NL2019107B1 - Panel suitable for assembling a floor or wall covering, and the like covering - Google Patents

Abstract

Panel suitable for assembling a floor or wall covering by interconnecting a plurality of said panels with each other, wherein the panel has a substantially planar top side, and a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges, the panel having a layered structure which comprises: - a main layer made from a mineral material, - a top layer provided on the top side of said main layer; wherein the mineral material is a composition comprising as primary components: - magnesium oxide and/or magnesium hydroxide, - a suitable binder, wherein the binder comprises magnesium sulfate, ferric sulfate, potassium salt, a plastic material, or an adhesive, or a combination of these compounds, with the proviso that the binder has a weight content magnesium chloride of less than 10%, preferably less than 3%, and most preferably less than 0.1%.

Description

Netherlands Patent Office © 2019107 (2?) Application number: 2019107 © Application filed: 22 June 2017 © B1 PATENT

Int. Cl .:

B32B 13/00 (2017.01) B32B 13/04 (2017.01) B32B 13/08 (2017.01) B32B 13/12 (2017.01) B32B 27/30 (2017.01) B32B 29/00 (2017.01) B32B 29/04 (2017.01)

0 Application registered: © Patent holder (s): January 7, 2019 CHAMPION LINK INTERNATIONAL CORPORATION at The Valley, Anguilla, Al. © Request published: © Inventor (s): © Patent granted: Thomas Luc Martine Baert January 7, 2019 in Sint-Martens-Latem (BE). Anthony Drevet in Jiaxing Zhejiang (CN). © Patent issued: May 6, 2019 0 Authorized representative: ir. H.Th. van den Heuvel et al. in 's-Hertogenbosch.

54) Panel suitable for assembling a floor or wall covering, and the like covering © Panel suitable for assembling a floor or wall covering by interconnecting a plurality of said panels with each other, the panel has a substantial planar top side, and a substantial planar bottom side, at least four substantially linear side edges including at least one pair of opposite side edges, the panel having a layered structure which comprises:

- a main layer made from a mineral material,

- a top layer provided on the top side or said main layer;

in which the mineral material is a composition comprising as primary components:

- magnesium oxide and / or magnesium hydroxide,

- a suitable binder, containing the binder comprises magnesium sulfate, ferric sulfate, potassium salt, a plastic material, or an adhesive, or a combination of these compounds, with the proviso that the binder has a weight of magnesium chloride or less than 10% , preferably less than 3%, and most preferably less than 0.1%.

NL B1 2019107

This patent has been granted regardless of the attached result of the research into the state of the art and written opinion. The patent corresponds to the documents originally submitted.

Panel suitable for assembling a floor or wall covering, and the like covering

The present invention relates to a panel suitable for assembling a floor covering by interconnecting a various of said panels with each other, the panel has a substantial planar top side, and a substantial planar bottom side, at least four substantially linear side edges including at least one pair or opposite side edges, the panel having a layered structure which comprises:

- a main layer made from a mineral material,

- a top layer provided on the top side or said main layer;

where the mineral material is a composition comprising as primary components:

- magnesium oxide and / or magnesium hydroxide,

- a suitable binder.

The invention further relates to a floor or wall covering composed of a variety of interconnected panels, which panels are in accordance with the invention.

In the relevant technical field or floor and wall panels, the use of magnesium boards is ubiquitous. These boards are basically made from a layer of a mineral material that is a composition containing as primary components magnesium oxide and / or magnesium hydroxide mixed with magnesium chloride as a binder. Further in this composition, hydrates or water molecules are included in minor amounts in the mineral material.

A relevant example of the above panel is given in EP2060389 which discloses such a panel of the binder is magnesium chloride. Furthermore, this panel is provided with interconnecting coupling means for interconnecting one panel with another.

Although being quite popular for its intrinsic advantages, the use of a magnesium board panel comes with some disadvantages as well: especially when magnesium board panels are used regularly under humid conditions, condensation or water from the humid air on the exposed surface of mineral material observed. Dependent on the circumstances and the exposed surface itself, the condensed water may be present over a longer period of time on the exposed surface. It is believed that this condensation effect may be promoted by the presence of chloride ions in the composition of the mineral material: the condensed water on the surface contains a relatively high content of dissolved chloride ions.

Importantly, the condensed water when present on a longer time on the panels, forms an ideal basis for the growth of mold or fungus on the exposed surfaces of the magnesium board panel.

The growth of mold is unwanted for humans as it impedes the hygienic circumstances. Furthermore, any condensed water that remains on the panels for a longer time, may enter the structure of the mineral material and soften the interconnecting coupling means that are provided on the sides of the panel. As such, the interconnecting means become less rigid, and hence the connections between adjacent panels that are interconnected by these means, become less reliable.

The negative effect of condensation on magnesium boards has recently been discussed in a scientific article by Hansen et al., That was published during the International RILEM Conference on Materials, Systems and Structures in Civil Engineering Conference segment on Moisture in Materials and Structures 22-24 August 2016, Technical University of Denmark, Lyngby, Denmark.

The objective of the invention is to reduce or eliminate the negative effect of condensation on panels with bare surfaces or mineral material, and thus to avoid the negative side effects of mold growth and softening or interconnecting structures.

According to a first aspect of the invention, the above objective is reached by providing:

a panel of the above type, the binder comprises magnesium sulfate, ferric sulfate, potassium salt, a plastic material, or an adhesive, or a combination of these compounds, with the proviso that the binder has a weight content of magnesium chloride or less than 10%, preferably less than 3%, and most preferably less than 0.1%. It is noted that the invention also includes a binder which is free from magnesium chloride.

It has been found that it is possible to develop an improved panel of the mineral material is not a substantial amount of magnesium chloride as a binder, but contains the major part of an alternative binder. As will be elucidated below by comparative tests, such a panel is improved in the sense that it shows significantly less absorption of water under humid conditions, in comparison to a panel in which magnesium chloride is used as a binder. A weight content of at most 10% magnesium chloride in the binder ensures that the amount of this compound is insufficient to contribute significantly to any condensation effect. Obviously, the lower the weight content magnesium chloride in the binder, the better the reduction or the condensation effect is ensured.

Examples of a plastic material suitable in the binder are PE, PET, PP, PU, or PVC. Examples of an adhesive suitable in the binder are polyurethane, polyester, isocyanate, phenol, or urea formaldehyde.

In the context of the invention, the primary components, i.e. magnesium oxide and a suitable binder, have a combined content in the total mineral material or about 60 to 90 wt.%.

Further, the weight ratio between magnesium oxide and a suitable binder, is in the range of 4: 1 to 2: 1, and preferably about 3: 1.

In the panel according to the invention, it is preferred that the major part of the binder component consists of magnesium sulfate. Advantageously, the weight content of magnesium sulfate in the binder is 50% or more, preferably above 75%.

Such a panel has been tested under humid conditions, and has a significantly reduced condensation effect.

In the context of this mineral composition, the term magnesium sulfate comprises any hydrated molecular form or magnesium sulfate. Typically, the mineral composition will predominantly contain the molecular form of magnesium sulfate heptahydrate.

The panel of the invention is preferably provided with interconnecting coupling means for interconnecting one panel with another.

Such a feature allows for connecting the panels with another without the need of glue, and creates a free floating floor surface.

It is preferred in the panel of the invention, that composition further comprises reinforcing fibers, perlite, fly ash, and / or foaming agent.

Reinforcing fibers contribute to the rigidity of the main layer, and hence the panel as a whole. Furthermore, the side edges having interconnecting coupling means are rendered more robust. The fibers may be homogeneously mixed throughout the mineral material. Alternatively, a net structure of fibrous material may be embedded within the main layer of mineral material.

Suitable reinforcing fibers for the invention, are organic fibers such as from wood, straw and bamboo.

With further preference, in the panel according to the invention, the density of the composition is at least 1250 kg / m3, preferably at least 1350 kg / m3.

It has been found that higher densities are achievable when using an alternative binder than magnesium chloride, and it is assumed that such may contribute to further reducing the condensation effect.

According to a preferred embodiment of the panel according to the invention, the main layer has a thickness of 4 to 12 mm.

Such a minimum thickness of the panel is needed in order to ensure the integrity of the panel, given the mineral material or the main layer.

It is preferred in the panel of the invention, that the top layer has suitable properties for its intended use as a waterproof layer, wear layer, and / or decorative layer.

Any suitable material may be used for the top layer, such as thermoplastic materials are preferred, such as vinyl. Alternatively, the top layer may be a resin impregnated paper layer. These materials are well-known in the art as top layers that can be used for the intended purposes.

Obviously, it is preferred that the top layer has waterproof properties as this will minimize the surface of the mineral material exposed to humid air, and thus further limits the condensation effect to the remaining exposed surfaces, ie the side edges and bottom side of the main layer.

Typically, the thickness of the top layer in the panel of the invention is in the range of 0.2 to 2.0 mm.

Preferably in the panel according to the invention, the top layer is adhered to the main layer by an adhesive material.

This is an effective way to avoid delamination between top layer and main layer, which would result in the creation of another exposed surface or mineral material, which is avoided as much as possible.

It is preferred in the panel according to the invention, that a backing layer is provided on the bottom side of the main layer.

A backing layer is helpful in providing an optimum interface between the panel and the underlying surface on which the panels are applied. The general advantageous effects or the backing layer are well described in the art. Furthermore, the backing layer can contribute to further limiting the exposed surface of mineral material or the panel.

As a further additional layer, the invention may include a sublayer that is positioned between the core and the top layer in order to reach a desired effect such as sound improvement, identification resistance improvement.

In the panel according to the invention, it is preferable that the interconnecting coupling means part of the main layer.

A further preferred embodiment of the panel according to the invention comprises two pairs of opposite side edges which are provided with interconnecting coupling means. As such, the panel may be coupled to adjacent panels in four directions, so that a surface area can be expediently covered by merely interconnected panels.

It is preferred in the panel according to the invention, that the interconnecting coupling means include a tongue and a groove the tongue is provided on one side edge or one pair or opposite side edges, and the groove is provided on the other side edge of the same pair or opposite side edges.

In a special preferred embodiment of the panel according to the invention, the interconnecting coupling means having an interlocking feature which avoids free movement or interconnected panels.

Typically, suitable panels for a floor covering have a width in the range of 100 to 600 mm and a length in the range of 300 to 2500 mm.

In a second aspect, the invention relates to a floor or wall covering composed of a various or interconnected panels, which panels are in conformity with the first aspect of the invention.

Such a floor or wall covering profits from the already discussed advantages of reduction of the condensation effect, so that the covering will suffer less from mold growth, and is moreover less prone to a weakening of the interconnecting parts by water absorption on the side edges.

The invention will be further explained with reference to the appended figures:

Fig 1 shows in perspective a preferred embodiment or the panel according to the invention;

FIG. 2 shows a cross section of the preferred embodiment or the panel according to the invention;

Figure 1 shows a panel 1 suitable for assembling a waterproof floor or wall covering by interconnecting a plurality of said panels with each other, the panel has a substantial planar top surface 3, and a substantial planar bottom surface 5, at least four substantially linear side edges 6a, 6b, 6c, 6d including at least one pair or opposite side edges 6a, 6c which are provided with interconnecting coupling means 7.8 for interconnecting one panel within another, the panel having a sandwich structure which comprises a main layer 10 basically composed of a mineral material, a top layer 12 and a bottom layer 14.

Figure 2 shows the same embodiment as Fig. 1 in cross-section, interconnecting coupling means 7.8 comprising a tongue 7 and a groove 8, each having an interlocking feature 20a (a projection) and 20b (a recess) which avoids free movement of interconnected panels when the tongue or one panel is inserted in the groove or another neighboring panel.

The central layer 10 is composed of a magnesium board material consisting basically of magnesium oxide with magnesium sulfate as a binder. For strength, reinforcing fibers are mixed into the magnesium board material.

Example

A hygroscopic comparative test has been performed for two different types of main layers:

A main layer according to the prior art, made from a composition based on the primary components MgO and MgCI2 as binder, referred to as type A;

A main layer according to invention, made from a composition based on the primary components MgO and MgSO4 as binder, referred to as type B.

The composition of type A and type B was as follows:

Composition a (wt.%) B (wt.%) Magnesium Oxide 53 58 Magnesium chloride 29 0 Magnesium sulfate heptahydrate 20 Water 8 8 Fly ash 1 5 Wood fibers 8 8 Perlite 1 0.5 Modifier aluminum sulfate 0 0.5

For both the type A and the type B composition, two samples were produced, with specific dimensions as indicated below. Intrinsic to the nature of the composition, higher densities were available for both type B samples.

Sample Composition (primary comp.) Density (kg / m3) Thickness (mm) Width (mm) Length (mm) A1 MgO + MgCl 2 1050 5.12 60.2 71.5 A2 MgO + MgCl 2 1210 5.20 61.1 58.7 B1 MgO + MgSO4 1380 5.87 59.3 58.7 B2 MgO + MgSO4 1400 5.91 60.5 45.0

The boards were first three at rel. humidity 30% and weighed, and subsequently subjected to a rel. humidity of 100% for 24 hrs. and weighed. The relative weight gain is a clear indication of the hygroscopic nature of each sample.

The results of the above test for each sample are shown in the table below.

Sample Composition (primary comp.) Density (kg / m3) Dry Weight (g) Weight (g) after test Relative weight gain (%) A1 MgO + MgCl 2 1050 16.49 23.15 40 A2 MgO + MgCl 2 1210 17.29 22.55 30 B1 MgO + MgSO4 1380 23.08 28.22 22 B2 MgO + MgSO4 1400 19.21 22.53 17

The above shows that samples B1 and B2 or a main layer according to the invention have a significantly lower weight gain after subjection to the humidity test, than the samples A1 and A2 according to the prior art.

Why, the B samples that are based on using magnesium sulfate as a binder instead of magnesium chloride, will suffer less from the condensation effect in general, and the detrimental consequences that are applied when applied in a panel according to the invention.

Claims (13)

Conclusions A panel suitable for assembling a floor covering by interconnecting a plurality of the panels, the panel having a substantially flat top and a substantially flat bottom, at least four substantially straight side edges that are at least one pair opposite each other include side edges, the panel having a layered structure comprising: - a main layer made of a mineral material, - a top layer provided on the top side of the main layer; the mineral material being a composition comprising as main components: - magnesium oxide and / or magnesium hydroxide, - a suitable binder, characterized in that the binder comprises magnesium sulphate, iron (III) sulphate, potassium salt, a plastic material or an adhesive, or a combination of these compounds, provided that the binder has a weight content of magnesium chloride of less than 10% , preferably less than 3% and most preferably less than 0.1%. A panel according to claim 1, wherein the major part of the binder component consists of magnesium sulfate, and wherein the panel is preferably provided with coupling means to connect one panel to the other. The panel according to any of the preceding claims, wherein the composition further comprises reinforcing fibers, perlite, fly ash and / or foaming agent. Panel according to one of the preceding claims, in which the density of the composition is at least 1250 kg / m ³ , preferably at least 1350 kg / m ³ . Panel according to one of the preceding claims, wherein the main layer has a thickness of 4 to 12 mm. Panel according to any of the preceding claims, wherein the top layer has suitable properties for its intended use as a water-resistant layer, wear layer and / or decorative layer. Panel according to one of the preceding claims, in which the top layer is adhered to the main layer with an adhesive material. Panel according to one of the preceding claims, wherein a bottom layer is provided on the bottom side of the main layer. 9. Panel as claimed in any of the foregoing claims, wherein the coupling means are part of the main layer. 10. Panel as claimed in any of the foregoing claims, comprising two pairs of opposite side edges which are provided with coupling means. 11. Panel as claimed in any of the foregoing claims, wherein the coupling means comprise a tongue and a groove, wherein the tongue is provided on one side edge of one pair of opposite side edges and the groove is provided on the other side edge of the same pair of opposite sides side edges. 12. Panel as claimed in any of the foregoing claims, wherein the coupling means have a locking element which avoids free movement of mutually connected panels. A floor or wall covering composed of a plurality of interconnected panels, which panels are as claimed in any one of the preceding claims. 1/1 ^Fi g. 1