EP4097060A1 - Panneau pour former un revêtement de sol et revêtement de sol de ce type - Google Patents

Panneau pour former un revêtement de sol et revêtement de sol de ce type

Info

Publication number
EP4097060A1
EP4097060A1 EP21705888.2A EP21705888A EP4097060A1 EP 4097060 A1 EP4097060 A1 EP 4097060A1 EP 21705888 A EP21705888 A EP 21705888A EP 4097060 A1 EP4097060 A1 EP 4097060A1
Authority
EP
European Patent Office
Prior art keywords
magnesium
panel
crystal structure
magnesium oxide
core layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21705888.2A
Other languages
German (de)
English (en)
Inventor
Tom VAN POYER
Sven Boon
Thomas Luc Martine BAERT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Champion Link International Corp
Original Assignee
Champion Link International Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Champion Link International Corp filed Critical Champion Link International Corp
Publication of EP4097060A1 publication Critical patent/EP4097060A1/fr
Pending legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02044—Separate elements for fastening to an underlayer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/10—Lime cements or magnesium oxide cements
    • C04B28/105—Magnesium oxide or magnesium carbonate cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
    • C04B28/32—Magnesium oxychloride cements, e.g. Sorel cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/12—Mixture of at least two particles made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/20—Particles characterised by shape
    • B32B2264/204—Rod- or needle-shaped particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/30—Particles characterised by physical dimension
    • B32B2264/302—Average diameter in the range from 100 nm to 1000 nm
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/30—Particles characterised by physical dimension
    • B32B2264/304—Particle length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0153—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement

Definitions

  • the invention relates to a panel, in particular a floor panel or a wall panel, suitable for forming a decorative floor or wall covering.
  • the invention furthermore relates to such floor covering.
  • the invention also relates to method for producing a panel, in particular a floor panel or a wall panel, suitable for forming a decorative floor or wall covering.
  • the flooring industry commonly uses mostly traditional materials for manufacturing (laminated) floor tiles.
  • these materials are: high density fiberboard (HDF), which can be merged together by a formaldehyde or phenol-based resin; heterogeneous or homogeneous polyvinyl chloride (PVC), which may possibly comprise any plasticizers, pieces of solid hardwood; layers of veneers glued together; and fired and glazed clay such as ceramic and porcelain tiles.
  • HDF high density fiberboard
  • PVC polyvinyl chloride
  • the purpose of use of these materials depends mainly on their material properties such as impact resistance, rigidity, acoustic performance and/or appearance.
  • an interest in the use of alternative materials has occurred over the last few years.
  • An example thereof is the use of mineral materials, since mineral materials generally benefit a relatively high and dimensional stability and sufficient resistance to heat, and have a low impact on the environment compared to traditional materials such as PVC or HDF.
  • mineral materials generally benefit a relatively high and dimensional stability and sufficient resistance to heat, and have a low impact on the environment compared to traditional materials such as PVC or HDF.
  • due to its development being focused on its use as a building material, in particular as a gypsum/drywall replacement it is not as of yet particularly suitable for use as component of a floor panel.
  • an improvement in the bending strength, impact resistance, indentation resistance, internal cohesion and surface adhesion of a panel made of such a mineral material is desirable to make it suitable for use as a component of a floor panel.
  • the invention provides thereto a panel, in particular a floor or wall panel, suitable for forming a floor or wall covering, comprising at least one core layer having a planar top side, and a planar bottom side, at least four linear side edges, wherein at least one core layer comprises a magnesium oxide composition comprising at least magnesium oxide and magnesium salt, wherein said magnesium oxide composition comprises a magnesium crystal structure which comprises at least 50 % by weight of at least one 5-phase magnesium crystal structure.
  • the core layer according to the present invention has greatly improved characteristics compared to conventional magnesium oxide based core layers due to the presence of an increased amount of crystal in an advantageous 5- phase magnesium crystal structure.
  • such core layer comprises more whisker or needle form magnesium crystals than magnesium crystals present in a flaky or irregular form.
  • the panel according to invention having a magnesium crystal structure which comprises at least 50 % by weight of at least one 5-phase magnesium crystal structure benefits of a notable improvement in internal cohesion, a good impact resistance and good bending strength to the panel. This results in the panel according to the present invention being particularly suitable for decorative residential and commercial flooring purposes.
  • the magnesium oxide composition could also comprise magnesium oxide, at least one magnesium salt and water.
  • a magnesium crystal structure also a magnesium oxide crystal structure can be meant.
  • the invention also relates to a panel, in particular a floor or wall panel, suitable for forming a floor or wall covering, comprising at least one core layer having a planar top side, and a planar bottom side, at least four linear side edges, wherein said at least one core layer comprises a magnesium crystal structure which comprises at least 50 % by weight of at least one 5-phase magnesium crystal structure.
  • the magnesium crystal structure can be formed by a magnesium oxide composition comprising at least magnesium oxide and magnesium salt.
  • the invention also relates to a panel, in particular a floor panel, suitable for forming a floor covering, wherein the panel has a substantially planar top side, a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges, and at least one core layer which at least partially comprises a magnesium crystal structure comprising magnesium oxide and at least one magnesium oxide compound chosen from the groups of magnesium (oxy)sulfate and magnesium (oxy)chloride.
  • the at least one core layer preferably comprises at least one organic compound comprising at least two hydroxyl groups. Preferably, said organic compound is present in the range of 0.05% to 5% by weight of the at least one core layer.
  • the core layer at least partially comprising a magnesium crystal structure which preferably comprises at least one organic compound comprising at least two hydroxyl groups, preferably wherein said organic compound is present in the range of 0.05% to 5% by weight, results in the crystal structure having an increased amount of crystal in an advantageous whisker or needle form than in a flaky or irregular form.
  • the invention also relates to a panel, in particular a floor panel, suitable for forming a floor covering, wherein the panel has a substantially planar top side, and a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges, the panel comprising a core layer comprising a magnesium oxide cement, wherein the magnesium oxide cement comprises magnesium oxide crystals in a flaky or irregular form and in a whisker or needle form, wherein there are more crystals in the whisker or needle form than in the flaky or irregular form.
  • the at least one core layer comprises a magnesium crystal structure, for example magnesium oxysulfate or oxychloride crystal structure, which at least partially, and preferably substantially entirely form a dense crystal microstructure in a whisker or needle form, thereby providing a notable improvement in internal cohesion, a good impact resistance and good bending strength to the panel. This results in the panel being particularly suitable for decorative residential and commercial flooring purposes.
  • the magnesium crystal structure comprises, preferably, magnesium oxysulfate or magnesium oxychloride crystals having a magnesium oxysulfate whisker or needle form and magnesium chloride crystals having a magnesium chloride whisker or needle form.
  • the core layer comprises a magnesium oxide composition or a magnesium oxide cement.
  • the magnesium salt is preferably magnesium sulfate and/or magnesium chloride.
  • the formation and microstructure of a magnesium oxide composition or cement can be described in “crystal” or “hydration” phases and expressed in terms of a ternary system consisting of the ratio of magnesia, a magnesium salt such as magnesium sulfate or magnesium chloride, and water. Crystalline phases are formed upon curing into a ceramic compound and can be expressed in an abbreviated version referring to the molar ratio of each compound in the crystal formed.
  • Magnesium oxysulfate cement which uses the salt magnesium sulfate as a key binding material, can form two stable crystalline phases under livable conditions; composed of the compounds magnesium oxide, magnesium sulfate and water, generally referred to as the 5-phase (also known as for example 5-1-3 phase, 5Mg(0H)2.MgS04.3H20), and 3-phase (also known as 3-1-8 phase, 3Mg(0H)2.MgS04.8H20).
  • the former shows a beneficial needle- or whisker- like crystal structure of 0.2-1 .0 pm diameter and a length of 20-50 pm that features good bending strength; whereas the latter shows a flaky or irregular crystal shape that results in a weaker composition.
  • magnesium (oxy)chloride cement which uses the salt magnesium chloride as a key binding material, is also known to form at least two stable crystalline phases under livable conditions, wherein the magnesium chloride crystalline phases can generally be present in a 5-phase (also 5-1-8 for 5Mg(0H)2.MgCI2.8H20) phase and/or a 3-phase (also 3-1-8 for 3Mg(0H)2.MgCI2.8H20).
  • the former shows a beneficial needle- or whisker-like crystal structure of similar dimensions and shape to the magnesium sulfate cement meant 5-phase; whereas the latter shows also irregular crystal shape that results in a weaker composition.
  • Magnesium cement refers to a magnesium composition comprising magnesium oxide, a magnesium salt and water.
  • Said magnesium salt can refer to magnesium oxysulfate or oxychloride. When combined, these compounds form a cementitious matter comprising crystal phases.
  • crystal phases for use in livable conditions are meant, being a ceramic composition comprising a crystal phase structure of magnesium comprising an oxysulfate and/or oxychloride 5-phase and/or 3-phase.
  • the 3- phase “flaky” or irregular structure is generally regarded to be the more stable phase structure under 20-60 degrees Celsius and livable atmospheric conditions.
  • more than 50%, more generally more than 90%, most generally substantially all of the formed crystal structure in oxysulfate or oxychloride cement consists of the 3-phase.
  • Other phases can form for both magnesium salts under extreme pressures and temperatures (up to hundreds of degrees Celsius) but are not stable under livable temperatures.
  • magnesium cement is prepared, naturally more than 50%, generally more than 90% of the composition consists of irregular, 3-phase crystals. Its flaky or irregular structure results in an efflorescence of the panel surface, and subsequently an inferior cohesion and low surface adhesion which makes it especially unsuitable for use as a component in a flooring panel.
  • the invention provides a floor panel comprising at least one core layer comprising a ratio of the magnesium oxysulfate or magnesium oxychloride 5 - phase to 3-phase of more than 1 .
  • the invention provides a floor or wall panel comprising at least one core layer comprising at least one magnesium cement composition comprising at least 50% by weight of at least one 5-phase crystal structure.
  • the magnesium oxysulfate whiskers (or 5-phase crystals) benefit of being stable under ambient conditions.
  • the magnesium oxysulfate whiskers may also be referred to as needles. Due to the magnesium oxysulfate whiskers at least partially forming a dense crystal structure, the magnesium oxysulfate whiskers will interlock with one another to form a high density, pore-filling microstructure. These interlocking whiskers thereby provide the improved strength to the core layer of the panel. Additionally, the panel according to the present invention benefits due to the presence of said core layer of a good impact resistance which is beneficial when applying multiple panels in a floor covering according to the invention.
  • the compressive and indentation resistance of the crystal structure of the 5-1 -3 oxysulfate and 5-1 -8 oxychloride whisker phase is above 50MPa when tested according to EN 310, whereas the 3-1-8 structure has a compressive and indentation resistance of only about 20 MPa.
  • the panel according to the invention also benefits of a good water and moisture resistance as the whiskers are not easily soluble in water, whereas the 3-phases of both salts are less stable under wet conditions.
  • the magnesium 5-phase crystals (whiskers) are not an obvious material for a skilled person to use in the core material for the purpose of the present invention and in order to form a crystal structure.
  • the invention provides a different material that, combined through novel means, results in a much higher ratio of whisker phase crystals than possible according to the state of the art. It is possible that the core according to the invention comprises at least 50% or up to 100% of magnesium crystals in a 5-phase crystal structure.
  • Magnesium oxysulfate and oxychloride whiskers can be produced via mixing of reactive magnesia with an aqueous magnesium sulfate or chloride solution. Said reactive magnesia can be obtained via a calcination process performed at temperatures in the range of 600 to 1300 degrees Celsius, and preferably in the range of 800 to 1000 degrees Celsius. Reactive magnesia (RM) can also be referred to as “caustic-calcined magnesia” (CCM) or light-burned magnesia.
  • CCM caustic-calcined magnesia
  • a core comprising a high ratio of 5-phase whisker crystals to 3-phase flake crystals therefore has less pores or openings than a core comprising a higher ratio of flakes to whiskers.
  • whisker crystal growth during the curing process is inhibited by a lack of space, such as by a lack of pores or openings, they even intergrow and form a denser, stronger structure than is normally the case for magnesium oxide cements.
  • flake crystal growth during the curing process is inhibited by a lack of space, it does not result in a stronger composition. It is therefore an object of the invention to provide a preparation method which solves at least some of the limitations of the existing art
  • a first condition for the formation of the desired magnesium oxide 5-phase whiskers is the ratio of the raw materials.
  • An aqueous magnesium salt solution is prepared by mixing MgSC>4 or MgCI2 with water at a ratio of 0.6-2 to 1 , stirring it for approximately 2 -5 minutes to allow it to dissolve, then added to a dry mixture containing at least reactive magnesia so that the mixture will form a ceramic material during curing. In this way, a magnesium oxide damp composition is obtained.
  • a ratio of the whisker crystal phase to flake crystal phase be more than 1
  • a ratio of MgO vs MgS04 of around 4.6-5.8 to 1 , more ideally
  • a second condition for the formation of the desired crystal structure is the addition of a (second) aqueous solution comprising 50% to 90% by weight of an organic compound comprising at least two hydroxyl (-OH) groups to the magnesium oxide damp composition.
  • the fraction of organic compound to be added is chosen such that it results in a core layer comprising a magnesium oxide composition comprising 0.05% to 10% by weight of at least one organic compound comprising at least two hydroxyl groups.
  • This mixture of ceramic material or ceramic cement and additives is poured onto a mold, and allowed to set.
  • a third condition for the formation of the desired crystal structure is the application of a slightly elevated temperature and pressure during at least the initial phase of the setting process. Best results were achieved at 45 to 55 degrees Celsius of temperature and 6-8 Mpa of pressure for at least 1 hour, more advantageously at least 6 hours. It was noted that 50 degrees Celsius of temperature and 7 Mpa of pressure reduced the ratio of flaky crystal phase to well under 50%.
  • the cured material benefits of a good strength and good fire- retardant properties, resulting in the material being in particular suitable for use in the building industry. Since the application of pressure during curing ensures that no pores or openings can be formed in the mixture, the formed 5-phase whisker crystal intergrow and form a denser, stronger structure than is normally the case for magnesium oxide cements.
  • the hydroxyl (-OH) groups of the additive serve to replace at least part of the H20 molecules present in the magnesium cement matrix, thereby locking the crystals in place and serving as a “seed” around which crystals can be formed.
  • This is only possible at increased temperature which allows the replacement of at least part of the H20 molecules by at least part of the additive’s hydroxyl or carboxyl groups.
  • the increased pressure ensures the (inter)growth of 5-phase crystals results in a denser, stronger structure than is known for magnesium oxide cements.
  • the molar ratio of MgO to magnesium salt also prevents the creation of undesired Mg(OH)2, an unstable byproduct of excess reactive magnesia with undesirable material properties, especially at elevated temperatures.
  • a panel according to the preferred embodiment of the invention comprises mostly a magnesium oxide whisker structure based on magnesium cement, in particular of oxychloride or oxysulfate 5-phase. It is theorized that the 5-1-3 phase oxysulfate whiskers or 5-1-8 oxychloride whiskers present in the panel according to the present invention are transformed into 5-1-2 oxysulfate whiskers or 5-1-7 oxychloride whiskers respectively, of which at least one water molecule is at least partially displaced by at least one of the hydroxyl groups of the organic additive.
  • the 5-1-3 phase, 5-1- 8 phase, 5-1-2 phase and or 5-1-7 phase can be meant.
  • the panel according to this invention preferably comprises a cement which at least partially consists of a 5-1-2 oxysulfate whisker or 5-1-7 oxychloride phase.
  • the 5-1-2 oxysulfate phase in particular has desirable characteristics, as it contains the smallest amount of H20 molecules of all of the disclosed phases, which has certain advantages in situations where a high moisture content is not desired, such as in hot-pressing of the board, or certain specific uses in the construction industry where a low moisture content is desired. It also offers a panel with a lower specific gravity than panels containing magnesium oxide cements based on phases containing larger amounts of H20 molecules.
  • a panel according to a preferred embodiment of the invention has a core layer having a thickness in the range of 3 to 10 millimeters.
  • the density of said core layer is typically from 1200-1500 kg/m 3 , more specifically around 1300-1400 kg/m 3 .
  • the density of the core layer is substantially constant over the entire volume of the core layer.
  • One embodiment of the invention can be composed of multiple layers of magnesium oxysulfate cement or magnesium oxychloride cement, each having a specific crystal structure, with beneficially at least a top layer comprising a ratio of 5-phase whisker to 3-phase flaky structure of more than 1 , or a top and bottom layer of a similar ratio, or the substantially entire core consisting of such a similar ratio depending on the specific requirements of the floor panel in question. It is to be understood that in one embodiment, different layers of the core can have different crystal structure ratios for enhanced acoustical performance.
  • the panel has a substantially planar top side, and a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges.
  • the panel is typically substantially rectangular or square. However, it is also conceivable that the panel has a substantial parallelogram shape. When it is referred to as a panel, this can both be a floor panel or a wall panel.
  • the term tile is interchangeable with the term panel.
  • the length-to-diameter ratio of at least a number of magnesium whiskers is typically at least 5, preferably at least 10, more preferably at least 20. In this embodiment the magnesium whiskers can provide sufficient (bending) strength to the core layer of the panel.
  • At least a number of magnesium whiskers have an average diameter in the range of 0.2 to 1.0 micrometre and/or at least a number of magnesium whiskers have an average length in the range of 1 to 50 micrometres.
  • at least a number of magnesium crystals of the 5-phase magnesium crystal structure may have an average diameter in the range of 0.2 to 1 .0 micrometers.
  • at least a number of magnesium crystals of the 5-phase magnesium crystal structure may have an average length in the range of 1 to 50 micrometers.
  • the exact shape of the magnesium whiskers may differentiate, due to the phase wherein the magnesium whiskers are stable at the given temperature and humidity.
  • the core layer comprises at least 50% by weight of magnesium 5- phase crystals, preferably at least 55% by weight and more preferably at least 60% by weight of the whisker-phase crystal structure.
  • the magnesium oxide composition possibly comprises a magnesium crystal structure which comprises at least 55% by weight of at least one 5-phase magnesium crystal structure.
  • the magnesium oxide composition comprises a magnesium crystal structure which comprises at least 60% by weight of at least one 5-phase magnesium crystal structure or more preferably at least 70% by weight of at least one 5-phase magnesium crystal structure.
  • the further volume of the core layer may have a non-crystal structure.
  • the further volume of the core layer may for example be at least partially porous. It is also conceivable that the entire magnesium crystal structure of the magnesium oxide composition is a 5- phase magnesium crystal structure.
  • At least one core layer of the panel could possibly comprise at least one a reinforcing layer .
  • the core layer comprises an upper part and a lower part and a reinforcing layer situated between said upper part and said lower part of the core layer.
  • the upper part of the core layer may even define the substantially planar top side, and the bottom part of the core layer may define the substantially planar bottom side of the panel.
  • the presence of at least one reinforcing layer may lead to improvement of the acoustic properties of the panel. This may for example result in improved sound dampening properties.
  • the presence of at least one reinforcing layer may also contribute to an improved strength of the panel as such.
  • the reinforcement layer may for example comprise a woven or non-woven fiber material.
  • the reinforcing layer may in a beneficial embodiment comprise fiberglass.
  • the reinforcing layer may in particular comprise a fiberglass mesh.
  • a non-limiting example thereof is a fiberglass mesh having a mesh size of at least 5x5 mm, and/or the fiberglass mesh having an area weight of at least 90 g/m2.
  • the fiberglass mesh may be provided with a coating, in order to prevent skin-reactions during physical contact.
  • the reinforcing layer has a thickness of about 0.2 to 0.4 millimeters.
  • At least one core layer further comprises two reinforcing layers and an intermediate layer sandwiched between said two reinforcing layers.
  • the core layer further comprises an intermediate part and a further reinforcing layer, wherein a first reinforcing layer is situated between said upper part and said intermediate part of the core layer, and a second reinforcing layer is situated between said intermediate part and said lower part of the core layer.
  • the first and second reinforcing layers can both consist of a reinforcing layer as described above.
  • the intermediate part of the core layer does not necessarily have the same material properties as the further parts of the core layer. It is for example conceivable that the intermediate part of the core layer is at least partially foamed.
  • the intermediate part may therefore comprise a foaming agent. Such, at least partially foamed intermediate part of the core layer may further improve the acoustic performance of the panel.
  • the panel preferably comprises at least one pair of opposite side edges which are provided with interconnecting coupling means.
  • the panel comprises two pairs of opposite side edges which are provided with interconnecting coupling means. This will contribute to the ease of connect of multiple panels when assembling for example a floor or a wallcovering.
  • the interconnecting coupling means typically comprise a tongue and a groove wherein the tongue is provided on one side edge (opposite) of one pair of opposite side edges, and the groove is provided on the other side edge of the same pair of opposite side edges.
  • the interconnecting coupling means of co acting panels may be provided with co-acting locking elements.
  • the tongue and/or the groove are made of a magnesium oxide composition comprising a magnesium crystal structure which comprises at least 50 % by weight of at least one 5-phase magnesium crystal structure. It is in particular conceivable that an upper lip and a lower lip of the groove are made of a magnesium oxide composition comprising a magnesium crystal structure which comprises at least 50 % by weight of at least one 5-phase magnesium crystal structure. Possibly, both the tongue and the groove comprise at least one magnesium crystal structure present in a whisker form and a flake form, wherein a ratio between the whisker form and the flake form is no less than 1 .
  • the core layer further comprises at least one polymer and/or wood based material. It is also conceivable that the core layer further comprises at least one binder.
  • the panel further comprises at least one top layer.
  • the top layer is typically provided on the top surface of the panel. It is beneficial if the top layer has suitable properties for its intended use such as a waterproof layer, wear layer, and/or decorative layer.
  • Said top layer can be directly or indirectly attached to the core layer of the panel, for example via an adhesive, a hot melt material and/or hot or cold pressing.
  • a decorative top layer if applied, may for example comprise at least one ply of cellulose-based layer and a cured resin, wherein the cellulose-based layer is preferably paper or kraft paper. Said ply of cellulose- based material may also be a veneer layer adhered to a top surface of the core layer.
  • the veneer layer is preferably selected from the group consisting of wood veneer, cork veneer, bamboo veneer, and the like.
  • Other decorative top layers that could possibly be applied for the present invention include a ceramic tile, a porcelain tile, a real stone veneer, a rubber veneer, a decorative plastic or vinyl, linoleum, and decorative thermoplastic film or foil.
  • the top layer may possibly be further provided with a wear layer and optionally a coating. Examples of thermoplastics that could be used in such top layer are PP, PET, PVC and the like. It is also possible to provide on the top facing surface of the core an optional primer and print the desired visual effect in a direct printing process.
  • the decorative top layer can receive a further finishing with a thermosetting varnish or lacquer such as polyurethane, PUR, or a melamine based resin.
  • the panel at least one backing layer.
  • This can be any suitable backing layer for use with (floor) panels.
  • the panel comprises (at its back surface) at least one balancing layer, generally composed of at least one layer of lignocellulose and a cured resin.
  • the panel may also comprise at least one acoustic layer, usually composed of a low density foamed layer of ethylene-vinyl acetate (EVA), irradiation-crosslinked polyethylene (IXPE), expanded polypropylene (XPP), expanded polystyrene (XPS), but also nonwoven fibers such as made from natural fibers like hemp or cork, or recycled/recyclable material such as PET.
  • EVA ethylene-vinyl acetate
  • IXPE irradiation-crosslinked polyethylene
  • XPP expanded polypropylene
  • XPS expanded polystyrene
  • the density of this acoustic layer preferably has a density between 65 kg/m 3 and 300 kg/m 3 , most
  • the invention also relates to a floor covering comprising multiple panels, in particular floor panels, according to any the preceding claims.
  • a wall covering comprising multiple panels according to the invention also falls within the scope of the present invention.
  • the invention further relates to a method for producing a panel, in particular a floor or wall panel, preferably according to any embodiment of the present invention, the method comprising the steps of: a) preparing a magnesium oxide damp composition comprising magnesium oxide and at least one magnesium salt; b) adding at least one slurry comprising at least one organic compound comprising at least two hydroxyl groups to the magnesium oxide damp composition; and c) applying a force of at least 7 MPa at a temperature in the range of 45 to 55 degrees Celsius for a predetermined period of time to form a core layer.
  • Preparing of the magnesium oxide damp composition comprising magnesium oxide and at least one magnesium salt can be done by mixing of a brine comprising at least one magnesium salt into said a composition comprising at least one magnesium oxide such that a magnesium oxide damp composition is formed.
  • the predetermined period of time is preferably at least one hour.
  • the method results in obtaining a core layer comprising a magnesium crystal structure comprising 0.05% to 5% by weight of at least one organic compound.
  • the invention thus also relates to a method for producing a panel, in particular a floor or wall panel, preferably according to any embodiment of the present invention, the method comprising the steps of: a1) providing a dry composition comprising at least one magnesium oxide; b1) providing a brine comprising at least one magnesium salt and water; c1) mixing of said brine into said dry composition of magnesium oxide such that a magnesium oxide damp composition is formed; d1) preferably adding at least one aqueous slurry comprising at least one organic compound comprising at least two hydroxyl groups to the magnesium oxide damp composition; e1) subjecting the magnesium oxide damp composition to at least one screening step f 1 ) applying at least one layer of the magnesium oxide damp composition upon a mold; and g 1 ) subjecting the layer of magnesium oxide damp composition to a force having a pressure of at least 7 MPa at a temperature at least in the range of 45 to 55 degrees Celsius for at least 1 hour such that a core layer comprising an upper core surface and a lower core surface is obtained.
  • the magnesium oxide damp composition can also be referred to as magnesium oxide cement damp composition.
  • the screening step can also be a seiving step.
  • the magnesium oxide dry composition can for example be a magnesium oxide powder. The method results in obtaining a core layer comprising a magnesium crystal structure comprising 0.05% to 5% by weight of at least one organic compound.
  • the aqueous slurry, applied in step b) (or d1 )) could for example comprise up to 90% of at least one organic compound comprising at least two hydroxyl groups.
  • Said organic compound comprising at least two hydroxyl (-OH) groups is typically an acid such as oxalic acid, citric acid, phosphoric acid and/or boric acid.
  • a fraction of said aqueous slurry is added during step b) (or d1)).
  • step c) or g1
  • a core layer, or core board whereof multiple core layers can be formed is obtained.
  • the method according to the preferred embodiment of the present invention allows to produce a core layer having a density in the range of 1200 kg/m 3 to 1600 kg/m 3 , in particular between 1350 kg/m 3 and 1550 kg/m 3 .
  • the method also enables that a core layer can be obtained having a density which is substantially constant over the entire volume of the core layer. This can at least partially be explained by the pressure applied at step c) (or g1)).
  • a substantially constant density is also beneficial for the overall strength of the panel.
  • the magnesium oxide damp composition e.g.
  • magnesium oxysulfate cement and magnesium chloride cement is formed by mixing at least one magnesium oxide powder and brine.
  • the magnesium oxide damp composition is in practice a substantially powdery composition, which has a lower water content than a convention magnesium oxide slurry.
  • the magnesium oxide damp composition is typically slightly wet but not soaked. Hence, the magnesium oxide damp composition can also be classified as textured composition.
  • the magnesium oxide damp composition is mixed prior to at least one screening step.
  • a mesh size between 10 and 35 mm could for example be applied.
  • the screening step can, for example, be achieved by making use of a processor which preferably comprises brushes and/or screens, for example screens having a mesh size between 10 and 35 mm. It is also possible that multiple subsequent screening steps are applied to ensure that the screened magnesium oxide cement damp composition is even.
  • the layer of magnesium oxide damp composition is preferably subjected to a temperature at least in the range of 45 to 55 degrees Celsius. It is beneficial that such relatively low temperature can be applied for multiple reasons, for example for efficiency, energy and safety reason.
  • the temperature is preferably substantially lower than 100 degrees Celsius and/or higher than 40 degrees Celsius. It is also conceivable that the magnesium oxide damp composition (during step c) or g1 )) is subjected to a temperature in the range of 40 to 60 degrees Celsius, in the range of 50 to 90 degrees Celsius or in the range of 50 to 75 degrees Celsius.
  • the method according to the present invention allows to achieve panels having a rather consistent density, which can be at least partially explained by the combination of steps a) and c) (or e1) and g1)). These steps also at least partially prevent bubble formation and/or remove gas and/or bubbles present in the damp composition. Step c) (or g1)) enables the (chemical) reaction of the components of the magnesium oxide damp composition to finish and/or to cure the magnesium oxide damp composition.
  • a further benefit of the method according to the present invention is that where conventional magnesium oxide cement based panels are typically produced by a process using excessive water, the panel according to the preferred embodiment of the present invention can produce via a more water efficient method.
  • a predetermined amount of water is applied for forming the magnesium oxide damp composition, wherein the amount is determined based upon the water required for the (chemical) reaction with magnesium oxide and optionally any further components and/or curing thereof.
  • the amount of water to be used can be controlled based upon the desired properties of the final product and the desired crystal structure in the core layer. More specifically, the amount of water in weight percentage or molar ratio added to the composition directly influences which crystal structure is formed in the core layer during the pressing phase.
  • Step c) (or g1))) of the method can, for example, be achieved via at least one pressing and/or compressing step.
  • Step c) (or g1)) enables the removal of excessive liquid from the magnesium oxide cement damp composition.
  • the magnesium oxide damp composition is typically dried and/or cured.
  • the at least one screening step enables that a more even magnesium oxide damp composition can be obtained.
  • a conveyer, container and/or a plate can also be meant. Basically, due to the magnesium oxide damp composition having a relatively functional structure, it is not required that the mold comprises raised edges and/or a rim.
  • the magnesium oxide damp composition has a relatively low moisture content, wherefore the damp composition does not behave like a liquid. This enables easier handling of the composition during processing thereof.
  • the method may for example involve applying a layer which is at least partially 4 to 7 cm in thickness of the magnesium oxide cement damp composition in or upon the mold. As indicated above, the method can also allow the production of core board whereof multiple core layers are formed.
  • a core layer comprising magnesium oxide cement and natural fibers may have a density in the range of 1350 kg/m 3 to 1550 kg/m 3 , resulting in a core layer having a relatively good flexural and structural strength.
  • the magnesium oxide damp composition formed at step a) (or d)) has a moisture content below 25 wt%, preferably below 10 wt%, more preferably at about 7% (7 wt% +/- 2 wt%). It is for example possible that the magnesium oxide damp composition formed at step a) (or d) has a moisture content between 10 wt% (+/- 2 wt%) and 7 wt% (+/- 2 wt%). It is possible to apply such relatively low moisture content due to the combination and/or fractions of materials used and the process steps applied in the present method.
  • the magnesium oxide damp composition may further comprise magnesium hydroxide, magnesium chloride and/or magnesium oxysulfate.
  • the magnesium oxide damp composition may further comprise any of the additives and/or fillers as described for the present invention.
  • the magnesium oxides damp composition may for example comprises at least 30 wt% natural fibers.
  • the natural fibers may comprise at least one element chosen from the group of: wood fibers, bamboo fibers, animal fibers, and/or mycelium fibers.
  • the natural fibers may be any of the above described natural fibers and may be present in any of the above described volumes.
  • the average length of the natural fibers may for example be at least 2 mm.
  • the natural fibers may comprise lignocellulose fibers, such as but not limited to wood fibers. Mixing of the magnesium oxide damp composition may contribute to at least part of the natural fibers being encapsulated by magnesium oxide cement. It is experimentally found that magnesium oxide and natural fibers effectively bond under pressure.
  • Step c) (or g1)) is typically performed for a duration of at least 2 hours, preferably at least 4 hours.
  • the panels can be demolded and/or cured.
  • the method may comprise the step of demolding of the obtained core layer.
  • the boards or panels typically have an initial strength that is at least 50% of the final strength after said duration intervals, and are the sufficiently strong to be further processed. Hence, the required process time is significantly shorter than the process time which are typically required for the production of a magnesium oxide based panel.
  • Conventional processes for the production of a magnesium oxide based panel typically have a duration of at least seven days, which can be even longer in case a layer of fiberglass is included in the panel.
  • the method may optionally comprise the step of attaching at least one decorative top layer to an upper core surface of the core layer, preferably by applying heat and/or pressure.
  • This step is made possible due to the technical possibility of avoiding the creation of a density gradient in the panel, in particular in the core layer of the panel, which is a result of the pressure applied at step c) (or g1)) and the consistency of the damp composition. It is also conceivable that a density gradient is present in the panel. It is possible to provide a core with a consistent density gradient, or a lack of density gradient, that being a core with an even specific gravity across the volume of the core.
  • the current method enables the production of a panel having a core layer with a density that is substantially constant over the entire volume of the core layer thereby increasing the overall strength thereof which allows the panel to withstand further application of heat and pressure without being damaged.
  • the core layer being free of any regions and/or zones having an increased density, which is typical of conventional magnesium oxide cement based panels
  • hot pressing of at least one layer of impregnated paper, or lignocellulose impregnated with a resin, to the upper and lower surfaces of the panel is made possible without causing the panel to warp or bend despite the core layer comprising magnesium oxide cement.
  • Hot pressing of at least one layer of impregnated paper to the upper and lower surfaces of the panel is typically done by applying heat and pressure to the panel, more specifically to the core layer thereof.
  • the core layer can be subjected to a sanding process to increase adhesion prior to hot pressing.
  • the core layer is subjected to a temperature ranging from 100 - 200 °C, more preferably 170 -200 °C, most preferably 175 -190°C and to pressure ranging from 5-25Mpa, more preferably 18-22Mpa, most preferably around 20Mpa.
  • the application of heat and pressure to the core layer is conceived to last for at least 10 seconds to about 45 minutes, more preferably at least 30 seconds to about 90 seconds, most preferably at least 50 seconds to about 80secs.
  • the method may also comprise the step of profiling and/or edging of at least one side edge of at least one panel, and in particular the core layer of the panel.
  • step may for example involve that at least one pair of complementary coupling parts is provided at least two opposite side edges of the panel, preferably wherein the complementary coupling parts are configured such that in a coupled state a pretension is existing.
  • the complementary coupling parts specifically contain a higher ratio of 5-phase whisker phase to 3-phase flake phase, allowing for a pretension to exist in the coupled state of the coupling parts due to the enhanced strength the 5-phase content provides to the coupling parts.
  • the coupling parts contain a 5-phase to 3-phase magnesium cement of more than 1 , where the rest of the core may have a different ratio.
  • the method may for comprise a step of attaching at least one decorative top layer to the upper core surface of the core layer and/or attaching at least one balancing layer to the lower core surface of the core layer.
  • balancing layers and/or decorative top layers to be used are described above for the panel according to the present invention.
  • the layer of magnesium oxide damp composition is during step c) (or g1)) subjected to a force having a pressure between 7 MPa and 20 MPa. It is, for example, also possible that the magnesium oxide damp composition is subjected to a force having a pressure below 18 MPa.
  • the preferred pressure applied is at least partially dependent of the desired thickness and/or density of the final product.
  • Panel in particular a floor panel, suitable for forming a floor covering, wherein the panel has a substantially planar top side, and a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges, the panel comprising: at least one core layer at least partially comprising a magnesium crystal structure, wherein said at least one core layer comprises 0.05% to 5% by weight of at least one organic compound comprising at least two hydroxyl groups.
  • magnesium crystal structure is a magnesium oxysulfate and/or magnesium oxychloride crystal structure.
  • the core layer comprises at least 5% by weight of magnesium oxysulfate whiskers, preferably at least 10% by weight and more preferably at least 20% by weight of the whisker- phase crystal structure.
  • said organic compound comprising at least two hydroxyl (-OH) groups is an acid such as oxalic acid, citric acid, phosphoric acid and/or boric acid.
  • the core layer comprises an upper part and a lower part and a reinforcing layer situated between said upper part and said lower part of the core layer.
  • the core layer comprises an intermediate part and a further reinforcing layer, wherein a first reinforcing layer is situated between said upper part and said intermediate part of the core layer, and a second reinforcing layer is situated between said intermediate part and said lower part of the core layer.
  • interconnecting coupling means comprise a tongue and a groove wherein the tongue is provided on one side edge of one pair of opposite side edges, and the groove is provided on the other side edge of the same pair of opposite side edges.
  • the core layer further comprises at least one binder.
  • Panel according to any of the preceding clauses comprising at least one top layer, the top layer comprises at least one decorative layer and/or protective layer.
  • Panel according to any of the preceding clauses comprising at least one optional backing layer for improved balance and/or acoustical performance
  • Floor covering comprising multiple panels, in particular floor panels, according to any the preceding clauses.
  • figure 1 a first possible embodiment of panel according to the present invention
  • figure 2 a second possible embodiment of a panel according to the present invention
  • figure 3 a third possible embodiment of a panel according to the present invention
  • figure 4 shows a perspective view of the panel according to the present invention
  • figure 5 shows a cross section of a further possible embodiment of a panel according to the present invention.
  • FIG. 1 shows a schematic representation of a cross section of a first embodiment of a panel (101) according to the invention.
  • the figure shows the panel (101) comprising a core layer (102) comprises a magnesium oxide composition comprising at least magnesium oxide and magnesium salt, wherein said magnesium oxide composition comprises a magnesium crystal structure (104).
  • the magnesium crystal structure (104) preferably comprises at least 50% by weight of at least one 5-phase magnesium crystal structure.
  • the 5-phase magnesium crystal structure comprising magnesium crystal whiskers (103). It can be seen that the magnesium crystal whiskers (103) interlock with another.
  • the panel (101) as shown, further comprises a top layer (105) and optionally a backing layer (106), which are both optional.
  • Figure 2 shows a schematic representation of a cross section of a second possible embodiment of a panel (201) according to the invention.
  • the figure shows the panel comprising a core layer (202) comprising an upper part (202a) and a lower part (202b) and a reinforcing layer (207) situated between said upper part (202a) and said lower part (202b) of the core layer (202).
  • Both parts (202a, 202b) of the core layer (102) comprise magnesium crystal whiskers (203) which at least partially form a 5-phase crystal structure (204).
  • the reinforcing layer (207) comprises a fiberglass mesh.
  • the panel (201) further comprises a top layer (205).
  • FIG. 3 shows a schematic representation of a cross section of a third possible embodiment of a panel (301) according to the invention.
  • the figure shows the panel comprising a core layer (302) wherein the core layer (302) comprises respectively an upper part (302a), a lower part (302b) and an intermediate part (302c). Said parts are separated via multiple reinforcing layers (307a, 307b). In the present embodiment, there is this intermediate part (302c) of the core layer (302), which is a foam layer.
  • the other parts (302a, 302b) of the core layer (102) comprise magnesium crystal whiskers (303) which at least partially form a crystal structure (304).
  • the panel (301) further comprises a top layer (305).
  • the panels as shown in figures 1-3 could optionally be provided with interconnecting coupling parts (for example as shown in figures 4 and 5) for interconnecting adjacent panels,
  • Figure 4 shows a perspective view of a possible embodiment of a flooring panel
  • the panel (401) comprises a core layer
  • the core layer (102) comprises two pairs of opposite side edges. In the shown embodiment, a first pair of opposite side edges is provided with interconnecting coupling parts (408a, 408b) for interconnecting adjacent panels (401).
  • the shown interconnecting coupling parts (408a, 408b) are shown as an illustration, any type of conventional coupling parts could be applied.
  • the core layer (402) comprises a magnesium crystal structure (404) comprising magnesium crystal whiskers (403).
  • FIG. 5 shows a cross section of a further possible embodiment of a flooring panel (501) according to the present invention.
  • the panel (501) comprises a core layer (501) and backing layer (506).
  • the panel (501) further comprises interconnecting coupling parts (508a, 508b) for interconnecting adjacent panels (501).

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Abstract

L'invention concerne un panneau, en particulier un panneau de plancher, approprié pour former un revêtement de sol, le panneau ayant un côté supérieur sensiblement plan, et un côté inférieur sensiblement plan, au moins quatre bords latéraux sensiblement linéaires comprenant au moins une paire de bords latéraux opposés, de préférence pourvus de moyens de verrouillage.
EP21705888.2A 2020-01-31 2021-01-29 Panneau pour former un revêtement de sol et revêtement de sol de ce type Pending EP4097060A1 (fr)

Applications Claiming Priority (2)

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NL2024805A NL2024805B1 (en) 2020-01-31 2020-01-31 Panel for forming a floor covering and such floor covering
PCT/EP2021/052217 WO2021152153A1 (fr) 2020-01-31 2021-01-29 Panneau pour former un revêtement de sol et revêtement de sol de ce type

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EP4097060A1 true EP4097060A1 (fr) 2022-12-07

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CN (1) CN113202253A (fr)
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CN101486267A (zh) * 2009-02-13 2009-07-22 南京林业大学 一种表面阻燃木塑复合材料板材及其制备方法
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