Patent Application
20240052641
This application claims priority to The Netherlands Patent Application No. 2032731 filed Aug. 11, 2022, the disclosure of which is hereby incorporated by reference in its entirety.
The invention relates to a panel for composing a floor covering, wall covering, or alternative covering, in particular for outdoor applications. The invention also relates to a panel system comprising at least one panel according to the invention. The invention further relates to a method of composing a covering, in particular a floor covering, by using a panel system according to the invention.
As is known, outdoor panels can be used to compose an outdoor floor covering in exterior environments of structures, for example balconies, terraces, swimming pools, gardens and courtyards. These panels serve to improve the appearance of the environment while also providing a solid and robust floor surface. Typically, these outdoor panels have identical side grooves at opposing side edges, which are used to co-act with metal or plastic fastening clips to fasten the panels onto a support structure. The use of these clips is laborious, time-consuming, wherein installation can normally only be performed by an educated installer. Moreover, since these panels are installed in exterior environments, the panels are commonly exposed to water, from rain or irrigation systems for example, as a consequence of which the water may stand on the surfaces of the tiles, forming puddles which are not only visually displeasing but may also lead to the formation of mosses on the surface of the panels. The water may also make the panels more slippery.
It is a first objective of the invention to provide a panel and/or a panel system which can be installed in a relatively user-friendly manner.
It is a second objective of the invention to provide an improved panel and/or improved panel system which can be installed in a relatively user-friendly manner, and which may be configured to drain water in an efficient manner.
It is a third objective of the invention to provide a light-weight panel and/or a light-weight panel system comprising at least one light-weight panel, which can be installed in a relatively user-friendly manner.
It is a fourth objective of the invention to provide an alternative panel and/or alternative panel system, which, according to some of its embodiments, is intended to resolve one or more of the problems arising from the prior art.
It is a fifth objective of the present invention is to overcome the aforesaid drawbacks of the prior art, in the context of a simple, rational and inexpensive solution.
To achieve one or more of these objectives, the invention provides a panel according to the preamble, comprising:
This interlocking is preferably such that said panel can be locked with respect to another panel in horizontal direction and/or vertical direction, preferably in both directions.
The panel according to the invention, which can be used as outdoor panel and/or as indoor panel, is preferably provided with one or more coupling profiles, which allow adjacent panels to be interlocked essentially and preferably without using separate clips and/or other mechanical or chemical fastening means, and/or which allow adjacent panels to be interlocked essentially by using less separate clips and/or other mechanical or chemical fastening means. This leads to a relatively user-friendly installation, without needing educated installers. Moreover, since the coupling profiles lock adjacent panels in horizontal and/or vertical direction, undesired uncoupling of the coupling profiles, and hence of the panels, can be counteracted. As indicated, the panel according to the invention preferably comprises at the first edge a plurality of first coupling profiles and/or comprises at the second edge a plurality of second coupling profiles. The application of a plurality of coupling profiles at a panel edge allows to create a distance between adjacent coupling profiles, which leads to a(n intermediate) segment which is preferably substantially free of any coupling profiles, which, as such, leads to a material saving, and hence a weight saving, as less material is needed to realize an interlockable panel. This leads to economical, environmental and practical benefits. One or more intermediate segment(s) of the panel edge(s) may also be free of any protruding elements laterally protruding from said panel edge. The intermediate segment(s) does not only lead to a material and weight saving, but may also be used to facilitate water drainage via said segment(s), in particular in coupled condition of adjacent panels. This allows water to be drained via one or more spaces enclosed by the first edge and facing second edge of interlocked adjacent panels. The width of this space may strongly vary, dependent on the specific panel design and/or intended application. The width of this intermediate space (or seam) enclosed by interlocked panels is preferably situated in between 0 and 10 millimetre, more preferably in between 10 micron and 6 millimetre.
In this case, the segment(s) may also be referred to as drainage segment(s). Drainage of water is typically important for outdoor application of the panel, but may also be(come) important for specific (or less specific) indoor applications, such as for example in wet indoor environments, such as indoor swimming pools or bathrooms, and/or in indoor spaces where wet cleaning is preferably regularly applied, such as in industrial spaces, commercial spaces, and/or residential spaces.
In a preferred embodiment, at least one (drainage) segment is enclosed by adjacent coupling profiles. As said, said segment is preferably free of any coupling profiles. It may be preferred that at least a part of at least one (drainage) segment is substantially delimited, preferably substantially entirely delimited, by a vertical plane defined by the corresponding edge. Said segment of the panel may be provided with at least one laterally protruding element for supporting an adjacent panel, in coupled condition of said panel, wherein said protruding element preferably does not contribute to interlocking of panels in coupled condition. It is also, typically additionally, imaginable that at least one segment is positioned at an outer portion of a side edge, wherein said segment is only one-sided delimited by one coupling profile.
Preferably, at least one edge of the first edge and second edge comprises at least three coupling profiles, wherein a segment, in particular drainage segment, is present in between each pair of adjacent first coupling profiles. Preferably, the coupling profiles are spread, more preferably substantially evenly, along the edge to secure a decent coupling along the practically entire edge. Preferably, the number of first coupling profiles corresponds to the number of second coupling profiles.
Preferably, the first edge comprises at least one first drainage segment, and the second edge comprises at least one second drainage segment. In this manner, water will be facilitated to be drained along both the first and second panel edge, and preferably along all panel edges. Preferably, at least one first drainage segment is at least partially aligned with at least one second drainage segment, such that said first drainage segment of said panel is facing said second drainage segment of an adjacent panel, in coupled condition of said panels. This preferably leads to open (linear) through-hole cavities connecting the upper side and the lower side of a covering composed of interlocked panels.
Preferably, at least one first coupling profile is at least partially aligned with at least one second coupling profile. This facilitates to realize a reliable interconnection between panels. It is conceivable that at least one first coupling profile has an identical length or deviating length (greater or smaller length), as seen in the direction of the first edge, compared to the length of the second coupling profile, as seen in the direction of the second edge. Preferably, the length of at least one first drainage segment exceeds the length of at least one second drainage segment (as seen in the direction of the first and second edges respectively). It may be preferred that the length of at least one drainage segment exceeds the length of at least one adjacent coupling profile. This may further improve the drainage capacity of a (floor) covering composed of a plurality of said panels. It may also, additionally or alternatively, be preferred that the length of at least one coupling profile exceeds the length of at least one adjacent coupling profile. This may further improve the coupling strength of interlocked panels.
In a preferred embodiment, at least one first coupling profile comprises:
A locking effect in vertical direction is realized by inserting the sideward tongue of a panel at least partially into the groove of an adjacent panel. Preferably, the first and second coupling profile are configured such that two of such panels can be coupled to each other by means of a turning movement and/or translation movement (preferably in a horizontal plane), wherein, in coupled condition: at least a part of the sideward tongue of a first panel is inserted into the groove of an adjacent, second panel, and wherein at least one second locking element of said first panel faces, and preferably co-acts with, the first locking element of said adjacent panel to interlock both panels both in horizontal and vertical direction.
The lower lip preferably comprises an inner segment, which is positioned directly below the upper lip, and a connecting outer segment, which extends beyond an outer vertical plane defined by the upper lip, wherein the maximum height of the inner segment is identical to or exceeds the maximum height of the outer segment. Hence, the upper surface of a lower lip is preferably substantially planar. It is however imaginable that said upper surface of the lower lip, preferably the outer segment of the lower lip, comprises at least one upward drainage groove. Such a drainage groove (further) facilitates drainage of water, such as water seep in between the coupling profiles.
Preferably, the lower lip of said panel is configured to engage a stop surface of the second profile of an adjacent panel, in coupled condition of said panels, wherein said stop surface is located at a lower level than the sideward tongue. Said stop surface is typically preferably to secure a minimum distance in between top sections of interlocked panels, which typically results in an open seam at the top sections in between interlocked panels which is in favour of the drainage capacity of the covering at least partially formed by said interlocked panels. Preferably, the first coupling profile comprises a first top portion located above the sideward tongue, wherein said first top portion preferably extends in a substantially vertical direction, and wherein an outer end of the upper lip defines a second top portion, wherein said second top portion preferably extends in a substantially vertical direction, and wherein said second top portion is configured to face the first top portion of an adjacent panel, in coupled condition of said panels, preferably such that the first top portion and the facing second top portion are positioned at a distance from each other. As said above, this open (top) seam improves the drainage capacity of the covering at least partially formed by said interlocked panels.
The stop surface is preferably a vertical stop surface. The distant end surface of the lower lip, configured to co-act with said stop surface of another panel, is preferably also oriented substantially vertically, which normally easily leads to a stable abutment of both substantially vertical surfaces. Preferably, a lower side of the panel is provided with a longitudinal cut-out portion connecting and parallel to the first edge for accommodating each lower lip in coupled condition of adjacent panels. Said cut-out portion is preferably partially defined by said stop surface and partially by a connecting horizontal part of the lower side of the panel.
The first locking element is preferably formed by at least one bulge, and the second locking element is preferably formed by at least one recess to accommodate said at least one bulge at least partially. This embodiment results in a more robust, and hence stronger, sideward tongue. Preferably, the bulge and/or the recess preferably has a rounded triangular shape, with typically two straight legs being connected by a rounded vertex. The curvature of the vertexes of the bulge and recess may be identical, wherein it is preferred though that a radius defining the vertex of the bulge exceeds the radius defining the vertex of the recess. This makes the bulge less sharp, and therefore less vulnerable for breakage. An inversed embodiment is also imaginable, wherein the first locking element may be formed by at least one recess, and the second locking element may be formed by at least one bulge to accommodate said at least one bulge at least partially. Alternative locking elements and/or other combinations of bulges and recesses are also imaginable as first locking element and second locking element.
Preferably, at least one lower lip is provided with at least one curved side edge, preferably two curved side edges, preferably as seen from a top view of the lower lip. Such curved side edges make the lower lip typically less vulnerable for damaging and/or breaking. The lower lip typically serves for supporting the sideward tongue in coupled condition of adjacent panels. Preferably, in coupled condition of adjacent panels, the sideward tongue is supported both by said inner segment and by said outer segment of the lower lip. Preferably, a distant end portion of the lower side of the sideward tongue, positioned below the first locking element, as said preferably formed by at least one bulge, is at least partially inclined upwardly towards the outer end of the sideward tongue. This inclination creates space which facilitates coupling of the coupling profiles, in particular which facilitates angling in of the sideward tongue into the groove. The outer end of the sideward tongue is preferably substantially vertical, which typically contributes to the robustness of the sideward tongue.
Preferably, at least one sideward tongue is provided with at least one curved and/or chamfered (inclined) side edge, preferably two curved and/or chamfered (inclined) side edges, preferably as seen from a top view of the sideward tongue. These one or more side edges may act as guiding surfaces for aligning the panel(s) with respect to a support structure.
At least two first coupling profiles, in particular as seen from a cross-sectional view, may be identical. Additionally or alternatively, at least two first coupling profiles, in particular as seen from a cross-sectional view, are mutually different. At least two first coupling profiles, in particular as seen from a top view, are mirror symmetric first coupling profiles. In this embodiment, the mirror symmetric first coupling profiles are preferably separated by an intermediate segment, in particular a drainage segment, which makes the two adjacent first coupling profiles look like an interrupted larger first coupling profile being divided into two smaller first coupling profiles. Said (fictive) larger first coupling profile may have the same length (as seen in the direction of the first edge) which as another (undivided) first coupling profiled located at said first edge. The same applies to the second coupling profiles which may be identical and/or deviating coupling profiles. At least two second coupling profiles, in particular as seen from a top view, may be mirror symmetric second coupling profiles.
In a preferred embodiment, at least one pair of at least one pair of adjacent first coupling profiles and at least one pair of opposing adjacent second coupling profiles encloses an accommodating space for accommodating a separate support structure for supporting said panel, wherein accommodating spaces are aligned with each other. Said accommodating space is typically a groove of limited length, which, in coupled condition of adjacent panels, preferably overlaps and/or coincides with an accommodating space of a connecting pair of coupling profiles. By inserting a part of the supporting support structure into said accommodating space(s) a more stable (floor) covering, and panel system as such (comprising interlocked panels supported by one or more support structures), can be obtained. Preferably, an upper side of each accommodating space is at least partially defined by a curved and/or inclined surface. This embodiment typically facilitates the insertion of (a(n upper) part of) the support structure into the accommodating space(s).
Preferably, the lower side of the panel comprises at least one bottom groove, preferably transverse bottom groove, preferably connecting the first edge and the second edge (or one or more other edges), wherein said bottom groove, preferably transverse bottom groove, is configured to accommodate a separate support structure for supporting said panel, and wherein the bottom groove, preferably transverse bottom groove, is preferably connected and aligned with a pair of opposing, aligned accommodating spaces (preferably as mentioned above) to form a continuous accommodating groove for accommodating a part of said separate support structure. Such a continuous bottom groove, preferably transverse bottom groove, renders it relatively easy to be placed on top of the (first) support structure, such that a part of said (first) support structure is accommodated within said continuous groove. Preferably, at least one accommodating space and/or at least one bottom groove, preferably transverse bottom groove, comprises at least one third coupling profile configured to interlockingly engage with at least one fourth coupling profile of said separate support structure, in horizontal direction and/or vertical direction. Realizing a coupling between the third profile and the fourth profiles is preferably done by placing the panel(s) on top of said (first) support structure and by subsequently translating (shifting) the panel(s) in horizontal direction make the third coupling profile and fourth coupling profile to interlockingly engage onto each other. Preferably, a clamping connection between the third coupling profile and the fourth coupling profile is realized in coupled condition of adjacent panels. The bottom groove, preferably transverse bottom groove, normally extends in transverse direction perpendicular to the length direction of the panel, and preferably perpendicular to the first edge and second edge. This embodiment typically provides a preferred stability of a panel covering supported by one or more (first) support structures, wherein the panels and the support structures are oriented in crosswise direction. It is however also imaginable that the bottom groove, preferably transverse bottom groove, extends in length direction of the panel.
Preferably, the first coupling profiles and/or second coupling profiles and/or third coupling profiles, more preferably all coupling profiles, make integral part of the panel, in particular a core of the panel. More preferably, the coupling profiles are at least partially formed by means of extrusion, preferably simultaneously with at least one layer, such as a core layer, of the panel. Said layer and the coupling profiles may therefore be made out of one piece of material. It is well imaginable that the coupling profiles are milled and/or otherwise brought into their final shape (also in length direction parallel to the first and second side edges) after extrusion. This latter post-processing step is typically done in order to create the segments, in particular the drainage segments. However, the latter processing step may also be incorporated in an extrusion process step, preferably in a co-extrusion process step. By incorporating the processing steps e.g. in a single co-extrusion process this may achieve benefits in terms of both cost and processing speed.
Preferably, a second pair of opposing edges, typically formed by a third edge and fourth edge, of the panel is entirely free of coupling profiles. Preferably these opposing edges are defined by substantially vertical end surfaces.
The panel is preferably a rectangular and/or oblong panel, more preferably a rectangular oblong panel. Other polygonal shapes, such as triangular, hexagonal or octagonal shapes or parallelogrammatic shapes are also imaginable for the panel according to the invention.
Although the covering (at least partially) composed of a plurality of interconnected panels according to the invention is preferably water permeable to allow water drainage, the panels as such are preferably water-resistant panels. Water-resistant means that the panels are dimensionally stable when exposed the water (and will e.g. not cup, expand, or shrink). It is imaginable and even favourable in case the panel is a substantially rigid panel. The panel may be used as indoor panel or as outdoor (decking) panel. The panels may also be referred to as tiles, planks, or decking boards, or covering elements, in particular floor covering elements or wall covering elements. Preferably, the length of the panel is situated in between 1 and 4 meter, preferably between 1.5 and 4 meter, more preferably between 3 and 4 meter, in particular up to 6 meter. This latter preferred range is in particular preferred in case the panel is used as outdoor panel. The thickness of the panel is preferably situated in between 3 and 80 millimetre, more preferably between 8 and 60 millimetre, most preferably between 10 and 55 millimetre. This latter range is in particular preferred in case the panel is used as outdoor panel. The width of the panel is preferably situated in between and 300 millimetre, more preferably between 40 and 250 millimetre, most preferably between 80 and 200 millimetre. This latter range is in particular preferred in case the panel is used as outdoor panel.
Preferably, the panel is at least partially an extruded panel, and preferably an entirely extruded panel, more preferably an entirely co-extruded panel. In a co-extruded panel two or more layers are simultaneously formed on top of each other (and/or side by side of each other) by using different adjacent extruders. This allows different panel layers to be composed of different compositions, which may lead to improved overall properties of the panel, such as acoustic properties (sound dampening properties), and/or anti-slip properties, and/or an improved user comfort. The coupling profiles may be formed by a single layer, although it is also imaginable that at least one coupling profile is partially formed by one layer and at least one other part of said coupling profile is formed by at least one other layer.
The panel according to the invention may be a monolithic panel. This means that the panel is entirely formed out of a single piece of material. However, the panel may also be a multi-layered panel, preferably a co-extruded multi-layered panel. Such a multi-layered panel preferably comprises a core layer and a top structure and/or a backing layer, directly or indirectly, affixed to said core layer. The top structure as such may also be composed of a plurality of layers, which may include, for example a décor layer, preferably a digitally printed décor layer, and at least one transparent and/or translucent cover layer. Preferably, the top structure comprises at least one primer layer applied onto the core layer, at least one, preferably printed, décor layer applied onto the (upper) primer layer, and at least one transparent and/or translucent wear layer on top of the décor layer, and optionally a top coating applied on top of the (upper) wear layer. It is, however, also conceivable that two or more layers of the top structure are formed by a single layer.
According to a preferred embodiment it is conceivable that the panel comprises a top structure, wherein said top structure, or a part thereof, at least partially covers the upper surface of the panel, and at least partially covers at least one side edge, preferably at least one of the first and/or second edge. Optionally the top structure substantially entirely covers at least one pair of opposing side edges, and possibly all side edges. It is imaginable one or more of the coupling profiles are at least partially covered by the top structure (or a part thereof). It is furthermore imaginable that said top structure or a part thereof, according to this embodiment, at least partially, preferably entirely, covers the bottom side of the panel. It is e.g. imaginable that the top structure comprises a primer layer which is present both at the upper surface of the panel, the bottom side of the panel, and optionally one or more side edges of the panel. This may give the panel an improved moisture resistance and/or may protect the panel against insects, fungi and/or bacteria.
It may be preferred to at least partially compose the top structure out of a polymer material. However, as indicated above, preferably the top structure comprises a plurality of (stacked) layers, including at least one optional primer layer, at least one decorative layer and at least one protective layer covering said decorative layer at least partially. According to this embodiment, a core of the panel may, for example, in particular be composed out of wood and/or a wood/plastic composite structure.
Preferably, the panel is a hollow panel, which preferably encloses at least one internal, preferably linear, channel connecting a third edge and a fourth edge, wherein said internal channel is preferably located at a distance from both the lower side of the panel and/or the upper side of the panel, and wherein each of the third edge and fourth edge preferably connects the first edge and the second edge. Preferably, each channel is situated at a distance from both the first edge and the second edge. A plurality of these channels may be applied, preferably arranged in a side-by-side orientation (lateral orientation). The cross-sectional shape of the channel may, for example, be round or polygonal, preferably polygonal with rounded corners. These one or more channels save material and weight. These one or more channels may easily be realized by means of extrusion, optionally by means of co-extrusion. In this latter case, at least one channel may partially be bordered by a first extruded panel layer and may for a remaining part be bordered by at least one other extruded panel layer. It is imaginable that the one or more channels are connected to the lower side of the panels. This typically leads to a panel with a rake-shaped or fork-shaped cross-section, wherein the channels of each pair of adjacent channels, if multiple channels are applied, are mutually separated by a downwardly extending leg. A lower portion of said leg may be widened with respect to the centre portion and/or upper portion of said leg. This may improve the stability of the panel.
The upper side of the panel may have a relief structure. This relief structure may be entirely functional, for example, to improve the anti-slip properties of the panel, but may also be aesthetical to improve the look and feel properties of the panel. A relief structure which is both functional and aesthetically attractive is also imaginable. The relief structure is, for example, an extruded relief structure and/or a pressed relief structure and/or a printed relief structure, preferably digitally printed relief structure. In an embodiment, the relief structure comprises a plurality of parallel oriented elongated excavations connecting the third edge and the fourth edge. These elongated excavations may also be referred to as top grooves. At least two of these excavations preferably run in parallel. Additionally or alternatively, at least two of these excavations may intersect and mutually enclose an angle, for example an angle of 90 degrees, 60, 45, or 30 degrees. Other angles are also possible. At least two excavations preferably run in length direction of the panel, which is typically, dependent on the panel design, parallel to the first and second edges. Such an orientation is often preferred from an aesthetic point of view. It is however also imaginable, and sometimes preferred, that the elongated excavations run in a transverse direction, thereby connecting the first edge and the second edge. This orientation typically reduces the length of the elongated excavations compared to a lengthwise orientation. This transverse orientation may, however, be more efficient for drainage of water, as the water drainage path will be shortened in this way, starting from a centre portion of an excavation. Irrespective of the excavation orientation, it may be preferred that the depth of at least one excavation increases towards at least one edge to which said excavation connects, which may be the first edge, the second, the third edge, or the fourth edge (or another edge) depending on the panel and excavation design. Preferably, the depth of at least one excavation that increases from a central portion of the upper surface towards the third edge and fourth edge of the panel. Such inclination(s) may force water to move towards the edge(s) where the water can be drained. This typically reduces the slipperiness of the panel, in particular in wet condition, and moreover, reduces the risk of moss formation onto the panel(s).
The excavations preferably have a maximum depth greater than 0.1 millimetre, in particular 0.5 millimetre. The excavations may be formed in various way, for example by milling (excavating), by pressing, by printing, and/or during extrusion of the panel (or a part of the panel).
Preferably, the décor layer and/or relief structure is/are shaped to represent a pattern, such as a wood pattern, that is to say the veining and knots of a wood pattern, a stone or a concrete pattern, a resin or any other design or pattern, such as an—optionally customized—image pattern. Preferably, the pattern is at least partially formed by a printed graphic element. The printing is preferably carried out using contactless printing methods such as digital inkjet printing or screen printing, since this makes it possible to print in high resolution even on the irregular configuration of a distressed edge. However, there is no reason why other printing techniques such as flexography, offset printing or rotogravure should not be used. Evidently, the pattern may comprise a colour or black and white design, but it may also be formed by solid colouring, in which case other decorative techniques are possible, such as aerography or cascade or film decoration. It is also imaginable that the décor layer and/or relief structure covers not only the top side of the panel, but also other sides of the panel, such as one or more, e.g. two or four, sidewalls of the panels, and/or the lower side of the panel. It is also possible that the panel is decorated with a whole body technique, that is to say one in which at least one pigment is mixed, according to a predefined design or in a random manner, with a base material of the panel, which is typically a polymer material, such as a thermoplastic material, like PVC, PP, PET, TPU, etcetera, which colours a part or preferably the whole thickness of the panel rather than just its upper surface. Furthermore, there is no reason why the pattern should not be applied to a suitable pre-printed substrate to be fixed to the support, for example a sheet of paper or plastic, PVC for example, which is affixed, e.g. glued or welded, onto a core layer of the panel, in particular where the core layer is wood-based and/or polymer-based.
According to an embodiment of the invention, the lower side of the panel may comprise a second relief structure. In particular, the second relief structure may have one or more of the characteristics described in relation to the relief structure of the upper surface. Preferably, each surface may represent a specific pattern, so that, during installation, the user can choose which surface is to be visible. For example, the second relief structure may be substantially specular to the relief structure of the upper surface, so that the weight and quantity of material is substantially balanced between the surfaces.
In a preferred embodiment, the panel, or at least one panel layer, is at least partially composed of at least one polymer material, preferably a thermoplastic material, wherein said polymer material is preferably enriched with at least one filler. Preferably, the thermoplastic material is chosen from the group consisting of: PVC, PET, PP, PS, thermoplastic polyurethane (TPU), PE, in particular MDPE and/or HDPE; and combinations thereof. PS may be in the form of expanded PS (EPS) in order to further reduce the density of the panel, which leads to a saving of costs and facilitates handling of the panels. Also in case another thermoplastic material is used, this material may be applied in foamed state in the core to reduce the density and costs. Nevertheless, it is also imaginable, and typically preferred, that the thermoplastic material used as main polymer is a solid polymer (i.e. an unfoamed polymer). Preferably, at least a fraction of the polymer used may be formed by recycled thermoplastic, such a recycled PVC or recycled PU. An advantage of thermoplastic material is that this material is typically suitable to be extruded, which allows the panel, or at least a part thereof, to be made by means of extrusion and/or co-extrusion. It is conceivable that a mix of virgin and recycled thermoplastic material is used to compose at least a part of the core. Instead of the thermoplastic material, also a thermoset polymer may be used, such as thermoset polyurethane.
As indicated above, said at least one polymer is preferably enriched with at least one filler. These one or more fillers can be applied to provide additional desired properties to said polymer(s) and/or to said panel. Preferably, at least one filler is preferably selected from the group consisting of: talc, chalk, wood, bamboo, cotton, coffee, limestone, calcium carbonate, titanium dioxide, calcined clay, porcelain, glass, carbon particles, metal, silicon particular, a(nother) mineral filler, such as marble dust, a(nother) natural filler, a(nother) (auxiliary) polymer, such as an elastomer and/or latex. It is also imaginable that rubber and/or elastomeric parts (particles) are dispersed within the polymer (matrix) to improve the flexibility and/or impact resistance at least to some extent. Although the panel is preferably rigid, the panel may also be semi-flexible, or flexible. The filler may be formed by fibres, such as glass fibers or synthetic or genuine leather fibers, and/or may be formed by dust-like particles. Here, the expression “dust” is understood as small dust-like particles (powder), like bamboo dust, wood dust, cork dust, or non-wood dust, like mineral dust, stone powder, in particular cement, and combinations thereof. The average particle size of the dust is preferably between 14 and 20 micron, more preferably between 16 and 18 micron. The filler may also be in the form of at least one layer, such as a woven and/or non-woven layer, preferably used to reinforce the panel. Hence, such a layer may also be referred to reinforcement layer. Alternatively or additionally, the filler may be in the form at least one filament, preferably a reinforcement filaments. These filaments are typically continuous strands and/or continuation filament yarns. These filler layer(s) and/or filler filament(s) are typically embedded in the polymer, and preferably extend between at least two opposing panel edges. This embedment can e.g. be realized by means of extrusion, for example by continuously placing at least one reinforcement filament (or filler layer) within molten thermoplastic polymer feed material as the thermoplastic polymer feed material is extruded through a die to form the panel (or a part thereof).
A primary role of this kind of filler can be to provide the panel sufficient hardness and/or to decrease the cost price of the panel, and/or to adjust other panel properties. Moreover, this kind of filler will typically also improve the impact strength of the core and of the panel as such. Preferably, and in particular in case an inert filler (e.g. calcium carbonate) is used, the filler content in the composite material of the panel, in particular of a core of the panel (which may be the sole panel layer), is between 30 and 75% by weight of the composite material of the core, more preferably between 50 and 60% by weight of the composite material of the core. Preferably, the polymer content in the composite material of the core is between 25 and 70% by weight of the composite material of the core, more preferably between 40 and 50% by weight of the composite material of the core. As indicated above, the polymer can either be foamed or unfoamed. Additionally or alternatively, preferably at least one filler is used selected from the group consisting of: a salt, a stearate salt, calcium stearate, and zinc stearate. Stearates have the function of a stabilizer, and lead to a more beneficial processing temperature, and counteract decomposition of components of the composite during processing and after processing, which therefore provide long-term stability. Instead of or in addition to a stearate, for example calcium zinc may also be used as stabilizer. The weight content of the stabilizer(s) in the composite will preferably be between 1 and 5%, and more preferably between 1.5 and 4%. Additionally or alternatively, the panel preferably comprises at least one impact modifier comprising at least one alkyl methacrylate, wherein said alkyl methacrylate is preferably chosen from the group consisting of: methyl methacrylate, ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, t-butyl methacrylate and isobutyl methacrylate. The impact modifier typically improves the product performance, in particular the impact resistance. Moreover, the impact modifier typically toughens the core layer and can therefore also be seen as toughening agent, which further reduces the risk of breakage. Often, the modifier also facilitates the production process, for example, as already addressed above, in order to control the formation of the foam with a relatively consistent (constant) foam structure. The weight content of the impact modifier in the composite will preferably be between 1 and 9%, and more preferably between 3 and 6%. At least one plastic material used in the panel is preferably free of any (toxic) plasticizer in order to increase the desired rigidity of the core layer, which is, moreover, also favourable from an environmental point of view. At least one filler applied in the panel may be a virgin filler, a recycled filler, and/or a combination thereof. For example, in case cotton is used as filler, recycled cotton (e.g. derived from recycled jeans or denim) may be used, and/or a combination of recycled cotton or virgin cotton. The panel, a core of the panel and/or another panel layer may comprise wood-based material, for example, MDF, HDF, wood dust, bamboo, prefabricated wood, more particularly so-called engineered wood. This wood-based material may be part of a composite material of the core. Alternatively, the panel and/or the panel core is at least partially composed of another base material, such as a mineral material, like magnesium oxide, magnesium hydroxide, gypsum, (lightweight) concrete, and/or clay; and/or a wood or a wood-based material, such as HDF or MDF, or any other thermoplastic-free material, may be used as base material.
The density of the core typically varies from about 0.1 to 1.5 grams/cm 3, preferably from about 0.2 to 1.4 grams/cm 3, more preferably from about 0.3 to 1.3 grams/cm 3, even more preferably from about 0.4 to 1.2 grams/cm 3, even more preferably from about 0.5 to 1.2 grams/cm 3, and most preferably from about 0.6 to 1.2 grams/cm 3. It is imaginable that each panel comprises a plurality of core (sub)layers. Different core (sub)layers may have either identical compositions or different compositions, and/or different densities.
The invention also relates to a covering at least partially composed of a plurality of interconnected and/or interconnectable panels according to the invention.
The invention further relates to a panel system for composing a floor covering or wall covering, in particular for outdoor use, comprising:
The panel system according to the invention, which can be used as outdoor panel system and/or as indoor panel system, comprises one or more panels, each panel having at least one bottom groove at its bottom side, for accommodating at least a part of at least one first support structure. This accommodation leads to a limited movement of the panels with respect to each other and with respect to the first support structure(s), which facilitates the realization of a stable covering, such as a floor covering or wall covering. Further advantages and embodiments of the panel system and its components are presented below.
Preferably at least one bottom groove of at least one panel is a transverse bottom groove, which preferably extends in a direction substantially perpendicular to a longitudinal axis of the panel. Preferably, at least one bottom groove of at least one panel connects (to) opposing panel edges. It is imaginable that one or more bottom grooves present at the bottom side of the panel enclose an angle with a longitudinal axis of the panel. It is imaginable that in case more bottom grooves are present at the bottom side of the panel that at least two of these bottom grooves run parallel and/or that at least two of these bottom grooves mutually enclose an angle, such as an angle between 15 and 165 degrees. It is imaginable that at least two bottom grooves of a panel mutually intersect. This latter provides more flexibility to install the panel onto a first support structure, and in particular provides more freedom on how to orient said panel with respect to said support structure. The installation pattern options can be increased by this latter option.
Each panel is preferably fixated with respect to the first support structure during installation of the panel system. This fixation is preferably such that it can be done easily, preferably without damaging the panel and/or the first support structure to allow a smooth de-installation. The fixation is preferably realized in horizontal direction and/or vertical direction, preferably in both horizontal direction and vertical direction. This fixation is preferably realized without using separate clips and/or other mechanical or chemical fastening means, which may e.g. be realizing by providing the panel(s) and/or first support structure(s) by one or more coupling profiles which allow each panel and each first support structure to be interlocked (coupled). It is however imaginable that separate clips and/or other mechanical and/or chemical fastening means are alternatively or additionally used to realize and/or to improve this mutual fixation.
The bottom groove(s) in of each panel may be elongated and/or may be formed by a cavity, slot, recess, impression, or alternative accommodating space. The bottom groove(s) may be linear and/or curvilinear, and/or may have an alternative shape, such as cross-shaped or square-shaped. Hence, the bottom groove may have different shapes, but is preferably linear, elongated (hence rectangular and oblong) and preferably connects opposing panel edges.
The panel system preferably comprises at least one panel according to the invention, and at least one first support structure configured to be partially accommodated within at least one pair of aligned accommodating spaces and/or bottom groove, preferably transverse bottom groove, applied in the lower side of said panel.
By inserting a part, in particular a top part, of the first support structure into at least one cavity or groove or alternative accommodating space, mutually displacement of the panel(s) and the first support structure during normal use can be counteracted, and/or minimized, and/or even eliminated, being in favour of the stability of the panel and a covering at least partially formed by a plurality of interlocked panels, during normal use.
Preferably, at least one panel at least one third coupling profile, and at least one first support structure comprises at least one fourth coupling profile configured to interlockingly engage with said third coupling profile. This interlocking is preferably such that said panel can be locked with respect to the first support structure in horizontal direction and/or vertical direction, preferably in both directions.
Preferably, at least one accommodating space and/or at least one bottom groove, preferably transverse bottom groove, of at least one panel comprises at least one third coupling profile, and wherein said first support structure comprises at least one fourth coupling profile configured to interlockingly engage with said third coupling profile, in horizontal direction and/or vertical direction. Such an interlocking engagement will further contribute to create a stable floor covering (or wall covering). In a preferred embodiment, the third coupling profile comprises at least one third tongue, preferably a third sideward tongue, and wherein the fourth coupling profile comprises at least one fourth groove configured to receive at least a part of at least one third sideward tongue, wherein said fourth groove is preferably defined by a fourth upper lip and a fourth lower lip. The third coupling profile preferably comprises two facing third sideward tongues which are at least partially positioned in the same plane at a distance from each other, wherein a space enclosed by said two third sideward tongues is configured to accommodate a part of at least one fourth coupling profile. From a cross-sectional view, the sideward tongues and the enclosed space together preferably form a symmetric arrangement. The application of a plurality of opposing, distant, third sideward tongues allow the panels to be mounted onto the support structure(s) in two directions, which makes a pre-alignment between panel and support structure less critical, which facilitates the installation of the system. Preferably, the fourth groove is configured to clamp at least one third sideward tongue. In this manner a horizontal locking effect between the third coupling profile and second coupling profile can be realized. Additionally, or alternatively, the third coupling profile may comprise at least one third locking element, such as a bulge and/or recess, and the fourth coupling profile may comprise at least one fourth locking element, such as a recess and/or bulge, configured to co-act with said third locking element(s) of an adjacent panel. In this manner, an additional locking effect, preferably in horizontal direction (and/or in vertical direction) may be realized. This counteracts undesired uncoupling of the panel(s) with respect to the (first) support structure(s). Preferably, the fourth lower lip is configured to support at least a third sideward tongue. The fourth lower lip may for example be formed by a horizontal plane and/or strip or alternative, optionally more spatial structure, with a supporting upper surface, preferably a horizontal supporting upper surface. The lower side of the third sideward tongue preferably coincides with and/or is formed by (or is forming) the lower side of the panel. The fourth upper lip is provided with at least one upwardly protruding ridge, which, in coupled condition of adjacent panels, is situated in between facing, distant surfaces, preferably chamfered and/or curved surfaces, of at least one third coupling profile. This typically leads to additional locking of the panel with respect to the (first) support structure. Preferably, the upwardly protruding ridge is configured to support the panel. This could reduce the local load and local pressure, which will be in favour of the load capacity of the (first) support structure. Preferably, each third coupling profile and each fourth coupling profile are configured to be coupled by means of a translational movement, preferably by means of a translation movement only, in particular in a (horizontal) direction parallel to the plane defined by the panel.
Preferably, the fourth coupling profile(s) make(s) integral part of the first support structure. This can e.g. be realized by means of extrusion, or alternatively by means of injection-moulding.
The panel system according to the invention preferably comprises a plurality of interlockable or interlocked panels, wherein first coupling profiles of at least one panel are configured to engage interlockingly with second coupling profiles of at least one other panel, such that pairs of aligned accommodating spaces of adjacent panels are aligned with each other and/or such that bottom grooves, preferably transverse bottom grooves, of adjacent panels are aligned with each other to collectively accommodate a part of at least one first support structure. Hence, the first support structure is preferably configured to simultaneously support a plurality of interconnected panels. To this end, it is favourable in case the length of the first support structure(s) is at least n times the panel width, wherein n is at least two and preferably at least five, more preferably at least ten. Preferably, the assembly of interlocked panels comprises third coupling profiles which interlockingly engage with at least one fourth coupling profile of said first support structure. Typically, the panel system comprises a plurality of first support structures. Preferably, a plurality of support structures, which may be first support structures, is oriented at a distance d from each other and in a parallel manner, wherein each first support structure interlockingly engages with a plurality of mutually interlocked panels. Said distance d is preferably at least 40 centimetre and/or preferably less than 150 centimetre. This allows a stable support of the panel for normal use e.g. as walking surface. For more heavy use, for example for transporting vehicles over said covering, the distance d can be reduced to a value below 40 centimetre.
An inversed embodiment is also imaginable, wherein the third coupling profile comprises a groove configured to accommodate at least a part of at least one tongue of the fourth coupling profile. The same applies to the above discussed further embodiments of the third coupling profile and fourth coupling profile.
The first support structure(s) is also referred to as active support structure. Additionally, the panel system preferably comprises at least one second support surface, free of any coupling profiles, configured to merely support at least one panel, preferably a plurality of mutually interlocked panels. Interlocked panels are preferable supported by an assembly of first and second support structures. Second support structures typically do not lock the panels in place and rather have a mere supporting function. The advantage of these second support structures is that the panels do not have to be weakened by accommodating spaces and/or grooves applied in the lower side of the panels at the supporting location of the second support structure, which will be in favour of maintaining the panels as strong and robust as possible. Preferably, the at least one (first and/or second) support structure comprises levelling feet, such as levelling screws, to level the support structure onto a subfloor. In this way the support structures can be mounted onto said subfloor in an entirely horizontal manner, or, if desired, at a slightly inclined manner e.g. to facilitate water drainage. Preferably, the panel system comprises at least one base plate configured to simultaneously support a plurality of levelling feet. In this manner a favourable load distribution of the levelling feet can be realized, which will be in the benefit of the stability of the support structure(s), and hence of the panel system as such.
The invention additionally relates to a first support structure for use in a panel system according to the invention.
The invention moreover relates to a method of composing a covering, in particular a floor covering, by using a panel system according to the invention, comprising the steps of:
Typically, step D) is performed prior to step E), although an inversed order (step E) prior to step D)) is also well imaginable. During step E) the first support structures, and the distance therein between preferably are aligned with the panels to be coupled to said first support structures in order to allow third coupling profiles of the panels to co-act with fourth coupling profiles of the first support structures to lock (fixate) the panels with respect to the first support structure. The method preferably also comprises step G) comprising the step of levelling each support structure with respect to the subfloor, wherein step G) is preferably performed prior to step F).
Further embodiments are described in the non-limitative set of clauses presented below:
Clauses
The present invention will hereinafter be further elucidated on the basis of the following non-limitative figures, wherein:
In respect of
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. Various embodiments of the panel as described above and in the appended claims may be combined with this alternative panel configuration.
By “horizontal” is meant a direction which extends parallel to a plane defined by the floor panel, and which may intersect the core. By “vertical” is meant a direction which is perpendicular to said plane defined by the floor panel. The ordinal numbers used in this document, like “first”, “second”, and “third” are used only for identification purposes. Hence, the use of the expressions “third coupling profile” and “fourth coupling profile” does therefore not necessarily require the co-presence of a “first coupling profile” and/or “second coupling profile”.
By “complementary” coupling profiles is meant that these coupling profiles can cooperate with each other. However, to this end, the complementary coupling profiles do not necessarily have to have complementary forms. The panel according to the invention may be applied, for example, as floor panel, but also as also applied as wall covering element, ceiling covering element, or alternative covering element. In this document, the directional expression “horizontal”
should be understood as being parallel to or falling together with a plane defined by the panel(s), and the direction expression “vertical” should be understood as perpendicular to the plane of the panel(s).
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 |
|---|---|---|---|
| 2032731 | Aug 2022 | NL | national |
