. Thus, it is preferable to delay the onset of the curing reaction as long as possible in order to facilitate 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, substantially 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 were considered optimal to ensure the penetration of the resin into the decorative layer. In addition, these values were found to be optimal for providing 100% resin coverage of the bottom surface of the decorative layer, since in some embodiments the resin is patterned and then distributed during said pressing step. Moreover, the inventors discovered that when pressure is maintained for a long pressing time, there is a possibility

- 16 045113 the possibility of improving the permeability of the decorative layer, for example, there is the possibility of achieving a greater depth of permeability. 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 second, preferably more than 10 seconds, for example 30 seconds. 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 resin, said pressing time is sufficient for coating 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 transportation of floor elements after pressing is prevented.

It should be noted that while 100% coverage of resin on 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 preventing or minimizing resin overflow onto connecting elements. In fact, in the case where the resin overflows onto the connecting element, it can adversely affect the connection between the floor elements. Several measures can be taken to prevent such 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 lower surface or on the upper surface, configured to collect part of the resin. If the mentioned grooves are provided on the decorative layer, they are made directly near the very edge of the decorative layer. If said grooves are provided on the decorative layer, they are provided in a portion of the top 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 a portion of the top surface that extends beyond the edges of the decorative layer. In any case, it is preferable 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 to apply pressure to the decorative layer and/or to the support layer to promote penetration of the resin 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 introduced into a static press mold to be subjected to a predetermined pressure by the press punch. Thus, it is possible to maintain 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 lamination step in which the layers are fed into the lamination equipment, for example, under a single laminating roller or belt or between a pair of laminating rollers to apply a predetermined pressure. Since lamination is a continuous process, it is possible to speed up the entire manufacturing process while applying sufficient pressure to the layers to ensure penetration into the decorative layer. During lamination, the pressing time depends on the speed of advance of the layers, therefore, the advance speed can be adjusted in order to speed up the process and at the same time guarantee sufficient pressing time.

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

It should also be noted that the characteristic feature that the floor element may include connecting elements in accordance with a first possibility on a first pair of opposing edges, and connecting elements in accordance with a second possibility on a second pair of opposing edges constitutes an independent idea of the invention, regardless from other signs of the floor element. Therefore, according to a sixth independent aspect, the invention relates to a floor element comprising a decorative layer made of a ceramic material and a support layer located below the decorative layer, the support layer comprising at least two pairs of opposing 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 corresponding edges, and wherein the second the connecting elements on the second pair of edges are configured to be connected to the connecting elements of adjacent floor elements by means of downward translational movement of the corresponding edges towards each other. This 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 to effect the mechanical connection of the second connecting elements without the need knock with a hammer or hit the floor element itself. This also occurs when the second connecting elements are deformed 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 there is no longer any need to apply force. It should be noted that the floor elements in accordance with 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 may 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 ceramics. It should also be noted that this sixth aspect can advantageously be applied with decorative layers having a density, expressed by a surface density, of at least 10 kg/ ^m2 , preferably more than 15 kg/ ^m2 , for example more than 19 kg/ ^m2 . regardless of the material forming the decorative layer.

The inventors have also discovered that the connection of the floor elements in accordance with the sixth independent aspect is further simplified if, in the connected state, the first connection 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, then, on the other hand, it complicates said connection of the first connecting elements, and in particular it complicates the maneuverability of the floor element. Therefore, the play contributes to said connection at the first pair of edges. This effect is further enhanced if the backlash is greater than 0.01 mm, preferably greater 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 concept of the invention, regardless of the presence of other features of the floor element itself, in particular the presence of an intermediate layer penetrating into the lower surface of the decorative layer. According to a seventh independent aspect, the invention relates to a floor element comprising a decorative layer made of a ceramic material and a support layer located under this decorative layer with the characteristic feature that said support layer is made of rigid PVC. It should be noted that the floor element in accordance with the seventh independent aspect may include one or more features described with respect to the first independent aspect.

It should be noted that said resin collection grooves may constitute the idea of the invention, regardless 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 comprising a resin, with the characteristic feature that the decorative layer and/or the support layer includes one or more grooves configured to collect a portion of the resin. It should be noted that the floor element in accordance with this eighth independent aspect may contain one or more features described in relation to any aspect of the invention.

In order to better show the features of the invention, several preferred forms of embodiments are described below by way of example and without any limitation in any way, with reference to the accompanying drawings, in which:

in fig. 1 is a top view of an embodiment of a floor member 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 area F3 marked in FIG. 2;

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

- 18 045113 in Fig. 5 shows, on a reduced scale, a top 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 line VIII-VIII of FIG. 5;

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

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

In fig. 1 shows a top view of an embodiment of a floor element 1 in accordance with the invention. 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 contains edges having a maximum length L of less than 1.5 m, preferably less than 0.9 m.

Decorative layer 1 has a top surface 4 containing decor 5. Decor 5 can have a variety of textures, patterns and shades. In the example shown, the decor imitates the structure of wood, containing veins and stratification. Preferably, the decor 5 is at least partially formed by a printed image 6. The printed image 6 is preferably produced by digital printing such as inkjet 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. According to the illustrated example, the decorative layer 2 contains a body 7 made of a ceramic material, for example red clay or porcelain.

The decorative layer 2 comprises a base coat 8 covering at least partially the upper surface of the body 7, containing, for example, at least a glaze. The base covering 8 is configured to receive a decor 5 on its top surface, for example configured to receive a printed image 6 on its top 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 covering at least partially the upper surface of the body 7, for example containing at least a 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 in the range of 4 to 15 mm, for example 6 mm, preferably more than 7 mm, for example 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, flexes under its own weight by less than 10 cm/m and even more preferably by less than 5 cm/m. The support layer 3 may also contain a large amount of fillers, such as calcium carbonate, for example more than 30 wt.% or more than 60 wt.% of such fillers.

Moreover, 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 ranging from 20 to 85 µm/m per 1°C, preferably from 40 to 60 µm/m per 1°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 includes longitudinal edges 10, in which are provided first connecting elements 11, 12, configured to achieve mechanical connection with the connecting elements 11, 12 of the adjacent floor element 1. In the examples shown, the connecting elements 11, 12 contain a male and covering parts located on opposite longitudinal edges 10.

The first connecting elements 11, 12 of the longitudinal edges 10 are designed to be connected to each other by means of angular movement around a horizontal axis parallel to

- 19 045113 longitudinal edges 10. The male and female parts are respectively made in the form of a tongue 11 and a groove 12, the tongue 11 extending outward beyond its respective longitudinal edge 10 in the horizontal direction X and the groove 12 extending 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 includes upper longitudinal edges 27 that 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 includes an intermediate layer 13 located between the decorative layer 2 and the support layer 3. The intermediate layer 13 contains a polymeric material, for example, a thermosetting resin or a thermoplastic resin. Examples of thermoset resin are epoxy, polyurethane, cyanoacrylate or acrylic resin. Examples of thermoplastic resin are hot melt adhesive, polyester thermoplastic, vinyl and so on. Preferably, the resin is a rigid 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 low temperature (eg, room temperature) curing of 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, for example 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 Shore Hardness D scale.

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 top 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 includes grooves 50 configured to collect part of the resin of the intermediate layer 13 in the event of its overflowing over the edges 26 of the decorative layer 2, to prevent the said resin from overflowing onto the connecting elements 11, 12. In this embodiment, the mentioned groove 50 is provided in part support layer 3 extending beyond the edges 26 of the decorative layer 2. In addition, said grooves 50 extend continuously and parallel to the edges 26 of the decorative layer 2. For simplicity, the grooves 50 are not shown in other drawings of the present application, but in any case they may be present in In any 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 area 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, according to 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 . 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 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. According to an embodiment, the support layer 3 includes transverse edges 15, in which second connecting elements 16, 17 are provided, configured to be mechanically connected to the second connecting elements 16, 17 of the adjacent floor element 1.

In the examples shown, the second connecting elements 16, 17 are different 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 a substantially vertical direction. In the examples shown, said second connecting elements 16, 17 are configured 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 includes upper transverse edges 29 that 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. Moreover, in the said preferred example, said distance D2 is equal to distance D1. For example, said distances D1 and D2 are greater than 0.5 mm, preferably greater than 0.75 mm, for example 1.5 mm.

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

In fig. 6 is an enlarged cross-sectional view taken along line VI-VI in FIG. 5. The floor covering 18 contains 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 can be a flexible or rigid grout. The resilient 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 polymer grouts are polyurethane-based and acrylic resin-based grouts.

In fig. 6 also shows a cross-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 help of FIG. 7.

In fig. 7 is an enlarged view of the area F7 indicated in FIG. 6. According to the preferred example shown in FIG. 7, the tongue 11 includes a jaw 20 extending in a horizontal direction and a downwardly projecting projection 21. The groove 12 includes a horizontal recess 22 for receiving the jaw 20 of the tongue 11 and an upwardly directed hollow portion 23 for receiving the projection 21 of the tongue 11 to allow insertion of the 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 a first set of first blocking surfaces 24 limiting the mutual movement of said floor elements 1 in a horizontal direction X perpendicular to the connected longitudinal edges 10.

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

The downwardly projecting projection 21 of the tongue 11 is inserted into the hollow portion 23 of the groove 12. The bottom surface of the downward projection projection 21 comes into contact with the hollow portion 23 to form a second set of second locking surfaces 25. In other words, the bottom surface of the tongue 16 comes into contact with the groove 12 exclusively in accordance with the downward projection 21.

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

Preferably, said play P is greater than 0.01 mm, preferably greater than 0.03 mm. Moreover, 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 provides the connection between the tongue 11 and the groove 12 occurs without deformation of the first connecting elements 11, 12. In fact, thanks to the play P and the non-working spaces S1, S2, the connection between the tongue 11 and the groove 12 is significantly simplified.

In fig. 8 is an enlarged cross-sectional view taken along line VIII-VIII in FIG. 5. In FIG. 8 shows a cross-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 help of FIGS. 9.

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Claims (2)

In fig. 9 is an enlarged view of the area F9 marked in FIG. 8. The second connecting elements 16, 17 include 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 a female portion, wherein the upper hook portion 16 defines a downward jaw forming the male portion. In the connected state, the downward jaw and the upward cavity form a first blocking surface 24 for limiting the 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 include undercut portions 30 so that, in the connected state, second locking surfaces 25 are formed to limit mutual movement of the floor members 1 in the vertical Y direction. In particular, for example, two sets of said second blocking surfaces 25 are formed on opposite sides of the male portion and the female portion. Preferably, the lower hook-shaped part 17 includes an elastic shoulder part 31, configured to deform when connecting the upper hook-shaped part 16 with the lower hook-shaped part 17 so that by means of said deformation the connection of the trimmed parts 30 is ensured. In fig. 10 shows some steps of the method for manufacturing a floor element. The method comprises a first step S1 of providing the decorative layer 2. In step S1, the decorative layer 2 is supplied to the resin application section 40, in which the uncured resin material R is applied to the lower surface of the decorative layer 2, for example, in accordance with the pattern. 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 area 40, the decorative layer is placed so that the top surface containing the decor 6 faces downward. Then, in step S2, the decorative layer 2 is moved to the placement portion 41 in which the support layer 3 is located. The support layer 2 is placed under the lower surface of the decorative layer 3, thereby forming a semi-finished layered structure 42. Preferably, in the said placement portion 41, the decorative layer 2 and the support layer 2 is suitably centered relative to each other. Thereafter, in step S3, the semi-finished layer structure 42 is moved 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 forming the intermediate layer 13. Preferably, pressure during pressing is maintained for at least 1 s, preferably 30 s, so that the uncured resin R can spread to cover at least 80%, preferably 100% of the lower surface of the decorative layer 2. Moreover, 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 compressed floor element 1 is moved to a storage area 44 for a predetermined time to allow resin R to continue to cure before packaging, transportation and/or use in a floor covering. Preferably, the storage time is such as to ensure that the resin R is at least 70% cured, preferably 85% cured, more preferably completely cured. For example, said storage time is at least 0.5 hours, preferably more than 1 hour, for example 2 hours. The present invention is in no way limited to the above embodiments, and such floor elements can be configured in accordance with various embodiments without departing from the scope of the present invention. CLAIM 1. A floor element (1) for forming a floor covering, wherein the floor element (1) contains a decorative layer (2) made of ceramic material, and a support layer (3) located under the specified decorative layer (2), wherein the support layer ( 3), containing rigid PVC and filler, contains edges (10, 15), in which connecting elements (11, 12, 16, 17) are provided, made with the possibility of mechanical connection with the connecting elements (11, 12, 16, 17) adjacent floor element (1), where the floor element (1) contains an intermediate layer (13) having a polymeric material that penetrates into the lower surface of the decorative layer, and where said filler contains mineral particles selected from chalk or calcium carbonate. 2. Floor element (1) according to claim 1, in which the polymer material contains epoxy, complex -