EP4097310A1 - Panel and method of producing such a panel - Google Patents

Panel and method of producing such a panel

Info

Publication number
EP4097310A1
EP4097310A1 EP21701812.6A EP21701812A EP4097310A1 EP 4097310 A1 EP4097310 A1 EP 4097310A1 EP 21701812 A EP21701812 A EP 21701812A EP 4097310 A1 EP4097310 A1 EP 4097310A1
Authority
EP
European Patent Office
Prior art keywords
core layer
panel
layer
tongue
situated
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
EP21701812.6A
Other languages
German (de)
French (fr)
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 EP4097310A1 publication Critical patent/EP4097310A1/en
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
    • E04F15/02044—Separate elements for fastening to an underlayer
    • 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
    • E04F15/102—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 of fibrous or chipped materials, e.g. bonded with synthetic resins
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/001—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by provisions for heat or sound insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B9/0407—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like being stiff and curved
    • 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
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0862—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
    • 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

Definitions

  • the invention relates to a panel, in particular a floor panel, a wall panel, or a ceiling panel.
  • a floor panel using PVC as core material is susceptible to temperature changes in its ambient environment which will cause the vinyl flooring to expand and contract with hot and cold fluctuations.
  • PVC panels also generally do not pass fireproofing ASTM tests.
  • floor panels with a core based on a mineral or cementitious material such as gypsum or magnesium can comprise a reinforcing layer of fiberglass, polypropylene, nylon and the like, as is described for construction boards in US7255907, and for stone-wood flooring in WO2012061300.
  • the invention thereto proposes a panel, in particular a floor panel, a wall panel, or a ceiling panel, comprising a core layer, comprising a mineral or a cementitious material; at least one reinforcing layer situated in said core layer; wherein the panel, in particular the core layer, comprises a first pair of opposite edges, wherein a first edge of said first pair of opposing edges comprises a first coupling part, and wherein a second edge of said first pair of opposing edges comprises a complementary second coupling part, said coupling parts allowing a plurality of panels to be mutually coupled; wherein the first coupling part comprises a sideward tongue extending in a direction substantially parallel to a plane defined by the panel, and wherein the second coupling part comprises a groove configured for accommodating at least a part of the sideward tongue of another panel, said groove being defined by an upper lip and a lower lip, wherein preferably at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panel, and wherein at least one rein
  • the invention also relates to a (floor) panel, comprising a core layer, comprising a mineral or a cementitious material, at least one reinforcing element situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue and a groove by local removal of material at the respective edge, and wherein the at least one reinforcing element is situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining core layer material at the location of the tongue or the groove.
  • Interlocking coupling parts can for example coupling parts that require elastic deformation, a click or a movement in multiple directions to couple or decouple the parts with or from each other.
  • the coupling parts are designed such that the height of the highest part of the top surface of the tongue substantially equals the height of the highest part of the bottom surface of the tongue.
  • the highest part of the bottom surface of the tongue is typically a substantially linear or flat area extending in a direction substantially parallel to a plane defined by the panel which is adjacent to a non-linear part defining the curvature of the tongue.
  • the panel comprises at least two reinforcing layers extends in a direction substantially parallel to the plane defined by the panel, such that each reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from the top surface of the panel to a highest part of the top surface of the tongue, and/or the bottom surface of the panel to a lowest part of the upper surface of the lower lip, and wherein adjacent reinforcing layers are positioned at a predetermined distance from another.
  • At least one reinforcing layer may be located at a level between 30-70 percent of the thickness from a top surface of the core layer to a highest part of a top surface of the tongue, and at least one further reinforcing layer is situated at a level between 30-70 percent of the thickness from a bottom surface of the core layer to a lowest top surface of the tongue.
  • At least one reinforcing layer may be located at a level between 40-60 percent of the thickness from a top surface of the core layer to a highest part of a top surface of the tongue, and at least one further reinforcing layer is situated at a level between 40-60 percent of the thickness from a bottom surface of the core layer to a lowest top surface of the tongue.
  • the reinforcing layer may be located halfway (center) of the remaining thickness from a top surface of the core layer to a highest part of a top surface of the tongue, and at least one further reinforcing layer is situated at the center of the remaining thickness from a bottom surface of the core layer to a lowest top surface of the tongue.
  • At least one reinforcing layer may be located halfway (center) of the remaining thickness from a top surface of the core layer to a highest part of a bottom surface of the tongue, and/or at least one reinforcing layer is situated at the center of the remaining thickness from a bottom surface of the core layer to a lowest top surface of the tongue.
  • bottom surface also a downward facing surface is meant.
  • top surface also an upward facing surface is meant. It is possible that the distance between the top surface of the core layer and at least one first reinforcing layer; and the distance between the bottom surface of the core layer and at least one further reinforcing layer, is substantially the same to achieve optimal balancing of the panel under temperature fluctuations.
  • the distance between the top surface of the core layer and at least one first reinforcing layer is greater than the distance between the bottom surface of the core layer and at least one further reinforcing layer, whereby a certain back- pull can be achieved on the panel for optimal stability in demanding environments with extreme temperatures and/or humidity fluctuations.
  • the floor panel according to the invention comprises at least two reinforcing layers, wherein a first of the reinforcing layers is situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining material at the location of the tongue, and wherein the second of the reinforcing layers is situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining material at the location of the groove.
  • both tongue and groove are further optimised, leading to an even more stable panel, with a very low damage and wear risk.
  • At least one reinforcing layer is situated at a level between 50 and 70 percent of the thickness from the top surface of the core layer to a highest part of the top surface of the tongue and/or wherein at least one reinforcing layer is situated at a level between 50 and 70 percent of the thickness from the bottom surface of the core layer to a lowest part of the upper surface of the lower lip.
  • At least one reinforcing layer is situated at a level between 50 and 60 percent of the thickness from the top surface of the core layer to a highest part of the top surface of the tongue and/or wherein at least one reinforcing layer is situated at a level between 50 and 60 percent of the thickness from the bottom surface of the core layer to a lowest part of the upper surface of the lower lip.
  • at least one reinforcing layer is positioned halfway the smallest thickness of the remaining material at the location of the tongue or closer to the tongue (than the top surface of the core layer) and/or the further of the reinforcing layers is positioned halfway the smallest thickness of the remaining material at the location of the groove or closer to the groove (than the bottom surface of the core layer).
  • Such embodiment achieves a relatively high modulus of elasticity (at any locations) in the upper and lower lip of the groove, resulting in a more rigid coupling parts.
  • the reinforcing layer may be a separate part, inserted in the panel, it may be a part of the same material with different properties, such as a different density or different material structure, or it may be a layer in the laminate.
  • Such reinforcing layer may be a closed layer or a mesh, sheet, or web material, that may be integrated or embedded in the core layer, especially when the core layer is made from a fluid or semi fluid material that requires curing.
  • the core layer has a top surface and a bottom surface, and in an embodiment, the remaining material at the location of the tongue or the groove extends to the top surface and a bottom surface. That means, when removing material for forming the tongue or the groove, only one side of the panel needs to be edited.
  • At least one reinforcing layer has a flexibility that is higher than the flexibility of the core material and/or the core layer.
  • Suitable materials to be applied as layer for the reinforcing layer for this purpose are fiberglass, polypropylene, cotton, silica or nylon. It is further conceivable that at least one reinforcing layer is situated between the top surface of the core layer and a highest part of the bottom surface of the tongue is made of a different material and/or has a different density than a further reinforcing layer which is situated between the bottom surface of the core layer and a lowest part of the upper surface of the lower lip.
  • a core layer comprising or consisting of magnesium oxide (MgO) and/or Magnesium Oxy Chloride cement and/or, Magnesium Oxy Sulphate cement and/or MgCI2 and/or MgS04, and preferably a suitable binder.
  • the core layer may comprise at least 70% in weight of MgO and/or Magnesium Oxy Chloride cement and/or, Magnesium Oxy Sulfate cement and/or MgCI2 and/or MgS04, and preferably a binder.
  • the core layer may for instance have a thickness between 3 and 8, in particular between 5 and 6 mm, wherein the smallest thickness of the tongue or groove is between 1 and 3 mm.
  • the complementary coupling parts are configured to form a click connection.
  • the (floor) panel according to the invention may comprise a laminate of said core layer and at least one of a decorative top layer, an acoustic dampening layer and/or a balancing layer.
  • 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.
  • the top layer may possibly be further provided with a wear layer and optionally a coating.
  • thermoplastics which 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 layer 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 comprises (at its back surface) at least one balancing layer, generally composed of at least one layer comprising 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/m3 and 300 kg/m3, most preferably between 80 kg/m3 and 150 kgm3.
  • Tests were performed with two different panel compositions, and reinforcing layers (in the form of a layer of the laminate, comprising fibreglass) at different locations.
  • the first panel has a core comprising Magnesium Oxy Chloride cement (MOC)
  • the second panel comprises a core comprising Magnesium Oxy Sulfate cement (MOS).
  • Table 1 shows the characteristics of various tested panels, in particular floor panels.
  • Table 1 characteristics of various tested panels.
  • the at least one reinforcing layer is best situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining core layer material at the location of the tongue or the groove.
  • 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 at least one magnesium oxide composition comprising magnesium oxide, water and at least one magnesium salt; b) applying at least two layers of magnesium oxide composition onto a mold, each layer separated by at least one reinforcing layer c) applying a force of at least 7MPa to the mixture at a temperature in the range of 45 to 55 degrees Celsius for a predetermined period of time such that a core layer of a certain thickness comprising an upper core surface and a lower core surface is obtained.
  • the magnesium oxide composition can also be referred to as magnesium oxide cement composition or magnesium cement composition.
  • the magnesium oxide composition is preferably subjected to at least one screening step, which can also be a sieving step.
  • the magnesium oxide composition can for example be a magnesium oxide powder.
  • the steps of said method are generally subsequent steps. After the pressure of step c) is released, 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/m3 to 1600 kg/m3, in particular between 1350 kg/m3 and 1550 kg/m3.
  • 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).
  • 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 composition is in practice a substantially powdery composition, which has a lower water content than a convention magnesium oxide slurry.
  • the magnesium oxide composition is typically slightly wet but not soaked. Hence, the magnesium oxide composition can also be classified as textured composition.
  • the magnesium oxide 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 composition is even.
  • 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) to c). These steps also at least partially prevent bubble formation and/or remove gas and/or bubbles present in the composition. Step c) enables the (chemical) reaction of the components of the magnesium oxide composition to finish and/or to cure the magnesium oxide 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. In practice, this means that substantially less watering process is used, and needed, during the production process and it also enables a significant reduction of the overall production time.
  • a predetermined amount of water is applied for forming the magnesium oxide 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) of the method can, for example, be achieved via at least one pressing and/or compressing step.
  • Step c) enables the removal of excessive liquid from the magnesium oxide cement composition.
  • the magnesium oxide composition is typically dried and/or cured. The at least one screening step enables that a more even magnesium oxide composition can be obtained.
  • a conveyer, container and/or a plate can also be meant.
  • the mold comprises raised edges and/or a rim.
  • the magnesium oxide composition has a relatively low moisture content, wherefore the 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 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/m3 to 1550 kg/m3, resulting in a core layer having a relatively good flexural and structural strength.
  • the magnesium oxide composition formed at step a) has a moisture content below 25 wt%, preferably below 10 wt%, more preferably at 7 +/- 2 wt%. It is for example possible that the magnesium oxide composition formed at step a) has a moisture content between 10 and 1 1 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. As indicated above, in the prior art it is known to produce magnesium oxide cement based panels via an extensive and time consuming process of drying of a magnesium oxide cement slurry, wherein the slurry contains at least 50 wt% of water, and often even over 60 wt% water.
  • the magnesium oxide composition may further comprise magnesium hydroxide, magnesium chloride and/or magnesium oxysulfate.
  • the magnesium oxide composition may further comprise any of the additives and/or fillers as described for the present invention. It is conceivable that natural fibers are added to the magnesium oxide composition after or during step a).
  • the magnesium oxides 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 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.
  • the method is typically performed under ambient conditions. However, it is also conceivable that the method is performed under vacuum or under a predetermined pressure above atmospheric pressure. Step c) is typically performed for a duration of at least 2 hours, preferably at least 4 hours. Step c) is in a further preferred embodiment performed for a duration between 6 hours to 12 hours. Afterwards, 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) and the consistency of the 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 , more preferably 170 -200 °C, most preferably 175 -190 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.
  • Such 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. It is possible and desirable therefore that 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 composition is during step c) subjected to a force having a pressure between 7 MPa and 20 MPa.
  • the magnesium oxide 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, a wall panel, or a ceiling panel, comprising: - a core layer, comprising a mineral or a cementitious material; at least one reinforcing layer situated in said core layer; wherein the panel, in particular the core layer, comprises a first pair of opposite edges, wherein a first edge of said first pair of opposing edges comprises a first coupling part, and wherein a second edge of said first pair of opposing edges comprises a complementary second coupling part, said coupling parts allowing a plurality of panels to be mutually coupled; wherein the first coupling part comprises a sideward tongue extending in a direction substantially parallel to a plane defined by the panel, and wherein the second coupling part comprises a groove configured for accommodating at least a part of the sideward tongue of another panel, said groove being defined by an upper lip and a lower lip, characterised in that: at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panel, such that said reinforcing layer is situated at
  • Panel according to clause 1 comprising at least two reinforcing layers, wherein the first reinforcing layer is situated in the core, extending parallel to the plane of the panel, situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway of the thickness of the tongue from the top surface of the core to the highermost bottom surface of the protrusion forming the tongue, and/or wherein a second reinforcing layer is situated in the core, extending parallel to the plane of the panel, situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway of the thickness from the bottom surface of the core to the lowermost top surface of the protrusion forming the groove.
  • Panel according to claim 1 or 2 wherein at least one reinforcing layer forms integral part of the core layer.
  • At least one reinforcing layer comprises mesh, sheet, or web material.
  • At least one reinforcing layer comprises fiberglass, polypropylene, cotton, PET, silica and/or nylon.
  • the core layer comprises MgO, Magnesium Oxy Chloride, Magnesium Oxy Sulfate, MgCI2, MgS04, and/or MgC03 and/or a binder.
  • the core layer comprises at least 70% in weight of MgO, Magnesium Oxy Chloride, Magnesium Oxy Sulfate, MgCI2, MgS04, and/or MgC03 and a binder .
  • the core layer has a thickness between 3 and 8 mm, in particular between 5 and 6 mm.
  • Panel according to any of the preceding clauses comprising a laminate of said core layer and at least one of:
  • figure 1 showing a core of a panel according to the present invention figure 2, showing a core of a panel according to the present invention figure 3, showing a core of a panel according to the present invention figure 4, showing a core of a panel according to the present invention figure 5, showing a core of a panel according to the present invention figure 6, showing a core of a panel according to the present invention figure 7, showing a core of a panel according to the present invention.
  • Figure 1 shows a first non-limiting example of a possible embodiment of a panel 1 according to the present invention.
  • Figure 1 shows two sides of a panel 1 , in particular a floor panel 1 , comprising a core layer 2, comprising a mineral or a cementitious material, at least one reinforcing layer 6, 7 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 9 and a groove 3 by local removal of material at the respective edge.
  • each reinforcing layer 6, 7 extends in a direction substantially parallel to the plane defined by the panel, such that said reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from the top surface of the panel to a highest part of the top surface of the tongue, and/or the bottom surface of the panel to a lowest part of the upper surface of the lower lip.
  • each reinforcing layer 6, 7, is situated halfway the smallest thickness 4, 5 of the remaining core layer material at the location of the tongue or the groove.
  • the core has a top surface 9 and a bottom surface 8, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
  • the coupling parts are designed such that the height of the highest part of the top surface of the tongue 9 substantially equals the height of the highest part of the bottom surface of the tongue 9. It can be seen that the highest part of the bottom surface of the tongue 9 is substantially linear and extending in a direction substantially parallel to a plane defined by the panel and is located adjacent to a non-linear part defining the curvature of the tongue 9 .
  • Figure 2 shows a second non-limiting example of a possible embodiment of a panel 21 according to the present invention.
  • Figure 2 shows two sides of a panel 21 , in particular a floor panel 21 , comprising a core layer 22, comprising a mineral or a cementitious material, at least one reinforcing layer 26, 27 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 290 and a groove 23 by local removal of material at the respective edge.
  • the reinforcing layer 26, 27, is situated halfway the smallest thickness 24, 25 of the remaining core layer material at the location of the tongue or the groove.
  • the core has a top surface 29 and a bottom surface 28, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
  • Figure 3 shows a third non-limiting example of a possible embodiment of a panel 31 according to the present invention.
  • Figure 3 shows two sides of a panel 31 , in particular a floor panel 31 , comprising a core layer 32, comprising a mineral or a cementitious material, at least one reinforcing layer 36, 37 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 390 and a groove 33 by local removal of material at the respective edge.
  • the reinforcing layer 36, 37 is situated halfway the smallest thickness 34, 35 of the remaining core layer material at the location of the tongue or the groove.
  • the core has a top surface 39 and a bottom surface 38, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
  • Figure 4 shows a fourth non-limiting example of a possible embodiment of a panel 41 according to the present invention.
  • Figure 4 shows two sides of a panel 41 , in particular a floor panel 41 , comprising a core layer 42, comprising a mineral or a cementitious material, at least one reinforcing layer 46, 47 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 490 and a groove 43 by local removal of material at the respective edge.
  • the reinforcing layer 46, 47 is situated halfway the smallest thickness 44, 45 of the remaining core layer material at the location of the tongue or the groove.
  • the core has a top surface 49 and a bottom surface 48, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
  • Figure 5 shows a fifth non-limiting example of a possible embodiment of a panel 51 according to the present invention.
  • Figure 5 shows two sides of a panel 51 , in particular a floor panel 51 , comprising a core layer 52, comprising a mineral or a cementitious material, at least one reinforcing layer 56, 57 situated in said core layer, wherein the panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of panels to each other, wherein the interlocking coupling parts are formed as a tongue 590 and a groove 53 by local removal of material at the respective edge.
  • the reinforcing layer 56, 57 is situated halfway the smallest thickness 54, 55 of the remaining core layer material at the location of the tongue or the groove.
  • the core layer has a top surface 59 and a bottom surface 58, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
  • Figure 6 shows a sixt non-limiting example of a possible embodiment of a panel 61 according to the present invention.
  • Figure 6 shows two sides of a panel 61 , in particular a floor panel 61 , comprising a core layer 62, comprising a mineral or a cementitious material and two reinforcing layers 66, 67 situated in said core layer 62.
  • the floor panel in particular the core layer 62, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 690 and a groove 63 by local removal of material at the respective edge.
  • the groove 63 is defined by a lower lip and an upper lip.
  • One reinforcing layer 66 is situated halfway between the top surface 69 of the core layer 62 and the higher most point on bottom surface of the tongue 690. Hence, the reinforcing layer 66 is situated halfway the thickness 64 defined by higher most point of the bottom surface of the tongue 690 and the top surface 69 of the core layer 62.
  • a further reinforcing layer 67 is positioned halfway between the bottom surface 68 of the core layer 67 and the lowermost point on the bottom surface of the tongue 690. Hence, this reinforcing layer 67 is situated halfway the thickness 65 defined by lowest point of the bottom surface of the tongue 690 and the bottom surface 68 of the core layer 62.
  • Figure 7 shows a seventh non-limiting example of a possible embodiment of a panel 31 according to the present invention.
  • Figure 7 shows two sides of a panel 71 , in particular a floor panel 71 , comprising a core layer 72, comprising a mineral or a cementitious material and two reinforcing layers 76, 77 situated in said core layer 72.
  • the core layer 72 comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of panels to each other, wherein the interlocking coupling parts are formed as a tongue 790 and a groove 73 by local removal of material at the respective edge.
  • An upper reinforcing layer 76 is situated halfway between the top surface 79 of the core layer 72 and the higher most point on bottom surface of the tongue 790. Hence, the reinforcing layer 76 is situated halfway the thickness 74 defined by higher most point of the bottom surface of the tongue 790 and the top surface 79 of the core layer 72.
  • a further reinforcing layer 77 is positioned halfway between the bottom surface 78 of the core layer 77 and the lowermost point on the bottom surface of the tongue 790. Hence, this reinforcing layer 77 is situated halfway the thickness 75 defined by lowest point of the bottom surface of the tongue 790 and the bottom surface 78 of the core layer 72. It can be seen that the highest part of the bottom surface of the tongue 790 is substantially linear and is located adjacent to a non-linear part defining the curvature of the tongue 790.
  • the distal end of the tongue is not taken into account as location for measuring the thickness.
  • the distal end of the tongue can be considered a transition region between the upper surface of the tongue and the lower surface of the tongue.
  • a panel comprises one reinforcing layer, three reinforcing layers or any other number of reinforcing layers.
  • at least one the reinforcing layer extends in a direction substantially parallel to the plane defined by the panel, such that said reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from the top surface of the panel to a highest part of the top surface of the tongue, and/or the bottom surface of the panel to a lowest part of the upper surface of the lower lip.
  • inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above- described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.

Abstract

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

Description

Panel and method of producing such a panel
The invention relates to a panel, in particular a floor panel, a wall panel, or a ceiling panel.
In the field of floor and wall coverings, panels based on wood materials or derivatives thereof are widely used as material for the main or core layer of the panel. An example is given in US patent 6,688,061. Major disadvantages of such panels are the hygroscopic nature of such wood-based materials, which affects the lifetime and durability of such panels; and the flammability of wood-based products. As an alternative, several thermoplastic materials can be used, such as polyvinyl chloride, which while being water resistant, present other disadvantages. Polyvinyl chloride (PVC) that is used for panels such as in patent CN 100419019, has a flexible quality. This requires a perfectly smooth and even surface of the substrate on which the panel covering is applied. If such is not the case, any unevenness will be visible through the panel as it conforms with the underlying substrate surface, which is a detrimental effect from an aesthetic point of view to the user.
Furthermore, a floor panel using PVC as core material is susceptible to temperature changes in its ambient environment which will cause the vinyl flooring to expand and contract with hot and cold fluctuations. PVC panels also generally do not pass fireproofing ASTM tests.
There is clearly a general need in the field to develop a floor panel which while having waterproof and temperature-proof properties, can be produced with a relatively high bending strength leading to a relatively even (flat) upper surface. There is also a need in the field to develop a floor panel of which the thickness can be adjusted relatively easily during production, while maintaining sufficient strength of the panel. There is furthermore a need to develop a fireproof panel to allow these panels to be used in commercial environments.
It is known to use wall panels with a mineral based or cementitious material based core to reach fireproofing standards. However, despite the advantages these materials offer with respect to wood or thermoplastic materials, reinforcement layers that that are applied for reasons of dimensional stability, have an impact on their performance in various strength tests that are applicable to flooring. In particular floor panels with a core based on a mineral or cementitious material such as gypsum or magnesium can comprise a reinforcing layer of fiberglass, polypropylene, nylon and the like, as is described for construction boards in US7255907, and for stone-wood flooring in WO2012061300.
These mineral panels, when combined with a reinforcing layer as described in the prior art, cannot feature a lockable tongue and groove connection at opposite edges of the panel to serve as part of a floating floor with interlocking coupling parts to prevent both horizontal as vertical movement. When combining this type of floor panel with a reinforcing layer of fiberglass, the structural integrity is weakened, resulting in fractures when engaging the lock and when put into its intended use, and in failure when tested to "ISO 4918 Resilient, textile and laminate floor coverings - Castor chair test". Hence, existing art attempts to solve this through non-locking profiles with an insert as in US20170204616, a non-locking tongue and groove on adjacent sides as in US2011058611 , or simply do not touch upon the technical problem presented in this invention, as in EP2060389.
It is therefore an objective of the invention to provide a panel with a mineral based or cementitious material based core, lacking at least part of the disadvantages of prior art panels.
The invention thereto proposes a panel, in particular a floor panel, a wall panel, or a ceiling panel, comprising a core layer, comprising a mineral or a cementitious material; at least one reinforcing layer situated in said core layer; wherein the panel, in particular the core layer, comprises a first pair of opposite edges, wherein a first edge of said first pair of opposing edges comprises a first coupling part, and wherein a second edge of said first pair of opposing edges comprises a complementary second coupling part, said coupling parts allowing a plurality of panels to be mutually coupled; wherein the first coupling part comprises a sideward tongue extending in a direction substantially parallel to a plane defined by the panel, and wherein the second coupling part comprises a groove configured for accommodating at least a part of the sideward tongue of another panel, said groove being defined by an upper lip and a lower lip, wherein preferably at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panel, and wherein at least one reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from the top surface of the core layer to a highest part of the top surface of the tongue or to a highest part of the bottom surface of the tongue, and/or wherein at least one reinforcing layer is situated at a level between 30 and 70 percent, in particular between 40 and 60 perfect, and preferably halfway of the thickness from the bottom surface of the core layer to a lowest part of the upper surface of the lower lip.
Experimentation with different locations of a reinforcing layer within the structure of both tongue and groove gives conclusive evidence for optimal strengthening of the locking system, whilst maintaining structural integrity. The panel according to the present application meets industry standards on structural integrity, while the locking system is durable and does not easily break. The invention also relates to a (floor) panel, comprising a core layer, comprising a mineral or a cementitious material, at least one reinforcing element situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue and a groove by local removal of material at the respective edge, and wherein the at least one reinforcing element is situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining core layer material at the location of the tongue or the groove. Interlocking coupling parts can for example coupling parts that require elastic deformation, a click or a movement in multiple directions to couple or decouple the parts with or from each other.
It is conceivable that the coupling parts are designed such that the height of the highest part of the top surface of the tongue substantially equals the height of the highest part of the bottom surface of the tongue. The highest part of the bottom surface of the tongue is typically a substantially linear or flat area extending in a direction substantially parallel to a plane defined by the panel which is adjacent to a non-linear part defining the curvature of the tongue. It is also conceivable that the panel comprises at least two reinforcing layers extends in a direction substantially parallel to the plane defined by the panel, such that each reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from the top surface of the panel to a highest part of the top surface of the tongue, and/or the bottom surface of the panel to a lowest part of the upper surface of the lower lip, and wherein adjacent reinforcing layers are positioned at a predetermined distance from another. Preferably, there is no direct contact between said at least two reinforcing layers.
Another preferred embodiment concerning the location of the reinforcing layer is that at least one reinforcing layer may be located at a level between 30-70 percent of the thickness from a top surface of the core layer to a highest part of a top surface of the tongue, and at least one further reinforcing layer is situated at a level between 30-70 percent of the thickness from a bottom surface of the core layer to a lowest top surface of the tongue. In a different embodiment, at least one reinforcing layer may be located at a level between 40-60 percent of the thickness from a top surface of the core layer to a highest part of a top surface of the tongue, and at least one further reinforcing layer is situated at a level between 40-60 percent of the thickness from a bottom surface of the core layer to a lowest top surface of the tongue. In still a different embodiment, the reinforcing layer may be located halfway (center) of the remaining thickness from a top surface of the core layer to a highest part of a top surface of the tongue, and at least one further reinforcing layer is situated at the center of the remaining thickness from a bottom surface of the core layer to a lowest top surface of the tongue.
In still a different embodiment, at least one reinforcing layer may be located halfway (center) of the remaining thickness from a top surface of the core layer to a highest part of a bottom surface of the tongue, and/or at least one reinforcing layer is situated at the center of the remaining thickness from a bottom surface of the core layer to a lowest top surface of the tongue. With bottom surface, also a downward facing surface is meant. With a top surface, also an upward facing surface is meant. It is possible that the distance between the top surface of the core layer and at least one first reinforcing layer; and the distance between the bottom surface of the core layer and at least one further reinforcing layer, is substantially the same to achieve optimal balancing of the panel under temperature fluctuations. It is further possible that the distance between the top surface of the core layer and at least one first reinforcing layer is greater than the distance between the bottom surface of the core layer and at least one further reinforcing layer, whereby a certain back- pull can be achieved on the panel for optimal stability in demanding environments with extreme temperatures and/or humidity fluctuations.
In an embodiment, the floor panel according to the invention comprises at least two reinforcing layers, wherein a first of the reinforcing layers is situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining material at the location of the tongue, and wherein the second of the reinforcing layers is situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining material at the location of the groove. In this embodiment, both tongue and groove are further optimised, leading to an even more stable panel, with a very low damage and wear risk.
Yet another embodiment is conceivable wherein at least one reinforcing layer is situated at a level between 50 and 70 percent of the thickness from the top surface of the core layer to a highest part of the top surface of the tongue and/or wherein at least one reinforcing layer is situated at a level between 50 and 70 percent of the thickness from the bottom surface of the core layer to a lowest part of the upper surface of the lower lip. It is also conceivable that at least one reinforcing layer is situated at a level between 50 and 60 percent of the thickness from the top surface of the core layer to a highest part of the top surface of the tongue and/or wherein at least one reinforcing layer is situated at a level between 50 and 60 percent of the thickness from the bottom surface of the core layer to a lowest part of the upper surface of the lower lip. Hence, preferably at least one reinforcing layer is positioned halfway the smallest thickness of the remaining material at the location of the tongue or closer to the tongue (than the top surface of the core layer) and/or the further of the reinforcing layers is positioned halfway the smallest thickness of the remaining material at the location of the groove or closer to the groove (than the bottom surface of the core layer). Such embodiment achieves a relatively high modulus of elasticity (at any locations) in the upper and lower lip of the groove, resulting in a more rigid coupling parts.
The reinforcing layer may be a separate part, inserted in the panel, it may be a part of the same material with different properties, such as a different density or different material structure, or it may be a layer in the laminate. Such reinforcing layer may be a closed layer or a mesh, sheet, or web material, that may be integrated or embedded in the core layer, especially when the core layer is made from a fluid or semi fluid material that requires curing.
In general, the core layer has a top surface and a bottom surface, and in an embodiment, the remaining material at the location of the tongue or the groove extends to the top surface and a bottom surface. That means, when removing material for forming the tongue or the groove, only one side of the panel needs to be edited.
When the complementary coupling parts are intended for forming a click, or need to bend in order to couple or to snap, it is preferable when at least one reinforcing layer has a flexibility that is higher than the flexibility of the core material and/or the core layer. Suitable materials to be applied as layer for the reinforcing layer for this purpose are fiberglass, polypropylene, cotton, silica or nylon. It is further conceivable that at least one reinforcing layer is situated between the top surface of the core layer and a highest part of the bottom surface of the tongue is made of a different material and/or has a different density than a further reinforcing layer which is situated between the bottom surface of the core layer and a lowest part of the upper surface of the lower lip.
These materials may be combined with a core layer comprising or consisting of magnesium oxide (MgO) and/or Magnesium Oxy Chloride cement and/or, Magnesium Oxy Sulphate cement and/or MgCI2 and/or MgS04, and preferably a suitable binder. In a practical embodiment, the core layer may comprise at least 70% in weight of MgO and/or Magnesium Oxy Chloride cement and/or, Magnesium Oxy Sulfate cement and/or MgCI2 and/or MgS04, and preferably a binder. The core layer may for instance have a thickness between 3 and 8, in particular between 5 and 6 mm, wherein the smallest thickness of the tongue or groove is between 1 and 3 mm.
It is conceivable that the complementary coupling parts (or interlocking coupling parts) are configured to form a click connection.
The (floor) panel according to the invention may comprise a laminate of said core layer and at least one of a decorative top layer, an acoustic dampening layer and/or a balancing layer. 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 which 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 layer 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. It is also conceivable that the panel comprises (at its back surface) at least one balancing layer, generally composed of at least one layer comprising 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. The density of this acoustic layer preferably has a density between 65 kg/m3 and 300 kg/m3, most preferably between 80 kg/m3 and 150 kgm3.
Tests were performed with two different panel compositions, and reinforcing layers (in the form of a layer of the laminate, comprising fibreglass) at different locations. The first panel has a core comprising Magnesium Oxy Chloride cement (MOC), and the second panel comprises a core comprising Magnesium Oxy Sulfate cement (MOS).
Table 1 shows the characteristics of various tested panels, in particular floor panels.
Table 1: characteristics of various tested panels.
All (floor) panels were tested according to standardised tests mentioned in table 2.
Table 2: tests performed
The test results for the panels from table 1 are shown in table 3.
Table 3: test results From the results it appears that the at least one reinforcing layer is best situated in the laminate, at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway the smallest thickness of the remaining core layer material at the location of the tongue or the groove.
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 at least one magnesium oxide composition comprising magnesium oxide, water and at least one magnesium salt; b) applying at least two layers of magnesium oxide composition onto a mold, each layer separated by at least one reinforcing layer c) applying a force of at least 7MPa to the mixture at a temperature in the range of 45 to 55 degrees Celsius for a predetermined period of time such that a core layer of a certain thickness comprising an upper core surface and a lower core surface is obtained.
The magnesium oxide composition can also be referred to as magnesium oxide cement composition or magnesium cement composition. The magnesium oxide composition is preferably subjected to at least one screening step, which can also be a sieving step. The magnesium oxide composition can for example be a magnesium oxide powder.
The steps of said method are generally subsequent steps. After the pressure of step c) is released, 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/m3 to 1600 kg/m3, in particular between 1350 kg/m3 and 1550 kg/m3. 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). A substantially constant density is also beneficial for the overall strength of the panel. Typically, 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 composition is in practice a substantially powdery composition, which has a lower water content than a convention magnesium oxide slurry. The magnesium oxide composition is typically slightly wet but not soaked. Hence, the magnesium oxide composition can also be classified as textured composition. Preferably, the magnesium oxide composition is mixed prior to at least one screening step. During 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 composition is even.
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) to c). These steps also at least partially prevent bubble formation and/or remove gas and/or bubbles present in the composition. Step c) enables the (chemical) reaction of the components of the magnesium oxide composition to finish and/or to cure the magnesium oxide 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. In practice, this means that substantially less watering process is used, and needed, during the production process and it also enables a significant reduction of the overall production time. Hence, no overload of water is applied during the production process, which is amongst others, beneficial from environmental point of view. Typically, a predetermined amount of water is applied for forming the magnesium oxide 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. For example, 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) of the method can, for example, be achieved via at least one pressing and/or compressing step. Step c) enables the removal of excessive liquid from the magnesium oxide cement composition. During step c), the magnesium oxide composition is typically dried and/or cured. The at least one screening step enables that a more even magnesium oxide composition can be obtained.
Where it is referred to a mold, a conveyer, container and/or a plate can also be meant. Basically, due to the magnesium oxide composition having a relatively functional structure, it is not required that the mold comprises raised edges and/or a rim. Typically, the magnesium oxide composition has a relatively low moisture content, wherefore the 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 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.
As indicated above, a core layer comprising magnesium oxide cement and natural fibers, may have a density in the range of 1350 kg/m3 to 1550 kg/m3, resulting in a core layer having a relatively good flexural and structural strength.
Preferably, the magnesium oxide composition formed at step a) has a moisture content below 25 wt%, preferably below 10 wt%, more preferably at 7 +/- 2 wt%. It is for example possible that the magnesium oxide composition formed at step a) has a moisture content between 10 and 1 1 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. As indicated above, in the prior art it is known to produce magnesium oxide cement based panels via an extensive and time consuming process of drying of a magnesium oxide cement slurry, wherein the slurry contains at least 50 wt% of water, and often even over 60 wt% water. The need to use an overload of water is overcome by the method according to the present invention. The magnesium oxide composition may further comprise magnesium hydroxide, magnesium chloride and/or magnesium oxysulfate. The magnesium oxide composition may further comprise any of the additives and/or fillers as described for the present invention. It is conceivable that natural fibers are added to the magnesium oxide composition after or during step a). The magnesium oxides 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 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.
The method is typically performed under ambient conditions. However, it is also conceivable that the method is performed under vacuum or under a predetermined pressure above atmospheric pressure. Step c) is typically performed for a duration of at least 2 hours, preferably at least 4 hours. Step c) is in a further preferred embodiment performed for a duration between 6 hours to 12 hours. Afterwards, 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) and the consistency of the 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. With 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. Optionally, the core layer can be subjected to a sanding process to increase adhesion prior to hot pressing. Preferably, the core layer is subjected to a temperature ranging from 100 - 200 , more preferably 170 -200 °C, most preferably 175 -190 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. Such 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. In a preferred embodiment, 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. It is possible and desirable therefore that 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. Non-limiting examples of possible balancing layers and/or decorative top layers to be used are described above for the panel according to the present invention. In a further possible embodiment, the layer of magnesium oxide composition is during step c) subjected to a force having a pressure between 7 MPa and 20 MPa.
It is, for example, also possible that the magnesium oxide 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.
The invention will be further elucidated based on the following non-limitative clauses.
1. Panel, in particular a floor panel, a wall panel, or a ceiling panel, comprising: - a core layer, comprising a mineral or a cementitious material; at least one reinforcing layer situated in said core layer; wherein the panel, in particular the core layer, comprises a first pair of opposite edges, wherein a first edge of said first pair of opposing edges comprises a first coupling part, and wherein a second edge of said first pair of opposing edges comprises a complementary second coupling part, said coupling parts allowing a plurality of panels to be mutually coupled; wherein the first coupling part comprises a sideward tongue extending in a direction substantially parallel to a plane defined by the panel, and wherein the second coupling part comprises a groove configured for accommodating at least a part of the sideward tongue of another panel, said groove being defined by an upper lip and a lower lip, characterised in that: at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panel, such that said reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from: o the top surface of the panel to a highest part of the top surface of the tongue, and/or o the bottom surface of the panel to a lowest part of the upper surface of the lower lip.
2. Panel according to clause 1 , comprising at least two reinforcing layers, wherein the first reinforcing layer is situated in the core, extending parallel to the plane of the panel, situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway of the thickness of the tongue from the top surface of the core to the highermost bottom surface of the protrusion forming the tongue, and/or wherein a second reinforcing layer is situated in the core, extending parallel to the plane of the panel, situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway of the thickness from the bottom surface of the core to the lowermost top surface of the protrusion forming the groove.
3. Panel according to claim 1 or 2, wherein at least one reinforcing layer forms integral part of the core layer.
4. Panel according to any of the preceding clauses, wherein the core layer has a top surface and a bottom surface, and wherein the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
5. Panel according to any of the preceding clauses, wherein at least one reinforcing layer comprises mesh, sheet, or web material.
6. Panel according to any of the preceding clauses, wherein at least one reinforcing layer has a flexibility that is higher than the flexibility of the core layer.
7. Panel according to claim any of the preceding clauses, wherein at least one reinforcing layer comprises fiberglass, polypropylene, cotton, PET, silica and/or nylon. 8. Panel according to any of the preceding clauses, wherein the core layer comprises MgO, Magnesium Oxy Chloride, Magnesium Oxy Sulfate, MgCI2, MgS04, and/or MgC03 and/or a binder.
9. Panel according to clause 8, wherein the core layer comprises at least 70% in weight of MgO, Magnesium Oxy Chloride, Magnesium Oxy Sulfate, MgCI2, MgS04, and/or MgC03 and a binder .
10. Panel according to any of the preceding clauses, wherein the core layer has a thickness between 3 and 8 mm, in particular between 5 and 6 mm.
11. Panel according to any of the preceding clauses, wherein the smallest thickness of the tongue or groove is between 1 and 3 mm.
12. Panel according to any of the preceding clauses, wherein the complementary coupling parts are configured to form a click connection.
13. Panel according to any of the preceding clauses, comprising a laminate of said core layer and at least one of:
- a decorative top layer;
- an acoustic dampening layer;
- a balancing layer.
The invention will now be elucidated into more detail with reference to the following figures: figure 1 , showing a core of a panel according to the present invention figure 2, showing a core of a panel according to the present invention figure 3, showing a core of a panel according to the present invention figure 4, showing a core of a panel according to the present invention figure 5, showing a core of a panel according to the present invention figure 6, showing a core of a panel according to the present invention figure 7, showing a core of a panel according to the present invention. Figure 1 shows a first non-limiting example of a possible embodiment of a panel 1 according to the present invention. Figure 1 shows two sides of a panel 1 , in particular a floor panel 1 , comprising a core layer 2, comprising a mineral or a cementitious material, at least one reinforcing layer 6, 7 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 9 and a groove 3 by local removal of material at the respective edge. Further, the reinforcing layers 6, 7 extends in a direction substantially parallel to the plane defined by the panel, such that said reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from the top surface of the panel to a highest part of the top surface of the tongue, and/or the bottom surface of the panel to a lowest part of the upper surface of the lower lip. In particular, each reinforcing layer 6, 7, is situated halfway the smallest thickness 4, 5 of the remaining core layer material at the location of the tongue or the groove. The core has a top surface 9 and a bottom surface 8, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface. In the shown embodiment, the coupling parts are designed such that the height of the highest part of the top surface of the tongue 9 substantially equals the height of the highest part of the bottom surface of the tongue 9. It can be seen that the highest part of the bottom surface of the tongue 9 is substantially linear and extending in a direction substantially parallel to a plane defined by the panel and is located adjacent to a non-linear part defining the curvature of the tongue 9 .
Figure 2 shows a second non-limiting example of a possible embodiment of a panel 21 according to the present invention. Figure 2 shows two sides of a panel 21 , in particular a floor panel 21 , comprising a core layer 22, comprising a mineral or a cementitious material, at least one reinforcing layer 26, 27 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 290 and a groove 23 by local removal of material at the respective edge. The reinforcing layer 26, 27, is situated halfway the smallest thickness 24, 25 of the remaining core layer material at the location of the tongue or the groove. The core has a top surface 29 and a bottom surface 28, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
Figure 3 shows a third non-limiting example of a possible embodiment of a panel 31 according to the present invention. Figure 3 shows two sides of a panel 31 , in particular a floor panel 31 , comprising a core layer 32, comprising a mineral or a cementitious material, at least one reinforcing layer 36, 37 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 390 and a groove 33 by local removal of material at the respective edge. The reinforcing layer 36, 37, is situated halfway the smallest thickness 34, 35 of the remaining core layer material at the location of the tongue or the groove. The core has a top surface 39 and a bottom surface 38, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
Figure 4 shows a fourth non-limiting example of a possible embodiment of a panel 41 according to the present invention. Figure 4 shows two sides of a panel 41 , in particular a floor panel 41 , comprising a core layer 42, comprising a mineral or a cementitious material, at least one reinforcing layer 46, 47 situated in said core layer, wherein the floor panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 490 and a groove 43 by local removal of material at the respective edge. The reinforcing layer 46, 47, is situated halfway the smallest thickness 44, 45 of the remaining core layer material at the location of the tongue or the groove. The core has a top surface 49 and a bottom surface 48, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
Figure 5 shows a fifth non-limiting example of a possible embodiment of a panel 51 according to the present invention. Figure 5 shows two sides of a panel 51 , in particular a floor panel 51 , comprising a core layer 52, comprising a mineral or a cementitious material, at least one reinforcing layer 56, 57 situated in said core layer, wherein the panel, in particular the core layer, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of panels to each other, wherein the interlocking coupling parts are formed as a tongue 590 and a groove 53 by local removal of material at the respective edge. The reinforcing layer 56, 57, is situated halfway the smallest thickness 54, 55 of the remaining core layer material at the location of the tongue or the groove. The core layer has a top surface 59 and a bottom surface 58, and the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
Figure 6 shows a sixt non-limiting example of a possible embodiment of a panel 61 according to the present invention. Figure 6 shows two sides of a panel 61 , in particular a floor panel 61 , comprising a core layer 62, comprising a mineral or a cementitious material and two reinforcing layers 66, 67 situated in said core layer 62. The floor panel, in particular the core layer 62, comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of floor panels to each other, wherein the interlocking coupling parts are formed as a tongue 690 and a groove 63 by local removal of material at the respective edge. The groove 63 is defined by a lower lip and an upper lip. One reinforcing layer 66 is situated halfway between the top surface 69 of the core layer 62 and the higher most point on bottom surface of the tongue 690. Hence, the reinforcing layer 66 is situated halfway the thickness 64 defined by higher most point of the bottom surface of the tongue 690 and the top surface 69 of the core layer 62. A further reinforcing layer 67 is positioned halfway between the bottom surface 68 of the core layer 67 and the lowermost point on the bottom surface of the tongue 690. Hence, this reinforcing layer 67 is situated halfway the thickness 65 defined by lowest point of the bottom surface of the tongue 690 and the bottom surface 68 of the core layer 62.
Figure 7 shows a seventh non-limiting example of a possible embodiment of a panel 31 according to the present invention. Figure 7 shows two sides of a panel 71 , in particular a floor panel 71 , comprising a core layer 72, comprising a mineral or a cementitious material and two reinforcing layers 76, 77 situated in said core layer 72. The core layer 72 comprises a first pair of opposite edges, said first pair of opposite edges comprising interlocking coupling parts allowing to mutually couple of plurality of panels to each other, wherein the interlocking coupling parts are formed as a tongue 790 and a groove 73 by local removal of material at the respective edge. An upper reinforcing layer 76 is situated halfway between the top surface 79 of the core layer 72 and the higher most point on bottom surface of the tongue 790. Hence, the reinforcing layer 76 is situated halfway the thickness 74 defined by higher most point of the bottom surface of the tongue 790 and the top surface 79 of the core layer 72. A further reinforcing layer 77 is positioned halfway between the bottom surface 78 of the core layer 77 and the lowermost point on the bottom surface of the tongue 790. Hence, this reinforcing layer 77 is situated halfway the thickness 75 defined by lowest point of the bottom surface of the tongue 790 and the bottom surface 78 of the core layer 72. It can be seen that the highest part of the bottom surface of the tongue 790 is substantially linear and is located adjacent to a non-linear part defining the curvature of the tongue 790.
When defining the location for the reinforcing layer to be positioned, preferably the distal end of the tongue is not taken into account as location for measuring the thickness. The distal end of the tongue can be considered a transition region between the upper surface of the tongue and the lower surface of the tongue.
Despite the figures showing embodiment comprising two reinforcing layers, it is also conceivable that a panel comprises one reinforcing layer, three reinforcing layers or any other number of reinforcing layers. However, preferably for all embodiments, at least one the reinforcing layer extends in a direction substantially parallel to the plane defined by the panel, such that said reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from the top surface of the panel to a highest part of the top surface of the tongue, and/or the bottom surface of the panel to a lowest part of the upper surface of the lower lip. Wherein in the figures the reinforcing layers are positioned substantially in the center of the defined location, in practice this could be in anywhere between 30 and 70 percent of the defined location. Where the term ‘bottom’ is used, the term ‘lower’ could be applied too and where the term ‘top’ is used the term ‘upper’ could be applied. It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.
The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above- described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.
The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof. When it is referred to reinforcing layer also a reinforcing element can be meant, or vice versa.

Claims

Claims
1 . Panel, in particular a floor panel, a wall panel, or a ceiling panel, comprising: a core layer, comprising a mineral or a cementitious material; at least one reinforcing layer situated in said core layer; wherein the panel, in particular the core layer, comprises a first pair of opposite edges, wherein a first edge of said first pair of opposing edges comprises a first coupling part, and wherein a second edge of said first pair of opposing edges comprises a complementary second coupling part, said coupling parts allowing a plurality of panels to be mutually coupled; wherein the first coupling part comprises a sideward tongue extending in a direction substantially parallel to a plane defined by the panel, and wherein the second coupling part comprises a groove configured for accommodating at least a part of the sideward tongue of another panel, said groove being defined by an upper lip and a lower lip, characterised in that: at least one reinforcing layer extends in a direction substantially parallel to the plane defined by the panel, such that said reinforcing layer is situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway, of the thickness from: o the top surface of the core layer to a highest part of the bottom surface of the tongue, and/or o the bottom surface of the core layer to a lowest part of the upper surface of the lower lip of the groove.
2. Panel according to claim 1 , comprising at least two reinforcing layers, wherein the first reinforcing layer is situated in the core layer, extending parallel to the plane of the panel, situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway of the thickness of the tongue from the top surface of the core layer to the highermost bottom surface of the protrusion forming the tongue, and/or wherein a second reinforcing layer is situated in the core, extending parallel to the plane of the panel, situated at a level between 30 and 70 percent, more in particular between 40 and 60 percent, and preferably halfway of the thickness from the bottom surface of the core layer to the lowermost top surface of the protrusion forming the groove.
3. Panel according to claim 1 or 2, wherein at least one reinforcing layer forms integral part of the core layer.
4. Panel according to any of the preceding claims, wherein the core layer has a top surface and a bottom surface, and wherein the remaining material at the location of the tongue or the groove extends to the top surface or the bottom surface.
5. Panel according to any of the preceding claims, wherein at least one reinforcing layer comprises mesh, sheet, or web material.
6. Panel according to any of the preceding claims, wherein at least one reinforcing layer has a flexibility that is higher than the flexibility of the core layer.
7. Panel according to claim any of the preceding claims, wherein at least one reinforcing layer comprises fiberglass, polypropylene, cotton, PET, silica and/or nylon.
8. Panel according to any of the preceding claims, wherein the core layer comprises MgO, Magnesium Oxy Chloride, Magnesium Oxy Sulfate, MgCI2, MgS04, and/or MgC03 and/or a binder.
9. Panel according to claim 8, wherein the core layer comprises at least 70% in weight of MgO, Magnesium Oxy Chloride, Magnesium Oxy Sulfate, MgCI2,
MgS04, and/or MgC03 and a binder .
10. Panel according to any of the preceding claims, wherein the core layer has a thickness between 3 and 8 mm, in particular between 5 and 6 mm.
11 . Panel according to any of the preceding claims, wherein the smallest thickness of the tongue or groove is between 1 and 3 mm.
12. Panel according to any of the preceding claims, wherein the complementary coupling parts are configured to form a click connection.
13. Panel according to any of the preceding claims, comprising a laminate of said core layer and at least one of:
- a decorative top layer;
- an acoustic dampening layer;
- a balancing layer.
14. Panel according to any of the preceding claims, wherein at least one reinforcing layer is situated at a level between 50 and 70 percent of the thickness from the top surface of the core layer to a highest part of the lower surface of the tongue, and/or wherein at least one reinforcing layer is situated at a level between 50 and 70 percent of the thickness from the bottom surface of the core layer to a lowest part of the upper surface of the lower lip or to a lowest part of the lower surface of the tongue.
15. Panel according to any of the preceding claims, wherein one of the reinforcing layers is situated at a center of remaining thickness of the tongue from a top surface of the core layer to a highest part of a lower surface of the tongue, and/or wherein at least one reinforcing layer is situated at a center of the thickness from a bottom surface of the core layer to a lowest part of the upper surface of the lower lip or to a lowest part of the upper surface of the tongue.
16. Panel according to any of the preceding claims, wherein the distance between the top surface of the core layer and at least one first reinforcing layer substantially equals the distance between the bottom surface of the core layer and at least one further reinforcing layer.
17. Panel according to any of the preceding claims, wherein the distance between the top surface of the core layer and at least one first reinforcing layer is greater than the distance between the bottom surface of the core layer and at least one further reinforcing layer.
18. Panel according to any of the preceding claims, wherein at least one reinforcing layer is positioned halfway the smallest thickness of the remaining material at the location of the tongue and/or the further of the reinforcing layers is positioned halfway the smallest thickness of the remaining material at the location of the groove.
19. Panel according to any of the preceding claims, wherein at least one reinforcing layer which is situated between the top surface of the core layer and a highest part of the bottom surface of the tongue is made of a different material and/or has a different density than a further reinforcing layer which is situated between the bottom surface of the core layer and a lowest part of the upper surface of the lower lip.
EP21701812.6A 2020-01-31 2021-01-29 Panel and method of producing such a panel Pending EP4097310A1 (en)

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