WO2024028677A1

WO2024028677A1 - Decorative panel and method for manufacturing decorative panels.

Info

Publication number: WO2024028677A1
Application number: PCT/IB2023/057232
Authority: WO
Inventors: Benjamin Clement; Jonas Deman; Jan De Rick; Laurent Meersseman; Christophe Naeyaert; Martin Segaert; Bruno Vermeulen; Kristof van Vlassenrode
Original assignee: Unilin, Bv
Priority date: 2022-08-05
Filing date: 2023-07-14
Publication date: 2024-02-08

Abstract

Decorative panel comprising one or more substrate layers and a top layer, said top layer comprising at least a decorative layer and a wear layer provided above said decorative layer, wherein at least a first substrate layer comprises a plurality of recesses, indentations and/or spaces, or wherein the decorative panel further comprises a corrugated layer positioned on the bottom side of one of said substrate layers, preferably the lowermost substrate layer.

Description

Decorative panel and method for manufacturing decorative panels.

The present invention relates to decorative panels and to a method for manufacturing decorative panels.

In particular, the invention relates to decorative panels comprising a substrate and a decorative top layer applied thereon. Such decorative panels are well-known in the art and form an alternative for natural decorative panels, e.g. floor panels, such as solid parquet flooring and natural stone. The decorative top layer may be printed with a pattern of wood or stone, or may comprise a layer of wood or stone. Examples of such floor panels are known, for example, from WO 97/47834, EP 1 038 689, EP 1 875 Oi l, WO 2017/087725, WO 2011/141849, WO 2018/087637 and WO 2018/087638. Laminate panels, as known from WO 97/47834, contain a core of MDF or HDF (Medium or High Density Fiberboard). Such core material cannot cope with prolonged exposure to moisture. Ceramic tiles, such as those known from EP 1 038 689, do not have this drawback, but require specialist knowledge for their installation. In order to remedy this, EP 1 875 011 and WO 2017/087725 propose floor panels comprising a mineral-based core and floor panels comprising a filled thermoplastic core, respectively. The core material of these floor panels is waterproof and is provided with mechanical coupling parts in order to make a smooth floating installation possible. The core material has a limited thickness, usually 5 mm or less, and is produced with a high density. The high density contributes to the stability of the floor covering. WO 2011/141849 proposes the use of a foamed core material. In order to keep the resistance to compression at a high level, additional measures are desirable with this type of floor panels. These measures do, however, increase the weight of the floor panel.

Panels as known in the art, may thus have the disadvantage that ergonomic problems may arise during installation, or that a packaging unit containing five panels or more may result in ergonomic problems during handling. Furthermore, transportation of such high- weight panels via the road or in containers is not optimal, and may lead to a particularly high fuel consumption. Lighter decorative panel alternatives are described in for example WO 2020/161609, which may show some disadvantages in that substantial adaption of existing manufacturing lines may be needed. WO 2021/180882 and WO 2022/050891 also aim to obtain alternative panels, however due to the provision of substantially large voids in the substrate material, and/or due to substantially heavy processing of the already solidified substrate material, there may be issues with strength and/or stability of the final panels. Another disadvantage may be that additional scrap material is generated during manufacturing of the panels, such as by milling away large amounts of substrate material from the back of the panel.

The prime object of the present invention is to provide an alternative floor panel, with various preferred embodiments offering a solution for the problems associated with the prior-art decorative panels.

A first independent aspect of the present invention is a decorative panel comprising one or more substrate layers and a top layer, said top layer comprising at least a decorative layer and a wear layer provided above said decorative layer, wherein at least a first substrate layer comprises a plurality of recesses, indentations and/or spaces. According to the invention, a decorative panel is thus obtained which combines various properties. In particular, the decorative panel may have the same thickness as panels known in the art, however combines a good stability with a lighter weight. The invention may have one or more advantages over what is known in that the decorative panel is more easy and more ergonomic to handle and/or to install. Furthermore, the decorative panels according to the invention may allow transportation having reduced fuel consumption, thus being more environmentally friendly. To add thereto, by reducing the amount of substrate material needed during the manufacturing process, the decorative panels of the invention thus provide a more sustainable and/or environmentally friendly alternative to known decorative panels, as more panels can be produced with a same amount of substrate material. Preferably, said recesses, indentations and/or spaces are foreign to the material of said substrate layer itself. For example, in the case of a foamed material, said recesses, indentations and/or spaces are different from the cells contained in said foamed material. In first instance, said recesses, indentations and/or spaces are macro-cavities, or cavities that have at least one dimension larger than 1 mm, or larger than 2 mm. Preferably said recesses, indentations and/or spaces have been formed by shaping and/or working said material of the substrate layer.

By preference, said decorative panel comprises a second substrate layer. The second substrate layer may or may not be provided with a plurality of recesses, indentations and/or spaces as well, however preferably is not provided with the latter, and is preferably free from recesses, indentations and/or spaces that are foreign to the material of said second substrate layer. By preference, said second substrate layer is positioned between said first substrate layer and said decorative layer. The second substrate layer may thus represent an unaltered substrate layer, which may be combined with a lighter first substrate layer, said layer comprising the recesses, indentations and/or spaces, thus obtaining a decorative panel which is lighter as a whole, though has sufficient strength and rigidity. In light of the invention, the term “unaltered substrate layer” is to be interpreted as a substrate layer which has not been provided with substantial recesses, indentations and/or spaces. More in particular, un unaltered substrate layer as described herein has a thickness which does not deviate more than 5%, preferably not more than 3%, more preferably not more than 1%, from its average thickness. The second substrate layer is preferably free from voids that are foreign to the material of the second substrate layer. The second substrate layer may be a closed-cell foam or may be unfoamed or solid.

The material of said second substrate layer preferably has a composition different from the composition of the material of said first substrate layer. Preferably the compositions of said first and second substrate layer show one or a combination of two or more of the following properties:

- the property that the compositions of the first and second substrate layer both comprise thermoplastic material and filler materials, wherein the weight ratio filler material : thermoplastic material is higher in said second substrate layer, e.g. at least 1.5 times higher;

- the property that the composition of the second substrate layer comprises thermoplastic material and filler materials, while the composition of the first substrate layer is free from filler materials, though preferably comprises the same thermoplastic material as said second substrate layer;

- the property that the material of said first substrate layer has a glass transition temperature that is lower than the glass transition temperature of said second substrate layer;

- the property that the composition of the first substrate layer comprises plasticizer at a rate of 5 phr or more, while the second substrate layer comprises less or no plasticizer;

- the property that the composition of the first substrate layer comprises an elastomer, e.g. chosen from the list of a rubber, e.g. nitrile butadiene rubber, an EPDM, a polyethylene, e.g. chlorinated polyethylene, a vinyl chloride copolymer, e.g. vinyl chi ori de-butyl acrylate-methyl methacrylate copolymer, a thermoplastic polyester and a thermoplastic polyurethane; and/or

- the property that the composition of the first substrate layer is such that it has a Shore hardness, in particular Shore A hardness, that is at least 5 lower than the Shore hardness, in particular Shore A hardness, of the second substrate layer, wherein the Shore hardness is measured in accordance with ISO 48-4:2018.

The decorative panel may be provided in a number of variants. In one embodiment, the first substrate layer extends uninterruptedly throughout the plane of the decorative panel, or otherwise said, the first substrate layer extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel. The first substrate layer may thus represent the substrate of the decorative panel on its own, optionally in combination with a second substrate layer. According to a further or another embodiment, the second substrate layer extends uninterruptedly throughout the plane of the decorative panel , or otherwise said, the second substrate layer extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel. Hence, the decorative panel may comprise two substrate layers, which each extend uninterruptedly throughout the plane of the decorative panel, or otherwise said, which extend in a horizontal direction H parallel to the plane of the decorative panel.

Additionally or alternatively, said second substrate layer extends uninterruptedly throughout the plane of the decorative panel (in a horizontal direction H parallel to the plane of the decorative panel), and said first substrate layer does not extend uninterruptedly throughout the plane of the decorative panel (in a horizontal direction H parallel to the plane of the decorative panel), wherein said first substrate layer is at least intermittently connected to said second substrate layer. In such a variant, the second substrate layer thus provides an uninterrupted substrate layer, while the first substrate layer is only intermittently present. By only having an intermittent presence of the first substrate layer, a further weight reduction may be possible, further improving the advantages related to ergonomics and sustainability.

According to a further or another embodiment, said plurality of recesses, indentations and/or spaces defines a structure, preferably having a pattern on at least one surface of the first substrate layer. By organizing the recesses, indentations and/or spaces as a structure, the first substrate layer may be visually more pleasing, if visible, and thus the decorative panel may give the impression of a more premium product, meanwhile the structure is still achieving its weight-reducing properties. In one embodiment, said structure on at least one surface of the first substrate layer is directed away from the second substrate layer. Preferably, said structure is thus present on the bottom side of the first substrate layer and potentially on the bottom side of the decorative panel. In another embodiment, the structure on at least one surface of the first substrate layer is directed towards the second substrate layer. Preferably, said structure is not visible from the bottom side of the decorative panel.

It is however not excluded that an additional backing layer is applied to the bottom surface of the lowermost substrate layer, for example to the bottom of said first substrate layer. Such a backing layer may for example be a softer cushioning layer, which may improve sound characteristics of the decorative panel, or a layer of IXPE (irradiation crosslinked polyethylene), a layer of foamed plasticized PVC, a layer of cork. According to a further or another embodiment, said structure has a repeating pattern in at least a first direction of the plane of the decorative panel. By using a repeating pattern, the first substrate layer, if visible, may be visually more pleasing and thus the decorative panel may give the impression of a more premium product, meanwhile the structure is still achieving its weight-reducing properties. Furthermore, by having a repeating pattern, properties like stability and strength are homogeneously distributed throughout the plane of the decorative panel, or alternatively said, the decorative panels may be free of regions which are substantially weaker or stronger than average. By preference, said structure has a repeating pattern in a first and a second direction of the plane of the decorative panel, preferably a second direction perpendicular to said first direction. By having a repeating pattern in two dimensions, the homogenous distribution of stability and strength throughout the plane of the decorative panel may be further improved.

According to a further or another embodiment, said structure has a shape which is chosen from the group of a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, a grooved shape, a waffle shape, or combinations thereof. Each of the aforementioned shapes provide a visually pleasing structure, if visible, which allows substantial weightreduction, meanwhile maintaining sufficient stability and strength of the decorative panel as a whole.

According to a special embodiment, said first substrate layer is shaped or formed as a net, for example comprising a plurality of adjacent meshes that are distanced by means of substrate material. Preferably, the width of the substrate material distancing said meshes is smaller than the diameter, or even smaller than the radius of the circumscribed circle of either of said meshes. Preferably the width of said substrate material is smaller than half the radius of said circumscribed circle.

According to a particularly preferred further or other embodiment, the first substrate layer is present as a plurality of strips on the bottom side of the second substrate layer. Herein said strips are preferably extending in one direction and are distanced from each other in a second direction, preferably perpendicular to said one direction. The distance between adjacent strips may form said recesses or spaces. Herein, the plurality of recesses and/or spaces preferably reach all the way through the entire thickness of the first substrate layer. By preference, the second substrate layer has a thickness of 2 to 7 mm, more by preference of 3 to 6 mm, even more by preference of 3 to 5 mm, even more by preference of 3,5 to 4,5 mm. Most by preference, the thickness of the second substrate layer is 4,5 mm. Additionally or alternatively, the first substrate layer has a thickness of between 0,5 and 2 mm, more by preference of between 0,5 mm and 1,5 mm. Most by preference the thickness of the first substrate layer is 1 mm. Additionally or alternatively, the plurality of strips of the first substrate layer have a width of between 5 mm and 50 mm, more by preference of between 10 and 40 mm, even more by preference of between 10 and 30 mm. Most by preference the width of the strips of the first substrate layer have a width of 20 mm. Additionally or alternatively, the plurality of recesses and/or spaces formed in between said strips has a width of between 5 mm and 50 mm, by preference of between 10 and 40 mm, more by preference of between 10 and 30 mm. Most by preference the width of the plurality of recesses and/or spaces have a width of 20 mm.

In general, said substrate, whether formed as a single substrate layer, or as at least two substrate layers, preferably forms at least half of the thickness of said decorative panel. Preferably, said first substrate layer or said second substrate layer, when available, is at least extending, preferably uninterruptedly, in a central location in the thickness of said decorative panel. In the most preferred embodiment, said decorative panel comprises a top layer with at least a decorative layer and a wear layer provided above said decorative layer, wherein said decorative layer comprises a thermoplastic decorative film applied immediately on top of said substrate, e.g. by thermal lamination, i.e. in the absence of separate glue layers, or, a printed pattern of inks applied directly to the top of said substrate with the intermediate of one or more primer layers, that are preferably liquidly applied on the top of said substrate. Potentially a backing layer is applied to the bottom of said substrate as a bottommost layer of said decorative panel. Such backing layer may be adhered to said bottom of said substrate by means of glue. Herein said substrate is preferably a single layered substrate, namely consisting of said first substrate layer, or a substrate consisting of two substrate layers, namely of said first and said second substrate layer. In the latter case said second substrate layer forms the top of said substrate, and said first substrate layer forms the bottom of said substrate. Preferably the composition of said first and second substrate layer show one or a combination of two or more of the above listed properties.

The recesses, indentations and/or spaces of the first substrate layer, as comprised in the decorative panel of the invention, preferably result in a weight reduction of at least 10% in comparison to the substrate layer or the decorative panel having no recesses, indentations and/or spaces. Such a large weight reduction is substantially advantageous with regard to the ease of handling and/or installing the decorative panels of the invention. Furthermore, the amount of substrate material needed is substantially reduced, thus providing a more environmentally friendly alternative to known decorative panels. By preference, the recesses, indentations and/or spaces of the first substrate layer result in a weight reduction of at least 12%. More by preference, the recesses, indentations and/or spaces of the first substrate layer result in a weight reduction of at least 15%. Even more by preference, a weight reduction of at least 16%, 17%, 18%, 19% or even 20% may be obtained. It is clear that said weight reduction is each time in respect of the substrate layer or decorative panel not having said recesses, indentations and/or spaces. The weight reductions as described herein are particularly relevant for heavy substrate materials, e.g. containing a high amount of filler, for example for substrate materials comprising a filled thermoplastic material, wherein the ratio by weight of filler : thermoplastic material is more than 1 : 1, for example at least 2,5: 1. Some embodiments of the invention may also provide a weight reduction lower than 10%, however preferably higher than 5%, more preferably higher than 7%, 8% or 9%.

In a preferred embodiment, the recesses, indentations and/or spaces are void, i.e. are containing air. It may however be possible that these recesses, indentations and/or spaces are filled with an alternative substrate material which is lighter than the material of the first substrate layer. According to some embodiments, the material of the first substrate layer has a density of more than 1000 kg/m³, preferably more than 1100 kg/m³, even more preferably more than 1200 kg/m³ or even 1300 kg/m³. The material of the first substrate layer preferably has a density of more than 1700 kg/m³, even more preferably of more than 1800 kg/m³, of more than 1900 kg/m³, even more preferably of more than 2000 kg/m³. It should be understood that the material of the first substrate layer excludes the recesses, indentations, and/or spaces. Should the recesses, indentations and/or spaces be filled with an alternative substrate material which is lighter than the material of the first substrate layer, said alternative substrate material may have a density of less than 500 kg/m³, or even of 300 kg/m³ or less. The respective spaces may be filled, for example, with a plastic foam or a mineral foam, such as vermiculite, perlite or pumice.

According to some embodiments, the recesses, indentations and/or spaces may have a depth which relates to the thickness of the decorative panel following a ratio of between 1 : 10 and 1 :2. By preference, the depth of the recesses, indentations and/or spaces relates to the thickness of the decorative panel following a ratio of between 1 : 10 and 4: 10, even more by preference of between 1 :10 and 3 : 10. Additionally or alternatively, it may be that the recesses, indentations and/or spaces have a depth of 0,1 to 2,0 mm, by preference of between 0,2 and 1,5 mm, more by preference of between 0,1 and 1,0 mm.

According to a special embodiment a plurality of said recesses, indentations and/or spaces may have a mutually different depth. For example, the depth of the recesses in a more central location of said first substrate layer, as seen in the plane of the floor panel may be deeper or less deep than at a location at one of the edges of said first substrate layer.

According to some embodiments, the thickness of the first substrate layer may relate to the thickness of the second substrate layer, if present, following a ratio of between 1 : 10 and 1 :2. By preference, the thickness of the first substrate layer and the thickness of the second substrate layer relate to one another following a ratio of between 1 : 10 and 4: 10, even more by preference of between 1 :10 and 3:10.

According to some embodiments, the first and/or second substrate layer preferably comprise a thermoplastic material, and optionally a filler material, such that in this latter case the substrate material comprises or is a filled thermoplastic material. So, for example, a vinyl-based substrate, such as PVC, a polyethylene-based substrate, a polypropylene-based substrate or a polyurethane-based substrate can be applied. These materials have a good resistance against water or moisture and are readily available. Herein it is remarked that the respective thermoplastic material does not necessarily form the majority of the volume or weight of the respective substrate material. For example in the case of a filled thermoplastic material, it may be that the filler forms the largest portion of the weight and/or volume of said filled thermoplastic material. In such case the thermoplastic material is still regarded as the basis material of the filled thermoplastic material as it preferably forms a continuous or matrix in which said filler material is embedded. In some embodiments, the substrate material comprises a foamed synthetic material. In some embodiments, the substrate material comprises a highly filled synthetic material, comprising a filler material such as, for example, calcium carbonate and/or talcum. According to a particular embodiment, the weight ratio of synthetic material to filler material is comprised between 1 : 1 and 1 :4, preferably between 1 : 1 and 1 :2. In some embodiments, said substrate material may or may not comprise at least one reinforcement layer such as a glass fiber layer. In a preferred embodiment, said thermoplastic material is polyvinylchloride (PVC) having a plasticizer content of less than 5 phr (5 parts per 100 parts of thermoplastic material or PVC). The content of fillers in the first and/or second substrate layer is by preference more than 40% by weight, more by preference between 65 and 87% by weight, namely approximately 80% by weight.

According to some embodiments, the decorative layer is a thermoplastic decorative layer. Preferably, said thermoplastic decorative layer is a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

According to some embodiments, the wear layer is or comprises a transparent and/or translucent thermoplastic wear layer. Preferably, said transparent and/or translucent thermoplastic wear layer is or comprises a thermoplastic film. Said transparent and/or translucent thermoplastic wear layer may further comprise a lacquer as an uppermost layer of said wear layer, for example coated on said thermoplastic film.

In some embodiments, on at least one pair of opposite edges, the decorative panel is provided with mechanical coupling parts, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges. By preference, no recesses, indentations and/or spaces, or recesses, indentations and/or spaces of a lesser depth, are present at the location of the mechanical coupling means, thereby improving the strength of the coupling. It is clear that the coupling parts per se may comprise one or more recesses that are active in said locking. According to a preferred embodiment, said coupling parts are basically shaped as a tongue-in-groove connection with locking parts preventing the drifting apart of said tongue and groove. The groove may be bordered by an upper and a lower lip. Preferably, at least said lower lip is at least partially, and preferably integrally, formed from said first substrate layer, wherein the bottom of said lower groove lip is free from said recesses, indentations and/or spaces that are otherwise available in said first substrate layer, or comprises recesses, indentations and/or spaces of a lesser depth than the recesses, indentations and/or spaces available at a more central location in the first substrate layer.

In general, the decorative panel of the invention may comprise a region along one or more edges which do not comprise recesses, indentations and/or spaces, or which comprise recesses, indentations and/or spaces having a lesser depth than the more centrally located recesses, indentations and/or spaces. Said region preferably has a width W of more than 3 mm, more preferably more than 4 mm, more preferably more than 5 mm. In such case hindrance of mechanical coupling parts at the respective edge may be minimized. Preferably such region is at least available at one or more edges comprising coupling parts in the form of a groove.

With the same object as in said first independent aspect, the present invention, in accordance with a second independent aspect is a decorative panel comprising a substrate, wherein said substrate comprises one or more substrate layers, and a top layer, said top layer comprising at least a decorative layer and a wear layer provided above said decorative layer, wherein the decorative panel further comprises a corrugated layer positioned on the bottom side of the one of said substrate layers, preferably the lowermost substrate layer. The corrugated layer of the decorative panel according to the invention allows the decorative panel to have substantial thickness, meanwhile achieving reduced weight of the panel as a whole.

In general, said substrate, whether formed as a single substrate layer, or as at least two substrate layers, namely as a first substrate layer and a second substrate layer available in between said first substrate layer and said decorative layer, preferably forms at least half of the thickness of said decorative panel. Preferably, said substrate is at least extending, preferably uninterruptedly, in a central location in the thickness of said decorative panel. In the most preferred embodiment, said decorative panel comprises a top layer with at least a decorative layer and a wear layer provided above said decorative layer, wherein said decorative layer comprises a thermoplastic decorative film applied immediately on top of said substrate, e.g. by thermal lamination, i.e. in the absence of separate glue layers, or, a printed pattern of inks applied directly to the top of said substrate with the intermediate of one or more primer layers, that are preferably liquidly applied on the top of said substrate. A corrugated layer is applied to the bottom of said substrate as a bottommost layer of said decorative panel. Such corrugated layer may be adhered to said bottom of said substrate by means of glue. Herein said substrate is a single layered substrate.

By preference, said corrugated layer is at least intermittently connected to said lowermost substrate layer. In the light of the present invention, the term “corrugated layer” needs to be interpreted as a layer that consists of a corrugated material sheet or plate. Such a layer could for example be obtained by repeatedly bending, folding or kinking a flat sheet or plate in an alternating opposite direction such that a corrugated shape is obtained. A corrugated layer has the advantage that it aids in providing stability and strength to the decorative panel, meanwhile achieving reduced weight of the panel as a whole. Furthermore, a corrugated layer as described herein may be easily manufactured and adhered to one or more substrate layers.

According to a further or another embodiment, said corrugated layer has a repeating pattern in at least a first direction of the plane of the decorative panel. Having a repeating pattern in at least a first direction of the plane of the decorative panel may lead to a more visually pleasing panel.

According to some embodiments, the corrugated layer preferably results in a weight reduction of at least 10% in comparison to a layer having the same overall thickness as the corrugated layer, but made from the material of the substrate layer to the bottom of which it has been provided. Such a large weight reduction is substantially advantageous with regard to the ease of handling and/or installing the decorative panels of the invention. Furthermore, the amount of substrate material needed is substantially reduced, thus providing a more environmentally friendly alternative to know decorative panels. By preference, the corrugated layer results in a weight reduction of at least 12%. More by preference, the corrugated layer results in a weight reduction of at least 15%. Even more by preference, a weight reduction of at least 16%, 17%, 18%, 19% or even 20% may be obtained. The weight reductions as described herein are particularly relevant for heavy substrate materials, e.g. containing a high amount of filler. Some embodiments of the invention may also provide a weight reduction lower than 10%, however preferably higher than 5%, more preferably higher than 7%, 8% or 9%.

According to some embodiments, the thickness of the corrugated layer may relate to the thickness of the substrate layer or the substrate, the bottom of which it has been provided to, following a ratio of between 1 : 10 and 1 :2. By preference, the thickness of the corrugated layer and the thickness of the substrate layer or of the substrate relate to one another following a ratio of between 1 :10 and 4:10, even more by preference of between 1 : 10 and 3: 10.

According to some embodiments, said one or more substrate layers preferably comprise a thermoplastic material, and optionally a filler material. So, for example, a vinyl-based substrate, such as PVC, a polyethylene-based substrate, a polypropylene-based substrate or a polyurethane-based substrate can be applied. These materials have a good resistance against water or moisture and are readily available. Herein it is remarked that the respective thermoplastic material does not necessarily form the majority of the volume or weight of the respective substrate material. For example in the case of a filled thermoplastic material, it may be that the filler forms the largest portion of the weight and/or volume of said filled thermoplastic material. In such case the thermoplastic material is still regarded as the basis material of the filled thermoplastic material as it preferably forms a continuous or matrix in which said filler material is embedded. In some embodiments, the substrate material comprises a foamed synthetic material. In some embodiments, the substrate material comprises a highly filled synthetic material, comprising a filler material such as, for example, calcium carbonate. According to a particular embodiment, the weight ratio of synthetic material to filler material is comprised between 1 : 1 and 1 :4, preferably between 1 : 1 and 1 :2. In some embodiments, said substrate material may or may not comprise at least one reinforcement layer such as a glass fiber layer. In a preferred embodiment, said thermoplastic material is polyvinylchloride (PVC) having a plasticizer content of less than 5 phr (5 parts per 100 parts of thermoplastic material or PVC). The content of fillers in the first and/or second substrate layer is by preference more than 40% by weight, more by preference between 65 and 87% by weight, namely approximately 80% by weight.

According to some embodiments, the wear layer comprises or is a transparent and/or translucent thermoplastic wear layer. Preferably, said transparent and/or translucent thermoplastic wear layer comprises or is a thermoplastic film.

In some embodiments, on at least one pair of opposite edges, the decorative panel is provided with mechanical coupling parts, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges. According to a preferred embodiment, said coupling parts are basically shaped as a tongue-in-groove connection with locking parts preventing the drifting apart of said tongue and groove. The groove may be bordered by an upper and a lower lip. Preferably, at least said lower lip is at least partially, and preferably integrally, formed from said one substrate layer, wherein the corrugated layer extends at least partially along the bottom of said lower groove lip.

With the same aim as in said first and second independent aspect, the present invention also relates to a method which is ideally suited to manufacture decorative panels in accordance with said first independent aspect.

With this aim, the present invention in accordance with its third independent aspect is a method for manufacturing decorative panels, comprising the steps of: providing a first substrate layer, optionally, providing a second substrate layer, providing at least a decorative layer and a wear layer onto said first substrate layer or, optionally, onto said second substrate layer, wherein said wear layer is located above said decorative layer, and wherein said first substrate layer is provided with a plurality of recesses, indentations and/or spaces.

The invention may have one or more advantages over what is known in that the resulting decorative panel is more easy and more ergonomic to handle and/or to install. Furthermore, the decorative panels according to the invention may allow transportation having reduced fuel consumption, thus being more environmentally friendly. To add thereto, by reducing the amount of substrate material needed during the manufacturing process, the decorative panels of the invention thus provide a more sustainable and/or environmentally friendly alternative to known decorative panels, as more panels can be produced with a same amount of substrate material.

By preference, said first substrate layer is provided with a plurality of recesses, indentations and/or spaces by means of a mechanical embossing step. A mechanical embossing step has the advantage that it is relatively easy to implement and that it is able to obtain recesses, indentations and/or spaces which are accurately formed. As such, recesses, indentations and/or spaces are obtained which are both functional and visually pleasing and which effectively allow to produce decorative panels with reduced weight.

It is clear that an embossing step as in the above preferred embodiment entails a displacement of material of said first substrate layer. Preferably, said displacement results at least in an increase of the thickness, or global thickness, of said first substrate layer. Alternatively, said displacement results at least in an increase of the length and/or width of said first substrate layer. An embossing step resulting in a pure compression of the material of said first substrate layer is not excluded, but is less preferred as the possibly attainable reduction in weight per millimeter thickness of the obtained decorative panel, in comparison to a decorative panel where the embossing step had not occurred, seems minimal.

Preferably, said embossing step results in a first substrate layer having portions that are at least 105% or at least 110% of the thickness of the first substrate layer before embossing. Preferably, said first substrate layer has a uniform, or about a uniform, thickness before embossing.

Preferably, said embossing results in a structured surface of said first substrate layer, wherein said structured surface comprises a plurality of indentations, that preferably have a uniform shape or size, and that are at least partially, or wholly, separated from each other by means of portions of said first substrate layer that form walls that form the thickest portions of said first substrate layer. In the finally obtained decorative panel said thickest portions or walls may support said first substrate layer on an underlying layer of the decorative panel, or on the underground over which the respective decorative panel is installed. As stated above, said thickest portion preferably have a thickness that is at least 105% or at least 110% of the thickness of the respective portion, or of the global thickness of said first substrate layer, before said embossing.

According to an alternative or in addition to said mechanical embossing, said first substrate layer is provided with a plurality of recesses or spaces by means of a cutting or perforating step, and, preferably, subsequently stretched in at least one direction. In so doing said first substrate layer may receive the form of a net, wherein said recesses or spaces form the meshes of said net. Preferably said recesses or spaces are regularly distributed with the remaining material of said first substrate layer surrounding said meshes. Preferably the width of said remaining material in between two adjacent meshes in the obtained net structure is smaller than the diameter, or the radius, of the circumscribed circle pertaining to either of the respective meshes. Said width may be even less than half said radius. Said first substrate layer may be provided with said recesses or spaces by means of a cutting or punching device preferably prior to said provision of said decorative layer and wear layer, or, prior to merging said first substrate layer to said optional second substrate layer. It is possible to provide said plurality of recesses or spaces initially in such manner that the perforated first substrate layer can be stretched in at least one direction. For example said cutting or perforating step may provide for slits having a length direction and enabling the stretching of said substrate layer in the width direction of said slits, thereby opening said slits and transforming them into said meshes.

According to a further or another embodiment, said first substrate layer extends uninterruptedly throughout the plane of the decorative panel. According to some embodiments, the second substrate layer extends uninterruptedly throughout the plane of the decorative panel as well.

Additionally or alternatively, said second substrate layer extends uninterruptedly throughout the plane of the decorative panel, and said first substrate layer does not extend uninterruptedly throughout the plane of the decorative panel, wherein said first substrate layer is at least intermittently connected to said second substrate layer. In such a variant, the second substrate layer thus provides an uninterrupted substrate layer, while the first substrate layer is only intermittently present. By only having an intermittent presence of the first substrate layer, a further weight reduction may be possible.

According to a further or another embodiment, said plurality of recesses, indentations and/or spaces defines a structure on at least one surface of the first substrate layer. By organizing the recesses, indentations and/or spaces as a structure, the first substrate layer, if visible, may be visually more pleasing and thus the decorative panel may give the impression of a more premium product, meanwhile the structure is still achieving its weight-reducing properties. In one embodiment, said structure on at least one surface of the first substrate layer is directed away from the second substrate layer. Preferably, said structure is thus present on the bottom side of the decorative panel. In another embodiment, the structure on at least one surface of the first substrate layer is directed towards the second substrate layer. Preferably, said structure is not visible from the bottom side of the decorative panel.

According to a further or another embodiment, said structure has a repeating pattern in at least a first direction of the plane of the decorative panel. By using a repeating pattern, the first substrate layer may be visually more pleasing and thus the decorative panel may give the impression of a more premium product, meanwhile the structure is still achieving its weight-reducing properties. Furthermore, by having a repeating pattern, properties like stability and strength are homogeneously distributed throughout the plane of the decorative panel, or alternatively said, showing no regions which are substantially weaker or stronger. By preference, said structure has a repeating pattern in a first and a second direction of plane of the decorative panel. By having a repeating pattern in two dimensions, the homogenous distribution of stability and strength throughout the plane of the decorative panel may be further improved.

According to a further or another embodiment, said structure has a shape which is chosen from the group of a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, a grooved shape, a waffle shape, or combinations thereof. Each of the aforementioned shapes provide a visually pleasing structure which allows substantial weight-reduction, meanwhile upholding sufficient stability and strength of the decorative panel as a whole.

The recesses, indentations and/or spaces of the first substrate layer, as comprised in the decorative panel of the invention, preferably result in a weight reduction of at least 10% in comparison to the first substrate layer or decorative panel having no recesses, indentations and/or spaces. Such a large weight reduction is substantially advantageous with regard to the ease of handling and/or installing the decorative panels obtained through the method of the third aspect of the invention. Furthermore, the amount of substrate material needed is substantially reduced, thus providing a more environmentally friendly alternative to know decorative panels. By preference, the recesses, indentations and/or spaces of the first substrate layer result in a weight reduction of at least 12%. More by preference, the recesses, indentations and/or spaces of the first substrate layer result in a weight reduction of at least 15%. Even more by preference, a weight reduction of at least 16%, 17%, 18%, 19% or even 20% may be obtained. The weight reductions as described herein are particularly relevant for heave substrate materials, e.g. containing a high amount of filler. Some embodiments of the invention may also provide a weight reduction lower than 10%, however preferably higher than 5%, more preferably higher than 7%, 8% or 9%.

In a preferred embodiment, the recesses, indentations and/or spaces are void, i.e. are containing air. It may however be possible that these recesses, indentations and/or spaces are filled with an alternative substrate material which is lighter than the material of the first substrate layer. According to some embodiments, the first substrate layer has a density of more than 1000 kg/m³, preferably more than 1100 kg/m³, even more preferably more than 1200 kg/m³ or even 1300 kg/m³. Should the recesses, indentations and/or spaces be filled with an alternative substrate material which is lighter than the material of the first substrate layer, said alternative substrate material may have a density of less than 500 kg/m³, or even of 300 kg/m³ or less. The respective spaces may be filled, for example, with a plastic foam or a mineral foam, such as vermiculite, perlite or pumice.

According to some embodiments, the recesses, indentations and/or spaces may have a depth which relates to the thickness of the decorative panel following a ratio of between 1 : 10 and 1 :2. By preference, the depth of the recesses, indentations and/or spaces relates to the thickness of the decorative panel following a ratio of between 1 : 10 and 4: 10, even more by preference of between 1 :10 and 3 : 10. Additionally or alternatively, it may be that the recesses, indentations and/or spaces have a depth of 0, 1 to 2,0 mm, by preference of between 0,2 and 1,5 mm, more by preference of between 0,1 and 1,0 mm. According to some embodiments, if present, the thickness of the first substrate layer may relate to the thickness of the second substrate layer following a ratio of between 1 :10 and 1:2. By preference, the thickness of the first substrate layer and the thickness of the second substrate layer relate to one another following a ratio of between 1 : 10 and 4: 10, even more by preference of between 1 :10 and 3:10.

According to some embodiments, the first and/or second substrate layer preferably comprise a thermoplastic material, and optionally a filler material. So, for example, a vinyl-based substrate, such as PVC, a polyethylene-based substrate, a polypropylene- based substrate or a polyurethane-based substrate can be applied. These materials have a good resistance against water or moisture and are readily available. In some embodiments, the substrate material comprises a foamed synthetic material. In some embodiments, the substrate material comprises a highly filled synthetic material, comprising a filler material such as, for example, calcium carbonate. According to a particular embodiment, the ratio of synthetic material to filler material is comprised between 1 : 1 and 1 :2, even up to 1 :4. In some embodiments, said substrate material may or may not comprise at least one reinforcement layer such as a glass fiber layer. In a preferred embodiment, said thermoplastic material is polyvinylchloride (PVC) having a plasticizer content of less than 5 phr (5 parts per 100 parts of thermoplastic material or PVC). The content of fillers in the first and/or second substrate layer is by preference more than 40% by weight, more by preference between 65 and 87% by weight, namely approximately 80% by weight.

According to some embodiments, providing the first and/or second substrate layer is performed by an extrusion operation.

Alternatively, providing the second substrate layer is performed by an extrusion operation, and providing the first substrate layer is performed by applying molten substrate material onto the second substrate layer.

In the case where said first substrate layer is provided by means of an extrusion operation, this may be a net extrusion, either a flat or tubular net extrusion. In case of a tubular net extrusion, the obtained tubular net is preferably subsequently cut open to form a flat net. Net extrusion is a continuous extrusion process resulting in a layer in the form of a net without the necessity of perforating or cutting operations. The extrudate may leave the die as strands. The strands may be united at intersections for example by drawing the strands over a forming mandrel, and potentially into water to cool. While moving over the forming mandrel, the material may be stretched. Examples of net extrusion are described in US 3,557,268, US 3,163,691, US 3,178,328 and US 4,294,646. The US’646 discloses cutting the obtained tubular net to form a flat net.

According to an embodiment, said molten substrate material is applied onto said second substrate layer as an uninterrupted layer, followed by embossing said uninterrupted layer. A mechanical embossing step has the advantage that it is relatively easy to implement and that it is able to obtain recesses, indentations and/or spaces which are accurately formed. As such, recesses, indentations and/or spaces are obtained which are both functional and visually pleasing and which effectively allow to produce decorative panels with reduced weight.

According to another embodiment, said molten substrate material is applied onto said second substrate layer as an interrupted layer. Herein, it needs to be understood that the molten substrate material is applied as such that the recesses, or precursors thereof, are already present. This may for example be done by applying the molten substrate material in varying application rates, by applying the molten substrate material using a specifically shaped spout, or by applying the molten substrate material using a plurality of individual spouts. In the latter example, said molten substrate material may preferably be applied as a plurality of strips. It may be possible that the thickness of the molten substrate material, in particular the thickness of the strips, is set by a calendaring operation following the application. In each of the aforementioned embodiments, the molten substrate material may be consolidated by cooling, either naturally or induced.

According to some embodiments, providing the second substrate layer is performed by an extrusion operation, and providing the first substrate layer comprises welding preformed substrate material onto the second substrate layer. This particular embodiment has the advantage that it is easy to implement and is relatively fast to operate. In light of the present invention, the term “welding” is to be interpreted as joining two elements together by heat, preferably by heat and pressure. The term “welding” as described herein, comprises joining two elements together, both in a substantially complete manner, or alternatively in an incomplete manner, meaning that only parts of the elements are adjoined together. The term “laminating” more specifically indicates joining two elements together by heat, preferably by heat and pressure, in a complete and/or continuous manner, meaning the elements are fully adjoined to one another.

According to a particularly preferred further or other embodiment, providing the second substrate layer is performed by an extrusion operation, and providing the first substrate layer comprises: cutting and/or slitting said first substrate layer, thereby obtaining a plurality of strips of said first substrate layer, distancing said plurality of strips, and subsequently laminating said distanced plurality of strips of the first substrate layer onto the second substrate layer.

This particular embodiment has the advantage that it is a cost-efficient means of obtaining weight reduction in a decorative panel, and is relatively fast to operate. A further advantage exists in that cutting of the first substrate layer as described may require less maintenance and/or replacements of the cutting device/and or cutting tools. As a further advantage, it is noted that little to no additional scrap material is generated during manufacturing the decorative panels according to the invention.

Additionally or alternatively, said first substrate layer is provided from a roll, and is unrolled prior to said step of cutting and/or slitting said first substrate layer. By preference, said first substrate layer, in particular the plurality of strips, is thermally laminated onto the second substrate layer.

By preference, the second substrate layer has a thickness of 2 to 7 mm, more by preference of 3 to 6 mm, even more by preference of 3 to 5 mm, even more by preference of 3,5 to 4,5 mm. Most by preference, the thickness of the second substrate layer 9 is 4,5 mm. Additionally or alternatively, the first substrate layer has a thickness of between 0,5 and 2 mm, more by preference of between 0,5 mm and 1,5 mm. Most by preference the thickness of the first substrate layer is 1 mm. Additionally or alternatively, the plurality of strips of the first substrate layer have a width of between 5 mm and 50 mm, more by preference of between 10 and 40 mm, even more by preference of between 10 and 30 mm. Most by preference the width of the strips of the first substrate layer have a width of 20 mm. Additionally or alternatively, the plurality of recesses, indentations and/or spaces has a width of between 5 mm and 50 mm, by preference of between 10 and 40 mm, more by preference of between 10 and 30 mm. Most by preference the width of plurality of recesses, indentations and/or spaces have a width of 20 mm. In this particular embodiment, it is to be understood that the plurality of recesses indentations and/or spaces forms the open space in between the plurality of strips. Additionally or alternatively, the width and/or spacing of the plurality of strips may be varied in accordance with the desired final product.

By preference, the step of laminating said distanced plurality of strips of the first substrate layer is performed in-line with the extrusion, more by preference in between extruding said second substrate layer and laminating the top layer. By preference, laminating said distanced plurality of strips of the first substrate layer is performed from the bottom side.

According to some embodiments, the wear layer is or comprises a transparent and/or translucent thermoplastic wear layer. Preferably, said transparent and/or translucent thermoplastic wear layer is or comprises a thermoplastic film.

The method according to some embodiments, may comprise the step of dividing the assembly of the one or more substrate materials and the top layer, in particular the decorative layer and the wear layer, into slabs comprising a plurality of decorative panels and/or consequently dividing said assembly or said slabs into decorative panels, or panels having about the dimensions of the finally to be obtained decorative panels.

In some embodiments, on at least one pair of opposite edges, the decorative panel is provided with mechanical coupling parts, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges. By preference, no recesses, indentations and/or spaces are present at the location of the mechanical coupling parts.

It is clear that the method of the third aspect is ideally suited for manufacturing the decorative panels of the first independent aspect and/or the preferred embodiments thereof.

With the same aim as in said first and second independent aspect, the present invention also relates to a method which is ideally suited to manufacture decorative panels in accordance with said second independent aspect.

With this aim, the present invention in accordance with its fourth independent aspect is a method for manufacturing decorative panels, comprising the steps of: providing one or more substrate layers, providing at least a decorative layer and a wear layer onto said one or more substrate layers, wherein said wear layer is located above said decorative layer, and wherein the method further comprises the step of providing a corrugated layer on the bottom side of one of said substrate layers, preferably the lowermost substrate layer.

By preference, said corrugated layer is at least intermittently connected to said lowermost substrate layer. The corrugated layer may for example be connected by means of welding, laminating or gluing. In case the corrugated layer is connected by means of a laminating process, the laminating roller should ideally have a shape which corresponds to the shape of the corrugated layer. According to a further or another embodiment, said corrugated layer has a repeating pattern in at least a first direction of the plane of the decorative panel, which may provide the decorative panel with a more visually pleasing appearance.

According to some embodiments, the corrugated layer preferably results in a weight reduction of at least 10% in comparison to a layer having the same overall thickness as the corrugated layer, but made from the material of the substrate layer to the bottom of which it has been provided. Such a large weight reduction is substantially advantageous with regard to the ease of handling and/or installing the decorative panels of the invention. Furthermore, the amount of substrate material needed is substantially reduced, thus providing a more environmentally friendly alternative to know decorative panels. By preference, the corrugated layer results in a weight reduction of at least 12%. More by preference, corrugated layer results in a weight reduction of at least 15%. Even more by preference, a weight reduction of at least 16%, 17%, 18%, 19% or even 20% may be obtained. The weight reductions as described herein are particularly relevant for heave substrate materials, e.g. containing a high amount of filler. Some embodiments of the invention may also provide a weight reduction lower than 10%, however preferably higher than 5%, more preferably higher than 7%, 8% or 9%.

According to some embodiments, the thickness of the corrugated layer may relate to the thickness of the first substrate layer following a ratio of between 1 : 10 and 1 :2. By preference, the thickness of the corrugated layer and the thickness of the first substrate layer relate to one another following a ratio of between 1 : 10 and 4: 10, even more by preference of between 1 : 10 and 3: 10.

According to some embodiments, said corrugated layer is provided by means of mechanically corrugating a thermoplastic sheet. This may or may not be done while applying heat to the thermoplastic sheet in order to allow easier deformation.

According to some embodiments, the decorative layer is a thermoplastic decorative layer. Preferably, said thermoplastic decorative layer is a thermoplastic decorative film, said thermoplastic decorative layer comprising a print. According to some embodiments, the wear layer is a transparent and/or translucent thermoplastic wear layer. Preferably, said transparent and/or translucent thermoplastic wear layer is a thermoplastic film.

In some embodiments, on at least one pair of opposite edges, the decorative panel is provided with mechanical coupling parts, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, also called the vertical direction, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges, also called the horizontal direction.

It is clear that the method of the fourth aspect is ideally suited for manufacturing the decorative panels of the second independent aspect and/or the preferred embodiments thereof.

With the same aim as in the first till fourth independent aspect, the present invention in accordance with its fifth independent aspect is a method for manufacturing decorative panels, comprising the steps of: providing a first substrate layer providing a second substrate layer, providing at least a decorative layer and a wear layer onto said second substrate layer, on the side opposite the first substrate layer, wherein said wear layer is located above said decorative layer, wherein providing the second substrate layer is performed by an extrusion operation, and wherein the first substrate layer is provided as a plurality of strips which are distanced apart such that a space is formed in between two of said strips, and wherein said plurality of strips are laminated onto the second substrate layer.

The fifth aspect of the invention may thus have one or more advantages over what is known in that the decorative panel is more easy and more ergonomic to handle and/or to install, as the spaces which are formed in between the strips of the first substrate layer may allow to obtain a significant weight reduction. Furthermore, the decorative panels according to the invention may allow transportation having reduced fuel consumption, thus being more environmentally friendly. To add thereto, by reducing the amount of substrate material needed during the manufacturing process, the decorative panels of the invention thus provide a more sustainable and/or environmentally friendly alternative to known decorative panels, as more panels can be produced with a same amount of substrate material. Meanwhile, the strength and/or stability of the obtained panels may be improved by using the manufacturing method as described herein.

By preference, the step of laminating said plurality of strips of the first substrate layer is performed in-line with the extrusion. By preference, laminating said distanced plurality of strips of the first substrate layer is performed from the bottom side. By preference, said first substrate layer, in particular the plurality of strips, is thermally laminated onto the second substrate layer.

According to some embodiments, providing the plurality of strips comprises the steps of: cutting and/or slitting a sheet of said first substrate layer, thereby obtaining a plurality of strips of said first substate layer, and distancing said plurality of strips prior to laminating said plurality of strips of the first substrate layer onto the second substrate layer.

By cutting and/or slitting a sheet of the first substrate layer into a plurality of strips, by distancing said plurality of strips, and by subsequently laminating said distanced plurality of strips, a plurality of spaces is defined in between the strips, which allows to obtain a substantially lighter panel in an efficient manner. An advantage exists in that little to no additional scrap material is generated during manufacturing. According to some embodiments, the steps of cutting and/or slitting a sheet of said first substrate layer and of distancing said plurality of strips are performed inline with the extrusion. As such, the distance in between two strips may be set during manufacturing of the decorative panels, thus setting the amount of weight reduction.

According to some embodiments, said first substrate layer is provided from a roll, and is unrolled prior to said step of cutting and/or slitting. Such a roll may thus have a width which is smaller than the width of the extruded second substrate layer.

According to some embodiments, providing the plurality of strips of the first substrate layer comprises providing the first substrate layer in an already cut and/or slitted form. Preferably, providing the plurality of strips of the first substrate layer comprises providing the first substrate layer in an already cut and/or slitted, and an already distanced form.

Said first substrate layer may thus be provided from a roll, wherein said roll comprises a plurality of strips of the first substrate layer which are distanced apart. Such a roll may thus have a width which equals about the width of the extruded second substrate layer.

In an alternative embodiment, the first substrate layer may be provided by an extrusion operation as well, preferably the first and the second substrate layer may be provided by a single extrusion operation. Herein, a reversed feedblock configuration may be used. The term “reversed feedblock configuration” need to be interpreted as a configuration wherein a feedblock is coupled to the outlet of the extruder, said feedblock being suitable for co-extrusion, i.e. for combining two melt streams into a single stream, however now mounted onto the outlet in the reversed direction. As such, the reversed feedblock configuration may allow splitting a single stream of substrate material in a first stream comprising the first substrate layer and a second stream which comprises the second substrate layer. Both streams may be respectively fed to a first die and a second die. It may be possible that the first die is shaped as such that the first substrate layer comprises a plurality of recesses when leaving the die and/or such that the first substrate layer leaves the die as distanced separated strips. Alternatively, the first die may have a width about half the width of the second die, wherein the extruded first substrate layer is sliced and/or cut, and subsequently spaced apart. Use may be made of a cutting device. As such, a plurality of strips may be obtained, which may be guided by a guide roller, which are laminated onto the second substrate layer. The guide roller may be formed as such that it comprises a number of protrusions which guide the plurality of strips and allows to properly distance them apart. An additional element may be needed to connect the reversed feedblock, onto the extruder. A number of calendaring and/or counter rollers may be available, which may allow efficient lamination of the decorative layer and the wear layer onto the second substrate layer, and which may allow adjoining the first and second substrate layer.

In any of the aforementioned embodiments, it may be possible that the first substrate layer is laminated onto the second substrate layer at least before the decorative layer is laminated onto the second substrate layer. It may however be noted that any calendaring and/or counter roller following the step of laminating the first substrate layer onto the second substrate layer may preferably be structured such that it accommodates the plurality of strips of the first substrate layer. By laminating the decorative layer and the wear layer after lamination of the first substrate layer, optimal lamination quality of the laminated decor and/or wear layers may be obtained. Alternatively, the first substrate layer may be laminated onto the second substrate layer after at least the wear layer has been laminated onto the decoration layer and/or second substrate layer. In such a case, no further calendaring and/or counter rollers need to be structured such that they accommodate the plurality of strips of the first substrate layer.

In any of the aforementioned embodiments, it may be possible that the decorative panel is provided with a decorative structure by embossing of the top layer. The first substrate layer may then be laminated onto the second substrate layer at least before the step of embossing. Alternatively, the first substrate layer man also be laminated onto the second substrate layer during and/or after the step of embossing. According to some embodiments, the thickness of the first substrate layer may relate to the thickness of the second substrate layer following a ratio of between 1 : 10 and 1 :2. By preference, the thickness of the first substrate layer and the thickness of the second substrate layer relate to one another following a ratio of between 1 : 10 and 4: 10, even more by preference of between 1 : 10 and 3: 10.

By preference, the second substrate layer has a thickness of 2 to 7 mm, more by preference of 3 to 6 mm, even more by preference of 3 to 5 mm, even more by preference of 3,5 to 4,5 mm. Most by preference, the thickness of the second substrate layer 9 is 4,5 mm. Additionally or alternatively, the first substrate layer has a thickness of between 0,5 and 2 mm, more by preference of between 0,5 mm and 1,5 mm. Most by preference the thickness of the first substrate layer is 1 mm. Additionally or alternatively, the plurality of strips of the first substrate layer have a width of between 5 mm and 50 mm, more by preference of between 10 and 40 mm, even more by preference of between 10 and 30 mm. Most by preference the width of the strips of the first substrate layer have a width of 20 mm. Additionally or alternatively, the plurality of strips are spaced apart following a distance of between 5 mm and 50 mm, by preference of between 10 and 40 mm, more by preference of between 10 and 30 mm. Most by preference the plurality of strips are spaced apart following a distance of 20 mm. Additionally or alternatively, the width and/or spacing of the plurality of strips may be varied in accordance with the desired final product.

In some embodiments, on at least one pair of opposite edges, the decorative panel is provided with mechanical coupling parts, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, also called the vertical direction, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges, also called the horizontal direction. By preference, no recesses, indentations and/or spaces are present at the location of the mechanical coupling parts. It is clear that the coupling parts per se may comprise one or more recesses that are active in said locking. According to a preferred embodiment, said coupling parts are basically shaped as a tongue-in-groove connection with locking parts preventing the drifting apart of said tongue and groove. The groove may be bordered by an upper and a lower lip. Preferably, at least said lower lip is at least partially, and preferably integrally, formed from said first substrate layer, wherein the bottom of said lower groove lip is free from said spaces that are otherwise available in between said strips of said first substrate layer. In other words, the bottom of said lower groove lip may be formed by a single strip of said first substrate layer, wherein said single strip preferably extends over and along the entire bottom of said lower groove lip.

It is noted that an extrusion operation making use of two different dies as described herein, forms an independent and inventive aspect of the invention as well. More in particular, a sixth independent aspect of the invention relates to a method of manufacturing a decorative panel, comprising the steps of: providing a first substrate layer, providing a second substrate layer, wherein said first and second substrate layer are provided by means of at least one extrusion operation, wherein a first substrate material is extruded through a first die, and wherein a second substrate material is extruded through a second die. This may have the advantage that the thickness of two individual substrate layers may be set directly during extrusion. In one embodiment, the first substrate material and the second substrate material may be extruded using a first and second extruder, which are respectively coupled to the first and the second die. Alternatively, it may be that the first substrate material and the second substrate material are the same, and that the first and second die are both coupled to the extruder. In this case, use may be made of a reversed feedblock configuration as described above.

Preferably, the first substrate layer and the second substrate layer are laminated to one another after extrusion.

According to some embodiments, the second substrate layer is provided with a decorative layer and a wear layer. It may be possible that the decorative panel is provided with a decorative structure by embossing of the top layer, in particular by embossing the wear layer and/or the decorative layer.

Preferred embodiments of other aspects may be combined with the sixth aspect of the invention as well, as far as compatible.

According to all aspects, in some preferred embodiments, the mechanical coupling parts have one or a combination of two or more of the following properties:

- the property that the mechanical or coupling parts are substantially in the form of a tongue and a groove delimited by an upper lip and a lower lip, wherein this tongue and groove are substantially responsible for the interlocking in the aforementioned vertical direction, and wherein the tongue and the groove are provided with secondary locking parts, substantially responsible for interlocking in the aforementioned horizontal direction; preferably, the locking parts comprise a locking groove on the bottom side of the edge with the tongue and a hookshaped portion being provided on the bottom groove lip, such coupling means and locking parts are known, for example, from WO 97/47834; - the property that the mechanical coupling means or coupling parts push the coupled decorative panels against each other, for example because these mechanical coupling means are produced with so-called pretension, as is known per se from EP 1 026 341; the tension at which the decorative panels are pressed against each other or towards each other may, for example, in combination with the above property, be achieved by means of a lower lip which is bent outwards in the coupled position and which presses against the bottom side of the tongue when it tries to spring back;

- the property that the mechanical coupling means allow a coupling towards each other by means of a horizontal, or nearly horizontal, sliding movement of the panels;

- the property that the mechanical coupling means allow a coupling by means of a turning movement along the respective edges;

- the property that the mechanical coupling means allow a coupling by means of a downwardly directed movement of a male coupling part, for example having a tongue, into a female coupling part, for example having a groove;

- the property that the mechanical coupling means, or at least the associated top edge, is produced by means of a milling operation using rotating milling tools

- the property that the mechanical coupling means are entirely realized in the material of said substrate, preferably substantially in said first substrate layer and/or in said second substrate layer, and in the material of the top layer.

According to all aspects, it may be that the coupling parts are partly interrupted, in particular over the length of the short side of the decorative panel, due to the presence of the plurality of recesses, indentations and/or spaces. This may allow improved bending of in particular the lower lip of the mechanical coupling means, thus improving coupling of two adjacent panels.

In order to better demonstrate the features of the invention, some preferred embodiments are described below, by way of example and without any limiting character, with reference to the accompanying drawings, wherein: figure 1 illustrates a perspective view of a decorative panel in accordance with the first independent aspect of the invention; figure 2 illustrates a cross-sectional view according to line II-II in figure 1; figures 3 and 4 in a same view as figure 2 represent variants; figure 5 illustrates a cross-sectional view according to line V-V in figure 1, albeit for an alternative decorative panel in accordance with the second independent aspect of the invention; figure 6 illustrates a bottom view of the decorative panel according to arrow F6 in figure 2; figure 7 in a same view as figure 6 represents a variant; figure 8 schematically illustrates an embodiment of a method for manufacturing a decorative panel in accordance with the third independent aspect of the invention; figure 9 schematically illustrates another embodiment of a method for manufacturing a decorative panel in accordance with the third independent aspect of the invention; figure 10 at a larger scale represent a view on the area indicated with F 10 in figure 9, though for a variant in accordance with the fourth independent aspect of the invention; figure 11 in an enlarged view on the area indicated with Fl 1 in figure 10 shows a variant in accordance with the fourth independent aspect of the invention; figure 12 in a view similar to figure 10 illustrates a variant in accordance with the fifth independent aspect of the invention; figure 13 illustrates a bottom view according to arrow F 13 in figure 12, figure 14 illustrates a cross-sectional view according to line XIV-XIV in figure 12, figures 15 is a perspective view and figure 16 is a frontal view illustrating alternative methods of providing a substrate layer having recesses, spaces or indentations; and figure 17 in a view similar to that of figure 8 schematically illustrates a variant of a method for manufacturing a decorative panel in accordance with the fifth independent aspect of the invention. Figures 1 and 2 show a decorative panel 1 according to the invention, in particular the first independent aspect of the invention, said decorative panel comprises a first substrate layer 2, and a top layer which comprises at least a decorative layer 3 and a wear layer 4 provided above said decorative layer 3. It is shown in Figure 2 that the first substrate layer 2 comprises a plurality of recesses, indentations and/or spaces 5. More specifically, in Figure 2, a plurality of indentations 5 is shown. In between these recesses, indentations and/or spaces 5, unaltered areas 6 of the first substrate layer 2 are shown. According to the embodiment shown in Figure 2, the first substrate layer 2 extends uninterruptedly throughout the plane of the decorative panel 1, more in particular the first substrate layer 2 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel. The plurality of recesses, indentations and/or spaces 5 define a structure on the bottom surface of decorative panel 1, in particular of the first substrate layer 2. The structure shows a repeating pattern in at least a first direction DI of the horizontal plane of the decorative panel 1.

Figure 2 shows that the recesses, indentations and/or spaces 5 may have a depth D which relates to the thickness of the decorative panel Tdp following a ratio of between 1 :10 and 1 :2. The recesses, indentations and/or spaces 5 may for example have a depth of between 0,1 and 2,0 mm. The recesses, indentations and/or spaces 5 as shown in Figure 2 may result in a weight reduction of at least 10% in comparison to the substrate layer having no recesses, indentations and/or spaces 5. Preferably, the decorative layer 3 is a thermoplastic decorative layer comprising a print, more preferably a thermoplastic decorative film. The wear layer 4 is preferably a transparent and/or translucent thermoplastic wear layer, more preferably a thermoplastic film.

As is shown in Figure 2, the decorative panel, on at least one pair of opposite edges, is provided with mechanical coupling parts 7-8, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction V perpendicular to the plane of the coupled decorative panels, and in a horizontal direction H parallel to the plane of the decorative panels and perpendicular to the coupled edges. Figures 3 and 4 show variants of the decorative panel as shown in Figure 2. In particular, Figure 3 shows a decorative panel 1 comprising a first substrate layer 2 and a second substrate layer 9, a top layer comprising at least a decorative layer 3 and a wear layer 4 provided above said decorative layer 3. It is shown in Figures 3 and 4 that the second substrate layer 9 is positioned between said first substrate layer 2 and said decorative layer 3. Following Figure 3, both the first substrate layer 2 and the second substrate layer 9 extend uninterruptedly throughout the plane of the decorative panel 1, more in particular the first substrate layer 2 and the second substrate layer 9 extend uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel. The first substrate layer 2 furthermore comprises a plurality of recesses, indentations and/or spaces 5. In between these recesses, indentations and/or spaces 5, unaltered areas 6 of the first substrate layer 2 are shown. Alternatively in Figure 4, it is shown that the second substrate layer 9 extends uninterruptedly throughout the plane of the decorative panel 1 while the first substrate layer 2 does not extend uninterruptedly throughout the plane of the decorative panel 1, in particular the second substrate layer 9 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel while the first substrate layer 2 does not extend uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel. In particular, the recesses, indentations and/or spaces 5 reach all the way through the entire thickness Ts of the first substrate layer 2.

The plurality of recesses, indentations and/or spaces 5 define a structure on the bottom surface of decorative panel 1, in particular of the first substrate layer 2. The structure shows a repeating pattern in at least a first direction DI of the horizontal plane of the decorative panel 1.

The first substrate layer 2 may be present as a plurality of strips on the bottom side of the second substrate layer 9. The unaltered areas 6 herein form the strips, while the plurality of recesses, indentations and/or spaces 5 are formed by the distance between said strips, and preferably reach all the way through the entire thickness Ts of the first substrate layer 2. The second substrate layer 9 may have a thickness of 2 to 7 mm, by preference of 3 to 6 mm, more by preference of 3 to 5 mm, even more by preference of 3,5 to 4,5 mm. Most by preference, the thickness of the second substrate layer 9 is 4,5 mm. The first substrate layer may have a thickness of between 0,5 and 2 mm, by preference of between 0,5 mm and 1,5 mm. Most by preference the thickness of the first substrate layer 2 is 1 mm. The plurality of strips which are formed by the unaltered areas 6 may have a width of between 5 mm and 50 mm, preferably of between 10 and 40 mm, more preferably of between 10 and 30 mm. Most by preference the width of the strips which are formed by the unaltered areas 6 have a width of 20 mm. The plurality of recesses, indentations and/or spaces 5 may have a width of between 5 mm and 50 mm, preferably of between 10 and 40 mm, more preferably of between 10 and 30 mm. Most by preference the width of plurality of recesses, indentations and/or spaces 5 have a width of 20 mm.

Figures 3 and 4 equally show that the recesses, indentations and/or spaces 5 may have a depth D which relates to the thickness of the decorative panel Tdp following a ratio of between 1 : 10 and 1 :2. The recesses, indentations and/or spaces 5 may for example have a depth of between 0,1 and 2,0 mm. The recesses, indentations and/or spaces 5 as shown in Figures 3 and 4 may obtain a weight reduction of at least 10% in comparison to the substrate layer having no recesses, indentations and/or spaces 5. Preferably, the decorative layer 3 is a thermoplastic decorative layer comprising a print, more preferably a thermoplastic decorative film. The wear layer 4 is preferably a transparent and/or translucent thermoplastic wear layer, more preferably a thermoplastic film.

As is shown in Figures 3 and 4, the decorative panel 1, on at least one pair of opposite edges, is provided with mechanical coupling parts 7,8, wherein said mechanical coupling parts 7,8 allow effecting a locking between two of such decorative panels 1 in a vertical direction V perpendicular to the plane of the coupled decorative panels, and in a horizontal direction H parallel to the plane of the decorative panels and perpendicular to the coupled edges.

Figure 5 shows a decorative panel 1 according to the second independent aspect of the invention. Herein, the decorative panel 1 comprises one or more substrate layers 2 and a top layer, said top layer comprising a decorative layer 3 and a wear layer 4. The decorative panel 1 as shown furthermore comprises a corrugated layer 10 positioned on the bottom side of the substrate layer 2. In the present example, only one substrate layer 2 is shown, although it is possible that multiple substrate layers are present. The corrugated layer 10 is intermittently connected to the first substrate layer 2, in case of multiple layers, this is the lowermost substrate layer. In the present example, only one substrate layer is present. The corrugated layer 10 has a repeating pattern in at least a first direction DI of the horizontal plane of the decorative panel 1. In Figure 5, a repeating pattern of the corrugated layer 10 in the length direction of the decorative panel 1 is illustrated. The corrugated layer 10 as shown may result in at least 10% weight reduction in comparison to a substrate layer having the same overall thickness as the corrugated layer 10.

As is shown in Figure 5, the decorative panel 1, on at least one pair of opposite edges, is provided with mechanical coupling parts 7-8, wherein said mechanical coupling parts 7,8 allow effecting a locking between two of such decorative panels 1 in a vertical direction V perpendicular to the plane of the coupled decorative panels, and in a horizontal direction H parallel to the plane of the decorative panels and perpendicular to the coupled edges. The substrate layers 2, 9 as shown in Figures 2 to 5 may comprise a thermoplastic material, and optionally a filler material, e.g. PVC and approximately 80% of filler. The decorative layer 3 may be a thermoplastic decorative film comprising a print. The wear layer 4 is a transparent and/or translucent thermoplastic film.

Figures 6 and 7 show the bottom side of a decorative panel 1 according to the invention. In particular, Figure 6 and 7 aim to show that the decorative panel 1 has a structure on its bottom sides which is formed of a plurality of recesses, indentations and/or spaces 5. The structure may have a grooved shape as is shown in Figure 6, or may have a waffle shape as is shown in Figure 7, namely in this case with a regular distribution of recesses having a rectangular or square opening towards the bottom of the panel 1. Alternative shapes are however possible, such as a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, or combinations thereof. Figures 6 and 7 furthermore show that the decorative panel may, on at least two of its edges, comprise regions which do not comprise recesses, indentations and/or spaces 5. This may be beneficial for the strength of mechanical coupling parts on the edges of the decorative panel 1. The regions which do not comprise recesses, indentations and/or spaces 5, may preferably have a width W of more than 3 mm, more preferably more than 4 mm, more preferably more than 5 mm.

Figure 8 schematically illustrates an embodiment of a method for manufacturing a decorative panel in accordance with the third independent aspect of the invention. The embodiment as shown in Figure 8 is especially suitable for manufacturing a decorative panel according to the first aspect of the invention. Figure 8 schematically shows the following steps: (SI) providing a first substrate layer 2, (S2) embossing said first substrate layer 2, (S3) providing at least a decorative layer 3 and a wear layer 4 onto said first substrate layer 2, wherein said wear layer 4 is located above said decorative layer 3. The embossing step (S2) as shown allows to provide the first substrate layer 2 with a plurality of recesses, indentations and/or spaces 5, which preferably define a structure on the bottom side 31 of the first substrate layer 2. Embossing the first substrate layer 2 may be performed by means of an embossing roller 11 as shown. The structure may have a repeating pattern in at least a first direction of the plane of the decorative panel, or may even have a repeating pattern in both a first and second direction of the plane of the decorative panel. In some embodiments, the structure may have a grooved shape or a waffle shape as illustrated in Figures 6 and 7, although other shapes are possible as well, such as a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, or combinations thereof.

As is shown in Figure 8, providing the first substrate layer 2 may be performed by an extrusion operation, which comprises a feed 12 for feeding raw material for the substrate material to the extruder 13. The raw material is extruded through a so-called flat die or slot die 14 in to a flat substrate material, i.e. the first substrate layer 2, for example having a width of 1 to 2.1 meter, preferably about 1.3 meter and a thickness of 2 to 7 mm, by preference of 3 to 6 mm, more by preference of 3 to 5 mm, even more by preference of 3,5 to 4,5 mm. The decorative layer 3 and the wear layer 4 may be provided onto the first substrate layer 2 by a lamination roller 15. It is shown that they are laminated together, however it is also possible that they are laminated separately and subsequently, by means of multiple lamination rollers 15. The decorative layer and the wear layer are respectively provided from feeding rollers 16 and 17. In the alternative, an embodiment of a method according to the third aspect of the invention is illustrated in Figure 9. The embodiment as shown in Figure 9 is especially suitable for manufacturing a decorative panel according to the first aspect of the invention. Figure 9 schematically shows the following steps: (SI) providing a first substrate layer 2, (S4) providing a second substrate layer 9, (S3) providing at least a decorative layer 3 and a wear layer 4 onto said first substrate layer 2, wherein said wear layer 4 is located above said decorative layer 3. Providing the second substrate layer 9 may be performed by an extrusion operation, which comprises a feed 12 for feeding raw material for the substrate material to the extruder 13. The raw material is extruded through a so-called flat die or slot die 14 in to a flat substrate material, i.e. the second substrate layer 9, for example having a width of 1 to 2.1 meter, preferably about 1.3 meter and a thickness of 2 to 7 mm, by preference of 3 to 6 mm, more by preference of 3 to 5 mm, even more by preference of 3,5 to 4,5 mm. The decorative layer 3 and the wear layer 4 may be provided onto the second substrate layer 9 by a lamination roller 15. It is shown that they are laminated together, however it is also possible that they are laminated separately and subsequently, by means of multiple lamination rollers 15. The decorative layer and the wear layer are respectively provided from feeding rollers 16 and 17. In the illustrated embodiment, the lamination of the decorative layer 3 and the wear layer 4 preferably occurs upside-down in comparison to what is illustrated in figure 8, as the first substrate layer 2 is applied onto the second substrate layer 9 in the form of a molten substrate material.

Although not explicitly illustrated, the first substrate layer 2 may be provided with a plurality of recesses, indentations and/or spaces by means of a mechanical embossing step. In such a case, the molten substrate material of the first substrate layer 2 may be applied as an uninterrupted layer, followed by said mechanical embossing step. Alternatively, said molten substrate material may also be applied onto said second substrate layer 9 as an interrupted layer, preferably as a plurality of strips. This may for example be done by applying the molten substrate material in varying application rates, by applying the molten substrate material using a specifically shaped spout 18, or by applying the molten substrate material using a plurality of individual spouts 18. In the latter example, said molten substrate material may preferably be applied as a plurality of strips. In each of the aforementioned examples, the molten substrate material may be consolidated by cooling, either naturally or induced. As an alternative which is not illustrated, the first substrate layer 2 may also be provided as a preformed layer, thus already comprising the plurality of recesses, indentations and/or spaces.

The plurality of recesses, indentations and/or spaces preferably defines a structure, which may have a repeating pattern in at least a first direction of the plane of the decorative panel, or may even have a repeating pattern in both a first and second direction of the plane of the decorative panel. In some embodiments, the structure may have a grooved shape or a waffle shape as illustrated in Figures 6 and 7, although other shapes are possible as well, such as a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, or combinations thereof.

The recesses, indentations and/or spaces 5 obtained in any of the aforementioned examples, may have a depth D which relates to the thickness Tdp of the decorative panel 1 following a ratio of between 1: 10 and 1 :2. The recesses, indentations and/or spaces 5 may for example have a depth D of between 0,1 and 2,0 mm. The recesses, indentations and/or spaces 5 as obtained may result in a weight reduction of at least 10% in comparison to the substrate layer having no recesses, indentations and/or spaces 5.

Figure 10 schematically illustrates parts of a method for manufacturing a decorative panel in accordance with the fourth independent aspect of the invention, which is particularly suitable for manufacturing a decorative panel according to the second aspect. In particular, Figure 10 shows the steps of (S4) providing one or more substrate layers 2, in the present case one substrate layer is shown, (S3) providing at least a decorative layer 3 and a wear layer 4 onto said one or more substrate layers 2, wherein said wear layer 4 is located above said decorative layer 3, and wherein the method further comprises the step of (S5) providing a corrugated layer 10 on the bottom side 31 of the substrate layer 2. Said corrugated layer 10 is at least intermittently connected to said substrate layer 2, and may have a repeating pattern in at least a first direction of the plane of the decorative panel. The corrugated layer 10 may for example be connected by means of welding, laminating or gluing. Although not explicitly shown, in case the corrugated layer 10 is connected by means of a laminating process, the laminating roller may ideally have a shape which corresponds to the shape of the corrugated layer.

Although not explicitly shown in Figure 10, providing the one or more substrate layers 2 may be performed by an extrusion operation as illustrated in Figure 8, which comprises a feed 12 for feeding raw material for the substrate material to the extruder 13. The raw material is extruded through a so-called flat die or slot die 14 in to a flat substrate material, i.e. the substrate layers 2, for example having a width of 1 to 2.1 meter, preferably about 1.3 meter and a thickness of 2 to 7 mm, by preference of 3 to 6 mm, more by preference of 3 to 5 mm, even more by preference of 3,5 to 4,5 mm. The decorative layer 3 and the wear layer 4 may be provided onto the first substrate layer 2 by a lamination roller 15. It is shown that they are laminated together, however it is also possible that they are laminated separately and subsequently, by means of multiple lamination rollers 15. The decorative layer and the wear layer are respectively provided from feeding rollers 16 and 17. The corrugated layer 10 may result in a weight reduction of at least 10% in comparison to a substrate layer having the same overall thickness. As illustrated, the corrugated layer 10 may be provided directly from a feeding roller 19.

Said corrugated layer 10 may also be provided by means of mechanically corrugating a thermoplastic sheet 20, such as illustrated in Figure 11. The thermoplastic sheet 20 may for example be fed from a feeding roller 21, which feeds the thermoplastic sheet 20 into a corrugating device 22, said corrugating device 22 comprising at least two cooperating gear-shaped rollers 23 which define the corrugated shape of the corrugated layer 10.

The substrate layers 2, 9, as shown in Figures 8 to 10 may comprise a thermoplastic material, and optionally a filler material, e.g. PVC and approximately 80% of filler. The decorative layer 3 may be a thermoplastic decorative film comprising a print. The wear layer 4 is a transparent and/or translucent thermoplastic film. Although not explicitly shown in Figures 8 to 10, the resulting assembly of the first substrate layer 2, the possible second substrate layer 9 and/or the possible corrugated layer 10, the decorative layer 3 and the wear layer 4, as well as optional other layers, may be further divided into slabs comprising a plurality of decorative panels and/or consequently the assembly or slabs may be divided into decorative panels 1, or panels having about the dimensions of the finally to be obtained decorative panels 1. In a subsequent step, these decorative panels may be further provided, on at least one pair of opposite edges, with mechanical coupling parts, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, and in a horizontal direction parallel to the plane of the decorative panels and perpendicular to the coupled edges.

Figures 12 and 13 illustrate a method for manufacturing decorative panels 1 according to the fifth independent aspect of the invention, comprising the steps of: (SI) providing a first substrate layer 2, (S4) providing a second substrate layer 9, (S3) providing at least a decorative layer 3 and a wear layer 4 onto said second substrate layer 9, on the side opposite the first substrate layer 2, wherein said wear layer 4 is located above said decorative layer 3, wherein providing the second substrate layer 9 is performed by an extrusion operation, and wherein the first substrate layer 2 is provided as a plurality of strips 29 which are distanced apart such that a space is formed in between two of said strips 29, and wherein said plurality of strips 29 are laminated onto the second substrate layer 9 in step S6. As shown in Figure 12, the step S6 of laminating said plurality of strips 29 of the first substrate layer 2 may be performed in-line with the extrusion operation, by preference after laminating the top layer. The plurality of strips 29 of the first substrate layer 2 is laminated from the bottom side of the second substrate layer 9. Providing the plurality of strips 29 of the first substrate layer 2 comprises the steps of: (S7) cutting and/or slitting a sheet 24 of said first substrate layer 2, thereby obtaining a plurality of strips 29 of said first substrate layer 2, and (S8) distancing said plurality of strips 29 prior to laminating said plurality of strips 29 of the first substrate layer 2 onto the second substrate layer 9. As is shown, the steps of (S7) cutting and/or slitting the sheet 24 of said first substrate layer 2 and of (S8) distancing said plurality of strips 29 are performed in line with the extrusion operation. As is further shown, the first substrate layer 2, in particular the sheet 24, is preferably provided from a roll 25. The sheet 24 of the first substrate layer 2 may be cut and/or slit using a cutting device 26, which may comprise a pair of cutting roller 27, 28. The strips 29 may be laminated onto the second substrate layer 9 by means of lamination roller 30. The decorative layer 3 may be provided from a roll 16, the wear layer 4 may be provided from a roll 17, and they may be laminated onto the second substrate layer 9 by means of a lamination roller 15.

It is preferred that the thickness Ts of the first substrate layer 2 relates to the thickness Ts2 of the second substrate layer 9 following a ratio of between 1 : 10 and 1 :2. The plurality of strips 29 of the first substrate layer 2 preferably have a width WS of between 5 and 50 mm, and the plurality of strips 29 of the first substrate layer 2 are preferably distanced apart following a distance of between 5 and 50 mm.

As shown in Figure 14, in particular, the second substrate layer 9 is provided with a decorative layer 3 and a wear layer 4, and the first substrate layer 2 is provided as a plurality of strips 29. The lamination roller 30 is shaped complementary or substantially complementary to the plurality of strips 29 such that a qualitative lamination is achieved. As is illustrated by the dotted lines, it may be possible that the lamination roller 30 comprises a plurality of segments 30A that are individually adjustable in order to accommodate other sizes of strips 29 of the first substrate layer 2 and/or to allow a different distribution of the plurality of strips 29 of the first substrate layer 2 on the surface of the second substrate layer 9.

In Figures 13 and 14, an embodiment is shown which makes use of eight strips 29. It may however be possible that less or more strips 29 are used, for example 6 or 7 strips, or up to 10, 15, or even 20 strips. In this respect, it may be possible to adjust the cutting device 26 in that several cutting elements are moveable as shown by means of the arrows 26A, such that the width and the number of strips 29 can be set.

Figure 15 shows a variant, in particular a variant of step S7 of cutting and/or slitting said sheet24 or said first substrate layer 2. Herein, the first substrate layer 2, in particular the sheet 24, is cut, in particular is perforated by means of cutting device 26, wherein recesses 5 are formed in the first substrate layer 2. As is shown, the cutting device 26 substantially cuts slits in the first substrate layer 12, which slits are able to expand into larger recesses 5 by stretching of the first substrate layer 2. A first substrate layer 2 having the shape or form of a net, wherein said recesses 5 form the meshes can be obtained. In the example of figure 15, said recesses 5 are regularly distributed with the remaining material of said first substrate layer 2 surrounding said meshes. As shown, the width WS of said remaining material in between two adjacent meshes in the obtained net structure is smaller than the radius R of the circumscribed circle pertaining to either of the respective meshes. In this case, said width WS is even less than half said radius.

The providing of said recesses 5 by means of said cutting device 26 is performed prior to the step S3 of providing said decorative layer 3 and wear layer 4 and prior to merging said first substrate layer 2 to said second substrate layer 9.

Figure 16 shows another variant, in particular a variant of step SI, wherein the first substrate layer 2 is provided, the first substrate layer 2 comprising recesses 5, wherein the substrate layer 2 is extruded directly in a shape comprising recesses 5 by means of an extrusion die 32. Figure 16 in particular illustrates tubular net extrusion for the provision of said first substrate layer 2. It is clear that the obtained tubular net may be opened to form a flat net for lamination to said second substrate layer 9. In the example of figure 16, said recesses 5 are regularly distributed with the remaining material of said first substrate layer 2 surrounding said meshes. As shown, the width WS of said remaining material in between two adjacent meshes in the obtained net structure is smaller than the radius R of the circumscribed circle pertaining to either of the respective meshes. In this case, said width WS is even less than half said radius

Figure 17 shows a variant, wherein the first substrate layer 2 and the second substrate layer 9 are both provided by means of a single extrusion operation. By using a reverse feedblock configuration 33, a single stream of substrate material may be split in a first stream 34 comprising the first substrate layer 2 and a second stream 35 which comprises the second substrate layer 9. Both streams 34, 35 may be respectively fed to a first die 36 and a second die 37, as to set the individual thicknesses of the first substrate layer 2 and the second substrate layer 9, e.g. according to the thickness ratios as described in relation to Figures 12 to 16. It may be possible that the first die 36 is shaped as such that the first substrate layer 2 comprises a plurality of recesses when leaving the die. Alternatively, the first die 36 may have a width about half the width of the second die 37, wherein the extruded first substrate layer 2 is sliced and/or cut, and subsequently spaced apart, as described in relation to Figures 12 to 16. Use may be made of a cutting device 26. As such, a plurality of strips 29 may be obtained, which may be guided by a guide roller 38, which are laminated onto the second substrate layer 9. The plurality of strips 29 may thus be guided apart. An additional element 40 may be needed to connect the reversed feedblock 33, onto the extruder 13. A number of calendaring and/or counter rollers 39 are shown, which may allow efficient lamination of the decorative layer 3 and the wear layer 4 onto the second substrate layer 9, and which may allow adjoining the first 2 and second substrate layer 9. Optionally, as shown in Figure 17, it may be possible that the decorative panel 1 is provided with an embossed top surface, by means of an embossing operation. Said embossing operation may be performed by an embossing roller 41 and a counter roller 39.

The present disclosure further comprises aspects and embodiments as defined by the following numbered paragraphs.

1.- Decorative panel 1 comprising one or more substrate layers and a top layer, said top layer comprising at least a decorative layer 3 and a wear layer 4 provided above said decorative layer, wherein at least a first substrate 2 layer comprises a plurality of recesses, indentations and/or spaces 5.

2.- Decorative panel according to numbered paragraph 1, wherein said decorative panel 1 comprises a second substrate layer 9, which second substrate layer is preferably positioned between said first substrate layer 2 and said decorative layer 3.

3.- Decorative panel according to numbered paragraph 1 or 2, wherein said first substrate layer 2 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1. 4.- Decorative panel according to numbered paragraph 2 or 3, wherein said second substrate layer 9 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1.

5.- Decorative panel according to numbered paragraph 2, wherein said second substrate layer 2 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1, and wherein said first substrate layer 2 does not extend uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1, wherein said first substrate layer 2 is at least intermittently connected to said second substrate layer 9.

6.- Decorative panel according to any one of preceding numbered paragraphs 1-5, wherein said plurality of recesses, indentations and/or spaces 5 defines a structure on at least one surface of the first substrate layer 2.

7.- Decorative panel according to numbered paragraph 6, wherein said structure on at least one surface of the first substrate layer 2 is directed away from the second substrate layer 9.

8.- Decorative panel according to numbered paragraph 6 or 7, wherein said structure is present on the bottom side of the decorative panel 1.

9.- Decorative panel according to numbered paragraph 6, wherein said structure on at least one surface of the first substrate layer 2 is directed towards the second substrate layer 9.

10.- Decorative panel according to numbered paragraph 6 or 9, wherein said structure is not visible from the bottom side of the decorative panel 1.

11.- Decorative panel according to any one of preceding numbered paragraphs 6-10, wherein said structure has a repeating pattern in at least a first direction DI of the plane of the decorative panel 1. 12.- Decorative panel according to any one of preceding numbered paragraphs 6-11, wherein said structure has a repeating pattern in a first and a second direction of plane of the decorative panel 1.

13.- Decorative panel according to any one of preceding numbered paragraphs 6-12, wherein said structure has a shape which is chosen from the group of a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, a grooved shape, a waffle shape, or combinations thereof.

14.- Decorative panel according to any one of preceding numbered paragraphs 1-13, wherein said recesses, indentations and/or spaces 5 of the first substrate layer 2 result in a weight reduction of at least 10% in comparison to the substrate layer having no recesses, indentations and/or spaces.

15.- Decorative panel according to any one of preceding numbered paragraphs 1-14, wherein the first 2 and/or second substrate layer 9, if present, comprise a thermoplastic material, and optionally a filler material.

16.- Decorative panel according to any one of preceding numbered paragraphs 1-15, wherein the decorative layer 3 is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

17.- Decorative panel according to any one of preceding numbered paragraphs 1-16, wherein the wear layer 4 is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film.

18.- Decorative panel according to any one of preceding numbered paragraphs 1-17, wherein said decorative panel 2, on at least one pair of opposite edges, is provided with mechanical coupling parts 7, 8, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction V perpendicular to the plane of the coupled decorative panels, and in a horizontal direction H parallel to the plane of decorative panels and perpendicular to the coupled edges.

19.- Decorative panel 1 comprising one or more substrate layers and a top layer, said top layer comprising at least a decorative layer 3 and a wear layer 4 provided above said decorative layer 3, wherein the decorative panel further comprises a corrugated layer 10 positioned on the bottom side of one of said substrate layers, preferably the lowermost substrate layer.

20.- Decorative panel according to numbered paragraph 19, wherein said corrugated layer 10 is at least intermittently connected to said lowermost substrate layer.

21.- Decorative panel according to numbered paragraph 19 or 20, wherein said corrugated layer 10 has a repeating pattern in at least a first direction DI of the plane of the decorative panel 1.

22.- Decorative panel according to any one of preceding numbered paragraphs 19-21, wherein said corrugated layer 10 results in a weight reduction of at least 10% in comparison to a substrate layer having the same overall thickness.

23.- Decorative panel according to any one of preceding numbered paragraphs 19-22, wherein said one or more substrate layers comprise a thermoplastic material, and optionally a filler material.

24.- Decorative panel according to any one of preceding numbered paragraphs 19-23, wherein the decorative layer 3 is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

25.- Decorative panel according to any one of preceding numbered paragraphs 19-24, wherein the wear layer 4 is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film. 26.- Decorative panel according to any one of preceding numbered paragraphs 19-25, wherein said decorative panel 1, on at least one pair of opposite edges, is provided with mechanical coupling parts 7-8, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges.

27.- Method for manufacturing decorative panels 1, preferably having the characteristics of any of numbered paragraphs 1 to 26 or 91 to 98, comprising the steps of:

(SI) providing a first substrate layer 2, optionally, (S4) providing a second substrate layer 9,

(S3) providing at least a decorative layer 3 and a wear layer 4 onto said first substrate layer or, optionally, onto said second substrate layer, wherein said wear layer is located above said decorative layer, and wherein said first substrate layer is provided with a plurality of recesses, indentations and/or spaces 5.

28.- Method according to numbered paragraph 27, wherein said first substrate 2 layer is provided with a plurality of recesses, indentations and/or spaces 5 by means of a mechanical embossing step S2, wherein said embossing preferably entails a displacement of material of said first substrate layer 2, wherein said displacement results at least in an increase of the thickness Ts of said first substrate layer 2.

29.- Method according to numbered paragraph 27 or 28, wherein said first substrate layer 2 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1.

30.- Method according to numbered paragraph 28 or 29, wherein said second substrate layer 9 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1. 31.- Method according to numbered paragraph 27 or 28, wherein said second substrate layer 9 extends uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel, and wherein said first substrate layer 2 does not extend uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1, wherein said first substrate layer is at least intermittently connected to said second substrate layer.

32.- Method according to any one of preceding numbered paragraphs 27-31, wherein said plurality of recesses, indentations and/or spaces 5 defines a structure on at least one surface of the first substrate layer 2.

33.- Method according to numbered paragraph 32, wherein said structure on at least one surface of the first substrate layer 2 is directed away from the second substrate layer 9.

34.- Method according to numbered paragraph 32 or 33, wherein said structure is present on the bottom side of the decorative panel 1.

35.- Method according to numbered paragraph 32, wherein said structure on at least one surface of the first substrate layer 2 is directed towards the second substrate layer 9.

36.- Method according to numbered paragraph 32 or 35, wherein said structure is not visible from the bottom side of the decorative panel 1.

37.- Method according to any one of preceding numbered paragraphs 32-36, wherein said structure has a repeating pattern in at least a first direction DI of the plane of the decorative panel 1.

38.- Method according to any one of preceding numbered paragraphs 32-37, wherein said structure has a repeating pattern in a first and a second direction of plane of the decorative panel 1.

39.- Method according to any one of preceding numbered paragraphs 32-38, wherein said structure has a shape which is chosen from the group of a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, a grooved shape, a waffle shape, or combinations thereof.

40.- Method according to any one of numbered paragraphs 27-39, wherein said recesses, indentations and/or spaces 5 of the first substrate layer 2 result in a weight reduction of at least 10% in comparison to the substrate layer having no recesses, indentations and/or spaces.

41.- Method according to any one of preceding numbered paragraphs 27-40, wherein the first 2 and/or second substrate layer 9 comprise a thermoplastic material, and optionally a filler material.

42.- Method according to any one of preceding numbered paragraphs 27-41, wherein providing the first 2 and/or second substrate layer 3 is performed by an extrusion operation.

43.- Method according to any one of preceding numbered paragraphs 28-41, wherein providing the second substrate layer 9 is performed by an extrusion operation, and wherein providing the first substrate layer 2 is performed by applying molten substrate material onto the second substrate layer 9.

44.- Method according to numbered paragraph 43, wherein said molten substrate material is applied onto said second substrate layer 9 as an uninterrupted layer, followed by embossing said uninterrupted layer.

45.- Method according to numbered paragraph 43, wherein said molten substrate material is applied onto said second substrate layer 9 as an interrupted layer, preferably as a plurality of strips.

46.- Method according to any one of preceding numbered paragraphs 28-41, wherein providing the second substrate layer 9 is performed by an extrusion operation, and wherein providing the first substrate layer 2 comprises welding preformed substrate material onto the second substrate layer 9.

47.- Method according to any one of preceding numbered paragraphs 27-46, wherein the decorative layer 3 is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

48.- Method according to any one of preceding numbered paragraphs 27-47, wherein the wear layer 4 is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film.

49.- Method according to any one of preceding numbered paragraphs 27-48, wherein said method comprises the step of dividing the assembly of the one or more substrate materials 2, 9, the decorative layer 3 and the wear layer 4 into slabs comprising a plurality of decorative panels 1 and/or consequently dividing said assembly or said slabs into decorative panels 1, or panels having about the dimensions of the finally to be obtained decorative panels 1.

50.- Method according to any one of preceding numbered paragraphs 27-49, wherein said method comprises the step of providing said decorative panels 1 on at least one pair of opposite edges, with mechanical coupling parts 7-8, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction V perpendicular to the plane of the coupled decorative panels, and in a horizontal direction H parallel to the plane of decorative panels and perpendicular to the coupled edges.

51.- Method for manufacturing decorative panels 1, comprising the steps of

(SI) providing one or more substrate layers 2,

(S3) providing at least a decorative layer 3 and a wear layer 4 onto said one or more substrate layers 2, wherein said wear layer 4 is located above said decorative layer 3, and wherein the method further comprises the step of S5 providing a corrugated layer 10 on the bottom side of one of said substrate layers 2, preferably the lowermost substrate layer.

52.- Method according to numbered paragraph 51, wherein said corrugated layer 10 is at least intermittently connected to said lowermost substrate layer 2.

53.- Method according to numbered paragraph 51 or 52, wherein said corrugated layer 10 has a repeating pattern in at least a first direction DI of the plane of the decorative panel.

54.- Method according to any one of preceding numbered paragraphs 51-53, wherein said corrugated layer 10 results in a weight reduction of at least 10% in comparison to a substrate layer having the same overall thickness.

55.- Method according to any one of preceding numbered paragraphs 51-54, wherein said corrugated layer 10 is provided by means of mechanically corrugating a thermoplastic sheet 20.

56.- Method according to any one of preceding numbered paragraphs 51-54, wherein said one or more substrate layers 2 comprise a thermoplastic material, and optionally a filler material.

57.- Method according to any one of preceding numbered paragraphs 51-55, wherein the decorative layer 3 is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

58.- Method according to any one of preceding numbered paragraphs 51-56, wherein the wear layer 4 is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film. 59.- Method according to any one of preceding numbered paragraphs 51-58, wherein said method comprises the step of dividing the assembly of the one or more substrate materials 2, the decorative layer 3 and the wear layer 4 into slabs comprising a plurality of decorative panels 1 and/or consequently dividing said assembly or said slabs into decorative panels 1, or panels having about the dimensions of the finally to be obtained decorative panels 1.

60.- Method according to any one of preceding numbered paragraphs 51-59, wherein said method comprises the step of providing said decorative panels 1 on at least one pair of opposite edges, with mechanical coupling parts 7-8, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction V perpendicular to the plane of the coupled decorative panels, and in a horizontal direction H parallel to the plane of decorative panels and perpendicular to the coupled edges.

61.- Method for manufacturing decorative panels 1, comprising the steps of:

(SI) providing a first substrate layer 2,

(S4) providing a second substrate layer 9,

(S3) providing at least a decorative layer 3 and a wear layer 4 onto said second substrate layer 9, on the side opposite the first substrate layer 2, wherein said wear layer 4 is located above said decorative layer 3, wherein providing the second substrate layer 9 is performed by an extrusion operation, and wherein the first substrate layer is provided as a plurality of strips 29 which are distanced apart such that a space is formed in between two of said strips, and wherein said plurality of strips are laminated onto the second substrate layer 9.

62.- Method according to numbered paragraph 61, wherein the step S6 of laminating said plurality of strips 29 of the first substrate layer 2 is performed in-line with the extrusion operation, by preference in between extruding said second substrate layer 9 and laminating the top layer. 63.- Method according to numbered paragraph 61 or 62, wherein the plurality of strips 29 of the first substrate layer 2 is laminated from the bottom side of the second substrate layer 9.

64.- Method according to any one of preceding numbered paragraphs 61-63, wherein providing the plurality of strips 29 of the first substrate layer 2 comprises the steps of:

(57) cutting and/or slitting a sheet 24 of said first substrate layer 2, thereby obtaining a plurality of strips 29 of said first substrate layer 2, and

(58) distancing said plurality of strips 29 prior to laminating said plurality of strips of the first substrate layer 2 onto the second substrate layer 9.

65.- Method according to numbered paragraph 64, wherein the steps of cutting and/or slitting the sheet 24 of said first substrate layer 2 and of distancing said plurality of strips 29 are performed in-line with the extrusion operation.

66.- Method according to numbered paragraph 64 or 65, wherein said first substrate layer 2 is provided from a roll 25.

67.- Method according to any one of preceding numbered paragraphs 61-64, wherein providing the plurality of strips 29 of the first substrate layer 2 comprises providing the first substrate layer 2 in an already cut and/or slitted form.

68.- Method according to numbered paragraph 67, wherein said first substrate layer 2 is provided from a roll, said roll comprising the plurality of strips 29 of the first substrate layer 2 which are distanced apart.

69.- Method according to any one of numbered paragraphs 61-68, wherein the thickness Ts of the first substrate layer 2 relates to the thickness Ts2 of the second substrate layer 9 following a ratio of between 1 : 10 and 1 :2, preferably of between 1 : 10 and 4: 10. 70.- Method according to any one of numbered paragraphs 61-69, wherein the plurality of strips 29 of the first substrate layer 2 have a width of between 5 and 50 mm, preferably of between 10 and 40 mm.

71.- Method according to any one of numbered paragraphs 61-70, wherein the plurality of strips 29 of the first substrate layer 2 are distanced apart following a distance of between 5 and 50 mm, preferably of between 10 and 40 mm.

72.- Method according to any one of preceding numbered paragraphs 61-71, wherein said first 2 and/or said second substrate layer 9 comprise a thermoplastic material, and optionally a filler material.

73.- Method according to any one of preceding numbered paragraphs 61-72, wherein the decorative layer 3 is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

74.- Method according to any one of preceding numbered paragraphs 61-73, wherein the wear layer 4 is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film.

75.- Method according to any one of preceding numbered paragraphs 61-74, wherein said method comprises the step of dividing the assembly of the first 2 and second substrate layers 9, the decorative layer 3 and the wear layer 4 into slabs comprising a plurality of decorative panels 1 and/or consequently dividing said assembly or said slabs into decorative panels 1, or panels having about the dimensions of the finally to be obtained decorative panels 1.

76.- Method according to any one of preceding numbered paragraphs 61-75, wherein said method comprises the step of providing said decorative panels 1 on at least one pair of opposite edges, with mechanical coupling parts 7-8, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction V perpendicular to the plane of the coupled decorative panels, and in a horizontal direction H parallel to the plane of decorative panels and perpendicular to the coupled edges.

77.- Method for manufacturing decorative panels 1, comprising the steps of: providing a first substrate layer 2, providing a second substrate layer 9, wherein said first and second substrate layer are provided by means of at least one extrusion operation, and wherein in said at least one extrusion operation: a first substrate material is extruded through a first die 36, and a second substrate material is extruded through a second die 37.

78.- Method according to numbered paragraph 77, wherein the first substrate material and the second substrate material are extruded using a first extruder and a second extruder, which first and second extruder are respectively coupled to the first die 36 and to the second die 37.

79.- Method according to numbered paragraph 77, wherein the first substrate material and the second substrate material are the same, and wherein the first die 36 and the second die 37 are coupled to a single extruder 13.

80.- Method according to numbered paragraph 79, wherein the first die 36 and the second die 37 are coupled to a single extruder 13 using a reversed feedblock configuration 33.

81.- Method according to any one of preceding numbered paragraphs 77-80, wherein the first substrate layer 2 and the second substrate layer 9 are laminated to one another after extrusion.

82.- Decorative panel 1 comprising at least a first substrate layer 2 and a second substrate layer 9 and a top layer, said top layer comprising at least a decorative layer 3 and a wear layer 4 provided above said decorative layer, wherein said second substrate layer 9 is positioned between said first substrate layer 2 and said decorative layer 3, wherein both said first substrate layer 2 and said second substrate layer 9 extend uninterruptedly in a horizontal direction H parallel to the plane of the decorative panel 1, characterized in that at least a first substrate layer 2 comprises a plurality of recesses, indentations and/or spaces 5 defining a structure with a repeating pattern in a first and a second direction of the plane of the decorative panel 1, wherein said structure is on the surface of said first substrate layer 2 that is directed away from said second substrate layer 9, and wherein the material of said second substrate layer has a composition different from the composition of the material of said first substrate layer.

83.- Decorative panel according to numbered paragraph 82, characterized in that the compositions of said substrate layer 2 and said second substrate layer 9 are different at least in that the compositions of the first substrate layer 2 and the second substrate layer 9 both comprise thermoplastic material and filler materials, wherein the weight ratio filler material : thermoplastic material is higher in said second substrate layer 9, e.g. at least 1.5 times higher than in said first substrate layer 2.

84.- Decorative panel according to numbered paragraph 82, characterized in that the compositions of said substrate layer 2 and said second substrate layer 9 are different at least in that the composition of the second substrate layer 9 comprises thermoplastic material and filler materials, while the composition of the first substrate layer 2 is free from filler materials, though preferably comprises the same thermoplastic material as said second substrate layer.

85.- Decorative panel according to any of numbered paragraphs 82 to 84, characterized in that the compositions of said substrate layer (2) and said second substrate layer (9) are different at least in that the material of said first substrate layer (2) has a glass transition temperature that is lower than the glass transition temperature of the material of said second substrate layer (9).

86.- Decorative panel according to any of numbered paragraphs 82 to 85, characterized in that the compositions of said substrate layer 2 and said second substrate layer 9 are different at least in that the composition of the first substrate layer 2 comprises plasticizer at a rate of 5 phr or more, while the second substrate layer 9 comprises less or no plasticizer.

87.- Decorative panel according to any of numbered paragraphs 82 to 86, characterized in that the compositions of said substrate layer 2 and said second substrate layer 9 are different at least in that the composition of the first substrate layer 2 comprises an elastomer, e.g. chosen from the list of a rubber, e.g. nitrile butadiene rubber, an EPDM, a polyethylene, e.g. chlorinated polyethylene, a vinyl chloride copolymer, e.g. vinyl chi ori de-butyl acrylate-methyl methacrylate copolymer, a thermoplastic polyester and a thermoplastic polyurethane.

88.- Decorative panel according to any of the numbered paragraphs 82 to 87, characterized in that the compositions of said substrate layer 2 and said second substrate layer 9 are different at least in that the composition of the first substrate layer 2 is such that it has a Shore hardness, in particular Shore A hardness, that is at least 5 lower than the Shore hardness, in particular Shore A hardness, of the second substrate layer 9, wherein the Shore hardness is measured in accordance with ISO 48-4:2018.

89.- Decorative panel according to any of the numbered paragraphs 82 to 88, characterized in that said decorative panel 1, on at least one pair of opposite edges, is provided with mechanical coupling parts 7-8, wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges.

The aspects and concepts disclosed in the claims and drawings may be combined with one another as long as they are not mutually contradictory. The present invention is by no means limited to the embodiments described above, however decorative panels may be realized according to various variants without departing from the scope of the present invention.

Claims

Claims.

1.- Decorative panel (1) comprising at least a first and a second substrate layer (2-9) and a top layer, said top layer comprising at least a decorative layer (3) and a wear layer (4) provided above said decorative layer, wherein said second substrate layer (9) is positioned between said first substrate layer (2) and said decorative layer (3), wherein both said first substrate layer (2) and said second substrate layer (9) extend uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1), characterized in that at least a first substrate layer (2) comprises a plurality of recesses, indentations and/or spaces (5) defining a structure with a repeating pattern in a first and a second direction of the plane of the decorative panel (1), wherein said structure is on the surface of said first substrate layer (2) that is directed away from said second substrate layer (9), and wherein the material of said second substrate layer has a composition different from the composition of the material of said first substrate layer.

2.- Decorative panel according to claim 1, characterized in that the compositions of said substrate layer (2) and said second substrate layer (9) are different at least in that the compositions of the first substrate layer (2) and the second substrate layer (9) both comprise thermoplastic material and filler materials, wherein the weight ratio filler material : thermoplastic material is higher in said second substrate layer (9), e.g. at least 1.5 times higher than in said first substrate layer (2).

3.- Decorative panel according to claim 1, characterized in that the compositions of said substrate layer (2) and said second substrate layer (9) are different at least in that the composition of the second substrate layer (9) comprises thermoplastic material and filler materials, while the composition of the first substrate layer (2) is free from filler materials, though preferably comprises the same thermoplastic material as said second substrate layer.

4.- Decorative panel according to any of the preceding claims, characterized in that the compositions of said substrate layer (2) and said second substrate layer (9) are different at least in that the material of said first substrate layer (2) has a glass transition temperature that is lower than the glass transition temperature of the material of said second substrate layer (9).

5.- Decorative panel according to any of the preceding claims, characterized in that the compositions of said substrate layer (2) and said second substrate layer (9) are different at least in that the composition of the first substrate layer (2) comprises plasticizer at a rate of 5 phr or more, while the second substrate layer (9) comprises less or no plasticizer.

6.- Decorative panel according to any of the preceding claims, characterized in that the compositions of said substrate layer (2) and said second substrate layer (9) are different at least in that the composition of the first substrate layer (2) comprises an elastomer, e.g. chosen from the list of a rubber, e.g. nitrile butadiene rubber, an EPDM, a polyethylene, e.g. chlorinated polyethylene, a vinyl chloride copolymer, e.g. vinyl chi ori de-butyl acrylate-methyl methacrylate copolymer, a thermoplastic polyester and a thermoplastic polyurethane.

7.- Decorative panel according to any of the preceding claims, characterized in that the compositions of said substrate layer (2) and said second substrate layer (9) are different at least in that the composition of the first substrate layer (2) is such that it has a Shore hardness, in particular Shore A hardness, that is at least 5 lower than the Shore hardness, in particular Shore A hardness, of the second substrate layer (9), wherein the Shore hardness is measured in accordance with ISO 48-4:2018.

8.- Decorative panel according to any of the preceding claims, characterized in that said decorative panel (1), on at least one pair of opposite edges, is provided with mechanical coupling parts (7-8), wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction perpendicular to the plane of the coupled decorative panels, and in a horizontal direction parallel to the plane of decorative panels and perpendicular to the coupled edges. 9.- Decorative panel comprising one or more substrate layers (2,

9) and a top layer, said top layer comprising at least a decorative layer (3) and a wear layer (4) provided above said decorative layer, wherein at least a first substrate layer (2) comprises a plurality of recesses, indentations and/or spaces (5).

10.- Decorative panel according to claim 9, wherein said decorative panel (1) comprises a second substrate layer (9), which second substrate layer is preferably positioned between said first substrate layer (2) and said decorative layer (3).

11.- Decorative panel according to claim 9 or 10, wherein said first substrate layer (2) extends uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1).

12.- Decorative panel according to claim 10 or 11, wherein said second substrate layer (9) extends uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1).

13.- Decorative panel according to claim 10, wherein said second substrate layer (2) extends uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1), and wherein said first substrate layer (2) does not extend uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1), wherein said first substrate layer (2) is at least intermittently connected to said second substrate layer (9).

14.- Decorative panel according to any one of claims 9 to 13, wherein said plurality of recesses, indentations and/or spaces (5) defines a structure on at least one surface of the first substrate layer (2).

15.- Decorative panel according to claim 14, wherein said structure on at least one surface of the first substrate layer (2) is directed away from the second substrate layer (9).

16.- Decorative panel according to claim 14 or 15, wherein said structure is present on the bottom side of the decorative panel (1).

17.- Decorative panel according to claim 14, wherein said structure on at least one surface of the first substrate layer (2) is directed towards the second substrate layer (9).

18.- Decorative panel according to claim 14 or 17, wherein said structure is not visible from the bottom side of the decorative panel (1).

19.- Decorative panel according to any one of preceding claims 14-18, wherein said structure has a repeating pattern in at least a first direction (DI) of the plane of the decorative panel (1).

20.- Decorative panel according to any one of preceding claims 14-19, wherein said structure has a repeating pattern in a first and a second direction of plane of the decorative panel (1).

21.- Decorative panel according to any one of preceding claims 14-20, wherein said structure has a shape which is chosen from the group of a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, a grooved shape, a waffle shape, or combinations thereof.

22.- Decorative panel according to any one of preceding claims 8-21, wherein said recesses, indentations and/or spaces (5) of the first substrate layer (2) result in a weight reduction of at least 10% in comparison to the substrate layer having no recesses, indentations and/or spaces.

23.- Decorative panel according to any one of preceding claims 8-22, wherein the first (2) and/or second substrate layer (9), if present, comprise a thermoplastic material, and optionally a filler material.

24.- Decorative panel according to any one of preceding claims 8-23, wherein the decorative layer (3) is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

25.- Decorative panel according to any one of preceding claims 8-24, wherein the wear layer (4) is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film.

26.- Decorative panel according to any one of preceding claims 8-25, wherein said decorative panel (2), on at least one pair of opposite edges, is provided with mechanical coupling parts (7,8), wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction (V) perpendicular to the plane of the coupled decorative panels, and in a horizontal direction (H) parallel to the plane of decorative panels and perpendicular to the coupled edges.

27.- Method for manufacturing decorative panels (1) preferably having the characteristics of any of claims 1 to 26, comprising the steps of:

(SI) providing a first substrate layer (2), optionally, (S4) providing a second substrate layer (9),

(S3) providing at least a decorative layer (3) and a wear layer (4) onto said first substrate layer or, optionally, onto said second substrate layer, wherein said wear layer is located above said decorative layer, and wherein said first substrate layer is provided with a plurality of recesses, indentations and/or spaces (5).

28.- Method according to claim 27, wherein said first substrate (2) layer is provided with a plurality of recesses, indentations and/or spaces (5) by means of a mechanical embossing step (S2), wherein said embossing preferably entails a displacement of material of said first substrate layer (2), wherein said displacement results at least in an increase of the thickness (Ts) of said first substrate layer (2).

29.- Method according to claim 27 or 28, wherein said first substrate layer (2) extends uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1).

30.- Method according to claim 28 or 29, wherein said second substrate layer (9) extends uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1).

31.- Method according to claim 27 or 28, wherein said second substrate layer (9) extends uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel, and wherein said first substrate layer (2) does not extend uninterruptedly in a horizontal direction (H) parallel to the plane of the decorative panel (1), wherein said first substrate layer is at least intermittently connected to said second substrate layer.

32.- Method according to any one of preceding claims 27-31, wherein said plurality of recesses, indentations and/or spaces (5) defines a structure on at least one surface of the first substrate layer (2).

33.- Method according to claim 32, wherein said structure on at least one surface of the first substrate layer (2) is directed away from the second substrate layer (9).

34.- Method according to claim 32 or 33, wherein said structure is present on the bottom side of the decorative panel (1).

35.- Method according to claim 32, wherein said structure on at least one surface of the first substrate layer (2) is directed towards the second substrate layer (9).

36.- Method according to claim 32 or 35, wherein said structure is not visible from the bottom side of the decorative panel (1).

37.- Method according to any one of preceding claims 32-36, wherein said structure has a repeating pattern in at least a first direction (DI) of the plane of the decorative panel (1).

38.- Method according to any one of preceding claims 32-37, wherein said structure has a repeating pattern in a first and a second direction of plane of the decorative panel (1).

39.- Method according to any one of preceding claims 32-38, wherein said structure has a shape which is chosen from the group of a serrated shape, a kinked shape, a toothed shape, a honeycomb shape, a grooved shape, a waffle shape, or combinations thereof.

40.- Method according to any one of claims 27-39, wherein said recesses, indentations and/or spaces (5) of the first substrate layer (2) result in a weight reduction of at least 10% in comparison to the substrate layer having no recesses, indentations and/or spaces.

41.- Method according to any one of preceding claims 27-40, wherein the first (2) and/or second substrate layer (9) comprise a thermoplastic material, and optionally a filler material.

42.- Method according to any one of preceding claims 27-41, wherein providing the first (2) and/or second substrate layer (9) is performed by an extrusion operation.

43.- Method according to any one of preceding claims 28-41, wherein providing the second substrate layer (9) is performed by an extrusion operation, and wherein providing the first substrate layer (2) is performed by applying molten substrate material onto the second substrate layer (9).

44.- Method according to claim 43, wherein said molten substrate material is applied onto said second substrate layer (9) as an uninterrupted layer, followed by embossing said uninterrupted layer.

45.- Method according to claim 43, wherein said molten substrate material is applied onto said second substrate layer (9) as an interrupted layer, preferably as a plurality of strips.

46.- Method according to any one of preceding claims 28-41, wherein providing the second substrate layer (9) is performed by an extrusion operation, and wherein providing the first substrate layer (2) comprises welding preformed substrate material onto the second substrate layer (9).

47.- Method according to any one of preceding claims 27-46, wherein the decorative layer (3) is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

48.- Method according to any one of preceding claims 27-47, wherein the wear layer (4) is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film.

49.- Method according to any one of preceding claims 27-48, wherein said method comprises the step of dividing the assembly of the one or more substrate materials (2,3), the decorative layer (3) and the wear layer (4) into slabs comprising a plurality of decorative panels (1) and/or consequently dividing said assembly or said slabs into decorative panels (1), or panels having about the dimensions of the finally to be obtained decorative panels (1).

50.- Method according to any one of preceding claims 27-49, wherein said method comprises the step of providing said decorative panels (1) on at least one pair of opposite edges, with mechanical coupling parts (7,8) , wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction (V) perpendicular to the plane of the coupled decorative panels, and in a horizontal direction (H) parallel to the plane of decorative panels and perpendicular to the coupled edges.

51.- Method for manufacturing decorative panels (1), comprising the steps of:

(SI) providing one or more substrate layers (2),

(S3) providing at least a decorative layer (3) and a wear layer (4) onto said one or more substrate layers (2), wherein said wear layer (4) is located above said decorative layer (3), and wherein the method further comprises the step of (S5) providing a corrugated layer(lO) on the bottom side of one of said substrate layers (2), preferably the lowermost substrate layer.

52.- Method according to claim 51, wherein said corrugated layer (10) is at least intermittently connected to said lowermost substrate layer (2).

53.- Method according to claim 51 or 52, wherein said corrugated layer (10) has a repeating pattern in at least a first direction (DI) of the plane of the decorative panel.

54.- Method according to any one of preceding claims 51-53, wherein said corrugated layer (10) results in a weight reduction of at least 10% in comparison to a substrate layer having the same overall thickness.

55.- Method according to any one of preceding claims 51-54 wherein said corrugated layer (10) is provided by means of mechanically corrugating a thermoplastic sheet (20).

56.- Method according to any one of preceding claims 51-54, wherein said one or more substrate layers (2) comprise a thermoplastic material, and optionally a filler material.

57.- Method according to any one of preceding claims 51-55, wherein the decorative layer (3) is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

58.- Method according to any one of preceding claims 51-56, wherein the wear layer (4) is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film.

59.- Method according to any one of preceding claims 51-58, wherein said method comprises the step of dividing the assembly of the one or more substrate materials (2), the decorative layer (3) and the wear layer (4) into slabs comprising a plurality of decorative panels (1) and/or consequently dividing said assembly or said slabs into decorative panels (1) , or panels having about the dimensions of the finally to be obtained decorative panels (1).

60.- Method according to any one of preceding claims 51-59, wherein said method comprises the step of providing said decorative panels (1) on at least one pair of opposite edges, with mechanical coupling parts (7,8), wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction (V) perpendicular to the plane of the coupled decorative panels, and in a horizontal direction (H) parallel to the plane of decorative panels and perpendicular to the coupled edges.

61.- Method for manufacturing decorative panels (1), comprising the steps of:

(SI) providing a first substrate layer (2),

(S4) providing a second substrate layer (9),

(S3) providing at least a decorative layer (3) and a wear layer (4) onto said second substrate layer (9), on the side opposite the first substrate layer (2), wherein said wear layer (4) is located above said decorative layer (3), wherein providing the second substrate layer (9) is performed by an extrusion operation, and wherein the first substrate layer is provided as a plurality of strips (29) which are distanced apart such that a space is formed in between two of said strips, and wherein said plurality of strips are laminated onto the second substrate layer (9).

62.- Method according to claim 61, wherein the step (S6) of laminating said plurality of strips (29) of the first substrate layer (2) is performed in-line with the extrusion operation, by preference in between extruding said second substrate layer (9) and laminating the top layer.

63.- Method according to claim 61 or 62, wherein the plurality of strips (29) of the first substrate layer (2) is laminated from the bottom side of the second substrate layer (9).

64.- Method according to any one of preceding claims 61-63, wherein providing the plurality of strips (29) of the first substrate layer (2) comprises the steps of:

(57) cutting and/or slitting a sheet (24) of said first substrate layer (2), thereby obtaining a plurality of strips (29) of said first substrate layer (2), and

(58) distancing said plurality of strips (29) prior to laminating said plurality of strips of the first substrate layer (2) onto the second substrate layer (9).

65.- Method according to claim 64, wherein the steps of cutting and/or slitting the sheet (24) of said first substrate layer (2) and of distancing said plurality of strips (29) are performed in-line with the extrusion operation.

66.- Method according to claim 64 or 65, wherein said first substrate layer (2) is provided from a roll (25).

67.- Method according to any one of preceding claims 61-64, wherein providing the plurality of strips (29) of the first substrate layer (2) comprises providing the first substrate layer (2) in an already cut and/or slitted form.

68.- Method according to claim 67, wherein said first substrate layer (2) is provided from a roll, said roll comprising the plurality of strips (29) of the first substrate layer (2) which are distanced apart.

69.- Method according to any one of claims 61-68, wherein the thickness of the first substrate layer (2) relates to the thickness of the second substrate layer (9) following a ratio of between 1 : 10 and 1 :2, preferably of between 1 : 10 and 4: 10.

70.- Method according to any one of claims 61-69, wherein the plurality of strips (29) of the first substrate layer (2) have a width of between 5 and 50 mm, preferably of between 10 and 40 mm.

71.- Method according to any one of claims 61-70, wherein the plurality of strips (29) of the first substrate layer (2) are distanced apart following a distance of between 5 and 50 mm, preferably of between 10 and 40 mm.

72.- Method according to any one of preceding claims 61-71, wherein said first (2) and/or said second substrate layer (9) comprise a thermoplastic material, and optionally a filler material.

73.- Method according to any one of preceding claims 61-72, wherein the decorative layer (3) is a thermoplastic decorative layer, preferably a thermoplastic decorative film, said thermoplastic decorative layer comprising a print.

74.- Method according to any one of preceding claims 61-73, wherein the wear layer (4) is a transparent and/or translucent thermoplastic wear layer, preferably a thermoplastic film.

75.- Method according to any one of preceding claims 61-74, wherein said method comprises the step of dividing the assembly of the first (2) and second substrate layers (9) , the decorative layer (3) and the wear layer (4) into slabs comprising a plurality of decorative panels (1) and/or consequently dividing said assembly or said slabs into decorative panels (1), or panels having about the dimensions of the finally to be obtained decorative panels (1).

76.- Method according to any one of preceding claims 61-75, wherein said method comprises the step of providing said decorative panels (1) on at least one pair of opposite edges, with mechanical coupling parts (7,8) , wherein said mechanical coupling parts allow effecting a locking between two of such decorative panels in a vertical direction (V) perpendicular to the plane of the coupled decorative panels, and in a horizontal direction (H) parallel to the plane of decorative panels and perpendicular to the coupled edges.

77.- Method for manufacturing decorative panels (1), comprising the steps of: providing a first substrate layer (2), providing a second substrate layer (9), wherein said first and second substrate layer are provided by means of at least one extrusion operation, and wherein in said at least one extrusion operation: a first substrate material is extruded through a first die (36), and a second substrate material is extruded through a second die (37).

78.- Method according to claim 77, wherein the first substrate material and the second substrate material are extruded using a first extruder and a second extruder, which first and second extruder are respectively coupled to the first (36) and to the second die (37).

79.- Method according to claim 77, wherein the first substrate material and the second substrate material are the same, and wherein the first (36) and the second die (37) are coupled to a single extruder (13).

80.- Method according to claim 79, wherein the first (36) and the second die (37) are coupled to a single extruder (13) using a reversed feedblock configuration (33).

81.- Method according to any one of preceding claims 77-80, wherein the first substrate layer (2) and the second substrate layer (9) are laminated to one another after extrusion.