Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
WO 2023/067174 PC
T/EP2022/079446
Decorative panel, and decorative panel covering
The invention relates to a decorative panel, in particular a floor panel,
ceiling panel
or wall panel. The invention also relates to a decorative panel covering, such
as a
decorative floor covering, decorative ceiling covering or decorative wall
covering,
comprising a plurality of panels according to the invention, wherein the
panels are
preferably interconnected. The invention further relates to an intermediate
layer for
use in a decorative panel according to the invention.
Laminated panels comprise a core layer onto which a decorative top structure
is
applied having a printed decorative image which typically has the appearance
of a
wood pattern. The decorative image is covered by a transparent layer to
preserve
and protect said the image. In order to improve the optical and haptic
appearance
of the decorative image of the decorative top structure, impressions can be
realized
in the transparent layer, this in order to obtain an e.g., imitation of wood
pores and
other unevennesses which can be present at the surface of real wood. Often PVC
is used as main constituent for composing the core. Often, the decorative
image is
digitally printed onto a PVC film, wherein said printed PVC film is affixed to
said
core. Although the digital printing techniques are constantly improving,
leading to
more realistic natural appearances, there is also a trend of leading flooring
manufacturers to develop more environmental-friendly decorative panels which
are
more composed of natural materials rather than of synthetic, in particular
thermoplastic, materials, such as PVC. To this end, flooring panels have been
developed which use a cork layer, rather than a PVC film, to bear a printed
d6cor
image. Although this solution constitutes an improvement from an environmental
point of view, it has been found that cork is rather expensive and it is
practically
impossibly to reach to same panel quality compared to panels wherein PVC are
used to bear the decorative image, in terms of image quality and panel
stability.
It is therefore a first objective of the invention to provide a relatively
environmental-
friendly, high-quality decorative panel.
It is therefore a second objective of the invention to provide a relatively
environmental-friendly decorative panel comprising a high-quality decor image.
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It is therefore a third objective of the invention to provide an environmental-
friendly,
inexpensive decorative panel.
At least one of these objective can be met by providing a decorative panel
according to the preamble, comprising: a core provided with an upper side and
a
lower side, a decorative top structure affixed, directly or indirectly, on
said upper
side of the core, said decorative top structure comprising: at least one
decorative
layer, preferably a printed decorative layer, more preferably a digitally,
printed
decorative layer, forming and/or bearing at least one decor image, and,
preferably,
at least one transparent and/or translucent protective layer covering said
decorative
layer; and at least one intermediate layer comprises non-human collagen and/or
leather, wherein said at least one intermediate layer is positioned underneath
said
decorative top structure.
Preferably, the decorative panel is an interlockable panel configured to
interlock
with adjacent panels. To this end, the decorative panel comprises a first
panel edge
comprises a first coupling profile, and a second panel edge, preferably
opposite to
the first panel edge, comprising a second coupling profile being designed to
engage interlockingly with said first coupling profile of an adjacent panel,
both in
horizontal direction and in vertical direction. Alternatively, it is also
conceivable that
the decorative panel according to the invention is a so-called dry-back panel
which
is configured to be glued onto a subfloor.
The intermediate layer is a collagen based layer. Skin, or animal hide, is
formed
primarily of collagen, a fibrous protein, and serves as source for composed at
least
a part of said intermediate layer. Collagen is a generic term for a family of
at least
28 distinct collagen types; animal skin is typically type I collagen, although
other
types of collagen may be used in forming leather. Collagens are characterized
by
repeating triplets of amino acids, -(Gly-X-Y) n -, so that approximately one-
third of
the amino acid residues are in collagen are glycine. X is typically proline
and Y is
typically hydroxyproline. The structure of collagen may consist of twined
triple units
of peptide chains of differing lengths. Different animals may produce
different
amino acid compositions of the collagen, which may result in different
properties
(and differences in the resulting leather). Collagen fiber monomers may be
produced from alpha-chains of about 1050 amino acids long, so that the triple
helix
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takes the form of a rod of about 300 nm long, with a diameter of 1.5 nm.
Triple
helices can be bound together in bundles called fibrils, and fibril bundles
come
together to create fibers. Fibers typically divide and join with each other
throughout
an animal skin layer. Variations of the crosslinking or linking may provide
strength
to the material. Fibers may have a range of diameters depending on the type of
animal hide. In addition to type I collagen, skin (hides) may include other
types of
collagen as well, including type III collagen (reticulin), type IV collagen,
and type VII
collagen. Leather derived from animal mainly consists of collagen type I when
hides
are obtained from adult animals, and significant proportion of collagen types
III and
IV, together with collagen type I when skins are derived from young animals.
The
composition and ratio of collagen types affect the physical properties of
leather, a
younger hide with proper tanning provides the softest leather.
The use of non-human collagen, and (bonded) leather in particular, is not only
technically driven, but also environmentally and morally driven. The global
leather
industry slaughters more than a billion animals per year. The leather skin
resulting
from this slaughtering process is often and largely treated as waste, which is
typically burned afterwards. By reusing this leather at least partially the
amount of
waste is reduced and a more circular production cycle can be realised.
Moreover,
these leather residues, typically offered as bonded leather, is relatively
inexpensive,
and therefore more attractive than other natural materials, such as cork,
which may
be used for this purpose.
Moreover, the application of a collagen and/or leather based intermediate
layer for
supporting the decorative top structure is favourable since, this intermediate
layer is
well-suitable for adhesion of a primer layer and/or a digital print layer of
the
decorative top structure. Moreover, due to the flexible (elastic) nature of
the
intermediate layer, the intermediate layer is typically configured to
compensate
differences in the temperature and/or moisture expansion coefficient of the
core
and at least a part of the decorative top structure. This prevents
delamination of the
panel, which is in favour of the lifetime of the panel. An additional
advantage of the
intermediate layer is it capability to be sawn, milled, and edged, which is
favourable
when profiling the panel to realising coupling profiles. Furthermore, the
intermediate
layer provide the panel additional strengthening. Additionally, the presence
of one
or more intermediate layer provides the panel improved acoustic dampening
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properties. Since at least the edges of at least one intermediate layer are
typically
exposing to the surrounding atmosphere, it is additionally favourable that the
intermediate layer(s) has/have a relatively good resistance against cleaning
agents.
Due to the above properties it can be advantageous that (i) at least one
intermediate layer is situated in between the core and the decorative top
structure,
and preferably affixed, either directly or indirectly, to the upper side of
the core,
and/or that (ii) at least one intermediate layer is embedded in the core,
and/or that
(iii) at least one intermediate layer is affixed, either directly or
indirectly, to the lower
side of the core.
The collagen present in the intermediate layer is preferably derived from
cows,
water buffaloes, horses, deers, crocodiles, or goats, as the tear strength of
this
leather types are relatively high, in particular higher than 60 N/mm. Hence,
the
intermediate layer(s) preferably comprise(s) bovine leather, which is
typically
preferred over ovine leather, also because there is a correlation between
leather
strength and fibril diameter in bovine leather. In bovine leather, the
collagen fibrils
are more aligned than in ovine skin, and it was found that where tissue
contains
highly aligned fibrils, the fibril diameter becomes a significant determinant
of
strength. In tissues where the fibrils are not well aligned, the influence of
fibril
alignment on strength is greater than that of fibril diameter. Therefore, in
leather
and skin, larger fibrils may lead to stronger material, but for weaker
leathers, fibril
diameter is secondary to fibril alignment for strength. Preferably, the fibril
length is
at least 66 nm, which is typical for cows and horses.
Preferably, the amount of (genuine) leather is preferably situated between 40
and
80% and more preferably approximately 60% by weight of the intermediate layer.
Although it is imaginable that the intermediate layer is entirely (100%)
composed of
leather, this will commonly be considered as a rather expensive solution
compared
to a composite material which comprises further to leather also one or more
other
materials.
Preferably, at least one intermediate layer is at least partially or entirely
composed
of bonded leather, also referred to as reconstituted leather or blended
leather.
Bonded leather is at least partially composed of (genuine) leather particles
bonded
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by means of a binding material, wherein the amount of binding material is
preferably situated between 10 and 40% and more preferably approximately 20%
by weight of the intermediate layer. Examples of suitable binding material are
natural rubber, such as latex, and polyurethane. Preferably, bonded leather
comprises a layered structure of a carrier layer onto which leather particles
are
bonded by means of said binding material. The carrier layer may, for example,
be
composed of a paper, fabric, cork, wood, and/or a, preferably natural polymer,
such
as natural rubber (latex). The carrier layer may be either a woven or non-
woven
layer. Preferably, the binding material is partially penetrated into the
carrier layer. It
is conceivable that the binding material is partially penetrated into the core
and/or
at least one other adjacent layer. Since the collagen of the intermediate
layer
typically has a porous structure, it typically allows penetration of other
materials. It
is therefore imaginable that the decorative top structure is partially
penetrated into
at least one intermediate layer situated in between the top structure and the
core.
More in particular, it is imaginable that a primer layer of the top structure,
is partially
penetrated into at least one intermediate layer situated in between the top
structure
and the core. Penetration of layers into each other typically increases the
bonding
strength between said layers.
Preferably, at least one intermediate layer comprises between 40-80%, more
preferably at least 50% and/or less than 70%, most preferably approximately
60%
(+/-3%), by weight of natural leather fibres. Preferably, at least one
intermediate
layer comprises between 10-40%, more preferably at least 15% and/or less than
35%, and most preferably approximately 20% (+/- 3%), by weight of synthetic
polymer and/or natural polymer, in particular natural latex. Preferably, at
least one
intermediate layer comprises between 1-20%, more preferably at least 5% and/or
less than 15%, and most preferably approximately 10% (+/- 3%), by weight of
fat, in
particular natural fat. Preferably, at least one intermediate layer comprises
between
1-20%, more preferably at least 5% and/or less than 15%, and most preferably
approximately 10% (+/- 3%), by weight of water and/or vegetable additive, such
as
vegetable tanning agent, and/or at least one other additive.
Preferably, at least one intermediate layer comprises at least one natural
fat, such
as fatty tissue derived from animals and/or vegetable oil, in particular
rapeseed oil,
wherein the amount of natural fat is preferably situated between 5 and 25%,
and
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more preferably approximately 10% by weight of the intermediate layer.
Typically,
such a natural fat, such as natural oil, in particular rapeseed oil, acts as
lubricant
within the intermediate layer. The presence of one or more lubricants
modulates or
controls fibril-fibril bonding during dehydration to leather which improves
the
strength of the intermediate layer. Other suitable lubricants include
surfactants,
anionic surfactants, cationic surfactants, cationic polymeric surfactants,
anionic
polymeric surfactants, amphiphilic polymers, fatty acids, modified fatty
acids, non-
ionic hydrophilic polymers, non-ionic hydrophobic polymers, poly acrylic
acids, poly
methacrylic, acrylics, natural rubbers, amphiphilic anionic polymer and
copolymers,
amphiphilic cationic polymer and copolymers and mixtures thereof as well as
emulsions or suspensions of these in water, alcohol, ketones, and other
solvents.
In case a polymeric substance is used as lubricant, preferably a natural
(bio)polymeric substance is used.
Furthermore, at least one intermediate layer comprises at least one additive,
such
as, preferably vegetable, tanning agent and/or water, wherein the amount of
additive is preferably situated between 5 and 20 % and more preferably 10% by
weight of the intermediate layer. Examples of vegetable tanning agents are
pyrogallol- or pyrocatechin-based tannins, such as valonea, mimosa, ten, tara,
oak,
pinewood, sumach, quebracho and chestnut tannins; chromium tanning agents
include chromium salts like chromium sulphate; aldehyde tanning agents include
glutaraldehyde and oxazolidine compounds, syntans include aromatic polymers,
polyacrylates, polymethacrylates, copolymers of maleic anhydride and styrene,
condensation products of formaldehyde with melamine or dicyandiamide, lignin
and
natural flours.
The intermediate layer(s) may comprise at least one filler, preferably an
inorganic
filler, such and calcium carbonate and/or clays. These fillers may fill the
interstitial
spaces in loose leathers and in between leather particles, and make the
looseness
less pronounced, and hence the intermediate as such more robust.
Preferably, at least one intermediate layer comprises synthetic particles, in
particular synthetic fibres, in particular polymer fibres. These particles may
e.g. be
formed by glass particles, carbon particles, silicon particles or other types
of
polymer fibres.
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It is imaginable that at least one intermediate layer has a textured upper
surface,
preferably an artificially textured upper surface. This increases the contact
surface
between the intermediate layer and an adjacent layer, which typically
increases the
bonding strength in between these layers. Moreover, this textured upper
surface
could contribute to a texture of the upper side of the panel.
Preferably, the density of at least one intermediate layer is between 0.75 and
0.95
g/cm3, preferably between 0.8 and 0.9 g/cm3, more preferably approximately
0.85
(+/- 0.02) g/cm3. The density is preferably measured by using ISO 2420.
Preferably, the thickness of at least one intermediate layer is between 0.75
and
0.95 mm, preferably between 0.77 and 0.87 mm, more preferably approximately
0.80 (+/- 0.02) mm. The thickness is preferably measured by using IS02589.
Typically, each non-human collagen comprising intermediate layer is a flexible
layer. This layer may be manufactured and marketed separately, preferably in a
rolled up condition, prior to manufacturing of the panel according to the
invention.
The core may be flexible, semi-rigid or substantially rigid. The core may be
solid or
at least partially foamed. The core is preferably at least partially, and more
preferably entirely composed, of a natural material, such as wood or mineral.
It is
preferred that the core is at least partially, and more preferably entirely
composed,
of high-density fibreboard (HDF) or medium-density fibreboard (MDF).
Alternatively,
it could be preferred that the core is preferably at least partially, and more
preferably entirely composed, of magnesium oxide and/or magnesium hydroxide.
It
is also imaginable that the core is formed by another type of mineral board,
such as
a cement board, in particular a fiber cement board. Alternatively, the core
may
comprise at least one polymer selected from the group consisting of: ethylene
vinyl
acetate (EVA), polyurethane (PU), polyethylene (PE), polypropylene (PP),
polystyrene (PS), polyvinylchloride (PVC), polyethylene terephthalate (PET),
Polyisocyanurate (PI R), or mixtures thereof. The polymer may be a virgin
polymer,
a recycled polymer, or a combination of virgin polymer and recycled polymer.
The
core may comprise at least one wood-based material. The core may comprise at
least one composite material of at least one polymeric material and at least
one
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non-polymeric material. The at least one non-polymeric material is preferably
selected from the group consisting of: talc, chalk, wood, calcium carbonate,
leather,
and a mineral filler. The non-polymeric material may be, for example, in the
form of
fibers and/or in the form of dust. The material of the core as such may also
be free
of any non-human collagen material. This latter doesn't mean that it is not
imaginable to embed at least one non-human collagen based intermediate layer
into the core. In this embodiment the core and the embedded intermediate
layer(s)
are considered as separate layer. It is possible though that core material,
such as
polymeric core material, at least partially penetrates the embedded
intermediate
layer(s).
As said, the decorative top structure preferably comprises at least one primer
layer
applied onto at least one intermediate layer. The primer layer is intended to
securely bond the ink of the decor image. The primer layer preferably
comprises at
least one acryl resin and/or at least one acrylate. The primer layer
preferably has a
white or whitish colour. The decor image may be directly printed on the primer
layer, or directly onto the intermediate layer in case a separate primer layer
is
omitted.
It is imaginable that the decor image is directly printed onto a(n)
(alternative) carrier
layer, such as a paper sheet and/or polymeric film, wherein said carrier layer
is
affixed to at least one intermediate layer and/or onto at least one primer
layer of the
decorative structure.
Preferably, at least one transparent and/or translucent protective layer is
formed by
a wear layer. It is imaginable and often preferred that a plurality of the
wear layers
is applied. Preferably, at least one transparent and/or translucent protective
layer is
formed by a top coating, such as a UV hardened top coating, preferably applied
on
top of at least one wear layer of the decorative top structure. One or more
transparent and/or translucent protective layers may be applied by printing,
in
particular digital printing.
The decorative top structure preferably comprises at least one decorative
layer and
at least one transparent wear layer covering said decorative layer. The
decorative
top structure may additionally comprise at least one back layer (also referred
to as
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backing layer) situated in between said decorative layer and the core, wherein
said
back layer is preferably at least partially made of a vinyl compound, another
polymer, wood, paper, textile, leather, such as cotton and/or recycled jeans
(denim), and/or combinations thereof. The one or more materials used in said
at
least one back layer may virgin materials, recycled materials, and
combinations
thereof. Here, it is for example imaginable and even preferred that the back
layer
comprises a mixture of wood, cotton, preferably recycled cotton, more
preferably
recycled cotton based upon recycled jeans (denim), and/or virgin cotton; and
at
least one binding agent. The recycled cotton can be post-consumer recycled
cotton, being a type of cotton that comes from garments which have been sold
to
and used by the consumer, such as jeans. Additionally or alternatively, the
recycled
cotton can be pre-consumer recycled cotton (cutting waste), which is a type of
cotton that comes from the waste that is produced in the manufacturing
process.
Preferably, the back layer comprises wood in an amount of 20-60% by weight of
the back layer, and a cotton based material, such as recycled jeans and/or raw
cotton (virgin cotton), in an amount of 30-70% by weight of the back layer,
and at
least one binding agent, preferably in an amount of 1-7% by weight of the back
layer. The back layer may be free of PVC and/or any other synthetic polymer.
Optionally, the back layer may act as decorative layer (which does not require
a
separate decorative layer on top).
A lacquer layer or other protective layer may be applied on top of said wear
layer.
The protective layer and/or wear layer preferably comprises silicon oxide
(SiO2).
Preferably, said protective layer is an UV cured protective layer, which is
preferably
applied, more preferably by using hot-coating, in liquid state prior to
curing. A
finishing layer, which may be an UV cured layer, may be applied in between the
decorative layer and the wear layer. The decorative layer will be visible and
will be
used to provide the panel an attractive appearance. To this end, the
decorative
layer may have a design pattern, which can, for example be a wood grain
design, a
mineral grain design that resembles marble, granite or any other natural stone
grain, or a colour pattern, colour blend or single colour to name just a few
design
possibilities. It is imaginable and may even be preferred that the decorative
layer
comprises at least one recycled material and/or at least one natural material,
such
as e.g. wood, coffee (e.g. coffee grounds, and/or ground coffee, and/or coffee
powder, and/or coffee chaff), textile, cotton, in particular recycled jeans
material,
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and/or mixtures thereof, for example a mixture of wood and a coffee based
material. In this latter embodiment, the decorative layer may e.g. comprise
wood in
an amount of 40-80% by weight of the decorative layer, and a coffee based
material, such as coffee grounds and/or coffee chaff, in an amount of 10-50%
by
weight of the decorative layer, and at least one binding agent, preferably in
an
amount of 1-7% by weight of the decorative layer. The decorative layer may be
free
of PVC and/or any other synthetic polymer. Additionally or alternatively, the
decorative layer comprises a film, such as a polymer film, for example a PVC
film,
and/or a paper film, onto which at least one decor image is printed,
preferably
digitally printed. Customized appearances, often realized by digital printing
during
the panel production process, are also imaginable. The decorative top
structure
may also be formed by a single layer. In an alternative embodiment, the
decorative
top structure is omitted, thus not applied, in the panel according to the
invention. In
this latter embodiment, the upper side of the core constitutes the upper side
of the
panel.
The top surface of the decorative top structure, which defines the top surface
of the
panel, may be provided by a provided with a texture, which is preferably
aligned in
register with at least a part of at least one decor image of the decorative
top
structure. Preferably, the texture is a result of digital printing of one or
more layers
of the decorative top structure.
In a preferred embodiment, the first coupling profile and the second coupling
profile
are preferably configured such that two of such panels can be coupled to each
other by means of a lowering movement (fold-down movement) and/or turning
movement. In case the panel is rectangular, then the first panel edge and
second
panel edge are typically situated at opposite short edges of the panel. The
panel
preferably also comprises at least one third coupling profile and at least one
fourth
coupling profile located respectively at a third panel edge and a fourth panel
edge,
wherein the third coupling profile comprises: a sideward tongue extending in a
direction substantially parallel to the upper side of the core, at least one
second
downward flank lying at a distance from the sideward tongue, and a second
downward groove formed between the sideward tongue and the second downward
flank, wherein the fourth coupling profile comprises: a third groove
configured for
accommodating at least a part of the sideward tongue of the third coupling
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an adjacent panel, said third groove being defined by an upper lip and a lower
lip,
wherein said lower lip is provided with an upward locking element,
wherein the third coupling profile and the fourth coupling profile are
configured such
that two of such panels can be coupled to each other by means of a turning
movement (angling down movement), wherein, in coupled condition: at least a
part
of the sideward tongue of a first panel is inserted into the third groove of
an
adjacent, second panel, and wherein at least a part of the upward locking
element
of said second panel is inserted into the second downward groove of said first
panel.
Preferably, the panel comprises a back layer (also referred to as underlay)
which is
affixed, either directly or indirectly, to a lower side of the core. As
mentioned above,
such a back layer may be formed by one of said intermediate layers. It is also
imaginable that the back layer is formed by, for example, a polymer layer, a
cork
layer, preferably a high density cork layer (typically having a density of at
least 150
kg/m3), a linoleum layer, and/or a composite layer, such as cork-linoleum
composite layer. Also other materials, which may optionally be expanded (low
density) or compressed (high density), may be used as backing layer. The
backing
layer is typically glued to the core. It is also imaginable that the backing
layer and
the core are fused together.
It is further preferred that the panel according to the invention has a
thickness in the
range of 3.0 mm to 20.0 mm, preferably in the range of 3.8 mm to
12.0 mm. The panel according to the invention, is preferably of a rectangular,
parallelogrammatic, or hexagonal shape. The panel preferably has an oblong
shape.
The invention also relates to a panel covering, in particular floor covering,
ceiling
covering, or wall covering, consisting of a plurality of, preferably mutually
coupled,
panels according to the invention.
The invention further relates to an intermediate layer comprising non-human
collagen, wherein said intermediate layer is intended for use in a decorative
panel
according to the invention. These layers, embodiments of which have been
described above and below in more detail, may be manufactured (and optionally
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separately marketed) separately and prior to the manufacturing of the
decorative
panels according to the invention.
The invention will be elucidated on the basis of non-limitative exemplary
embodiments shown in the following figures. Herein:
- Figure 1 shows a rectangular floor panel according to the present
invention;
- Figure 2 is a cross-sectional view indicated by section A-A in Figure 1;
- Figure 3 is a cross-sectional view indicated by section B-B in Figure 1;
- Figures 4a-4f show different views of the successive steps for
interconnecting multiple floor panels according to Figures 1-3 for forming a
floor
covering;
- Figures 5a-5e show different embodiments of the first and second edges of
a floor panel according to the invention;
- Figure 6 shows a different embodiment of the third and fourth edges of a
floor panel according to the invention; and
Figure 7 shows a detailed cross-sectional view of a panel according to one
of Figures 1-6, wherein various (bonded) leather based intermediate layers are
shown.
Figure 1 shows a rectangular floor panel 1 according to the present invention.
The
panel 1 is interconnectable with similar panels for forming a covering, as
will be
shown in further figures. The floor panel 1 can be made of any material,
though
typical materials are wood, in particular HDF, MDF, and LDF, and plastic, in
particular thermoplastic, more in particular PVC. Commonly, the floor panel 1
is
made of a laminate comprising a central layer (core layer) enclosed by a
backing
structure and a top structure (not shown). The top structure commonly
comprises a
decorative layer, which may be printed onto the central layer, on top of which
a
protective layer is applied. The panel 1 comprises a centrally located core 2
provided with an upper side 3 and a lower side 4. The core 2 is integrally
connected
with a first pair of opposite edges, in particular a first edge 5 and a
complementary
second edge 6, located at the long lateral sides of the panel 1. The core is
also
integrally connected with a second pair of opposite edges, in particular a
third edge
7 and a complementary fourth edge 8, located at the short sides of the panel 1
in
this exemplary embodiment.
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Figure 2 is a cross-sectional view indicated by section A-A in Figure 1. In
this cross-
section, the shape of the complementary first edge 5 and second 6 edge are
shown
in detail. The first edge 5 comprises a sideward tongue 9 which is integrally
connected to the core 2. By means of the vertical dashed line the border
between
the sideward tongue 9 and the core 2 is visualised. A front region 9a of the
sideward tongue 9 is provided with a rounded bottom surface 10. An outer end
of
the rounded bottom surface 10 adjoins an inclined locking surface 11. An
opposite
end of the rounded bottom surface 10 adjoins a bearing surface 12 making part
of a
back region 9b of the sideward tongue 9. The second edge 6 of the panel 1
comprises an upper lip 13 and a lower lip 14 defining a recess 15. Both lips
13, 14
are integrally connected to the core 2. By means of the vertical dashed line
the
border between the lips 13, 14 and the core is visualised. As shown in Figure
2, the
width of the upper lip 13 is substantially smaller than the width of the lower
lip 14.
The recess 15 has a shape which is complementary to the shape of the sideward
tongue 9. More in particular, a top surface 16 of a back region 14a of the
lower lip
14 has a (complementary) rounded shape, configured to co-act with the rounded
front region 9a of the sideward tongue 9, while a front region 14b of the
lower lip 14
is provided with a upwardly protruding shoulder 17, configured to co-act with
the
bearing surface 12 of the sideward tongue 9. A lower surface 18 of the upper
lip 13
is inclined and corresponds to the locking surface 11 of the sideward tongue
9.
Locking at the first edge 5 and the second edge 6 of adjacent panels 1 by
insertion
of the sideward tongue 9 of a panel 1 to be coupled into the recess 15,
wherein
said panel 1 is initially held in an inclined position. After insertion of the
sideward
tongue 9 into the recess, the panel 1 to be coupled will be pivoted (angled)
in
downward direction about an axis parallel to the first edge 5 until both
panels 1 are
positioned in the same ¨ commonly horizontal ¨ plane, wherein the locking
surface
11 of the sideward tongue 9 will engage the locking surface of the upper lip
18, and
wherein at least a bottom front part is accommodated substantially form-
fittingly in
the recess 15, and wherein the bearing surface 12 is supported by the shoulder
17.
Locking at the first edge 5 and the second edge 6 leads to locking of the
connected
panels 1 in both horizontal direction and vertical direction. The angling down
locking principle of the first and second edges 5, 6 is a relatively easy
locking
principle which facilitates mutual coupling of panels at these edges 5, 6
tremendously. Further details relating to this locking mechanism are
visualised in
Figures 4 and 5.
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Figure 3 is a cross-sectional view indicated by section B-B in Figure 1. In
this cross-
section, the shape of the complementary third edge 7 and second 8 edge are
shown in detail. The third edge 7 comprises an upward tongue 19, an upward
flank
20 and an upward groove 21 formed between upward tongue 19 and upward flank
20. The upward tongue 19 is connected to the core 2 by means of a bridge 22,
which is preferably resilient to some extent. A side 19a of upward tongue 19
facing
toward upward flank 20 extends in the direction of the normal Ni of the upper
side
3 of the core 2. The tangent R1 and the normal Ni of the upper side 3 of the
core 2
are thus directed toward each other (converging orientation), wherein the
angle
enclosed by R1 and Ni is preferably between 0 and 10 degrees in this exemplary
embodiment. Due to the converging orientation of the upward flank 20 and the
side
19a of the upward tongue 19 facing toward to the upward flank 20, the upward
groove 22 is a closed groove, which is only accessible to a complementary
counterpart by deformation of the upward tongue 19 and/or bridge 22. Another
side
19b of upward tongue 19 facing toward upward flank 20 forms an aligning edge
enabling facilitated realization of a coupling to an adjacent floor panel 1.
As shown,
this side 19b functioning as aligning edge is directed away from the normal Ni
of
upper side 3 of the core 2. An upper side 19d of upward tongue 19 does however
extend in the direction of the normal Ni of the upper side 3 of the core 2,
and runs
inclining downward in the direction of the side 19e of upward tongue 19 facing
away from upward flank 20. This chamfering provides the option of giving the
complementary fourth edge 8 a more robust and therefore stronger form. A part
of
the side 19e of upward tongue 19 facing away from upward flank 20 is oriented
substantially vertically and is moreover provided with an outward bulge 23. A
lower
part 20a of upward flank 20 is oriented diagonally, while an upper part 20b of
upward flank 20 is shown to be substantially vertical and forms a stop surface
for
fourth edge 8. In between the inclined part 20a and the substantially vertical
part
20b of the upward flank an additional coupling element, in particular an
additional
bulge 24, is provided. A lower wall part 21a of upward groove 21 is oriented
substantially horizontally in this exemplary embodiment.
The fourth edge 8 is substantially complementary to third edge 7. The fourth
edge 8
comprises a downward tongue 25, a downward flank 26 and a downward groove
27 formed between downward tongue 25 and downward flank 26. The downward
tongue 25 is connected to the core 2 by means of a bridge 28, which is
preferably
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resilient to some extent. A side 25a of downward tongue 25 facing toward
downward flank 26 lies in the direction of the normal N2 of the lower side 4
of the
core 2. This means that a tangent R2 of side 25a of downward tongue 25 and the
normal of the lower side 4 of the core 2 are mutually converging, wherein the
angle
enclosed by R2 and N2 is preferably between 0 and 10 degrees in this exemplary
embodiment. More preferably, the inclination of R1 is identical to the
inclination of
R2; hence, R1 and R2 are preferably parallel. Due to the converging
orientation of
the downward flank 26 and the side 25a of the downward tongue 25 facing toward
to the downward flank 26, the downward groove 27 is a closed groove, which is
only accessible for the upward tongue 19 of an adjacent panel 1 by deformation
of
the downward tongue 25 and/or bridge 28, as a result of which the entrance of
the
downward groove can be widened (temporary).
A side 25b of the downward tongue 25 facing away from downward flank 26 is
diagonally oriented, but has a flatter orientation than the complementary side
20a of
upward flank 20, whereby a gap (air space) will be formed in the coupled
position,
which will generally facilitate coupling between two floor panels 1. The
inclining side
25b of downward tongue 25 also functions as aligning edge for the purpose of
further facilitating coupling between two floor panels 1. Another side 25c
facing
away from downward flank 26 takes a substantially vertical form, though is
provided
with a small cavity 29 configured to co-act with the additional bulge 24 of
another
panel 1. A top part of the side 25c facing away from downward flank 26 forms a
complementary stop surface for stop surface 20b of upward flank 20 (of an
adjacent floor panel). Downward flank 26 is oriented substantially vertically
and is
provided with a recess 30 adapted to receive the outward bulge 23 of the
upward
tongue 19 (of an adjacent floor panel).
Figures 4a-4f show different views of the successive steps for interconnecting
multiple floor panels 1 according to Figures 1-3 for forming a floor covering
31.
Figures 4a and 4b relate to the first step of the installation process,
wherein a first
row of floor panels 1 is generated by connecting the third edge 7 of a panel 1
to the
fourth edge 8 of an adjacent panel, by pressing ¨ in a substantially vertical
direction
(as indicated by the arrow) ¨ the fourth edge 8 of a panel 1 to be coupled
onto and
into the third edge 7 of an already installed panel 1. Due to the vertical
displacement, the third edge 7 and/or the fourth edge 8 will be deformed
slightly,
such that the downward tongue 25 will be pushed into the upward groove 21, and
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the upward tongue 19 will be pushed into the downward groove 27. Moreover, the
bulges 23, 24 will be positioned in the corresponding recesses 29, 30 to
better
secure the floor panels 1 with respect to each other. Due to this temporary
deformation, wherein both the upward groove 21 and the downward grove 27 will
be widened temporary for the insertion of the downward tongue 25 and the
upward
tongue 19 respectively, both edges 7, 8 will snap into each other.
Figures 4c and 4d relate to the second step of the installation process,
wherein a
second row of floor panels 1 is created which is connected to the first row of
floor
panels. To this end, a first edge 5 of a floor panel 1 to be coupled is
positioned in
an inclined orientation against a second edge 6 of an already installed panel
1,
such that the sideward tongue 9 is at least partially inserted in the
complementary
recess 15 of the second profile 6. After this partial insertion the inclined
panel is
pivoted (angled) down ¨ see arrow ¨ around an axis parallel to the first edge
5, until
the panel 1 is located in the same plane as defined by the first row of
panels, as a
result of which the sideward tongue 9 will be locked into the recess 15 both
in at
least one horizontal direction and in vertical direction.
The first two steps as shown in Figures 4a-4d are preparatory steps for
installation
of one or more subsequent panels 1 which are to be coupled at multiple edges
instead of only at a single edge. Installation of a subsequent floor panel 1
is
visualised in Figures 4e and 4f. Again, a floor panel 1 to be coupled is held
at
inclined position, wherein the sideward tongue 9 of the floor panel 1 is
inserted
partially into the corresponding recess 15 of a second edge of at least one
floor
panel already installed. The fourth edge 8 of the floor panel 1 to be
installed is
positioned substantially above the third edge 7 of the panel 1 already
installed in
the second row, wherein the fourth edge 8 and the third edge 7 mutually
enclose an
angle (being the inclination angle of the panel to be coupled). During angling
down
of the panel 1 to be coupled (see arrow) both the first edge 5 and the fourth
edge 8
of the panel 1 will be connected to adjacent panels 1. More in particular,
during
angling down of the panel 1, the front region of the sideward tongue 9 will be
accommodated in the recess 15, and will be held in position by means of the
limiting shoulder 17 and the limiting locking surface 18 of the upper lip 13
of the
second edge 6 of the panel(s) already installed in the first row. Moreover,
simultaneously the fourth edge 8 of the panel 1 to be coupled will make a
downward scissoring movement with respect to the underlying third edge 7 and
will
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zip (snap) into the third edge 7 and vice versa, leading to a firm and durable
connection between the panels 1.
Figures 5a-5e show different embodiments of the first and second edges of a
floor
panel according to the invention. In Figure 5a the embodiment according to
Figures
1-4f is shown, while in Figures 5b-5e alternative embodiments of these edges
are
shown. More in particular, Figure 5b shows a first and second edge 40, 41 of a
floor
panel 42, wherein, instead of a smoothly rounded bottom portion a more hooked
(segmented rounded) bottom portion is shown. In Figure 5c, an embodiment of a
floor panel 43 is shown which is almost identical to the floor panel shown in
Figure
5a, though wherein the first and second edges 44, 45 are provided with
horizontal
locking surfaces 44a, 45b instead of inclined locking surfaces. In Figure 5d,
an
alternative embodiment of a floor panel 46 is shown, wherein the first and
second
edges 47, 48 are shaped such that a bottom contact portion between the two
edges 47, 48 is partially smoothly rounded and partially discontinuously
rounded
(segmented rounded). Locking surfaces 50, 51 of a sideward tongue 49 of the
first
edge 47 and of an upper lip 52 of the second edge have a substantially
horizontal
orientation. In Figure 5e, an embodiment of a floor panel 53 almost identical
to the
floor panel 46 as shown in Figure 5d is shown, with the difference that a
front
bottom part 54a of a sideward tongue 54 is not smoothly rounded, but flat
giving a
bottom portion of the sideward tongue 54 as such a segmented rounded (hooked)
shape.
Figure 6 shows a different embodiment of the third and fourth edges of a floor
panel
57 according to the invention. Floor panel 57 comprises a core 58 provided
with an
upper side 58a and a lower side 58b, and coupling parts 59, 60 positioned on
opposite longitudinal sides of core 58 and connected integrally to core 58. A
first
coupling part 59 comprises an upward tongue 61, an upward flank 62 and an
upward groove 63 formed between upward tongue 61 and upward flank 62. A side
61a of upward tongue 61 facing toward upward flank 62 is inclined and extends
in
the direction of the normal Ni of the upper side 58a of core 58. The tangent
R1 and
the normal Ni of upper side 58a of core 58 are thus directed toward each other
(converging orientation), wherein the angle enclosed by R1 and Ni amounts to 3-
5
degrees. On top of side 61a, a substantially flat upward aligning edge 61b of
the
upward tongue 61 is positioned, which faces toward upward flank 62 and which
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enables facilitated realization of a coupling to an adjacent floor panel. The
inclined
surface 61a, acting as locking surface, and the adjoining upward aligning edge
61b
together form the inner side surface of the upward tongue 61. As shown, this
side
61b functioning as upward aligning edge is substantially flat and, moreover,
directed away from the normal Ni of upper side 58a of the core. A (single)
upper
side 61d of upward tongue 61 does however extend in the direction of the
normal
Ni of upper side 68a of core 68, and runs inclining downward in the direction
of the
side 61e of upward tongue 61 facing away from upward flank 62. The angle of
inclination is about 30 degrees. This chamfering provides the option of giving
the
complementary second coupling part 60 a more robust and therefore stronger
form,
as will be elucidated below. The side 61e of upward tongue 61 facing away from
upward flank 62 is oriented substantially vertically and is moreover provided
with an
outward bulge 64 which clearly extends with respect to vertically oriented
parts of
the outer side wall 61 of the upward tongue 59. A lower part 62a of upward
flank 62
is oriented diagonally, while an upper part 62b of upward flank 62 is shown to
be
substantially vertical and forms a stop surface for second coupling part 60. A
lower
wall part 63a of upward groove 43 is oriented substantially horizontally in
this
exemplary embodiment. A bridge 65 lying between lower wall part 63a of upward
groove 63 and a lower side 59a has a somewhat elastic nature and is adapted to
allow upward tongue 61 to slightly pivot relative to upward flank 62, this
resulting in
a (temporary) widening of upward groove 63, whereby coupling of floor panel 57
to
an adjacent floor panel can be facilitated. Second coupling part 60 is
substantially
complementary to first coupling part 59. Second coupling part 60 comprises a
downward tongue 66, a downward flank 67 and a downward groove 68 formed
between downward tongue 66 and downward flank 67. A side 66a of downward
tongue 66 facing toward downward flank 67 is inclined and extends in the
direction
of the normal N2 of the lower side 58b of core 58. This means that a tangent
R2 of
side 66a of downward tongue 66 and the normal of the lower side 58b of core 58
are mutually converging. In this exemplary embodiment the tangent R2 and the
normal N2 enclose a mutual angle of 3-5 degrees. A side 66b facing away from
downward flank 67 is diagonally oriented, but has a flatter orientation than
the
complementary side 62a of upward flank 62, whereby a gap (air space) will be
formed in the coupled position, which will generally facilitate coupling
between two
floor panels 57. The inclining side 66b of downward tongue 66 also functions
as
aligning edge for the purpose of further facilitating coupling between two
floor
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panels 57. Another side 66c facing away from downward flank 67 takes a
substantially vertical form and forms a complementary stop surface for stop
surface
62b of upward flank 62 (of an adjacent floor panel). Downward tongue 66 is
further
provided with a small aligning edge 66d which is facing toward downward flank
67.
Because upper side 61d of upward tongue 61 has an inclining orientation, an
upper
side 68a of downward groove 68 likewise can be given, and in this embodiment
has, a corresponding inclining orientation, whereby the (average) distance
between
upper side 68a of downward groove 68 and an upper side 60a of second coupling
part 60 is sufficiently large to impart sufficient strength to second coupling
part 60
as such. Downward flank 67 is oriented substantially vertically and is
provided with
a recess 69 adapted to receive the outward bulge 64 of upward tongue 61 (of an
adjacent floor panel).
A bridge 70 lying between upper side 68a of downward groove 68 and upper side
60a has a somewhat elastic nature due its reduced thickness close to the
downward tongue 66 (and possibly also due to material characteristics), and is
adapted to allow downward tongue 66 to slightly pivot relative to downward
flank
67, this resulting in a (temporary) widening of downward groove 68, whereby
coupling of floor panel 67 to an adjacent floor panel can be facilitated. This
pivoting
point (point of deformation) is typically formed by the weakest point in the
bridge
70, which is indicated by the sign "P". The shown floor panel 67 can form a
parquet
floor panel, a plank, a laminated floor panel and/or a plastic floor panel.
The
coupling parts 59, 60 and the core 58 are preferably integrally connected.
Figure 7 shows a detailed cross-sectional view of a panel 57 according to one
of
Figures 1-6 and/or which can be combined (integrated) with a panel as shown in
one the previous figures. The panel 57 shown in figure 7 comprises a core 58,
wherein said core 58 comprises an upper side 58a and a lower side 58b.
According
to this non-limitative embodiment of the panel 57 the upper side 58a of the
core 58
is provided with at least one intermediate layer 71, on top of which
intermediate
layer 71 a decorative top structure 72 is provided. It is conceivable that
said core
layer 58 is optionally provided with a further intermediate layer 79 that is
embedded
in the core 58, said further intermediate layer 79 may function as
reinforcement of
the core. The optional intermediate layer 79 may, for example, be a woven or
non-
woven glass fibre layer. Another, yet further intermediate layer 78 may
optionally
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be affixed to the lower side 58b of the core 58, and as such function as a
damping
or sound absorbing layer. Said intermediate layers 71, 78, 79 comprise at
least a
non-human collagen and/or leather, more preferably bonded leather. It is
conceivable that at least one, or all intermediate layers 71, 78, 79 comprise
a
layered structure having at least a carrier layer, onto which carrier layer
particles,
such as leather particles, are bonded by means of a binding material. It is
conceivable that said carrier layer may be composed out of a paper, fabric,
and/or
a polymer layer and may either be woven or non-woven. In order to adhere the
leather particles to said carrier layer, the binding material may partially
penetrate
into the carrier layer. At least one intermediate layer 71, 78, 79 may in
particular
comprise between 40-80% by weight of genuine leather fibres, preferably 60% of
genuine leather fibres, between 10-40% by weight of natural latex, preferably
20%
by weight of natural latex, preferably additionally between 5-25% by weight of
natural fat, preferably 10% by weight of natural fat, and preferably between 5-
20%
by weight of miscellaneous raw material, preferably 10% by weight of
miscellaneous raw material. Said raw material may as a non-limited example be
a
vegetable tanning agent, water, or the like.
The encircled portion, A, of the panel 57 is enlarged for the sake of clarity
to further
elucidate the structure of the layers 73, 74, 75, 76, 77 provided onto the
upper side
58a of the core 58. At least one carrier layer provided with leather particles
73
(which is a specific embodiment of the intermediate layer 71), as described
above,
is affixed directly onto the upper side 58a of the core 58. The carrier layer
with
leather particles 73 may optionally be referred to as a bonded leather layer
73. The
side of the carrier layer comprising the leather particles preferably faces
away from
said upper side 58a. A primer 74 is provided onto said carrier layer provided
with
leather particles 73. Preferably, said primer layer 74 partially penetrates
the
intermediate layer 71, 73, and a digital print layer 75 may as a result be
affixed
sufficiently to said intermediate layer 71, 73. However, optionally, it is
conceivable
that said print layer 75 is, preferably digitally, printed directly on top of
the
intermediate layer 71, 73 and/or primer layer 74. To protect the bonded
leather
layer 73 and the print layer 75 it is conceivable that at least one wear layer
76 is
provided over at least a part of the print layer 75, preferably covering
essentially the
entire panel 57. Although in this figure only one wear layer 76 is depicted,
the
skilled person would realise that a plurality of wear layers 76 may be
provided. A
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top coating 77 essentially entirely covers the wear layer 76, which top
coating 77
may for example be a lacquer or the like.
Although the intermediate layers 71, 78, 79 and the decorative top structure
72 are
only depicted in this particular figure, it may be realized that said layers,
either in
this particular non-limitative configuration or separately, may be applicable
to any of
the embodiments according to the preceding figures. That is, all the layers
elucidated in this figure, may be combined separately of one another in
various
embodiments according to the present invention.
The ordinal numbers used in this document, like "first", "second", "third",
and
"fourth" are used only for identification purposes. Hence, the use e.g. of the
expressions "third locking element" and "second locking element" does
therefore
not necessarily require the co-presence of a "first locking element". The
decorative
panels according to the invention may also be referred to as decorative tiles.
By
"complementary" coupling profiles is meant that these coupling profiles can
cooperate with each other. However, to this end, the complementary coupling
profiles do not necessarily have to have complementary forms. By locking in
"vertical direction" is meant locking in a direction perpendicular to the
plane of
the panel. By locking in "horizontal direction" is meant locking in a
direction
perpendicular to the respective coupled edges of two panels and parallel to or
falling together with the plane defined by the panels.
It will be apparent that the invention is not limited to the working examples
shown
and described herein, but that numerous variants are possible within the scope
of
the attached claims that will be obvious to a person skilled in the art.
The verb "comprise" and conjugations thereof used in this patent publication
are
understood to mean not only "comprise", but are also understood to mean the
phrases "contain", "substantially consist of", "formed by" and conjugations
thereof.
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