Patent Grant
11377855
The present application claims the benefit of Swedish Application No. 1950364-8, filed on Mar. 25, 2019. The entire contents of e Swedish Application No. 1950364-8 are hereby incorporated herein by reference in their entirety.
The disclosure generally relates to a mineral-based panel. More specifically, the disclosure relates to a mineral-based panel comprising a mineral-based core, wherein the panel comprises at least one groove, preferably a plurality of grooves. The disclosure also relates to a method for forming such grooves in a mineral-based panel. The mineral-based panel may be a building panel, floor panel, wall panel, ceiling panel or furniture panel. Optionally, the panel may comprise a locking system on at least one edge portion of the panel, preferably on two opposite edge portions of the panel. The disclosure also relates to a locking system in a mineral-based panel comprising a mineral-based core and polymer-based lower layer(s).
There is an increased demand for boards, such as floor boards, that are sustainable and in particular recyclable. There is also a need for fire resistant and water resistant boards, especially those that may maintain or even improve the properties that typically are associated with the boards, such as their dimensional stability under temperature variations of the ambient temperature and/or under moisture variations and, optionally, their flexibility.
Examples of such boards are magnesium oxide boards and cement boards or fibre cement boards. For example, a magnesium oxide board may have a layer structure attached thereto, such as comprising HPL panel.
However, such boards are still typically relatively heavy and there is need for improvements. Moreover, there is need for more robust locking systems for such, and similar, boards.
It is therefore an object of at least embodiments of the present inventive concept to provide a mineral-based panel having a reduced weight and/or material content.
It is also an object of at least embodiments of the present inventive concept to reduce cost in producing such panels.
Additionally, it is an object of at least embodiments of the present inventive concept to provide a method for forming such grooves in a mineral-based panel.
It is also an object of at least embodiments of the present inventive concept to regulate, such as improve, sound properties of the mineral-based panel.
Another object of at least embodiments of the present inventive concept is to provide an improved locking system for a mineral-based panel.
At least some of these and other objects and advantages that will be apparent from the description have been achieved by the various aspects described below.
In accordance with a first aspect of the inventive concept, there is provided a mineral-based panel, such as a floor panel, comprising a mineral-based core, wherein the panel comprises at least one groove, preferably a plurality of grooves.
The mineral-based panel may be a floor panel, a building panel, a wall panel, a ceiling panel or a furniture panel.
The panel may comprise a front side and a rear side. The front side may be a visible side of the panel and the rear side may be concealed in an installed state of the panel, such as facing a subfloor, a subroof or a subwall.
A thickness of the panel may be 2-40 mm, such as 4-12 mm or 2-10 mm. For example, a floor panel may have a thickness of 2-10 mm. A groove length of each groove may be larger than 5 mm, preferably larger than 50 mm.
The mineral-based panel may be a cementitious panel comprising cement. For example, the mineral-based core, or core for short, may be a cementitious core.
The cementitious panel or core may comprise non-hydraulic cement. The non-hydraulic cement may comprise magnesium oxide, and optionally magnesium chloride (e.g. MgCl2) and/or magnesium sulphate (e.g. MgSO4). For example, the non-hydraulic cement may comprise or may be Sorel cement.
The cementitious panel or core may comprise hydraulic cement. The hydraulic cement may comprise silicates, such as calcium silicates, and optionally oxides. For example, the cement may be fibre cement, such as comprising or being Portland cement.
The at least one groove may be provided in a rear side of the panel.
The at least one groove may be provided in a lower side of the mineral-based core.
The at least one groove may be provided in an upper side of the mineral-based core.
The mineral-based core may comprise magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate.
The mineral-based core may comprise gypsum or may be a gypsum board. This may be particularly advantageous for a wall panel or a ceiling panel.
The mineral-based core may comprise an inorganic matrix material. For example, the inorganic matrix material may comprise magnesium oxide, cement, such as hydraulic or non-hydraulic cement, or gypsum, preferably in an amount of at least 20 wt %, such as at least 30 wt %.
Generally, the core may further comprise at least one selected from the group of a filler, such as an organic and/or inorganic filler, additive(s) and a binding agent. The filler may be a functional filler. For example, the functional filler may reinforce the core, improve the bonding to a, preferably inorganic, matrix material of the core, increase a rigidity of the core, etc.
The core may comprise organic material, such as at least one selected from the group of wood fibres, cellulose fibres, natural fibres, carbon fibres, and bamboo.
The core may comprise inorganic material, such as calcium carbonate, fly ash, silica, or perlite.
The mineral-based core may comprise cement.
The mineral-based core may comprise reinforcing material, such as fibre reinforcement. The fibre reinforcement may be organic, such as comprising cellulose fibres or wood fibres, or inorganic, such as comprising glass fibres.
The mineral-based core may be a cement board, such as a fibre cement board.
Generally, a density of the mineral-based core, for example comprising magnesium oxide or cement, may be between 1000 and 2000 kg/m3, such as between 1200 and 1700 kg/m3. A larger density may provide a larger rigidity and/or a larger flexural rigidity of the core.
The mineral-based panel may further comprise a lower arrangement comprising at least one lower layer which is attached to a lower side of the mineral-based core.
The at least one groove may be at least partly provided in the lower arrangement, such as the at least one groove fully penetrating at least one lower layer of the lower arrangement.
At least two lower layers may be attached together by means of an adhesive or may be laminated together, or a combination thereof. The adhesive may be compatible with the materials of the attached layers.
In a first example, the lower arrangement may be attached to the core by means of an adhesive. In a second example, the lower arrangement may be laminated to the core.
The lower arrangement may comprise a backing layer, which preferably is a bottommost layer of the lower arrangement. The backing layer may impact the balancing properties and/or the stability of the panel.
The material content of any, some or each lower layer may be the same as in the core, whereby reference is made to the above.
In any of the embodiments herein, a density of at least one lower layer, such as all lower layers, in the lower arrangement may be larger than a density of the mineral-based core. Generally, the density may be between 1100 and 2100 kg/m3, such as between 1300 and 1400 kg/m3.
At least one lower layer in the lower arrangement, preferably all lower layers, may comprise magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate. Each such lower layer may comprise an inorganic matrix material. For example, the inorganic matrix material may comprise magnesium oxide, cement, such as hydraulic or non-hydraulic cement, or gypsum, preferably in an amount of at least 20 wt %, such as at least 30 wt %.
At least one lower layer in the lower arrangement, preferably all lower layers, may comprise cement.
The at least one lower layer may be a cement board, such as a fibre cement board.
The lower arrangement may comprise at least one polymer-based layer, such as at least one thermoplastic layer, for example comprising polyvinyl chloride (PVC), polyethylene (PE), thermoplastic polyurethane (TPU), polypropylene (PP), polyethylene terephthalate (PET), polyolefin copolymers or acrylonitrile butadiene styrene (ABS), or at least one thermosetting layer, for example comprising a melamine-formaldehyde resin, or melamine resin for short, epoxy resin, preferably crosslinked with an amine hardener, polyurethane (PU), polyurea or acrylate polymers.
The lower arrangement may comprise at least one wood-based layer or cellulose-based layer, such as a veneer, paper, such as impregnated paper, preferably paper impregnated with a melamine resin, solid wood layer, MDF layer, HDF layer, layer of Direct Pressure Laminate (DPL) or High Pressure Laminate (HPL), or particle board layer.
The mineral-based panel may further comprise an upper arrangement comprising at least one upper layer and which is attached to an upper side of the mineral-based core.
At least two upper layers may be attached together by means of an adhesive or may be laminated together, or a combination thereof. The adhesive may be compatible with the materials of the attached layers.
In a first example, the upper arrangement may be attached to the core by means of an adhesive. In a second example, the upper arrangement may be laminated to the core.
In any of the embodiments and examples herein, the adhesive attaching a first structure to a second structure, may be a polyurethane, silane-terminated epoxy resin, or silane-terminated polyurethane. Any of these may be two component. Moreover, the adhesive may be a non-reactive or reactive hot-melt adhesive, for example being based on polyurethane or polyolefin. More generally, the adhesive may be a two-component adhesive. Preferably, the adhesive is moisture resistant and/or heat resistant.
The material content of any, some or each upper layer may be the same as in the core, whereby reference is made to the above.
In any of the embodiments herein, a density of at least one upper layer, such as all upper layers, in the upper arrangement may be larger than a density of the mineral-based core. Generally, the density may be between 1100 and 2100 kg/m3, such as between 1300 and 1400 kg/m3.
At least one upper layer in the upper arrangement, preferably all upper layers, may comprise magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate. Each such upper layer may comprise an inorganic matrix material. For example, the inorganic matrix material may comprise magnesium oxide, cement, such as hydraulic or non-hydraulic cement, or gypsum, preferably in an amount of at least 20 wt %, such as at least 30 wt %.
At least one upper layer in the upper arrangement, preferably all upper layers, may comprise cement.
The at least one upper layer may be a cement board, such as a fibre cement board.
The upper arrangement may comprise at least one polymer-based layer, such as at least one thermoplastic layer, for example comprising PVC, PE, TPU, PP, PET or ABS, or at least one thermosetting layer, for example comprising a melamine-formaldehyde resin, epoxy resin, preferably crosslinked with an amine hardener, PU, polyurea or acrylate polymers.
In a first example, the upper and lower arrangements may comprise the same polymer-based material compositions, such as being provided with the core in an ABA layered structure. In a second example, the upper and lower arrangements may comprise different polymer-based material compositions, such as being provided with the core in an ABC layered structure. For example, the core (“layer B”) may comprise magnesium oxide and the upper and lower arrangements may each comprise a thermoplastic material and, preferably, a filler.
The upper arrangement may comprise at least one wood-based layer or cellulose-based layer, such as a veneer, paper, such as impregnated paper, preferably paper impregnated with a melamine resin, solid wood layer, MDF layer, HDF layer, or particle board layer.
The at least one polymer-based layer of the upper and/or lower arrangement(s) may comprise plasticized and/or flexible layer(s), such as being a Luxury Vinyl Tile (LVT) panel or an LVT sheet. Alternatively, the at least one polymer-based layer of the upper and/or lower arrangement(s) may comprise rigid layer(s), such as being a Stone Plastic (Polymer) Composite (SPC) panel or an SPC sheet.
The at least one polymer-based layer of the upper and/or lower arrangement(s) may be a powder-based layer comprising a thermosetting resin, optionally further comprising at least one veneer layer.
The at least one wood-based or cellulose-based layer of the upper and/or lower arrangement(s) may be a high-pressure laminate (HPL) panel.
The at least one wood-based or cellulose-based layer of the upper and/or lower arrangement(s) may be a powder-based separate surface layer (SSL) as described in WO 2009/065769 A2. For example, the SSL layer may have a thickness of about 0.3-3.0 mm. The surface layer may have a high density and impact resistance even if it is combined with rather soft core materials.
In some embodiments, the upper arrangement may comprise at least one ceramic tile, for example attached to a carrier layer of the upper arrangement or to the core by an adhesive.
The upper arrangement and/or the lower arrangement(s) may be rigid. For example, the upper arrangement and/or the lower arrangement(s) may be more rigid than the core.
At least one upper and/or lower layer may comprise a filler. The filler may be a filler, such as a functional filler, in complete analogy with any of the embodiments of the filler of the core described elsewhere herein.
The upper arrangement and/or the lower arrangement(s) may be soft. For example, the upper arrangement and/or the lower arrangement may be softer than the core. In any embodiment of the upper and/or lower arrangement(s), any, some or all lower and/or upper layer(s) may comprise a plasticizer. This may be particularly relevant for thermoplastic layers. If so, an adhesive which is compatible with a plasticizer may be preferred.
In a first example, the upper and/or lower arrangement(s) may be balanced per se. Thereby, a balanced panel may be obtained. In a second example, the panel may be balanced by providing a lower and an upper arrangement.
The at least one groove may be provided in the core, wherein the core is provided between an upper and a lower arrangement. For example, the upper and a lower arrangement may each comprise a polymer-based material, such as a thermoplastic material and, preferably, a filler.
The mineral-based panel may further comprise a top structure provided on, such as attached to, an upper side of the mineral-based core or provided on, such as attached to, an upper arrangement of the mineral-based panel, the top structure preferably comprising a décor layer.
The top structure may comprise or may be a top layer.
The décor layer may comprise a printed décor, such as a digitally printed décor. For example, the printed décor may be provided directly on the upper side of the core or directly on the upper arrangement. Optionally, a primer, such as a UV primer, may be provided on the core or the upper arrangement under the printed décor.
The décor layer may comprise a print film.
The top structure may comprise a coating layer, such as a UV curable coating layer, a lacquer or a hot-melt coating layer, and/or a wear layer, such as comprising aluminium oxide, a thermoplastic film, or a thermosetting resin, such as a melamine resin. The thermoplastic film may comprise PVC, PU, TPU or PET.
In a first example, the coating layer and/or wear layer is provided on the upper arrangement, optionally comprising a décor layer. In a second example, the coating layer and/or wear layer is provided on the mineral-based core, optionally comprising a décor layer.
The mineral-based panel may further comprise a cover layer. The cover layer may at least partly, preferably completely, cover the grooves. The cover layer may be attached to a lower side of the core or to the lower arrangement, such as a lowermost lower layer thereof.
Preferably, the cover layer is continuous and thereby does not comprise any openings or grooves. However, it is equally conceivable that the cover layer is discontinuous, such as comprising openings.
For example, the cover layer may be a flexible layer, such as a foam layer. In non-restrictive examples, the cover layer may comprise an irradiated cross-linked polyethylene (IXPE) foam, Ethylene Vinyl Acetate (EVA) foam, foam rubber, cork, a natural material, or Polyurethane (PU) foam.
The mineral-based panel may further comprise at least one reinforcement layer, such as a glass-fibre layer. Generally, at least one woven or nonwoven reinforcement layer may be used.
The at least one reinforcement layer may be a metal-based layer, such as a mesh, for example comprising steel. This may be particularly advantageous for a panel, such as a core, comprising cement.
Any, some or each of the at least one reinforcement layer may be a mesh, such as a glass-fibre mesh.
At least one reinforcement layer may be provided between the core and an upper arrangement of the panel and/or between the core and a lower arrangement of the panel.
The at least one reinforcement layer may be provided in the mineral-based core, for example in a centre portion of the core.
At least one reinforcement layer may be positioned in a top portion and/or a bottom portion of the mineral-based core. In a first example, at least one reinforcement layer may be positioned a distance from an upper and/or a lower side of the core which is less than ⅙, preferably less than ⅛, more preferably less than 1/16, of a thickness of the core. In a second example, at least one reinforcement layer may be positioned a distance from an upper and/or a lower side of the core which is less than 2 mm, such as less than 1 mm. A thickness of the core may be 2-40 mm, such as 4-12 mm or 2-10 mm. In a third example, at least one reinforcement layer may be positioned essentially at the upper and/or lower side of the core.
Alternatively or additionally to reinforcement layers, the core may comprise reinforcing material, such as fibre reinforcement or, more generally, separate reinforcement particles. The fibre reinforcement may be organic, such as comprising wood fibres or cellulose fibres, or inorganic, such as comprising glass fibres.
The at least one reinforcement layer may be provided in the upper and/or the lower arrangement(s).
The at least one groove may be provided spaced from, such as below, the at least one reinforcement layer. Thereby, the at least one reinforcement layer may be left intact. In some embodiments, however, the at least one groove may be provided through the at least one reinforcement layer.
In some embodiments, the core or a lower layer, such as a bottommost layer, of the lower arrangement may comprise separate reinforcement particles and the at least one groove may be provided in the lower layer or the core only. For example, the at least one groove may be provided below each of the at least one reinforcement layer. Thereby, the panel may be reinforced while reducing the weight of the panel.
The at least one reinforcement layer may be positioned in a top portion and/or a bottom portion of any lower layer and/or upper layer. The first, second and third examples described above in relation to the core are valid also for the lower layer and/or upper layer, whereby reference is made thereto.
Generally, any, some, or all of the lower and/or upper layer(s) in any of the embodiments described herein may comprise reinforcing material, such as fibre reinforcement or, more generally, separate reinforcement particles. The fibre reinforcement may be organic, such as comprising cellulose fibres or wood fibres or cellulose fibres, or inorganic, such as comprising glass fibres. Moreover, the lower and/or upper arrangement(s) may comprise sound-dampening fillers. Alternatively, or additionally, the core may comprise sound-dampening fillers.
In some embodiments, such as when the panel is a floor panel, the panel may be configured to be installed in a floor system, such as a floating floor system. In some embodiments, no horizontal or vertical mechanical locking system may be provided in the panel. For example, the panel may be configured to be nailed or glued to a subfloor. In another example, the panel may be configured to be installed loosely on a subfloor without any mechanical locking system.
In some embodiments, the panel, such as a floor panel or a wall panel, may comprise a locking system and may be configured to be locked to an adjacent panel by angling of the panel and/or by a vertical displacement V of the panel, such as a so-called fold-down system.
In some embodiments, the panel, such as a floor panel or a wall panel, may comprise a locking system comprising a tongue and groove configuration and/or may be configured to be locked to other panels by separate clips.
In some embodiments, the panel, such as a ceiling panel, may be configured to be installed in a grid of profiles.
The vertical locking system, such as on long and/or short edge portions, may be integrally formed with the panel.
The mineral-based panel may further comprise a locking system, such as a mechanical locking system, for horizontal and/or vertical locking. Thereby, the panel may be locked to adjacent panels of a similar type.
The locking system may be a locking system on a first pair and a second pair of opposite edge portions of the panel, the first pair preferably comprising long edge portions of the panel and the second pair preferably comprising short edge portions thereof.
Any horizontal locking system may comprise a locking element and a locking groove, and/or any vertical locking system may comprise a tongue and a tongue groove. Alternatively, or additionally, the locking element and locking groove may comprise vertical locking surfaces configured to cooperate for vertical locking. In a first example, the tongue is integrally formed with the panel, preferably with the core. This is conceivable on a long and/or a short edge portion. In a second example, and as preferred on a short edge portion, the tongue is separately formed from the panel, and may be provided in a displacement groove provided in the panel, preferably in the core.
The mineral-based panel may comprise a plurality of grooves, wherein at least two grooves have different characteristics, such as groove depths and/or groove widths. Alternatively, or additionally, a cross-sectional shape and/or a groove length of at least two grooves may be different.
In some embodiments, at least two grooves, preferably all grooves, have the same characteristics, such as groove depths and/or groove widths. Alternatively, or additionally, a cross-sectional shape and/or a groove length of the at least two grooves may be the same.
In any of the embodiments herein, a groove depth may be at least 0.2, such as 0.3, preferably 0.4, times a thickness of the panel.
The at least one groove may comprise an opening having a groove width that is larger than a groove width of an inner part of the at least one groove.
The at least one groove may be provided in an interior of the panel, such as in the rear side of the panel, thereby being spaced from a pair of opposite edge portions, such as opposite short edge portions, of the panel, preferably being spaced from all edge portions of the panel.
The at least one groove may be provided inwardly of a locking system on a first pair and/or a second pair of opposite edges of the panel. For example, a groove length of at least one groove, preferably all grooves, may be smaller than a distance between the locking systems at opposite short edge portions.
The at least one groove may extend to at least one edge portion, such as two edge portions, of a pair of opposite edge portions, such as opposite short edge portions, of the panel. For example, the at least one groove may extend to an edge portion comprising a locking groove.
At least one groove may be provided below an underside of an edge portion comprising a locking groove.
A shape of one or both end portions of the at least one groove along its longitudinal direction may be curved.
One end portion or both end portions may be parallel with a front side of the panel, preferably such that they intersect at least a portion of the strip and/or at least a portion of the locking groove.
The panel may be rectangular with long edge portions and short edge portions, wherein the at least one groove, such as its longitudinal direction, is parallel with the long edge portions.
The panel may be rectangular with long edge portions and short edge portions, wherein the at least one groove, such as its longitudinal direction, is parallel with the short edge portions.
The at least one groove may be continuous, preferably being parallel with long edge portions of the panel.
The at least one groove may be discontinuous, preferably being parallel with long edge portions of the panel.
The mineral-based panel may comprise at least two groove arrangements, such as a plurality of groove arrangements, wherein adjacent pairs of groove arrangements preferably are separated by a separation portion.
An area of the of a surface in which the at least one groove is provided, such as the rear side or the lower and/or upper side of the core, may be less than 90%, such as less than 80%, of an area of a front side of the panel. Alternatively, or additionally, a volume of the groove(s) may be at least 5 vol %, such as at least 10 vol %, preferably 5-30 vol %, such as 10-20 vol %. The volume may be a volume occupied by the groove(s) within the panel, such as being limited by a horizontal plane provided along the rear side. When the grooves are internal grooves, preferably being provided in the core, the volume may be a volume occupied by the grooves within the panel.
In accordance with a second aspect of the inventive concept, there is provided a set of panels comprising a plurality of panels in accordance with any of the embodiments or examples of the first aspect. The details and advantages as well as embodiments and examples of the second aspect are largely analogous to those of the first aspect, wherein reference is made thereto.
In accordance with a third aspect of the inventive concept, there is provided a method for forming at least one groove in a mineral-based panel, such as a floor panel, comprising: arranging the panel on a support member, and forming at least one groove in the panel by removing material, such as chips, from the panel. The details and advantages as well as embodiments and examples of the third aspect are largely analogous to those of the first aspect, wherein reference is made thereto. In addition, at least the following embodiments are conceivable.
The at least one groove may be provided in a rear side of the panel.
The at least one groove may be formed by rotational processing with at least one tooth element, such as by a rotating cutting device.
The at least one groove may be formed by non-rotational processing with at least one tooth element, such as by carving, preferably using a carving tool.
The method may further comprise forming a locking system, such as a mechanical locking system, for horizontal and/or vertical locking of the mineral-based panel.
In accordance with a fourth aspect of the inventive concept, there is provided a mineral-based panel, such as a floor panel, comprising a mineral-based core and a lower arrangement comprising at least one polymer-based lower layer, wherein the lower arrangement is attached to a lower side of the mineral-based core. The mineral-based panel further comprises a locking system for horizontal and/or vertical locking, wherein the locking system comprises a strip extending horizontally beyond an upper portion of the mineral-based panel. At least a horizontal portion of the strip is entirely formed in the lower arrangement.
Thereby, especially when, but not limited to, the polymer-based lower layer is a thermoplastic layer, the strip may become more flexible. A risk of damaging or breaking the strip during locking of the panel to an adjacent panel may be reduced. Additionally, the locking system and hence the panel may become more resistant to heavy loads. It is emphasized that the fourth aspect is equally applicable to a panel without any groove(s) being formed therein.
The strip may extend from vertical plane VP defined by immediately juxtaposed upper portions of two neighboring joint edge portions of two joined panels. The strip may be a strip at a short edge portion and/or at a long edge portion. Optionally, the strip may comprise a lower panel portion provided below the tongue groove.
The horizontal portion may extend along a first and/or a second horizontal direction of the mineral-based panel and may have a vertical extension, such as extending from a rear side of the panel to an upper surface of the strip.
The strip may comprise a locking element. Preferably, the horizontal portion is at least provided horizontally inwardly of the locking element.
The horizontal portion may comprise the entire strip, preferably including a locking element.
The locking element may comprise a portion of the mineral-based core, such as at a distal end portion of the locking element. The distal end portion may be a vertical distal end portion.
A horizontal and/or a vertical locking surface may be provided in the lower arrangement.
Alternatively, or additionally, a horizontal and/or a vertical locking surface may be provided in the upper arrangement, which preferably also comprises at least one polymer-based layer, such as a thermoplastic layer. Thereby, by analogy with the discussion above, the portion of the panel comprising said vertical locking surface may become more flexible and consequently more resistant to damage or breaking, etc.
The horizontal locking system may comprise a locking element and a locking groove and/or the vertical locking system may comprise a tongue and a tongue groove. Hence, a horizontal locking surface may be provided on the locking element and locking groove and/or a vertical locking surface may be provided on the tongue and tongue groove. Alternatively, or additionally, the locking element and locking groove may comprise vertical locking surfaces configured to cooperate for vertical locking.
Generally, a locking surface may be configured to lock two adjacent panels in one direction. Therefore, the horizontal and vertical locking system preferably comprises at least a pair of horizontal locking surfaces and at least a pair of vertical locking surfaces be configured to lock two adjacent panels in two opposite horizontal and vertical directions, respectively. In some embodiments, the horizontal and vertical locking surfaces may be provided by a common, preferably inclined, surface.
A horizontal extension of the tongue from a vertical plane may be smaller than an extension of the strip from a vertical plane. A horizontal extension of the tongue groove may be substantially the same as the extension of the tongue.
The mineral-based panel may further comprise an upper arrangement comprising at least one upper layer being attached to an upper side of the mineral-based core.
Embodiments of the material composition of each of the core and the lower arrangement comprising polymer-based layer(s), and optionally the upper arrangement, preferably comprising at least one polymer-based layer, may be the same as those of the first aspect, whereby reference is made thereto. Reference is also made thereto for embodiments of the top structure and/or reinforcement layer(s).
Other embodiments and examples of the fourth aspect, such as embodiments of optional groove(s), may be the same as those of the first aspect, wherein reference is made thereto.
Further aspects of the inventive concept and embodiments and examples of each of the first, second and third aspects are provided in an embodiment section below. It is emphasized that the embodiments and examples of any aspect herein, including the fourth aspect, may be combined with embodiments and examples of any other aspect.
Generally, all terms used in the claims and in the items in the embodiment section below are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to “a/an/the [element, device, component, means, step, etc.]” are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise.
The disclosure will in the following be described in connection to exemplary embodiments and in greater detail with reference to the appended exemplary drawings, wherein:
Next, various embodiments of a panel 1 is described with reference to the embodiments in
Below, embodiments of the mineral-based panel 1 will mostly be described in the context of a floor panel, but it is understood that the panel also may be a building panel, a wall panel, a ceiling panel or a furniture panel.
As shown in an embodiment in the cross-sectional side view in
A top structure 11 is provided on, such as attached to, an upper side 3b of the core 3. Various types of top structures are conceivable. The top structure 11 may comprise a décor layer 11a. In a first example, the décor layer 11a comprises a printed décor, such as a digitally printed décor. In a second example, the décor layer comprises a print film. The printed décor may be provided directly on the upper side of the core. Optionally, a primer may be provided on the core under the printed décor. Moreover, a coating layer 11b, such as a UV curable coating layer, a lacquer or a hot-melt coating layer, and/or a wear layer 11c may be provided on the décor layer. In some examples, the coating layer 11b may be provided on the wear layer 11c.
In the embodiments in the cross-sectional side views in
As shown in
The at least one groove 19 may be at least partly provided in the lower arrangement 5 as shown in
As shown in
In any of the embodiments herein, such as in any of
The panel in any of the
In some embodiments, the lower 5 and/or upper 7 arrangement(s), such as in any of
Any, or preferably both, of the lower 5 and upper 7 arrangements may comprise at least one thermoplastic layer 5a-c, 7a-c, for example comprising PVC, PE, TPU, PP, PET or ABS. The core 3 may comprise magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate.
Any, or preferably both, of the lower 5 and upper 7 arrangements may comprise at least one thermosetting layer 5a-c, 7a-c, for example comprising a melamine-formaldehyde resin, epoxy resin, preferably crosslinked with an amine hardener, PU, polyurea or acrylate polymers.
In some embodiments, the lower 5 and/or upper 7 arrangement(s), such as in
At least one lower layer, preferably all lower layers, may comprise magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate. Moreover, at least one upper layer, preferably all upper layers, may comprise magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate. Any of these embodiments may be particularly advantageous when the core comprises magnesium oxide.
At least one lower layer, preferably all lower layers, may comprise cement, such as at least 30 wt % of cement. Moreover, at least one upper layer, preferably all upper layers, may comprise cement, such as at least 30 wt % of cement. Any of these embodiments may be particularly advantageous when the core comprises cement.
Embodiments and examples of the panel 1 in the cross-sectional side views in
Generally herein, the panel may extend in a first horizontal direction x and in a perpendicular second horizontal direction y. Moreover, the panel may extend in a vertical direction z which may be perpendicular to the first and second horizontal directions. The panel 1 may comprise a first pair of opposite edge portions 1a, 1b, which may be long edge portions, and a second pair of opposite edge portions 1c, 1d, which may be short edge portions. The long edge portions may extend along the first horizontal direction x and the short edge portions may extend along the second horizontal direction y.
Preferably, and as shown in e.g.
The panel in any of the embodiments in
Alternatively, or additionally, any of the panels in
Preferably, the grooves 19 are formed in an interior of the rear side 4 and are spaced from the first 1a, 1b and/or second 1c, 1d pair of opposite edge portions, preferably both of them. For example, the entire parts of the at least one groove may be provided inside a vertical plane VP at all edge portions 1a-d. The vertical plane VP may be defined by immediately juxtaposed upper portions of two neighboring joint edge portions of two joined panels, such as floor panels, and may be perpendicular to a horizontal plane HF and/or HR, respectively, provided along the front side 2 and rear side 4. A groove length GL of at least some grooves 19, preferably all grooves, may be smaller than a length BL, preferably a maximal length, of the rear side. The length BL may be a length which is parallel with the long edge portions of the panel.
The at least one groove 19 in any of
In some embodiments, however, and as shown in the side view in
The at least one groove may be continuous as shown in e.g.
The at least one groove may be discontinuous as shown in e.g.
As illustrated in
The groove arrangements 40 may be discontinuous, such as along the first horizontal direction x. The groove arrangements 40 may be separated by a separation portion 30.
Preferably, the separation portion extends continuously between a pair of opposite edge portions 1a, 1b, such as long edge portions, along the second horizontal direction y. For example, the separation portion may be rectangular.
In some embodiments, there may be a middle area MA without any grooves as shown in
Before grooves are formed in the panel 1, an area A′ of the front side 2 may be essentially the same as an area A of the rear side 4, cf.
The at least one groove reduces the area A of the rear side. The area A of the rear side may be less than 90% of the area A′ of the front side, such as 60-85%. In some embodiments the area A may be less than 80% of the area A′, such as less than 70%. Alternatively, or additionally, a volume VG of the groove(s) may be at least 5 vol %, such as at least 10 vol %, preferably 5-30 vol %, such as 10-20 vol %.
A plurality of grooves 19 may have the same characteristics, such as groove depths GD and/or groove widths GW. Alternatively, or additionally, a cross-sectional shape of at least two grooves may be the same. As shown e.g. in the embodiments in
At least two grooves of a plurality of grooves 19 may have different characteristics, such as groove depths GD and/or groove widths GW. Alternatively, or additionally, a cross-sectional shape CS of at least two grooves may be different.
In non-limiting examples, any groove depth GD herein may be at least 0.2, such as at least 0.3, preferably at least 0.4, times a thickness T of the panel 1. The groove depth GD may be for example 0.1-0.6 times the panel thickness T. When the thickness is 2-40 mm, a groove depth of any of the grooves may be at least 0.2-24 mm, such as 0.5-10 mm. For example, a floor panel having a thickness of 2-10 mm may have groove depth which is at least 0.2-1.0 mm, such as 1.2-6.0 mm.
In any of the embodiments described above, the groove width GW may be 0.2-1.5, such as 0.5-1.0, times the panel thickness T. Moreover, there may be a space S extending between the grooves along the second horizontal direction y. For example, the space S may be at least 0.2-1.0 times the panel thickness T.
In any of the embodiments herein, such as in
As shown in
Generally, and as shown in
Alternatively, or additionally, and as shown in e.g.
The at least one reinforcement layer 17, 15 may be provided in any upper layer 7a, 7b, 7c and/or any lower layer 5a, 5b, 5c, as illustrated in
The at least one groove may be provided below the at least one reinforcement layer, such as below any, some or all of the at least one reinforcement layer selected from the group of the reinforcement layers 13, 15, 17 and 18a-b described above. In some embodiments, however, and as shown in e.g.
Alternatively, or additionally, to the reinforcement layers, the core 3, and optionally any lower 5a, 5b, 5c and/or upper 7a, 7b, 7c layer, may comprise separate reinforcement particles 26, such as fibres. In some embodiments, and as illustrated in
In some embodiments, the at least one groove may be at least partially filled, such as completely filled, with a separate material 27. Preferably, the separate material may impact the properties of the panel, such as its sound properties. This may be particularly advantageous when a cover layer 12 is provided on the rear side 4, such as in
In some embodiments, the grooves 19 may be formed by a non-rotating operation, such as by carving. A non-rotating tool may be utilized, for example a carving tool 22 comprising at least one tooth element 23a-23d.
Preferably, the carving tool 22 is fixedly mounted in a frame member (not shown), at least in a direction along the carving axis CA. In operation of the carving tool, the panel may be displaced with respect to the frame member in the feeding direction. The panel may be displaced against the carving tool 22 in the feeding direction FD. Each tooth may carve at least 0.05 mm, such as at least 0.1 mm, for example 0.05-0.5 mm, e.g. in a mineral-based material, such as in the core 3 and/or in the lower arrangement 5.
In some embodiments, however, the carving tool may be displaceably mounted in the frame member. For example, carving tool may be a jumping carving tool.
The material 21 removed from the panel when forming the grooves, such as chips, may be recycled. Magnesium oxide may be recycled, such as fully recycled, for example by heating the removed material above a critical temperature so that it assumes powder form.
The method described above is equally conceivable for a mineral-based board element 80. The mineral-based board element may be dividable or may be divided into at least two panels 1, such as by sawing, cutting or breaking. In a first example, the grooves are formed before dividing the board element. In a second example, the grooves are formed after dividing the board element. In the second example, the grooves may be formed before or after forming of the locking system on opposite edge portions 1a, 1b and/or 1c, 1d.
Preferably, an upper arrangement 7 comprising at least one upper layer 7a, 7b, 7c is attached to the upper side 3b of the core 3 in any of
The bottom view in
Optionally, as shown in
As shown in
In any embodiment herein, the lower arrangement 5 may comprise a single lower layer 5a, and optionally a second 5b and/or a third 5c lower layer, cf.
In any embodiment herein, such as in
The polymer-based lower layer(s) 5a, 5b, 5c may be thermoplastic layer(s), for example comprising PVC, PE, TPU, PP, PET or ABS, preferably being provided on the magnesium oxide core 3 described in the previous paragraph. The panel 1 may further comprise thermoplastic upper layer(s) 7a, 7b, 7c, for example comprising PVC, PE, TPU, PP, PET or ABS. In a first example, the panel comprises a lower layer 5a and an upper layer 7a, each comprising PVC in an amount of 40-60 wt %, a filler, such as calcium carbonate or talc, in an amount of 40-60 wt %, a plasticizer, such as dioctyl terephthalate (DOTP), in an amount of 0-10 wt %, and additive(s), such as pigments, a lubricant, a stabilizer, or an acrylic processing aid, in an amount of 0-5 wt %. In a second example, the panel comprises a lower layer 5a and an upper layer 7a, each comprising PE, PP, PET, TPU or polyolefin copolymers in an amount of 30-60 wt %, a filler, such as calcium carbonate or talc, in an amount of 40-70 wt %, and additive(s), such as pigments, a coupling agent, a lubricant, or an antioxidant, in an amount of 0-5 wt %. A thickness of the panel may be 5-10 mm, such as 4-7 mm, and a thickness of each of the upper and lower arrangements may be 15-35%, such as 20-40%, of the thickness of the panel.
In some embodiments, the polymer-based lower layer(s) 5a, 5b, 5c may be thermosetting layer(s), for example comprising a melamine resin, epoxy resin, preferably crosslinked with an amine hardener, PU, polyurea or acrylate polymers, preferably being provided on the magnesium oxide core 3 described in the penultimate paragraph above. The panel 1 may further comprise thermoplastic upper layer(s) 7a, 7b, 7c, for example comprising a melamine resin, epoxy resin, preferably crosslinked with an amine hardener, PU, polyurea or acrylate polymers. In a third example, the panel comprises a lower layer 5a and an upper layer 7a, each comprising an epoxy resin and an amino hardener or polyols and isocyanates in an amount of 40-60 wt %, a filler, such as calcium carbonate, barium sulphate, sand or talc, in an amount of 20-50 wt %, and additive(s), such as pigments, a catalyst, a defoaming agent, a dispersing agent, or a chain extender, in an amount of 0-5 wt %. A thickness of the panel may be 4-7 mm, and a thickness of each of the upper and lower arrangements may be 15-35%, such as 20-40%, of the thickness of the panel.
In any of the first, second and third examples above, the upper and lower arrangements may comprise the same polymer-based material compositions, such as being provided with the core in an ABA layered structure, or different polymer-based material compositions, such as being provided with the core in an ABC layered structure.
In
In
As shown in e.g.
In some embodiments, and as shown in e.g.
Alternatively, or additionally, and as shown e.g. in
It is clear that in some embodiments herein, at least one vertical locking surface 6b, 6b′ may be at least partially provided in the core 3 as shown in e.g.
It is understood that embodiments may include a set of panels comprising a plurality of panels 1 in accordance with any of the embodiments and examples herein, such as in
The inventive concept has mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the inventive concept, as defined by the appended patent claims and items in an embodiment section below. In addition, it is noted that the locking system 50a, 50b described in relation to e.g.
Further aspects of the inventive concept are provided below. Embodiments and examples of these aspects are largely analogous to the embodiments and examples as described above, whereby reference is made to the above for a detailed description.
Item 1. A mineral-based panel (1), such as a floor panel, comprising a mineral-based core (3), wherein the panel comprises at least one groove (19), preferably a plurality of grooves.
Item 2. The mineral-based panel according to item 1, wherein the at least one groove (19) is provided in a rear side (4) of the panel.
Item 3. The mineral-based panel according to item 1 or 2, wherein the at least one groove is provided in a lower side (3a) of the mineral-based core.
Item 4. The mineral-based panel according to any of the preceding items, wherein the at least one groove is provided in an upper side (3b) of the mineral-based core.
Item 5. The mineral-based panel according to any of the preceding items, wherein the mineral-based core comprises magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate.
Item 6. The mineral-based panel according to any of the preceding items, wherein the mineral-based core comprises cement.
Item 7. The mineral-based panel according to any of the preceding items, further comprising a lower arrangement (5) comprising at least one lower layer (5a) being attached to a lower side (3a) of the mineral-based core.
Item 8. The mineral-based panel according to item 7, wherein the at least one groove is at least partly provided in the lower arrangement, such as the at least one groove fully penetrating at least one lower layer (5a) of the lower arrangement.
Item 9. The mineral-based panel according to item 7 or 8, wherein at least one lower layer (5a, 5b, 5c) in the lower arrangement, preferably all lower layers, comprises magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate.
Item 10. The mineral-based panel according to any of the preceding items 7-9, wherein at least one lower layer (5a, 5b, 5c) in the lower arrangement, preferably all lower layers, comprises cement.
Item 11. The mineral-based panel according to any of the preceding items 7-10, wherein the lower arrangement (5) comprises at least one polymer-based layer, such as at least one thermoplastic layer, for example comprising PVC, PE, TPU, PP, PET or ABS, or at least one thermosetting layer, for example comprising a melamine-formaldehyde resin, epoxy resin, preferably crosslinked with an amine hardener, PU, polyurea or acrylate polymers.
Item 12. The mineral-based panel according to any of the preceding items 7-11, wherein the lower arrangement (5) comprises at least one wood-based layer or cellulose-based layer, such as a veneer, paper, solid wood layer, MDF layer, HDF layer, DPL layer, HPL layer or particle board layer.
Item 13. The mineral-based panel according to any of the preceding items, further comprising an upper arrangement (7) comprising at least one upper layer (7a) being attached to an upper side (3b) of the mineral-based core.
Item 14. The mineral-based panel according to item 13, wherein at least one upper layer (7a, 7b, 7c) in the upper arrangement, preferably all upper layers, comprises magnesium oxide and, optionally, magnesium chloride and/or magnesium sulphate.
Item 15. The mineral-based panel according to item 13 or 14, wherein at least one upper layer (7a, 7b, 7c) in the upper arrangement, preferably all upper layers, comprises cement.
Item 16. The mineral-based panel according to any of the preceding items 13-15, wherein the upper arrangement (7) comprises at least one polymer-based layer, such as at least one thermoplastic layer, for example comprising PVC, PE, TPU, PP, PET or ABS, or at least one thermosetting layer, for example comprising a melamine-formaldehyde resin, epoxy resin, preferably crosslinked with an amine hardener, PU, polyurea or acrylate polymers.
Item 17. The mineral-based panel according to any of the preceding items 13-16, wherein the upper arrangement (7) comprises at least one wood-based layer or cellulose-based layer, such as a veneer, paper, solid wood layer, MDF layer, HDF layer, DPL layer, HPL layer or particle board layer.
Item 18. The mineral-based panel according to any of the preceding items, further comprising a top structure (11) provided on, such as attached to, an upper side of the mineral-based core or provided on, such as attached to, an upper arrangement (7) of the mineral-based panel, said top structure preferably comprising a décor layer (11a).
Item 19. The mineral-based panel according to item 18, wherein the top structure (11) comprises a coating layer (11b), such as a UV curable coating layer, a lacquer or a hot-melt coating layer, and/or a wear layer (11c), such as comprising aluminium oxide, a thermoplastic film, or a thermosetting resin.
Item 20. The mineral-based panel according to any of the preceding items, further comprising a cover layer (12) at least partly covering the grooves.
Item 21. The mineral-based panel according to any of the preceding items, further comprising at least one reinforcement layer (13; 15; 17; 18a, 18b), such as a glass-fibre layer.
Item 22. The mineral-based panel according to item 21, wherein the at least one reinforcement layer (13) is provided in the mineral-based core.
Item 23. The mineral-based panel according to item 21 or 22, wherein at least one reinforcement layer (13) is positioned in a top portion and/or a bottom portion of the mineral-based core.
Item 24. The mineral-based panel according to any of the preceding items, wherein the at least one reinforcement layer (17; 15) is provided in an upper (7) and/or a lower (5) arrangement.
Item 25. The mineral-based panel according to any of the preceding items, further comprising a locking system (50a; 50b), such as a mechanical locking system, for horizontal and/or vertical locking.
Item 26. The mineral-based panel according to item 25, wherein the horizontal locking system comprises a locking element (8; 8′) and a locking groove (14; 14′), and/or wherein the vertical locking system comprises a tongue (10; 10′; 10″) and a tongue groove (9; 9′).
Item 27. The mineral-based panel according to any of the preceding items, comprising a plurality of grooves, wherein at least two grooves (19) have different characteristics, such as groove depths (GD) and/or groove widths (GW).
Item 28. The mineral-based panel according to any of the preceding items, wherein said at least one groove is provided in an interior of the panel, such as in the rear side (4) of the panel, being spaced from a pair of opposite edge portions (1c, 1d), such as opposite short edge portions, of the panel, preferably being spaced from all edge portions (1a-1d) of the panel.
Item 29. The mineral-based panel according to any of the preceding items, wherein the at least one groove (19) extends to at least one edge portion, such as two edge portions, of a pair of opposite edge portions (1c, 1d), such as opposite short edge portions, of the panel.
Item 30. The mineral-based panel according to any of the preceding items, wherein the at least one groove (19) is provided below an underside (4a, 4c) of an edge portion (1a, 1c) comprising a locking groove (14, 14′).
Item 31. The mineral-based panel according to any of the preceding items, wherein a shape of one or both end portions (16) of the at least one groove (19) along its longitudinal direction is curved.
Item 32. The mineral-based panel according to any of the preceding items, wherein one end portion (16) is, or both end portions (16), are parallel with a front side (2) of the panel, preferably such that they intersect at least a portion of the strip (6′) and/or at least a portion of the locking groove (14′).
Item 33. The mineral-based panel according to any of the preceding items, wherein the panel is rectangular with long edge portions (1a, 1b) and short edge portions (1c, 1d) and wherein the at least one groove is parallel with the long edge portions.
Item 34. The mineral-based panel according to any of the preceding items, wherein the at least one groove is continuous or discontinuous, preferably being parallel with long edge portions of the panel.
Item 35. The mineral-based panel according to any of the preceding items, comprising at least two groove arrangements (40), such as a plurality of groove arrangements, wherein adjacent pairs of groove arrangements preferably are separated by a separation portion (30).
Item 36. The mineral-based panel according to any of the preceding items, wherein an area (A) of a surface in which the at least one groove is provided, such as the rear side or the lower and/or upper side of the core, is less than 90%, such as less than 80%, of an area (A′) of a front side (2) of the panel.
Item 37. A method for forming at least one groove (19) in a mineral-based panel (1), such as a floor panel, comprising:
Item 38. The method according to item 37, wherein the at least one groove (19) is provided in a rear side (4) of the panel.
Item 39. The method according to item 37 or 38, wherein the at least one groove (19) is formed by rotational processing with at least one tooth element (24a-24d), such as by a rotating cutting device (20).
Item 40. The method according to any of the preceding items 37-39, wherein the at least one groove (19) is formed by non-rotational processing with at least one tooth element (23a-23d), such as by carving, preferably using a carving tool (22).
Item 41. The method according to any of the preceding items 37-40, further comprising forming a locking system (50a; 50b), such as a mechanical locking system, for horizontal and/or vertical locking of the mineral-based panel.
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| Number | Date | Country | |
|---|---|---|---|
| 20200308846 A1 | Oct 2020 | US |
