NL2024805B1 - Panel for forming a floor covering and such floor covering - Google Patents
Panel for forming a floor covering and such floor covering Download PDFInfo
- Publication number
- NL2024805B1 NL2024805B1 NL2024805A NL2024805A NL2024805B1 NL 2024805 B1 NL2024805 B1 NL 2024805B1 NL 2024805 A NL2024805 A NL 2024805A NL 2024805 A NL2024805 A NL 2024805A NL 2024805 B1 NL2024805 B1 NL 2024805B1
- Authority
- NL
- Netherlands
- Prior art keywords
- panel
- core layer
- magnesium
- layer
- panel according
- Prior art date
Links
- 239000010410 layer Substances 0.000 claims description 57
- 239000012792 core layer Substances 0.000 claims description 55
- 239000013078 crystal Substances 0.000 claims description 48
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 45
- 239000011777 magnesium Substances 0.000 claims description 45
- 229910052749 magnesium Inorganic materials 0.000 claims description 45
- CENHPXAQKISCGD-UHFFFAOYSA-N trioxathietane 4,4-dioxide Chemical compound O=S1(=O)OOO1 CENHPXAQKISCGD-UHFFFAOYSA-N 0.000 claims description 35
- 230000003014 reinforcing effect Effects 0.000 claims description 20
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 8
- 150000002894 organic compounds Chemical class 0.000 claims description 7
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 claims description 6
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 claims description 6
- 230000001788 irregular Effects 0.000 claims description 6
- 230000008878 coupling Effects 0.000 claims description 5
- 238000010168 coupling process Methods 0.000 claims description 5
- 238000005859 coupling reaction Methods 0.000 claims description 5
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 4
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 3
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 2
- 239000011230 binding agent Substances 0.000 claims description 2
- 239000004327 boric acid Substances 0.000 claims description 2
- IQYKECCCHDLEPX-UHFFFAOYSA-N chloro hypochlorite;magnesium Chemical compound [Mg].ClOCl IQYKECCCHDLEPX-UHFFFAOYSA-N 0.000 claims description 2
- 235000006408 oxalic acid Nutrition 0.000 claims description 2
- 239000003365 glass fiber Substances 0.000 claims 2
- 239000002253 acid Substances 0.000 claims 1
- 239000011241 protective layer Substances 0.000 claims 1
- 239000000463 material Substances 0.000 description 23
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 20
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 13
- 239000000395 magnesium oxide Substances 0.000 description 13
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 10
- 239000004568 cement Substances 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
- 229910001868 water Inorganic materials 0.000 description 8
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 7
- 235000019341 magnesium sulphate Nutrition 0.000 description 7
- 239000011152 fibreglass Substances 0.000 description 6
- 230000009286 beneficial effect Effects 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 5
- 239000000919 ceramic Substances 0.000 description 5
- 229910001629 magnesium chloride Inorganic materials 0.000 description 5
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 238000005452 bending Methods 0.000 description 4
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 4
- 239000011162 core material Substances 0.000 description 4
- 238000009408 flooring Methods 0.000 description 4
- 229910052500 inorganic mineral Inorganic materials 0.000 description 4
- 235000010755 mineral Nutrition 0.000 description 4
- 239000011707 mineral Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 238000007373 indentation Methods 0.000 description 3
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- -1 salt magnesium sulfate Chemical class 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000001913 cellulose Substances 0.000 description 2
- 229920002678 cellulose Polymers 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 235000015165 citric acid Nutrition 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000021615 conjugation Effects 0.000 description 2
- 239000007799 cork Substances 0.000 description 2
- 125000000524 functional group Chemical group 0.000 description 2
- 159000000003 magnesium salts Chemical class 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 229920000915 polyvinyl chloride Polymers 0.000 description 2
- 229910052573 porcelain Inorganic materials 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 235000017166 Bambusa arundinacea Nutrition 0.000 description 1
- 235000017491 Bambusa tulda Nutrition 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 244000082204 Phyllostachys viridis Species 0.000 description 1
- 235000015334 Phyllostachys viridis Nutrition 0.000 description 1
- 206010040914 Skin reaction Diseases 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000011425 bamboo Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 230000002860 competitive effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 150000001991 dicarboxylic acids Chemical class 0.000 description 1
- 238000010017 direct printing Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000006253 efflorescence Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 239000011094 fiberboard Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 239000011121 hardwood Substances 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 239000004719 irradiation crosslinked polyethylene Substances 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- XEEVLJKYYUVTRC-UHFFFAOYSA-N oxomalonic acid Chemical compound OC(=O)C(=O)C(O)=O XEEVLJKYYUVTRC-UHFFFAOYSA-N 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 206010037844 rash Diseases 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000012266 salt solution Substances 0.000 description 1
- 230000035483 skin reaction Effects 0.000 description 1
- 231100000430 skin reaction Toxicity 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000002966 varnish Substances 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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
- E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
- B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/10—Lime cements or magnesium oxide cements
- C04B28/105—Magnesium oxide or magnesium carbonate cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/30—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing magnesium cements or similar cements
- C04B28/32—Magnesium oxychloride cements, e.g. Sorel cement
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
- E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
- E04F15/206—Layered panels for sound insulation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/102—Oxide or hydroxide
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/10—Inorganic particles
- B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/12—Mixture of at least two particles made of different materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/20—Particles characterised by shape
- B32B2264/204—Rod- or needle-shaped particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/30—Particles characterised by physical dimension
- B32B2264/302—Average diameter in the range from 100 nm to 1000 nm
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
- B32B2264/30—Particles characterised by physical dimension
- B32B2264/304—Particle length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/72—Density
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/60—Flooring materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2201/00—Joining sheets or plates or panels
- E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
- E04F2201/0153—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Chemical & Material Sciences (AREA)
- Structural Engineering (AREA)
- Ceramic Engineering (AREA)
- Civil Engineering (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Laminated Bodies (AREA)
- Floor Finish (AREA)
- Finishing Walls (AREA)
Abstract
The invention relates to a panel, in particular a floor panel, suitable for forming a floor covering, wherein the panel has a substantially planar top side, and a 5 substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges, preferably provided with locking means.
Description
Panel for forming a floor covering and such floor covering The invention relates to a panel, in particular a floor panel, suitable for forming a floor covering. The invention furthermore relates to such floor covering.
The flooring industry commonly uses mostly traditional materials for manufacturing (laminated) floor tiles. Examples of these materials are: high density fiberboard (HDF), which can be merged together by a formaldehyde or phenol-based resin; heterogeneous or homogeneous polyvinyl chloride (PVC), which may possibly comprise any plasticizers, pieces of solid hardwood; layers of veneers glued together; and fired and glazed clay such as ceramic and porcelain tiles. The purpose of use of these materials depends mainly on their material properties such as impact resistance, rigidity, acoustic performance and/or appearance. However, an interest in the use of alternative materials has occurred over the last few years.
An example thereof is the use of mineral materials, since mineral materials generally benefit a relatively high and dimensional stability and sufficient resistance to heat, and have a low impact on the environment compared to traditional material such as PVC or HDF. However, due to its development having been focused on its use as building material, in particular as a gypsum/drywall replacement, it is not as of yet particularly suitable for use as component of a floor panel. Among other characteristics, an improvement in the bending strength, impact resistance, indentation resistance, internal cohesion and surface adhesion of a panel made of such a mineral material is desirable to make it suitable for use as a component of a floor panel.
lt is a goal of the invention to provide at least an alternative embodiment of a composite mineral panel, in particular a floor panel, having competitive material properties with respect to the state of the art.
The invention provides thereto a panel, in particular a floor panel, suitable for forming a floor covering, wherein the panel has a substantially planar top side, and a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges, the panel comprising at least one core layer at least partially comprising a magnesium crystal structure wherein said at least one core layer comprises at least one organic compound comprising at least two hydroxy! groups, preferably wherein said organic compound is present in the range of 0.05% to 5% by weight. The core layer at least partially comprising a magnesium crystal structure which comprises at least one organic compound comprising at least two hydroxy! groups, preferably wherein said organic compound is present in the range of 0.05% to 5% by weight, results in the crystal structure having an increased amount of crystal in an advantageous whisker or needle form than in a flaky or irregular form.
The invention thus also relates to a panel, in particular a floor panel, suitable for forming a floor covering, wherein the panel has a substantially planar top side, and a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges, the panel comprising a core layer comprising a magnesium oxide cement, wherein the magnesium oxide cement comprises magnesium oxide crystals in a flaky or irregular and in a whisker or needle form, wherein there are more crystals in the whisker or needle form than in the flaky or irregular form. The core layer comprising at least one core layer comprising a magnesium crystal structure, for example magnesium oxysulfate whiskers, which at least partially form a dense crystal microstructure, provides a notable improvement in internal cohesion in combination with a good impact resistance and good bending strength to the panel. This results in the panel being in particular suitable for flooring purposes. The magnesium crystal structure comprises magnesium crystals, preferably magnesium oxysulfate crystals. In particular, the core layer comprises a magnesium oxide cement. The formation and microstructure of a magnesium oxide cement can be described in “crystal” or “hydration” phases and expressed in terms of a ternary system consisting of the ratio of magnesia, a magnesium salt such as magnesium sulfate or magnesium chloride, and water. Crystalline phases are formed upon curing into a ceramic compound and can be expressed in an abbreviated version referring to the molar ratio of each in the crystal formed. Magnesium oxysulfate cement, which uses the salt magnesium sulfate as a key binding material, can form two stable crystalline phases under ambient conditions; one of which is composed of the compounds magnesium oxide, magnesium sulfate and water, generally referred to as the 5- phase (also known as 5-1-3 phase, standing for 5Mg(OH)2.MgS04.3H20), and 3- phase (also known as 3-1-8 phase, standing for 3Mg(OH)2.MgS04.8H20). The former shows a beneficial needle- or whisker- like crystal structure of 0.2-1.0 um diameter and a length of 20-50 um that features good bending strength; whereas the latter shows a flaky or irregular crystal shape that results in a weaker composition.
When it is referred to magnesium oxysulfate cement meant for use in livable conditions, a ceramic composition comprising either the crystal phase structure of magnesium oxysulfate whiskers of the 5-1-3 phase or the magnesium oxysuliate flakes of the 3-1-8 structure is meant.
The 3-1-8 “flaky” structure is generally regarded to be the more stable phase structure under 20-60C and livable atmospheric conditions.
Other phases can form under extreme pressures and temperatures but are not stable under livable temperatures.
When magnesium oxysulfate cement is prepared, naturally at least 50% of the composition consists of the 3-1-8 crystals.
Its flaky or irregular structure results in an efflorescence of the panel surface, and subsequently an inferior cohesion and low surface adhesion which make it especially unsuitable for use as a component in a flooring panel.
The invention provides for a floor panel comprising at least one core layer comprising a ratio of the magnesium oxysulfate 5-1-3 “whisker” phase to 3-1-8 “flake” phase of more than 1. The magnesium oxysulfate whiskers benefits of being formed under ambient conditions.
The magnesium oxysulfate whiskers may also be referred to as needles.
Due to the magnesium oxysulfate whiskers at least partially forming a crystal structure, the magnesium oxysulfate whiskers will interlock with another to form a high density microstructure.
These interlocking whiskers thereby provide the improved strength to the core layer of the panel.
Additionally, the panel according to the present invention benefits due to the presence of said core layer of a good impact resistance which is for example beneficial when applying multiple panels in a floor covering according to the invention.
The compressive and indentation resistance of the crystal structure of the 5-1-3 phase is above 50MPa when tested according to EN 310, whereas the 3-1-8 structure has a compressive and indentation resistance of only about 20 MPa.
The panel according to the invention also benefits of a good water and moisture resistance as the whiskers are not easily soluble in water, whereas the 3-1-8 phase is less stable under wet conditions. The magnesium oxysulfate whiskers are not an obvious material for a skilled person to use in the core material for the purpose of the present invention and in order to form a crystal structure. The skilled person would commonly use the more common magnesium (oxy)chloride cement which can also form a crystal phase, wherein the magnesium chloride whiskers can be present in a 5-1-8 {(5Mg(OH)2.MgCl..8H:0) phase and/or 3-1-8 (3Mg(OH)2.MgCl2.8H20) phase.
However, these magnesium chloride crystals are relatively intolerant to water, since water may leach out soluble magnesium chloride, which may result in a substantial loss of strength of the material. The magnesium oxysulfate whiskers do not experience this drawback. Instead of providing further additives to improve the material properties, the invention provides a different material. It is however not excluded that the floor panel according to the invention comprises a relatively small fraction of magnesium chloride, for example, up to at most 5% by weight, preferably less than 1%.
Magnesium oxysulfate whiskers can be produced via mixing of reactive magnesia with an aqueous magnesium sulfate solution. Said reactive magnesia can be obtained via a calcination process performed at temperatures in the range of 600 to 1300 degrees Celsius, and preferably in the range of 800 to 1000 degrees Celsius. Reactive magnesia (RM) can also be referred to as “caustic-calcined magnesia” (CCM) or light-burned magnesia.
A first condition for the formation of the desired MOS whiskers is the ratio of the raw materials. An aqueous magnesium salt solution is prepared by mixing MgSO4 with water at a ratio of 0.6-2 to 1, stirring it for approximately 2 minutes to allow for it to dissolve, the such that the mixture will form a ceramic material during curing.
To ensure a ratio of the whisker crystal phase to flake crystal phase of more than 1, a ratio of MgO vs MgSO4 of around 4.6-5.8 to 1, more ideally 4.9-5.2 should be maintained. A second condition for the formation of the desired crystal structure is the addition of 0.05% to 10% by weight to the slurry of a second aqueous solution comprising 50% to 90% by weight of an organic compound comprising at least two hydroxyl (-OH) groups. This includes functional groups that comprise a hydroxyl group such as carboxyls (-COOH) that are noted to have the same effect on the formation of the MOS whisker crystals. Best results were achieved with dicarboxylic acids that contain two carboxyl functional groups -COOH, most favorably with a short chain length, such as oxalic acid C2H204 (two carboxyl -COOH groups) or 5 mesoxalic acid C3H205 (two to four carboxyl -COOH groups based on presence of water). Good results were also achieved with citric acid C6H8O7 (four -OH hydroxyl groups), and boric acid H3BO3 (three —OH hydroxy! groups). It is found that the addition of at least a fraction of these elements influences the crystal structure of the core layer and increases and enhances the crystallization of the MgO into the preferred crystal phase that is advantageous for the foreseen use as a flooring panel. It is also conceivable that phosphoric acid is applied. This mixture of ceramic material or ceramic cement and additives is poured onto a mold, and allowed to set at either ambient or elevated temperature until it has cured. The cured material benefits of a good strength and good fire-retardant properties, resulting in the material being in particular suitable for use in the building industry. it is, however, also possible that the magnesium oxysulfate whiskers are manufactured via water-heat synthesis from magnesium sulfate and magnesium hydroxide.
A panel according to the invention typically has a core layer having a thickness in the range of 3 to 10 millimeters. The density of said core layer is typically from 1200-1500kg/m3, more specifically around 1300-1400kg/m3. One embodiment of the invention can be composed of multiple layers of magnesium oxysulfate cement, each having a specific crystal structure, with beneficially at least a top layer comprising a ratio of 5-1-3 MOS whisker phase to 3-1-8 of more than 1, or a top and bottom layer of a similar ratio, or the substantially entire core consisting of such a similar ratio depending on the specific requirements of the floor panel in question. it is to be understood that in one embodiment, different layers of the core can have different crystal structure ratios for enhanced acoustical performance. The panel has a substantially planar top side, and a substantially planar bottom side, at least four substantially linear side edges comprising at least one pair of opposite side edges. The panel is typically substantially rectangular or square.
However it is also conceivable that the panel has a substantial parallelogram shape. When it is referred to panel, this can both a floor panel or a wall panel. The term tile is interchangeable with the term panel.
The length-to-diameter ratio of at least a number of magnesium oxysulfate whiskers is typically at least 5, preferably at least 10, more preferably at least 20. In this embodiment the magnesium oxysulfate whiskers can provide sufficient (bending) strength to the core layer of the panel. Possibly, at least a number of magnesium oxysulfate whiskers have an average diameter in the range of 0.2 to 1.0 micrometre and/or at least a number of magnesium oxysulfate whiskers have an average length in the range of 1 to 50 micrometres. The exact shape of the magnesium oxysulfate whiskers may differentiate, due to the phase wherein the magnesium oxysulfate whiskers are stable at the given temperature and humidity. it is not required that the magnesium oxysulfate whiskers in the core layer form a crystal structure over the substantially entire core layer. In fact, in a preferred embodiment the core layer comprises at least 50% by weight of magnesium oxysulfate whiskers, preferably at least 55% by weight and more preferably at least 60% by weight of the whisker-phase crystal structure. The further volume of the core layer may have a non-crystal structure. The further volume of the core layer may for example be at least partially porous. In some embodiments, it is beneficial if the part of the core layer comprises a crystal structure of magnesium oxysulfate whiskers below 50% by weight. A higher percentage may result in a reduced mechanical strength of the core layer, and therefore of the panel.
In a possible embodiment the core layer comprises an upper part and a lower part and a reinforcing layer situated between said upper part and said lower part of the core layer. The upper part of the core layer may even define the substantially planar top side, and the bottom part of the core layer may define the substantially planar bottom side of the panel. The presence of at least one reinforcing layer may lead to improvement of the acoustic properties of the panel. This may for example result in improved sound dampening properties. The presence of at least one reinforcing layer may also contribute to an improved strength of the panel as such. The reinforcement layer may for example comprise a woven or non-woven fibre material. The reinforcing layer may in a beneficial embodiment comprise fiberglass.
The reinforcing layer may in particular comprise a fiberglass mesh. A non-limiting example thereof is a fiberglass mesh having a mesh size of at least 5x5 mm, and/or the fiberglass mesh having an area weight of at least 90 g/m2. In a possible embodiment may the fiberglass mesh be provided with a coating, in order to prevent skin-reactions during physical contact.
It is conceivable that the reinforcing layer has a thickness of about 0.2 to 0.4 millimeters.
In a further possible embodiment, the core layer further comprises an intermediate part and a further reinforcing layer, wherein a first reinforcing layer is situated between said upper part and said intermediate part of the core layer, and a second reinforcing layer is situated between said intermediate part and said lower part of the core layer.
The first and second reinforcing layer can both consist of a reinforcing layer as described above.
The intermediate part of the core layer does not necessarily have the same material properties as the further parts of the core layer.
It is for example conceivable that the intermediate part of the core layer is at least partially foamed.
The intermediate part may therefore comprise a foaming agent.
Such, at least partially foamed intermediate part of the core layer may further improve the acoustic performance of the panel.
In a preferred embodiment comprises the panel two pairs of opposite side edges which are provided with interconnecting coupling means.
This will contribute to the ease of connect of multiple panels when assembling for example a floor covering.
The interconnecting coupling means typically comprise a tongue and a groove wherein the tongue is provided on one side edge of one pair of opposite side edges, and the groove is provided on the other side edge of the same pair of opposite side edges.
The interconnecting coupling means of co-acting panels may be provided with co-acting locking elements.
In a possible embodiment of the panel according to the invention the core layer further comprises at least one polymer and/or wood based material.
It is also conceivable that the core layer further comprises at least one binder. it is also possible that the panel further comprises at least one top layer.
The top layer is typically provided on the top surface of the panel.
It is beneficial if the top layer has suitable properties for its intended use such as a waterproof layer, wear layer, and/or decorative layer.
Said top layer can be directly or indirectly attached to the core layer of the panel, for example via an adhesive, a hot melt material and/or hot or cold pressing. A decorative top layer, if applied, may for example comprise at least one ply of cellulose-based layer and a cured resin, wherein the cellulose- based layer is preferably paper or kraft paper. Said ply of cellulose-based material may also be a veneer layer adhered to a top surface of the core layer. The veneer layer is preferably selected from the group consisting of wood veneer, cork veneer, bamboo veneer, and the like. Other decorative top layers that could possibly be applied for the present invention include a ceramic tile, a porcelain tile, a real stone veneer, a rubber veneer, a decorative plastic or vinyl, linoleum, and decorative thermoplastic film or foil. The top layer may possibly be further provided with a wear layer and optionally a coating. Examples of thermoplastics 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 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.
In a further possible embodiment comprises the panel at least one backing layer. This can be any suitable backing layer for use with (floor) panels. 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.
The invention also relates to a floor covering comprising multiple panels, in particular floor panels, according to any the preceding claims. However, a wall covering comprising multiple panels according to the invention also falls within the scope of the present invention.
The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures. Herein shows: figure 1 a first possible embodiment of panel according to the present invention, figure 2 a second possible embodiment of a panel according to the present invention, and figure 3 a third possible embodiment of a panel according to the present invention. Figure 1 shows a schematic representation of a cross section of a first embodiment of a panel (101) according to the invention. The figure shows the panel (101) comprising a core layer (102) comprising magnesium oxysulfate whiskers (103) which at least partially form a crystal structure (104). It can be seen that the magnesium oxysulfate whiskers (103) interlock with another. The panel (101) further comprises a top layer (105) and optionally a backing layer (106).
Figure 2 shows a schematic representation of a cross section of a second possible embodiment of a panel (201) according to the invention. The figure shows the panel comprising a core layer (202) comprising an upper part (202a) and a lower part (202b) and a reinforcing layer (207) situated between said upper part (202a) and said lower part (202b) of the core layer (202). Both parts (202a, 202b) of the core layer (102) comprise magnesium oxysulfate whiskers (203) which at least partially form a crystal structure (204). It can be seen that only a part of the total volume of the core layer (202) comprises a crystal structure (204). The reinforcing layer (207) comprises a fiberglass mesh. The panel (201) further comprises a top layer (205).
Figure 3 shows a schematic representation of a cross section of a third possible embodiment of a panel (301) according to the invention. The figure shows the panel comprising a core layer (302) wherein the core layer (302) comprises respectively an upper part (302a), a lower part (302b) and an intermediate part (302c). Said parts are separated via multiple reinforcing layers (307a, 307b). In the present embodiment is the intermediate part (302c) of the core layer (302) a foam layer. The other parts (302a, 302b) of the core layer (102) comprise magnesium oxysulfate whiskers (303) which at least partially form a crystal structure (304). The panel (301) further comprises a top layer (305).
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 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.
Claims (19)
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NL2024805A NL2024805B1 (en) | 2020-01-31 | 2020-01-31 | Panel for forming a floor covering and such floor covering |
CN202010661689.8A CN113202253A (en) | 2020-01-31 | 2020-07-10 | Panel for forming a floor covering and such a floor covering |
EP21705888.2A EP4097060A1 (en) | 2020-01-31 | 2021-01-29 | Panel for forming a floor covering and such floor covering |
PCT/EP2021/052217 WO2021152153A1 (en) | 2020-01-31 | 2021-01-29 | Panel for forming a floor covering and such floor covering |
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NL2024805A NL2024805B1 (en) | 2020-01-31 | 2020-01-31 | Panel for forming a floor covering and such floor covering |
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CN101486267A (en) * | 2009-02-13 | 2009-07-22 | 南京林业大学 | Surface flame-retardant wood-plastic composite material plate and preparation thereof |
CN102731937A (en) * | 2012-07-23 | 2012-10-17 | 江苏森诺塑胶科技有限公司 | Foaming plastic wood composite material board and preparation method thereof |
EP3516130B1 (en) * | 2016-09-23 | 2023-05-10 | Shaw Industries Group, Inc. | Resilient flooring product and methods of making same |
CN110121583A (en) * | 2016-10-11 | 2019-08-13 | 核心创新有限公司 | Composite floor board product and its manufacturing method |
CN106957182A (en) * | 2017-03-30 | 2017-07-18 | 张函青 | A kind of glass base PLASTIC LAMINATED and its manufacturing process |
NL2019108B1 (en) * | 2017-06-22 | 2019-01-07 | Champion Link Int Corp | Floor panel and method of producing such a floor panel |
US10167232B1 (en) * | 2017-11-07 | 2019-01-01 | Jet Products, Llc | Process for making an ultra stable cementitious construction material |
US11180416B2 (en) * | 2018-11-06 | 2021-11-23 | MgO SYSTEMS LTD. | Structural assembly board and method of manufacturing same |
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2020
- 2020-01-31 NL NL2024805A patent/NL2024805B1/en active
- 2020-07-10 CN CN202010661689.8A patent/CN113202253A/en active Pending
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CN101386516A (en) * | 2008-10-21 | 2009-03-18 | 张文枝 | Magnesium lightweight synthetic fire proof floor plate and production process |
WO2012061300A2 (en) * | 2010-11-01 | 2012-05-10 | Finish Systems International, Llc | Stone-wood composite base engineered flooring |
DE102012000468A1 (en) * | 2012-01-13 | 2013-07-18 | Falquon Gmbh | Floor panel for use as e.g. Sorel cement flooring in residential building, has core including first layer that comprises mixture of magnesium oxide and magnesium chloride with aggregates, to which second and third layers are attached |
US20150059621A1 (en) * | 2013-08-12 | 2015-03-05 | Certainteed Gypsum, Inc. | Struvite-K and Syngenite Composition for Use in Building Materials |
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WO2020114645A1 (en) * | 2018-12-03 | 2020-06-11 | I4F Licensing Nv | Decorative panel, and decorative floor covering consisting of said panels |
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EP4097060A1 (en) | 2022-12-07 |
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