Patent Application
20210285227
This application claims priority to The Netherlands Patent Application No. 2025115 filed Mar. 12, 2020, the disclosure of which is hereby incorporated by reference in its entirety.
The invention relates to a decorative surface covering element, in particular a floor surface covering element, ceiling surface covering element or wall surface covering element. The invention also relates to a surface covering element covering, such as a floor covering, ceiling covering or wall covering, comprising a plurality of surface covering elements according to the invention. The invention further relates to a method of producing a decorative surface covering element according to the invention.
During the construction of a home, building or other structure, there will almost always be an unfinished floor surface such as a slab of concrete, a wood sub-structure or the like, which needs to be finished to offer a more appealing and/or polished appearance. This is also the case for most unfinished wall surfaces. In many cases, tiles will be used to finish either a floor surface or a wall surface, with the tiles often being made of real marble or stone, or depending on budgetary constraints, of porcelain or ceramic. Traditionally, such tiles are secured to the unfinished floor slab or wall surface using a cement-like mixture, with one or more tiles disposed closely next to each other, and leaving a small separation between the sides of adjacent tiles. Forming this separation between tiles is often tedious and requires the use of spacers to ensure uniformity and alignment of the tiles. Also, this separation will later be filled with a grout mixture as part of the installation process, which creates a “grout line” around the sides of the tiles. In general, the process of installing tile and creating the grout line involves a significant amount of time, which adds to the labor and overall cost of the project.
Over the last several years, flooring products and tiles have been made from synthetic materials and configured to imitate the look of a real tile of marble, stone or ceramic. For example, laminate and vinyl flooring products are known, including some that imitate the look of real stone, marble, or ceramic tiles. These flooring products create an optical or visual illusion so that the surface of the tile looks like real stone, marble or ceramic or even like real wood flooring. Traditionally, however, such flooring products are manufactured so as to require that the individual tiles be installed directly next to each other, often in abutting relation, although some of these products are installed with a slight separation between them to facilitate installation on uneven floor surfaces. While this slight separation may be observable and in some cases may appear as a small seam or even as a micro groove, these types of known tiles do not offer any structure to represent or closely resemble the look and feel of a real grout line. This is also true for most existing imitation flooring products having an interconnecting mechanism to facilitate installation, such as correspondingly disposed “tongue” and “groove” structures formed along a side of a tile. In more recent imitation flooring products imitation grout lines, also referred to as faux grout lines, are created by mechanically milling one of more side edges of the tile during production, wherein material of a top layer and an underlying decorative layer is removed to exposed an edge part of the core layer acting as faux grout line. However, this cut-away of material at the tile edge(s) is laborious and leads to dust waste which is undesired from an economic and health point of view. Moreover, by exposing the core to the atmosphere, and hence to moisture and temperature variations and fouling, during daily use may easily affect the core and therefore the tile (covering) as such.
It is a first object of the invention to provide an improved surface covering element having an improved bevel and/or grout line, in particular faux grout line.
It is a second object of the invention to provide an improved surface covering element having an alternative bevel and/or grout line, in particular faux grout line.
At least one of these objects can be achieved by providing a surface covering element according to the invention, 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 forming at least one décor image, a substantially transparent or translucent printed covering structure at least partially covering said decorative layer, wherein the printed covering structure comprises: a, preferably rectangularly shaped, printed center portion covering a, preferably rectangularly shaped, center portion of the decorative layer, and at least one printed peripheral portion adjacent to said center portion, and extending along a length of a side of the center portion, wherein said at least one peripheral portion covers at least one peripheral portion of the decorative layer, wherein the peripheral portion of the covering structure is recessed with respect to the center portion of the covering structure, and wherein the printed recessed peripheral portion of the covering structure represents a peripheral bevel and/or a peripheral grout line, in particular a peripheral faux grout line.
By printing a peripheral portion (edge portion) of the covering structure, either directly or indirectly, on a peripheral portion (edge portion) of the decorative layer, a three-dimensional bevel and/or grout line structure can be created, with improved freedom of design, and without having to cut-away material during the production process, which will prevent uncontrolled distribution of cut-away material (dust), which is advantageous from an economic, logistic, and health/safety point of view. Due to the increased freedom of design which is available during the printing process of the transparent and/or translucent ink, resin, or varnish onto the decorative layer, improved, and more realistic haptonomic (tactile) properties of the bevel and/or (faux) grout line can be obtained. Moreover, by printing the bevel structure and/or grout structure (formed by the peripheral portion of the covering structure) on top of the decorative layer, the decorative layer will remain in tact and can therefore contribute to the appearance of the bevel and/or (faux) grout line, which improves a realistic visual appearance of the bevel and/or (faux) grout line. The peripheral portion of the covering structure is recessed at least partially, and preferably entirely, recessed with respect to the center portion of covering structure. Hence, the average height, and often also the maximum height, of the peripheral portion of the covering structure, as measured from the decorative layer, is smaller than the average height, and often also the maximum height, of the center portion of the covering structure.
The (average) height of the center portion of the covering structure exceeds the (average) height of the peripheral portion of the covering structure, and wherein the printed peripheral portion of the covering structure represents a peripheral bevel and/or a peripheral grout line, in particular a peripheral faux grout line.
A bevel is typically a slanted and/or chamfered edge, which runs in downward direction in a direction away from the center portion of the covering surface. A bevel is typically used to make seams in between surface covering elements less visible and/or may be used to improve the decorative appearance of the surface covering element. A peripheral grout line, in particular a faux grout line, could include a bevel, and forms a recess, typically a channel or groove, at a peripheral edge (near the top surface) of the surface covering element, which closely resemble the look and feel of an actual grout line, and wherein the underlying decorative layer can be used to provide an improved depth effect and a more realistic visual appearance of the faux grout line. Said channel could have a concave cross-section, a rectangular cross-section, or a more complex cross-section. In addition to this, the printed center portion of the covering structure could also comprise at least one recessed channel representing an internal grout line, in particular an internal faux grout line. The use of one or more internal grout lines will optically the surface covering elements into a plurality of surface covering elements. The depth of the internal grout line is preferably substantially equal to the depth of the peripheral grout line. Preferably, the width of the internal grout line is substantially equal to the width of the peripheral grout line. In this case, there is no clear visual distinction between the peripheral grout line(s) (external grout line(s)) and the internal grout line(s). In case the printed center portion of the covering structure comprises a plurality of internal grout lines, typically formed by recessed channels, these grout lines could have different orientations and could, for example, intersect each other and/or could have a parallel orientation.
Typically, the height of at least a part of the printed peripheral portion of the covering structure decreases in a direction away from the printed center portion of the covering structure. This can, for example, be a gradual (continuous) decrease and/or a step-like decrease of the height. It is for example imaginable that a part of the peripheral portion of the covering structure, which is directly connected to the center portion of the covering structure, has a chamfered (inclined) top surface, acting like a bevel, while a more distant part of the peripheral portion of the covering structure could have a curved shape, and/or could have an orientation which is parallel and/or perpendicular to the plane defined by the core. Preferably, at least a part of the peripheral portion of the covering structure has a substantially flat top surface. Preferably, at least a part of the peripheral portion of the covering structure has a curved top surface. Preferably, at least a part of the peripheral portion of the covering structure has a top surface which is substantially parallel to a plane defined by the core. Preferably, at least a part of the peripheral portion of the covering structure has a textured top surface.
The covering structure is preferably an integrally formed covering structure, preferably formed during a single pass printing step. This means that both the peripheral portion(s) and the center portion of the covering structure are made out of the same layer. This will prevent the present of vulnerable and undesired seams in between each peripheral portion and the center portion of the surface covering element.
The transition between the center portion of the covering structure and the peripheral portion of the covering structure is preferably defined by a sharp edge. This sharp edge may for example enclose a 90 degrees angle, a 30 degrees angle, a 45 degrees angle, a 60 degrees angle, or any other angle between 0 and 90 degrees.
Preferably, the covering structure comprises a plurality of printed peripheral portions adjacent to the center portion of the covering structure, the peripheral portion extending along a length of different sides of the center portion, wherein at least one, and preferably each, peripheral portion covers at least one peripheral portion of the decorative layer. Here, it could be preferred that only two adjacent edges of the surface covering elements are provided with a printed peripheral portion. However, it is also imaginable that all edges, typically all four edges, of the surface covering element are provided with a printed peripheral portion of the covering element.
The maximum height difference between a lowest region of the peripheral portion of the covering structure and an highest region of the center portion of the covering structure is preferably situated between 200 and 800 micron, preferably between 200 and 500 micron. This restricted depth (height) saves material and facilitates the cleanability of the recessed peripheral portion during use.
The printed peripheral portion of the covering structure is preferably formed by at least one, at least partially cured layer provided with at least one indented zone, in particular a chemically embossed indented zone, extending in longitudinal direction of the peripheral portion, and/or at least one at least partially cured elevated pattern layer formed by at least one elevated zone extending in longitudinal direction of the peripheral portion. This printing process could be considered as a printing process where an embossed structure is created to eventually form the bevel(s) and/or the grout line(s). One could say that applying at least one, at least partially cured layer provided with at least one indented zone, in particular a chemically embossed indented zone, could be considered as a negative embossing step, as firstly a (initially liquid) base layer is applied which is position-selectively reduced in height in a subsequent step by means of mechanically pressing and/or by means of a reactive chemical substance. The application of at least one at least partially cured elevated pattern layer formed by at least one elevated zone can be considered as a positive embossing step, as an embossed structure is created (built), from bottom to top, onto, either directly or indirectly, the decorative layer. The elevated zone could be printed on the decorative layer. A combination of this negative embossing step and (successive) positive embossing step is also imaginable in order to form the peripheral portion(s) of the covering structure. The elevated zone could, for example, be printed on said at least partially cured layer provided with at least one indented zone.
Preferably, at least one peripheral portion of the decorative layer is provided with a different print compared to the print of the center portion of the decorative layer. This different print could for example be a different colour, for example grey, to imitate real grouts as realistic as possible. However, it is also imaginable that at least one peripheral portion of the decorative layer is provided with a darker (decorative) print compared to the (decorative) print of the center portion of the decorative layer. This darker print could lead to an enhanced depth effect, and therefore a more realistic
The center portion of the covering structure is preferably an embossed center portion. This will provide the center portion a three-dimensional structure, also referred to as embossing structure. The three-dimensional embossing structure preferably comprises one or more printed embossing layers, wherein each embossing layer is substantially composed of (embossing) ink, as will be elucidated below in more detail. Preferably, roughening of the texture of at least of part of the upper surface of the embossing structure is taking place when the embossing ink is partially cured, hence partially (still) soft, which allows the embossing ink to be mechanically deformed and/or mechanically treated relatively easily. Typically, the roughened texture is provided to at least a part of the upper surface of the embossing structure by means of mechanical interaction with said upper surface, preferably by making use of one or more (rotating) brush rollers, such as metal, in particular steel, brush rollers. During this mechanical treatment of at least a part of the upper surface of the embossing structure, material will be removed from and/or displaced of the initial embossing structure, leading to a roughening (sharpening) of the texture of the embossing structure. This roughening effect leads to a relief which comes closer to the look and feel of natural wood nerves, typically also having sharp edges rather than smooth, rounded edges, which improves the visual appearance and/or haptonomic (tactile) properties of the surface covering element according to the invention. In this context it has to be taken into account that a printed embossing structure provides infinite possibilities and flexibility to design a desired embossing structure, but the drawback and risk of this printed embossing structure is that this embossing structure is printed by using a liquid ink, which could relatively easily flow (to some extent) directly after printing, which easily leads to a more smooth (rounded) texture than intended. This drawback can be overcome by (mechanically) roughening the printed embossing—preferably soon/directly—after printing to get a more realistic embossing structure (embossing texture) and/or an embossing structure being more in line with the embossing structure as initially intended/desired. Typically, the roughened texture of the upper surface of the embossing structure comprises a plurality of adjacent (connecting), typically substantially flat, surface facets mutually enclosing angle. This lead to one or more sharp edges, which typically improves the look and feel of the surface covering element as experienced by a user. The roughened texture comprises a plurality of scratches and/or grooves. These can e.g. be realized by means of the mechanical brush, in particular a brush roller. It could be preferred that the recessed peripheral portion(s) of the covering structure is/are free any of (mechanically) roughened surface.
The surface covering element is preferably a board, a cladding, a sheet, a tile, or a panel, such as a floor panel, ceiling panel, wall panel, or furniture covering panel. These panels are typically square or rectangular. It is imaginable that surface covering element is a strip (or sheet) provided as a roll to be laid out by unrolling from said roll. The length of such a strip is typically between 4 and 30 meter. In the context of this document the expressions “surface covering element” and “panel” are interchangeable.
It is preferred in case the embossing structure (i.e. the embossed center portion of the covering structure) comprises at least one thixotropic agent. Typically this thixotropic agent makes part of the ink composition for forming the printed embossing structure. Thixotropy is a time-dependent shear thinning property. This allows the embossing ink used to build (at least a part of) the embossing structure to be thick or viscous under static conditions, wherein the viscosity of the ink will decrease upon exertion of mechanical pressure or force allowing the ink to flow and to be deformed more easily. After release of the mechanical pressure or force, the ink returns to a more viscous state. A possible ink composition to be used as embossing ink may comprise: a) at least one organic and/or water-based ink vehicle, (b) at least one ethanolamine compound, and (c) at least one color-imparting material, such as a pigment. The ethanolamine compound(s) is/are combined with the organic ink vehicle and pigment in sufficient concentration to provide a composition which exhibits desirable thixotropic properties as well as physical, chemical, and visual/colour characteristics suited to the intended application. The organic ink vehicles usable in ink compositions of the present invention include various (a) ink oils and (b) organic resins and/or combinations thereof. Examples of ink oils which are preferably used in the present invention include naphthenic ink oils. The ethanolamine thixotropic agents which may be used in the present invention include monoethanolamine, diethanolamine, and/or triethanolamine. Of these, triethanolamine is presently preferred for use as a thixotropic additive in oil and/or resin-based printing ink compositions. In addition to their ability to impart desirable rehological properties, the inclusion of ethanolamine compounds, such as TEA, within the ink compositions of the present invention has been found to bring about improved rub resistance of the applied printing ink. Such improvement in rub resistance is identified as an additional advantage to be gained by incorporating the ethanolamine compounds of the present invention into ink compositions used in applications wherein rub-off is a typical problem. The colour-imparting additives employable in ink compositions of the present invention include various pigments and/or pigment-containing pastes. Pre-dispursed pigment pastes generally comprise one or more colored pigments dispursed in a vehicle and/or solvent. The vehicle(s) employed in such pre-dispursed pigment paste may comprise one or more of the organic ink vehicles described herein as basic components of ink compositions of the present invention and/or other vehicles which differ from the above-described organic ink vehicles. The embossing ink compositions which may be used to realize a surface covering element according to the present invention may be prepared at room temperature without the addition of extraneous heat. Such printing ink compositions are known to exhibit desirable thixotropy as well as increased rub resistance. Other thixotropic agents that may be used in the embossing ink to be used are, for example fumed silica and/or clay-type thixotropic agents.
Preferably, the entire upper surface of the embossing structure is provided with a roughened texture. Preferably, each roughened part of the upper surface of the embossing structure is roughened a plurality of times, more preferably by applying a plurality of successive mechanical roughening actions. Each roughening action can roughen the surface of the embossing structure in the same direction, but it is also conceivable that at least two roughening actions treat the upper surface of the embossing structure in mutually different directions.
Preferably, the embossing structure (i.e. the embossed center portion of the covering structure) comprises: at least one, at least partially cured base layer provided with a plurality of indentations, and/or at least one at least partially cured elevated pattern layer formed by a plurality of elevations printed on top of said base layer. The roughened texture is provided both to at least a part of the base layer and to at least a part of the pattern layer. It is also conceivable that the peripheral portion(s) of the covering structure is/are provided with the same type of embossing.
The surface covering element according to invention preferably comprises a multi-layer embossing structure which comprises at least one negative embossing layer, wherein indentations (recesses) are applied in a base layer, and at least one positive embossing layer, wherein elevations (protrusions) are provided on top of said negative embossing layer. This results in a more pronounced (rough and hilly) embossing structure, wherein relatively deep embossings may be created, which leads to a more realistic appearance of the surface covering element as such. Due to the relatively deep embossings which may be created by applying the multi-level layered embossing structure, a more realistic light effect as well as a better depth effect can be obtained, wherein the colours of the decor image are typically better perceptible. Typically, an upper side of the base layer defines an embossing base level, and wherein the indentations and at least a part and/or at least a number of the elevations are situated at opposite sides of said embossing base level. It is also imaginable that the indentations and at least a part and/or at least a number of the elevations are situated at the same side of said base level.
Typically, a part of the base layer is provided with said plurality of indentations, and wherein another part of the base layer is free of indentations. Hence, in this embodiment, the base layer is merely partially embossed. The elevations, of at least a part thereof and/or a number thereof, are preferably printed on the part of the base layer which is free of indentations, which leads to an increased depth effect of the embossing structure as such.
It is imaginable that the plurality of indentations of the base layer forms a discontinuous and/or a continuous indentation pattern. It is also imaginable that the plurality of indentations of the base layers forms a regular indentation pattern. Typically, the indentation pattern to be realized is strongly, or even completely, dependent on at least one decor image of the decorative layer.
Preferably, the base layer is a printed base layer. This means that the base layer, initially in liquid state, is printed either directly or indirectly on top of the decorative layer. One or more indentations may be provided in the base layer when the base layer is still in liquid state and/or one or more indentations may be provided in the base layer during and/or after curing (solidifying) the base layer. Providing one or more indentations in the liquid base layer is preferably done by means of chemically embossing. To this end, preferably (small) droplets of an embossing liquid are position-selectively printed (sprayed) onto the liquid base layer to cause a chemical reaction between the material of the printed droplets and the still liquid base layer, wherein the subsequent reaction product changes the structure at this location of the base layer optically and/or haptically. Providing one or more indentations in the base layer during or after curing may be done by either chemical embossing (as described above) and/or by mechanical embossing e.g. by using a laser or particle beam, such as a water beam.
Preferably, the indentations provided in the base layer have a depth situated in between 2 micron and 100 micron, preferably situated in between 3 micron and 50 micron. Preferably, the elevations of the elevated pattern layer have a height situated in between 2 micron and 500 micron, preferably situated in between 3 micron and 300 micron. The total embossing depth is determined by the sum of the greatest indentation depth and the greatest elevation height. In case a plurality of base layers and/or a plurality of elevated pattern layers is applied, an increase of the total embossing depth can be achieved.
In a preferred embodiment, and if applied, at least a part of the indentations of the base layer of the center portion of the covering structure is aligned in register with at least a part of at least one decor image formed by the decorative layer, in particular the printed decorative layer. Preferably, and if applied, at least a part of the elevations of the elevated pattern layer of the center portion of the covering structure is aligned in register with at least a part of at least one decor image formed by the decorative print layer. More preferably, both at least a part of the indentations of the base layer is aligned in register with at least a part of at least one decor image formed by the decorative print layer and at least a part of the elevations of the elevated pattern layer is aligned in register with at least a part of at least one decor image formed by the decorative print layer. This leads to a dual embossing in register, also referred to a dual synchronised embossing. By applying such an alignment in register a very realistic and/or artistic design and appearance and tactile properties of the surface covering element can be realized. The decor image may be formed by a wood (nerve) pattern, such as an oak (nerve) pattern. It is also conceivable that the peripheral portion(s) of the covering structure is/are provided with the same type of (mono or dual synchronized) embossing in register. The embossed structure, in particular due to the roughened texture thereof, can match this wood (nerve) pattern, resulting in a very realistic look and feel appearance of the surface covering element according to the invention. However, instead of wood (nerve) patterns, it is well thinkable that the decor image represents another kind of pattern, such as, for example, a customized picture and/or a mosaic pattern or tile pattern. In case of a mosaic pattern or tile pattern, artificial tiles may be depicted which are aesthetically separated by one or more grouts. Here, the embossing structure applied may comprise a base layer having thicker layer parts covering the artificial tiles and thinner layer parts covering to one or more grouts. Here, it is also imaginable that elevations of the elevated pattern are predominantly or merely covering the artificial tiles and less or not at all the artificial tiles. In this manner, a realistic surface relief can be realized which is practically equal to the surface relief obtained when using real tiles and grouts.
It is imaginable that at least one additional decorative print layer is situated in at least one base layer and at least one elevated pattern layer. In this manner a multi-layer decorative pattern can be realized. This further increases the freedom of design of creating an decorative top structure including the embossing structure and the plurality of decorative layers, and this, for example, also allows to create a three-dimensional effect to the overall decor image(s). It is also imaginable that a coloured coating is provided in the indentations and onto the base layer. This coloured coating may be considered as additional decorative print layer.
Preferably, the grammage of the base layer is at least 40 g/m2, preferably at least 50 g/m2. Typically, the base layer is made of a radiation-curing material. Preferably, the base layer, at least in the initial liquid state, is made of at least one resin selected from the group consisting of: epoxy acrylates, polyester acrylates, polyether acrylates, amino acrylates, silicone acrylates, urethane acrylates, polyisoprene acrylates, polybutadiene acrylates and acrylate monomers. The term acrylates, also referred to as acrylic resin, includes both acrylate resins and methacrylate resins. The previously described resins are associated in that they polymerize and harden by virtue of the electromagnetic energy irradiated by e.g. a laser, typically a UV laser, an infrared source, and/or a mercury (Hg) light source. In a preferred embodiment, (meth)acrylate resin has a high solid content, for example equal to 20-30% by weight with respect to the weight of the resin, which typically leads to a desired volume increase of the base layer. Optionally, the base layer may comprise one or more photo-initiators to facilitate curing of the base layer. The (transparent and/or translucent) base layer may comprise fillers, such as (i) aluminium oxide, to increase the abrasion resistance thereof, (ii) talc to modify the rheology thereof, (iii) silica to reduce the brilliance thereof, calcium carbonate and/or (iv) other additives, such as rheology modifiers, and/or colorants. Optionally, the base layer may comprise silicones which are capable of increasing the depth of the embossing. Typically, silicones are added in an amount of 0.01-20% by weight of the base layer, preferably in an amount of 0.01% to 10%, more preferably in an amount of 0.01% to 2% by weight of the base layer. Suitable silicones include, for example, silicones, silicone polyethers, silicone acrylates, and silicone polyether acrylates.
Preferably, the base layer, at least in the initial liquid state, comprises propylidynetrimethanol, ethoxylated, esters with acrylic acid, and preferably also N-ethylamine, more preferably N-ethylethanamine. These products typically react with each other leading to an amine modified acrylic oligomer which can be polymerised by free radicals. And this latter property is used for radiation-curing of the base layer.
The base layer, at least in the initial liquid state, preferably comprises an epoxy acrylate oligomer, more preferably bisphenol A epoxy diacrylate. Bisphenol A epoxy diacrylate is a colourless liquid. This epoxy acrylate oligomer provides high gloss, imparts excellent reactivity and features outstanding chemical and mechanical fastness properties for the radiation-curable base layer.
Preferably, the base layer, at least in liquid state, comprises at least diacrylate, preferably at least one diacrylate chosen from the group consisting of: tricyclodecanedimethanol diacrylate; 1,6-hexanediol diacrylate; hexamethylene diacrylate; oxybis(methyl-2,1-ethanediyl) diacrylate; and 3-methyl 1,5-pentanediol diacrylate. These di-functional acrylic monomers are very reactive and are typically printed and/or sprayed, as embossing liquid (embossing ink), onto the original based layer (in liquid state) in order to create, position-selectively, indentations in the base layer. Droplets of this embossing ink can be applied onto the base layer in a very accurate manner, typically with a resolution of approximately 500-1,000 dpi (or more).
The grammage of the elevated pattern layer is at least 60 g/m2, preferably at least 70 g/m2. The grammage of the elevated pattern layer is preferably higher than the grammage of the base layer. The elevated pattern layer preferably comprises acrylic resin. More preferably, the elevated pattern layer, at least in liquid state, comprises biacrylate, preferably tripropylene glycol biacrylate. The elevated pattern layer can be printed and/or sprayed, position-selectively, onto the base layer. This printing process is preferably also executed in a very accurate manner, typically with a resolution of approximately 500-1,000 dpi (or more).
The covering structure is preferably at least partially covered by a lacquer layer (wear layer). The lacquer layer can comprise any suitable known abrasion-resistant material, such as an abrasion-resistant macromolecular material coated onto the layer beneath it, or a known ceramic bead coating. If the wear layer is furnished in layer form, it can be bonded to the layer beneath it. The wear layer can also comprise an organic polymer layer and/or inorganic material layer, such as an ultraviolet coating or a combination of another organic polymer layer and an ultraviolet coating. For example, an ultraviolet paint capable of improving the surface scratch resistance, glossiness, antimicrobial resistance and other properties of the product. Other organic polymers including polyvinyl chloride resins or other polymers such as vinyl resins, and a suitable amount of plasticizing agent and other processing additives can be included, as needed. In an embodiment of a surface covering element according to the invention, at least at least a part of the indentations of the base layer is left uncovered by the lacquer layer. In this manner, a further embossing effect (relief effect) can be achieved, and, moreover, glossy and matt areas may be created in this manner, which may further contribute to a desired aesthetical appearance of the surface covering element as such. Here, for example, in case the décor image is formed by artificial tiles separated by grouts, the artificial tiles may be covered by the lacquer layer to provide these tiles a glossy effect, while the grouts are left substantially uncovered by the lacquer layer to maintain a more matt appearance.
It is imaginable that at least a part of at least one decorative layer is printed, preferably digitally printed, directly onto the upper side of the core. It is also imaginable that the upper side of the core is provided with at least one carrier layer, preferably formed by at least one primer or a film, wherein at least a part of the decorative layer is printed, preferably digitally printed, directly onto the carrier layer. The carrier layer can be affixed directly or indirectly (via one or more intermediate layers) onto the core. In case a primer is applied, then it is imaginable to apply at least two different primers, such as a glossy primer and a matt primer, which are position-selectively applied, side by side (adjacently), onto the core, preferably aligned in register with the decorative print layer to be applied on top of said primers. Also in this manner, a glossy effect and a matt effect can be realized at position-selective locations which can further contribute to a desired, realistic and/or artificial look (and feel) of the surface covering element as such. Alternatively, though this is commonly less preferred, a paper layer or thermoplastic film provided with a déor image may act as decorative layer. This separate layer will typically have to be attached first, either directly or indirectly, to the core, after which the covering structure is applied.
In an embodiment of the surface covering element according to the invention, in between the printed decorative layer and the covering structure at least one intermediate layer is situated. This intermediate layer is normally transparent, preferably very transparent, and/or translucent. Preferably, at least one intermediate layer is formed by a transparent or translucent, light-reflective thermoplastic layer, preferably a polyester layer, more preferably a polyethylene terephthalate layer (PET layer). This light-reflective thermoplastic layer acts as protective layer to protect the déor image against degradation due to exposure to daylight (or artificial light). Moreover, this light-reflective thermoplastic layer also prevents heating of the surface covering element due to exposure to daylight (or artificial light) and therefore counteracts thermal action (expansion and shrinkage), which is in favour of the durability and reliability of both the surface covering element as such and a floor covering consisting of a plurality of, preferably mutually coupled, surface covering elements. The light-reflective thermoplastic layer is preferably glued onto the printed decorative layer, more preferably by using a hot melt glue. The base layer may be applied directly on top of the light-reflective thermoplastic layer.
Typically, a backing layer is affixed to a lower side of the core. Non-limiting examples of materials whereof the backing layer can be made of are polyethylene, cork, polyurethane and ethylene-vinyl acetate. The thickness of a polyethylene backing layer is for example typically 2 mm or smaller. The backing layer commonly provides additional robustness and impact resistances to each tile as such, which increases the durability of the tiles. Moreover, the (flexible) backing layer may increase the acoustic (sound-dampening) properties of the surface covering element.
In a preferred embodiment, a first panel edge (a first surface covering element edge) comprises a first coupling profile, and a second panel edge (a second surface covering element 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 surface covering element, both in horizontal direction and in vertical direction, wherein the first coupling profile and the second coupling profile are preferably configured such that two of such surface covering elements can be coupled to each other by means of a lowering movement (fold-down movement). In case the surface covering element is rectangular, then the first panel edge and second panel edge are typically situated at opposite short edges of the surface covering element. The surface covering element 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 profile of an adjacent surface covering element, 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 surface covering elements 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 surface covering element is inserted into the third groove of an adjacent, second surface covering element, and wherein at least a part of the upward locking element of said second surface covering element is inserted into the second downward groove of said first surface covering element.
The core may be flexible, semi-rigid or substantially rigid. The core may be solid or at least partially foamed. 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 (PIR), or mixtures thereof. 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 non-polymeric material. The at least one non-polymeric material is preferably selected from the group consisting of: talc, chalk, wood, calcium carbonate, and a mineral filler. The core may comprise magnesium oxide and/or magnesium hydroxide. The upper side of the core is preferably substantially flat.
The invention also relates to a surface covering element covering, such as a panel covering, in particular floor covering, ceiling covering, or wall covering, consisting of a plurality of, preferably mutually coupled, surface covering elements according to the invention. Here, it is imaginable that at least two surface covering elements have a distinctive decor image, wherein each decor image represents a partial image, and wherein the combination of said déor images together form a single image (picture or photo). This single image may continue within the peripheral portion(s) of the covering structure, or may—if desired—be interrupted within said peripheral portion(s).
The invention further relates to a method of producing a decorative surface covering element according to the invention, comprising the steps of: A) forming at least one decorative layer onto the upper side of the core by means of printing, preferably digital printing, B) applying a liquid base layer on at least a part of at least one déor image formed during step A) to form a center portion and at least one peripheral portion of the covering structure, position-selectively printing of a plurality of embossing droplets on the still liquid base layer in a manner, that the thickness of the base layer changes on the positions where the embossing droplets are spayed on, such that at these positions indentations are formed in the liquid base layer, and such that the average height of the center portion of the covering structure exceeds the average height of the peripheral portion of the covering structure, wherein the printed peripheral portion of the covering structure is formed as peripheral bevel and/or a peripheral grout line, in particular a peripheral faux grout line, C) at least partially curing said base layer provided with said indentations, D) optionally, position-selectively printing an elevated pattern layer formed by a plurality elevations on at least a part of the covering structure, preferably after at least partially curing of the covering structure during step C), and partially curing said pattern layer, wherein said base layer and said pattern layer, if applied together form the embossed covering structure, and E) optionally mechanically treating at least a part of the upper surface of the embossed covering structure to provide a roughened texture to the embossed structure.
During step E) material is preferably removed from and/or deformed of the embossing structure. In order to keep the base layer sufficiently hard (rigid) to prevent easy flow and to keep the base layer sufficiently soft to allow easy roughening of the base layer, it is advantageous in case during step C) and/or step D) between 60 and 90% of the base layer is cured. The same applies to the pattern layer. During step E), preferably at least a part of the upper surface of the covering structure is treated by using at least one axially rotating brush roller, preferably a metal brush roller, in particular a steel brush roller. The rotation speed of these rollers may vary, but is preferably between 400 and 800 revolutions per minute. The diameter of the roller may vary, but is preferably situated between 20 and 40 centimeter. Preferably, during step E) at least a part of the upper surface of the embossing structure is treated at least two times by using at least two successive axially rotating brush rollers, preferably metal brush rollers, in particular steel brush rollers. Preferably, during step E) at least two brush rollers are rotated in opposite directions. Preferably, each roller is accommodated in an individual or shared cage or housing to prevent uncontrolled distribution of cut-away material (dust), and more preferably this cage or housing is connected to a vacuum exhaust conduit to remove as much as cut-away material as possible during the brushing action.
It is advantageous in case the method comprises step F) comprising the step of mechanical cleaning the surface covering element, in particular the embossing structure, subsequent to executing step E). This cleaning action according to step F) can be performed mechanically, for example by means of a cleaning brush, in particular a cleaning brush roller, such as a textile roller and/or a nylon roller. This cleaning action is normally primarily applied in order to remove (evacuate) cut-away material (dust) from the embossing structure during step E).
Preferably, the method comprises step G) comprising the step of cutting the surface covering element into a plurality of smaller surface covering elements, like for example planks or panels. During step B), preferably at least one shared peripheral portion is created which is enclosed by at least two center portions of two surface elements to be formed, and wherein during step G) each shared peripheral portion is cut along its length to form a plurality of surface covering elements each having at least one peripheral portion located at its side edge(s
Preferably, the method comprises step H) comprising the profiling at least one edge of at least one surface covering element and/or at least one panel or plank formed during step G).
Further advantages and embodiments of the surface covering element have been discussed above already in an extensive manner. During step C) the embossing droplets are preferably printed onto the liquid base layer according to a first digital template, which is aligned in register with at least a part of at least one déor image formed during step A). During step D) the elevated pattern is preferably printed onto the base layer according to a second digital template, which is aligned in register with at least a part of at least one déor image formed during step A). More preferably, the first digital template differs from the second digital template. Preferably, curing of the base layer according to step C) and/or curing of the pattern layer according to step D) is performed of radiation curing, preferably by means of UV radiation and/or electron radiation and/or IR radiation and/or monochromatic radiation. Step A), and/or step B), and/or step D) may be performed by using one of more digital printers, in particular inkjet printers.
The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures:
Hence, the above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.
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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2025115 | Mar 2020 | NL | national |
