Decorative article with multilayered porosity base

Abstract

The present disclosure provides an improved trim article useful as a trim floor panel. A decorative article includes a laminate structure having a core layer and a top layer. The core layer includes separate upper and lower sections having different resistance to compressibility such that the upper section of the core layer exhibits a lower resistance to compressibility than the lower section. In some embodiments, for example, the upper and lower sections of the core layer may be foamed layers having different porosities and densities. In some disclosed embodiments, the top layer over the core layer may include a coating, a wear layer, and a finish layer. According to some embodiments, a plurality of apertures may extend through the top layer, or through only a portion of the top layer, to further improve acoustic performance of the decorative article.

Description

(19) State Intellectual Property Office (12) Invention Patent Application (10) Application Publication Number (43) Application Publication Date (21) Application Number 202480032987.7 (22) Application Date 2024.10.02 (30) Priority Data 63 / 601,993 2023.11.22 US PCT / US24 / 021611 2024.03.27 US (85) PCT International Application Entering National Phase Date 2025.11.17 (86) PCT International Application Application Data PCT / US2024 / 049590 2024.10.02 (87) PCT International Application Publication Data WO2025 / 111062 EN 2025.05.30 (71) Applicant: Xiao Industrial Group Co., Ltd. Address: Georgia, USA (72) Inventors: A. Drevit, S. Liao, Ouyang Jing (74) Patent Agency: China Patent Agency (Hong Kong) Ltd. 72001 Patent Attorney: Wu Junhou, Yun Zhong (51) Int.Cl. B32B 27 / 22 (2006.01) B32B 5 / 18 (2006.01) E04F 15 / 022 (2006.01) (54) Invention Title: Decorative Article with Multilayer Porous Base (57) Abstract: This disclosure provides an improved decorative article that can be used as a decorative floor panel. The decorative article includes a laminated structure having a core layer and a top layer. The core layer includes separate upper and lower segments with different compressibility resistance, such that the upper segment of the core layer exhibits lower compressibility resistance than the lower segment. In some embodiments, for example, the upper and lower segments of the core layer may be foamed layers with different porosities and densities. In some disclosed embodiments, the top layer above the core layer may include a coating, an abrasion layer, and a finishing layer. According to some embodiments, a plurality of holes may extend through the top layer, or through only a portion of the top layer, to further improve the acoustic performance of the decorative article. Claims 2 pages, Description 14 pages, Drawings 11 pages, CN 121175189 A 2025.12.19 CN 1 21 17 51 89 A 1. A decorative article comprising: a top layer including a finishing layer and an abrasion layer; and a core layer including an upper segment and a lower segment, the upper segment having lower compressibility than the lower segment, and wherein the upper segment comprises a foamed thermoplastic material and a plasticizer, wherein the top layer is positioned above the upper segment of the core layer, and the upper segment of the core layer is positioned above the lower segment of the core layer, and wherein the lower segment of the core layer includes a locking system configured to interconnect with at least one adjacent decorative article. 2. The decorative article of claim 1, wherein the decorative article is a decorative floor panel.3. The decorative article of claim 1, wherein the ratio of the thickness of the upper segment of the core layer to the thickness of the lower segment of the core layer is between about 0.2 and about 0.6. 4. The decorative article of claim 3, wherein the thickness of the upper segment of the core layer is in the range of about 1 mm to about 4 mm. 5. The decorative article of claim 1, wherein the upper segment of the core layer has a density between 1350 and 1700 kg / m³. 6. The decorative article of claim 1, wherein the lower segment of the core layer comprises a foamed thermoplastic material. 7. The decorative article of claim 1, wherein the upper segment of the core layer comprises at least 50 phr of plasticizer. 8. The decorative article of claim 7, wherein the upper segment of the core layer comprises at least 75 phr of plasticizer. 9. The decorative article of claim 1, wherein the upper segment of the core layer is a separate material layer attached to the top surface of the lower segment of the core layer. 10. The decorative article of claim 1, wherein the compressibility of the lower segment of the core layer is approximately twice that of the compressibility of the upper segment of the core layer. 11. The decorative article of claim 1, wherein the compressibility of the upper segment is between approximately 4% and approximately 20%. 12. The decorative article of claim 11, wherein the compressibility of the upper segment is between 5% and 8%. 13. The decorative article of claim 1, wherein the upper segment has a Shore D surface hardness of approximately 50. 14. The decorative article of claim 1, wherein the lower segment has a Shore D surface hardness of approximately 55. 15. The decorative article of claim 1, wherein the finishing layer is located less than 0.2 mm above the upper segment of the core layer. 16. The decorative article of claim 1, wherein the locking system is formed along the outer edge of the lower segment of the core layer. 17. The decorative article of claim 16, wherein the locking system is a latch-type locking system. 18. The decorative article of claim 1, further comprising a resilient soft layer beneath the core layer. 19. The decorative article of claim 1, wherein the lower segment of the core layer comprises a honeycomb structure.20. A decorative article comprising: a top layer including a finishing layer and an abrasion-resistant layer; and a core layer including an upper segment and a lower segment, the upper segment having lower compressibility than the lower segment, wherein the upper segment comprises a thermoplastic material and a plasticizer, wherein the top layer is positioned above the upper segment of the core layer, and the upper segment of the core layer is positioned above the lower segment of the core layer, and wherein the lower segment of the core layer includes a locking system configured to interconnect with at least one adjacent decorative article. 21. The decorative article of claim 20, wherein the thermoplastic material comprises a foamed thermoplastic material. 22. The decorative article of claim 20, wherein the upper segment of the core layer comprises a plasticizer between approximately 70 and 80 phr. 23. A decorative article comprising: a top layer including a finishing layer; and a core layer including an upper section, a middle section, and a lower section, the middle section having greater compressibility resistance than the upper section of the core layer, wherein the upper section comprises a foamed thermoplastic material and a plasticizer, wherein the top layer is positioned above the upper section of the core layer, the upper section of the core layer is positioned above the middle section of the base layer, and the middle section of the core layer is positioned above the lower section of the core layer, and wherein the middle section of the base layer includes a locking system configured to interconnect with at least one adjacent decorative article. 24. The decorative article of claim 23, wherein the upper section of the core layer comprises at least 50 phr of plasticizer. Claims 2 / 2 Page 3 CN 121175189 A Decorative article having a multilayered porous base

[0001] Priority This application claims the benefit of priority to Patent Cooperation Treaty (PCT) International Application No. PCT / US24 / 21611, filed March 27, 2024, entitled “Decorative Article With Multilayered Porosity Base” (which subsequently claims priority to U.S. Provisional Application Serial No. 63 / 454,881, filed March 27, 2023, entitled “Decorative Article With Multilayered Porosity Base”), and also claims the benefit of priority to U.S. Provisional Application Serial No. 63 / 601,993, filed November 22, 2023, all of which are hereby incorporated in their entirety by reference, as if fully set forth herein.Technical Field

[0002] This disclosure generally relates to decorative articles, and more particularly, to a novel decorative article having a multi-layered compressible structure for a base layer and improved acoustic effects. Background Art

[0003] Conventional decorative articles, such as decorative surface coverings, are typically made of hardwood or other materials. Natural wood panels can warp, bend, crack, swell, thermally expand, etc., under a variety of environmental conditions. For this reason, decorative articles formed using more rigid and environmentally stable composite materials have become more common in both residential and commercial installations. Summary of the Invention

[0004] Decorative articles (such as decorative floor coverings) are typically formed as laminated structures comprising a rigid base layer and a decorative layer (finishing layer) often designed to mimic the appearance of natural hardwood or stone. The rigid base layer (such as materials including wood-plastic composites (WPC), stone-plastic composites (SPC), expanded plastic composites (EPC), or rigid composite boards (RCB)) may have a locking system that is formed directly (e.g., milled) into the rigid base layer and is strong enough to ensure long-term locking between adjacent decorative articles of similar construction. In contrast, flexible substrates (such as those used in many luxury vinyl tiles (LVT)) do not have such locking systems formed in the substrate because, due to the flexibility of the material, the locking system would be too weak to securely interlock adjacent decorative elements. As used herein, a rigid substrate can be any substrate, including semi-rigid substrates that can support locking systems formed in the substrate in accordance with the exemplary embodiments disclosed herein.

[0005] Conventional rigid substrates can be formed from various types of thermoplastics, such as polyvinyl chloride (PVC), polyurethane (PU), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), etc. Natural or synthetic fibers, powders, and / or fillers can be added to the thermoplastic matrix material (binder) to form a composite for the rigid substrate. For example, a wood-plastic composite may include a thermoplastic binder in combination with wood fibers or other natural or synthetic fillers, fibers, and / or powders. For example, a stone-plastic composite may include a thermoplastic binder in combination with limestone powder or other mineral powders or fillers, wherein the weight percentage of the filler is greater than the weight percentage of the thermoplastic.

[0006] To form a decorative floor panel, a finishing layer is positioned above a rigid base layer within a laminated structure. The finishing layer may include a pattern or image that visually resembles the appearance of natural wood or stone (or any other suitable and desired appearance). A protective layer may be formed above the finishing layer to protect its pattern or image from wear and tear (e.g., due to foot traffic). The laminated structure may include a layer beneath the rigid base layer, for example, for cushioning or stability.

[0007] Decorative floor panels can be installed using various types of fastening or locking systems for interconnecting adjacent panels.For example, the rigid base layer of a decorative floor panel can be designed to include a tongue-and-groove portion along one of its outer edges and a grooved portion along the opposite edge. During installation, the tongue-and-groove along the edge of the first floor panel can be shaped to fit into the groove of the edge of the adjacent panel, thereby locking the two panels together to prevent both vertical and horizontal movement during floor installation. This process of interlocking adjacent floor panels can be repeated to fully cover the large floor area.

[0008] Decorative floor panels must include a sufficiently dense and rigid base layer to create a strong inter-panel locking system and to provide resistance to bending, warping, denting, cracking, etc., under normal loads. Due to the required hardness and rigidity of the base layer in conventional decorative floor panels, they can be excessively noisy and / or uncomfortable to walk on.

[0009] There is a need for improved decorative articles, such as improved decorative floor panels, which still provide the required density and stiffness to avoid harmful bending, warping, denting, cracking, etc., of the panels or damage to their locking systems, while simultaneously improving the acoustics and underfoot comfort (which may also include warmth) of the panels when a user walks on them. As used herein, acoustic effects may refer to sound generated or reflected in a room. Additionally, in some instances, acoustic effects may refer to room-to-room transmission of sound (e.g., from an upper room to a lower room or between adjacent rooms on the same floor).

[0010] The disclosed embodiments of the present invention provide improved decorative articles, such as decorative floor panels, having a laminated structure with at least a top layer and a base layer. In some disclosed embodiments, the decorative article may also include a resilient soft layer beneath the base layer, which may function as an anti-slip layer for loosely laid floor panels. In some embodiments, the resilient soft layer may be a separate layer having a specific texture and composition different from the base layer. For example, the resilient layer may include an underlay material adhered to or bonded to the bottom surface of or below the base layer, and may include rubber, LVT, or another dense material with good acoustic properties (e.g., compared to cork, irradiated cross-linked PE (IXPE), or EVA foam). In some instances, the resilient layer may include tacky or absorbent features (e.g., including micron or nanon absorbent features) at the bottom of the resilient layer. In other embodiments, the resilient layer may be integrally formed with the base layer, or in some embodiments, formed as a pattern on the bottom surface of the base layer. In some disclosed embodiments, the top layer positioned above the base layer may include a coating, an abrasion layer, and a finishing layer.

[0011] Unlike the rigid base layer in conventional decorative flooring panels, the base layer in the disclosed embodiments is preferably designed with separate upper and lower sections, such that the upper section has lower compressibility than the lower section. In some cases, the lower section of the base layer may have approximately twice the compressibility of the upper section.

[0012] For example, to measure the compressibility of each segment of the multi-layered base layer in a decorative flooring panel formed according to the disclosed embodiments, the inventors used a modified version of the ASTM 1914 test method (Standard Indentation Test). In this type of test, the inventors replaced the indenter plate and used a 28 mm circular indenter from ASTM 970 (Test for Recovery After Static Load); the inventors also reduced the time under pressure to 30 seconds and measured the compression rate after 30 seconds of loading. For this test, all pre-attached pads were removed because the inventors were only concerned with the surface properties of the decorative flooring panel. To measure sound reduction, the inventors recorded and measured the sound of a metal ball falling from a height of 12 inches onto the panel.

[0013] The inventors found that the compressibility of the upper segment of the tested decorative flooring panel correlated with a reduction in footstep sound, and the compressibility of the lower segment of the base layer correlated with the dent resistance of the decorative flooring panel product. The higher the compressibility of the upper segment of the base layer, the lower the footstep sound. However, for flooring applications, the dent resistance (or indentation resistance) of the decorative flooring panel is also preferred. If the compressibility of the decorative flooring panel is too high, it can lead to dents. Furthermore, the lower the compressibility of the lower section of the subfloor, the higher the snap-fit ​​strength of the decorative flooring panel (e.g., as measured according to ISO 24334).

[0014] According to the inventors' research, conventional resilient rigid flooring panels may have a core upper layer compressibility (e.g., measured as a percentage of compression or "compressibility" or "compressibility") between 2% and 4%. In contrast, some decorative flooring panels formed according to the disclosed embodiments have a larger upper section compressibility, for example, between approximately 5% and approximately 30%. The inventors recognized that an upper section compressibility greater than 10% can cause dent resistance to decrease to levels that may be unacceptable for some flooring applications. However, for some flooring applications, upper section compressibility exceeding 10% and up to 30% is within the scope of this disclosure. The inventors' research shows that a compressibility of approximately 5% to approximately 10% for the upper section represents a good trade-off: in some cases, this range of upper section compressibility can result in significant sound reduction while maintaining acceptable dent resistance. Conventional resilient rigid floor panels may have less than 5% compressibility for the sub-core section. Some of the inventors' test samples, with a sub-core lower section compressibility of approximately 4% and a sub-core upper section compressibility of approximately 8%, provide exemplary solutions for improved decorative floor panels with sufficient noise reduction and dent resistance for current market needs. The inventors have also manufactured other test samples, for example, with a sub-core lower section compressibility of approximately 2% and an upper section compressibility of approximately 5%.Based on the inventors’ research, a ratio of approximately two (2) of upper section compressibility to lower section compressibility appears to offer a good trade-off for quality, noise reduction, and cost. In some instances, the ratio of upper section compressibility to lower section compressibility is at least 1.5, or at least 1.6, or at least 1.7, or at least 1.8, or at least 1.9, or at least 2, for a good balance between desired or acceptable indentation resistance and sound / noise reduction.

[0015] The inventors’ research also found that the amount of indentation in the decorative flooring panels formed according to the disclosed embodiments can be less than 25%, as measured according to ASTM F1914. In some embodiments, for example, the amount of indentation measured by ASTM F1914 can be less than 20%, less than 15%, less than 10%, or less than 5%. Furthermore, in some disclosed embodiments, the amount of indentation in the decorative flooring panels, as measured by ASTM F1914, can be between approximately 1% and approximately 25%.

[0016] The inter-panel locking system is formed only in the less compressible lower section of the substrate, such as by milling tongues and grooves or other locking systems (or any other audible cue generation system used to indicate locking) along its edges. Advantageously, the lower section of the substrate can be rigid and stiff enough to support a strong inter-panel locking system and provide resistance to bending, warping, denting, cracking, etc., while the more compressible upper section can provide a softer, more comfortable, and improved acoustic effect (e.g., less noisy footsteps) compared to conventional decorative flooring panels.

[0017] According to some embodiments, both the upper and lower sections of the substrate may include air pockets. For example, both the upper and lower sections of the substrate may be foamed. In some disclosed embodiments, the size and / or distribution of the air pockets formed in the upper and lower sections of the substrate may differ, such that the average density of the upper section may be less than the average density of the lower section (at least in part due to their different porosities). For this purpose, the upper section of the substrate may contain, on average, larger and / or more air pockets than in the lower section. Preferably, the cavities in the lower section are small and spaced sufficiently so that they do not create significant gaps that would prevent auditory feedback from building up to the latching system in the lower section, and also maintain sufficient structural strength and impact resistance of the base layer. In some instances, the upper section of the base layer may have a higher density than the lower section of the base layer. In other instances, the upper and lower sections may have substantially the same density. In some instances, the density of the upper section of the base layer may be between about 700 kg / m³ and about 1700 kg / m³, such as at least 900 kg / m³, or between 900 kg / m³ and 1450 kg / m³, or between 1000 kg / m³ and 1450 kg / m³, or between 1100 kg / m³ and 1450 kg / m³.

[0018] In one or more embodiments, the density of the upper section of the base layer may be between 1350 and 1700 kg / m³.For example, in some exemplary embodiments, the density of the upper section may be between 1400 and 1600 kg / m³. In some other exemplary embodiments, the density of the upper section may be about 1500 kg / m³, wherein a variation of + / - 50 kg / m³ is within the range of this disclosure. In some exemplary embodiments, the density of the lower section of the base layer (e.g., when the lower section includes WPC) may be between 800 and 1100 kg / m³. In some exemplary embodiments, the density of the lower section of the base layer (e.g., when the lower section includes WPC) may be about 1000 kg / m³, wherein a variation of + / - 50 kg / m³ is within the range of this disclosure as stated on page 3 / 14 of CN 121175189 A.

[0019] In one or more embodiments, both the top and bottom surfaces of the upper section of the base layer may have a Shore D surface hardness of about 50, wherein a variation of up to + / - 9 is within the range of this disclosure. In some embodiments, the Shore D surface hardness of the upper section of the base layer can be measured as the surface hardness of the upper section in combination with one or more other layers, such as coatings, abrasion layers, and / or finish layers disposed above the upper section of the base layer. Therefore, as used herein, the surface hardness of the upper section of the base layer (or any surface thereof) can correspond to the surface hardness of the upper section alone or in combination with one or more other layers. In some instances, both the top and bottom surfaces of the upper section of the base layer can have a Shore D surface hardness of about 50, with a variation of up to + / - 5 within the range of this disclosure. In some embodiments, the Shore D hardness of the top and bottom surfaces of the upper section of the base layer can be the same, or can be slightly different from each other, while still being about 50, with a variation of up to + / - 5 within the range of this disclosure. In one or more embodiments, both the top and bottom surfaces of the lower section of the base layer can have a Shore D surface hardness of about 55, with a variation of up to + / - 5 within the range of this disclosure. The Shore D hardness of the top and bottom surfaces of the lower section of the base layer may be the same or may be slightly different from each other, while still being about 55, with a variation of up to + / - 5 within the scope of this disclosure. As used herein, the surface hardness of the lower section of the base layer (or any surface thereof) may correspond to the surface hardness of the lower section alone or in combination with one or more other layers. In one or more exemplary embodiments, the Shore D surface hardness of the top and / or bottom surfaces of the lower section of the base layer may be greater than the Shore D surface hardness of the top and / or bottom surfaces of the upper section of the base layer.

[0020] In some disclosed embodiments, cavitation in the upper and lower sections of the base layer may be formed using a foaming agent (such as a mechanical or chemical foaming agent) added to the thermoplastic binder during the manufacturing process. In such embodiments, a “foamed” base layer may be created that contains cavitation in both its upper and lower sections.Examples of foaming agents may include Expandex® 5-PT, AIBN (azobisisobutyronitrile), ADC (azodicarbonamide), or any other suitable foaming agent. Different amounts of foaming agent and / or different foaming agents may be added to the thermoplastic binder in each of the upper and lower sections to create different amounts of foam in each section of the substrate. Utilizing foamed upper and lower sections in the substrate can reduce the total amount of material required to produce decorative flooring panels, resulting in lighter and more affordable products than previously available in the residential flooring market.

[0021] While both the upper and lower sections of the substrate may be foamed in some embodiments, in other embodiments, the upper section may be foamed while the lower section of the substrate is not. More generally, the lower section of the substrate may contain relatively fewer voids (or may have none) compared to the upper section, resulting in a relatively less compressible lower section capable of supporting a robust locking system, and a relatively more compressible upper section for providing improved acoustics and / or comfort. In some embodiments, the lower segment may include a distribution of voids formed using a non-foaming process (such as extrusion molding or one or more other processes for forming voids). In such embodiments, voids of various sizes, shapes, and / or distributions may be formed in one or more areas of the lower segment. In some disclosed embodiments, the pattern shape of the void areas in the lower segment may resemble a honeycomb pattern. Those skilled in the art will recognize that, in alternative embodiments, the voids in the lower segment may include any other geometry and / or pattern. Furthermore, in some disclosed embodiments, the lower segment of the base layer may be formed without intentionally creating any voids therein.

[0022] In some disclosed embodiments of the invention, the base layer may further include an intermediate segment between the upper and lower segments of the base layer. Moreover, in some exemplary embodiments, the upper and lower segments of the base layer may be foamed, while the intermediate segment may not be foamed. For example, instead of cavities that may be formed in the upper and lower segments of the base layer by a chemical or physical foaming process, the intermediate segment may include a distribution of voids formed using a different process (such as extrusion molding or one or more other processes for forming voids). In such embodiments, voids having various sizes, shapes, and / or distributions may be formed in one or more areas of the intermediate segment. For example, the pattern shape of the void areas in the intermediate segment may resemble a honeycomb pattern. Those skilled in the art will recognize that, in alternative embodiments, the voids in the intermediate segment may include any other geometry and / or pattern.

[0023] In the disclosed embodiments in which the base layer includes an upper segment, an intermediate segment, and a lower segment, both the upper and lower segments may have lower compressibility resistance compared to the compressibility resistance of the intermediate segment.In some embodiments, for example, the upper and lower sections may be formed to have compressibility resistance that is substantially the same as, but less than, that of the middle section; in other embodiments, the upper and lower sections may have different compressibility resistances, but again, each of their compressibility resistances is lower than that of the middle section. As an example, the compressibility resistance of the middle section in the base layer may be at least twice that of each of the upper and lower sections. The inter-panel locking system may be formed only in the less compressible middle section of the base layer, such as by milling tongues and grooves or other locking systems along its edges.

[0024] According to the disclosed embodiments, there may be different ways in which multi-layer base layers comprising upper and lower sections can be formed. In some embodiments, the base layers may be formed using a fully mechanical forming process, wherein the material of the base layers undergoes plastic deformation and is obtained to their desired shape and size by applying appropriate forces. Because material is not removed in some mechanical forming processes, the material of the base layer may be able to be recycled from one decorative floor panel to the next, making the base layer of one floor panel replaceable and deformable to create a base layer for a new second floor panel. In some embodiments, the foamed base layer may be formed using a nitrogen, carbon dioxide, or SCF (supercritical fluid) foaming process to create the foamed thermoplastic used in the upper and lower segments. In some embodiments, for example, the base layer may be formed using a co-extrusion process using different sources of foamed thermoplastic corresponding to the upper and lower segments. In such embodiments, the upper and lower segments may be formed together. In other embodiments, the upper and lower segments of the base layer may be made separately, such as by extruding foamed thermoplastic separately for each segment. In some embodiments, the upper segment may be formed of a different material (such as dioctyl terephthalate (DOTP) LVT or rubber) compared to the material used to form the lower segment of the base layer. In exemplary embodiments having separately formed upper and lower segments of the base layer, the separate upper segment may be adhered or bonded to the lower segment to form the base layer, or in some embodiments, the upper layer may be formed or deposited directly onto the top surface of the lower segment. The lower segment of the base layer may be significantly thicker than the upper segment, for example, where the thickness of the upper segment is less than 30% of the total thickness of the base layer. In some embodiments, for example, the thickness of the upper segment may be less than 2 mm, such as in the range of 0.5 mm to 1 mm or 0.5 mm to 1.5 mm. In some instances, the total thickness of the base layer may be between approximately 2 mm and approximately 25 mm, such as between 2.5 mm and 25 mm, or between 4 mm and 12 mm. In one or more embodiments, the thickness ratio of the upper and lower segments of the base layer (i.e., the thickness of the upper segment of the base layer divided by the thickness of the lower segment of the base layer) may range from approximately 0.2 to approximately 0.6. In some exemplary embodiments, the thickness ratio of the upper and lower segments of the base layer may range from 0.25 to 0.5.In some exemplary embodiments, the total thickness of the base layer may range from about 4 mm to about 12 mm, the thickness of the upper section of the base layer may range from about 1 mm to about 4 mm, and the thickness of the lower section of the base layer may range from about 3 mm to about 9 mm. For example, in some exemplary embodiments, the total thickness of the base layer may range from 6 mm to 10 mm, the thickness of the upper section of the base layer may range from 2 mm to 3 mm, and the thickness of the lower section of the base layer may range from 4 mm to 7 mm.

[0025] In some disclosed embodiments, the upper and lower sections of the base layer may be formed of a thermoplastic composite material comprising binders, fillers (e.g., natural or synthetic; organic or inorganic), additives, and cavitation. In some embodiments, for example, the thermoplastic binder of the base layer may be any of PE, PET, PP, PU, ​​or PVC, and in some embodiments, may constitute at least 40% by weight of the base layer. In some embodiments, carbon fibers may be added to one or both of the upper and lower sections of the base layer to improve the thermal resistance and strength of the base layer. Such embodiments may include chopped carbon fibers, woven carbon fibers, non-woven carbon fibers, or combinations thereof. The upper and lower sections of the base layer may be formed using the same thermoplastic binder material, whereby the upper and lower sections comprise separate foamed layers with different distributions and / or sizes (and therefore different densities). In other embodiments, the upper and lower sections of the base layer may be formed using different types of thermoplastic binder materials. Furthermore, in some illustrative embodiments, the upper section of the base layer may include more than 25 parts per hundred parts of resin (phr), while the lower section may contain virtually no plasticizer (e.g., less than 5 phr of plasticizer, less than 3 phr of plasticizer, or in some embodiments, no plasticizer at all). Further still, in some embodiments, the top coating, abrasion layer, and finish layer, as well as the upper and lower sections of the base layer, may be completely PVC-free. In other embodiments, the top coating, abrasion layer, and finish layer, as well as the upper and lower sections of the base layer, may be PVC-based.

[0026] Because many non-PVC thermoplastics (such as PE and PP) have chemically inert and non-porous surfaces with very low surface polarity, such materials often exhibit undesirably low levels of adhesion between the top coating, abrasion layer, and finish layer, the base layer, and the resilient soft layer beneath the base layer. In some embodiments, additives may be included in one or more of these layers to increase the intersurface polarity between these PVC-free layers to provide sufficient interlayer adhesion.For example, the interfacial polarity of the PVC-free layer can be improved by including additives with relatively high polarity (such as, but not limited to, amines, nitro compounds, etc.), which can further provide a sufficient level of interlayer adhesion between the top PVC-free coating, the abrasion layer and the finishing layer, the base layer, and the resilient soft layer beneath the base layer. Additionally, in some disclosed embodiments, the surface tension of each of these various layers can be greater than or equal to 40 dyns / cm to also provide sufficient adhesion between layers.

[0027] In alternative disclosed embodiments, the upper and lower sections of the foamed base layer can be flexible or rigid to varying degrees. Depending on the application of the decorative article, a more flexible foamed base layer may be more desirable than a more rigid one. The inventors have discovered several techniques for adjusting the level of flexibility in the upper and lower sections of the base layer. For example, the flexibility of the upper and lower sections of the base layer can be adjusted by: (1) adding an elastomer, such as an olefin (like a polyolefin), thermoplastic polyurethane, rubber, polyether polyol, etc., with a different weight percentage to each of the upper and lower sections of the base layer; (2) changing the weight percentage of filler added to the upper and lower sections of the base layer; and / or (3) modifying the density (i.e., foaming and cavitation characteristics) of the upper and lower sections of the base layer.

[0028] According to some disclosed embodiments, the top layer may be positioned above the base layer and comprises a soft and flexible thermoplastic material. The top layer may include some combination of finishing layers, abrasion layers, and / or coatings. In some embodiments, the top layer may be PVC-free, i.e., it does not include PVC. In some instances, the top layer may further include a scratch layer. In other instances, the coating may function as a scratch layer. In yet another instance, the abrasion layer may be configured to provide both abrasion resistance and scratch resistance. In some embodiments, the top layer may be less than or equal to 30 thousandths of an inch (mil) thick. In some instances, both the finishing layer and the abrasion layer may have a thickness between approximately 0.1 mm and approximately 0.5 mm; in some exemplary embodiments, the combined thickness of the finishing layer and the abrasion layer may be between approximately 0.1 mm and approximately 0.5 mm. The finishing layer may comprise a layer of paper with a non-PVC substrate and a decorative pattern printed thereon. In alternative embodiments, the finishing layer may comprise a decorative layer of another suitable thermoplastic material of a film, vinyl plastic, rubber, or overlay laminate structure. In some embodiments, the finishing layer may comprise a woven or non-woven material. In some embodiments, the finishing layer may be adhered to or bonded to the substrate. In other embodiments, the decorative layer may be printed on or over the substrate using rotary gravure printing or direct digital printing techniques. For example, in some embodiments, the finishing layer may be digitally printed or otherwise formed on the substrate without any sublayer between the finishing layer and the substrate. In alternative embodiments, the finishing layer may be digitally printed or otherwise formed on at least one sublayer positioned between the finishing layer and the substrate.In some embodiments, the finishing layer may be located less than 0.2 mm above the upper section of the base layer. In some cases, an abrasion layer (PVC or non-PVC) may be applied over the finishing layer. In some embodiments, a protective coating may be applied over the upper surface of the topmost layer (such as on top of the abrasion layer). In some embodiments, the abrasion layer may be a portion of the protective coating. The protective coating may include a radiation (UV / EB) cured polyurethane varnish. Similarly, one or more layers may be included under the base layer, such as for additional cushioning or stability. In some instances, the abrasion layer may be a cured liquid abrasion layer. Specification 6 / 14 pages 9 CN 121175189 A

[0029] In some exemplary embodiments, the base layer may be a wood-plastic composite. In some instances, the wood-plastic composite may not include wood. Alternatively, the wood-plastic composite layer may include equal or substantially equal weight percentages of thermoplastic and filler, or such that the weight percentage of thermoplastic is greater than the weight percentage of filler. In some instances, the wood-plastic composite includes wood, thermoplastic, and one or more fillers. In other exemplary embodiments, the base layer may be a mineral layer (e.g., magnesium oxide and salt-based layers). In yet another exemplary embodiment, the base layer may be a stone-plastic composite. In some exemplary embodiments, the upper section of the base layer may include an LVT layer, while the lower section of the base layer may include WPC (e.g., as a foamed layer) or SPC (e.g., as a non-foamed layer). In some embodiments including a WPC lower section of the base layer, the WPC may be foamed (i.e., at least partially foamed) and may include plastic or polymeric components and fillers. In some embodiments, the WPC lower section may be foamed throughout its thickness. In other exemplary embodiments, the WPC lower section may be foamed substantially throughout its thickness and still include substantially non-foamed layers (“hard shells”) at or near its top and bottom surfaces, wherein the top hard shell and bottom hard shell substantially sandwich the foamed central portion of the WPC lower section. In some embodiments, the amount of plastic or polymeric component may be greater than the amount of filler in the WPC lower section (e.g., by weight %). In some embodiments, the WPC lower section of the base layer may further include wood or woody components. In another disclosed embodiment where the lower section of the base layer includes SPC, the SPC lower section may be non-foamed and may include plastic or polymer components and fillers, for example, wherein the amount of filler component may be greater than the amount of plastic or polymer component (e.g., by weight %). Filler components may include, but are not limited to, calcium carbonate, chalk, etc.

[0030] Decorative articles (such as decorative floor panels) of the disclosed embodiments can provide several acoustic benefits superior to conventional decorative floor panels. For example, in some embodiments, the foamed upper and lower sections of the base layer, or more particularly, the cavitation in the upper and lower sections of the base layer, can dissipate and / or absorb sound waves, thus reducing the propagation of unwanted noise (such as footsteps).Furthermore, the different types of materials and the varying sizes and distributions of air pockets in the upper and lower sections of the substrate will substantially block and / or attenuate different sound frequencies (high and / or low frequencies). Because the upper and lower sections of the substrate in the disclosed embodiments may contain air pockets of varying sizes and / or distributions, the upper and lower sections together can block a wider frequency spectrum of sound than conventional substrates with a more uniform density and only one foamed layer or a combination of foamed and non-foamed layers. Therefore, the multi-layered porous substrate in the disclosed embodiments provides improved sound insulation and noise reduction compared to conventional decorative flooring panels. For example, in some embodiments, the LVT upper section of the substrate (or other materials in the upper section) can absorb most of the impact energy from pedestrian traffic or falling objects, and the lower section of the substrate may be selected to include a material with a relatively low density, such as a foamed WPC layer, to dampen sound and provide better acoustic performance. In some exemplary embodiments, the decorative article may include a top layer disposed above a base layer, the top layer including a coating, an abrasion layer, and / or a finish layer, the base layer including an upper section (such as an LVT upper section) and a lower section (such as a WPC lower section). In still other exemplary embodiments, the decorative article may include a top layer disposed above a base layer, the top layer including a coating, an abrasion layer, and / or a finish layer, the base layer including each of an upper section (such as an LVT upper section), an intermediate section (such as a WPC intermediate section), and a lower section.

[0031] In addition to the cavitation in the foamed upper and lower sections of the base layer, the inventors have found that additionally including pores in the decorative floor panel further improves the acoustic performance and sound attenuation quality of the decorative floor panel. In some embodiments, a plurality of pores may be included in the top layer of the decorative floor panel or other decorative articles consistent with the embodiments disclosed herein. In such embodiments, the plurality of pores may further reduce the amount of sound reflected and / or transmitted by the decorative floor panel at certain audible frequencies by dissipating sound waves encountering the pores. In some embodiments, the holes may extend through the entire depth of the top layer, which includes the coating, abrasion layer, and finish layer. In other disclosed embodiments, the holes may extend only through a portion of the top layer. For example, in some embodiments, the holes may be formed through the coating and abrasion layer. In still other alternative embodiments, multiple holes may instead be formed in portions of the base layer, for example, at least in the upper section of the base layer.

[0032] According to certain disclosed embodiments of the decorative articles described herein, various tools and methods can be used to create multiple holes. For example, in some embodiments, these methods and tools may include the use of studded rollers, milling, and / or mechanical pinning during the forming and / or manufacturing process to create holes of a desired diameter, depth, and / or distribution. In other embodiments, laser ablation or other non-contact techniques may be used to form multiple holes.The inventors have discovered that the number of holes in a decorative floor panel, as well as the average diameter, depth, and spacing / distribution of the holes, can be directly related to the amount of sound allowed to pass through or be reflected from the decorative article (such as a decorative floor panel). Generally, the more holes there are and the smaller their size, the better the acoustic performance of the decorative article will be, while maintaining its desired surface hardness. For example, in some embodiments, the holes may preferably have a diameter between approximately 1 mm and approximately 5 mm, and the distance between the holes (hole spacing) is preferably between approximately 2 mm and approximately 10 mm. The holes may be arranged in a random pattern, a semi-random pattern, or an intentional pattern (e.g., a geometric pattern). In some instances, each hole may have a circular opening (or a cylindrical hole). In other instances, each hole may have a non-circular opening shape (e.g., pentagonal, square, hexagonal, octagonal, etc.). In other instances, adjacent holes may have openings of different shapes.

[0033] The term “base layer” may also be used interchangeably herein as a core layer or a base layer without departing from the broader scope of this disclosure. It should also be noted that the term "decorative article" can be used interchangeably as "acoustic article" or "acoustic decorative article" without departing from the broader scope of this disclosure. Although the floor panel is referred to as a decorative article, it should be noted that, as described throughout this disclosure, the article is both aesthetically pleasing and functional, some of which are described herein.

[0034] These and other advantages of the disclosed embodiments will be apparent to those skilled in the art from the foregoing description and the following detailed description and drawings of illustrative embodiments of the present disclosure. Brief Description of the Drawings

[0035] The particular features and advantages of the invention will become apparent from the following description taken in conjunction with the accompanying drawings, in which similar reference numerals indicate the same or functionally similar elements. The following figures depict details of the disclosed embodiments. While the drawings are provided by way of example only, the invention is not limited to the precise arrangement shown in these figures: FIG1 is a vertical cross-section of an exemplary decorative floor panel according to a first exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having an upper section having lower compressibility than a lower section.

[0036] FIG2 is a vertical cross-section of an exemplary decorative floor panel according to a second exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having upper sections with lower compressibility than lower sections, wherein the upper sections are formed using a different manufacturing process than the lower sections.

[0037] FIG3 is a vertical cross-section of the exemplary decorative floor panel of FIG1 according to a first exemplary embodiment of the present disclosure, further showing exemplary compression zones on portions of the upper sections of the top layer and the core layer.

[0038] FIG4 is a vertical cross-section of the exemplary decorative floor panel of FIG3 according to a second exemplary embodiment of the present disclosure, further showing exemplary compression zones on portions of the upper sections of the top layer and the core layer.

[0039] FIG. 5 is a vertical cross-section of an exemplary decorative floor panel according to a third exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having an upper section having lower compressibility than a lower section, wherein the upper section corresponds to a foamed area of ​​the core layer, and the lower section of the core layer is not foamed.

[0040] FIG. 6 is a vertical cross-section of an exemplary decorative floor panel according to a fourth exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having an upper section having lower compressibility than a lower section, wherein the upper section is foamed, and the lower section is not foamed, and the upper section is formed using a different manufacturing process than the lower section.

[0041] FIG. 7 is a vertical cross-section of an exemplary decorative floor panel according to a fifth exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having an upper section, a middle section, and a lower section, wherein the middle section of the core layer has greater compressibility than both the upper and lower sections.

[0042] FIG8 is a vertical cross-section of an exemplary decorative floor panel according to a sixth exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having an upper section having lower compressibility than a lower section, wherein the upper section is non-foamed and the lower section is foamed.

[0043] FIG9 is a vertical cross-section of an exemplary decorative floor panel according to a seventh exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having an upper section, a middle section and a lower section, wherein the middle section of the core layer has greater compressibility than both the upper and lower sections, and wherein the upper and lower sections are non-foamed and the middle section is foamed.

[0044] FIG10 is a vertical cross-section of an exemplary decorative floor panel according to an eighth exemplary embodiment of the present disclosure, the exemplary decorative floor panel comprising a multilayer core layer having an upper section having lower compressibility than a lower section, wherein the lower section of the core layer comprises a honeycomb structure.

[0045] FIG11 is a top view of an exemplary decorative floor panel according to another exemplary embodiment of the present disclosure, the exemplary decorative floor panel including a plurality of holes formed on at least its top outermost surface, the other exemplary embodiment being used alone or in combination with any of the various disclosed embodiments of the multilayer core layer described herein. Detailed Description

[0046] Unlike conventional decorative floor panels, the disclosed embodiments herein provide a laminated structure having a core layer having separate upper and lower sections with different compressibility. The upper and lower sections of the core layer may be foamed layers with different porosities and densities (or may include other materials with different compressibility), such that the upper section exhibits less compressibility than the lower section.In some of the disclosed embodiments described herein, the core layer may include an upper section, a middle section, and a lower section. In such embodiments, one or more of the upper, middle, and lower sections of the core layer may be a foamed layer with associated porosity and density, such that the middle section exhibits greater compressive strength than both the upper and lower sections.

[0047] FIG1 shows a vertical cross-sectional view of a decorative floor panel according to a first exemplary embodiment. The panel includes: a top layer 1, which includes a finishing layer; and a core layer 2, which has both an upper section 3 and a lower section 4. In some embodiments, the top layer 1 may be completely PVC-free. In other embodiments, the top layer 1 may include PVC. Furthermore, in some embodiments, the top layer 1 may further include an abrasion layer and a coating over the finishing layer. In FIG1, the upper section 3 is designated by shading the upper section of the core layer 2 with a diagonal line. The upper section 3 may be located at or near the top surface of the finished product (e.g., less than or equal to 30 mil from the top surface of the top layer 1). In the core layer 2, the lower segment 4 may be significantly thicker than the upper segment 3. For example, in some embodiments, the upper segment 3 may include 30% or less of the thickness of the core layer 2. Although not shown in FIG1, in some instances, the top layer 1 and one or more of the upper segment 3 and the lower segment 4 of the core layer 2 may further include a plurality of holes 7 extending completely or partially through it.

[0048] In some disclosed embodiments of the decorative floor panel, the finish layer may be printed or otherwise directly attached or bonded to the top of the upper segment 3. Alternatively, one or more sub-layers (not shown) may exist between the finish layer and the core layer 2. In some embodiments, the finish layer is located less than 0.2 mm above the core layer 2.

[0049] In some disclosed embodiments, neither the upper segment 3 nor the lower segment 4 includes any PVC. In other embodiments, the upper segment (3) and / or the lower segment (4) may include PVC without departing from the broader scope of this disclosure. Both upper segment 3 and lower segment 4 may also contain cavitation (e.g., as shown in FIG. 1, in the two segments of the exemplary core layer 2). Cavitation can be formed in each of these segments using one or more mechanical and / or chemical foaming agents, and in some embodiments, may include nitrogen, carbon dioxide, and SCF foaming processes. In FIG. 1, upper segment 3 of core layer 2 may contain cavitation of a different average size and / or distribution than lower segment 4, in order to provide relatively lower compressibility to the upper segment. The upper and lower segments of core layer 2 may be formed together as a single layer, for example using a co-extrusion process, or another type of manufacturing process in which core layer segments 3 and 4 may be formed together. Alternatively, the upper and lower segments of core layer 2 may be formed independently and subsequently adjacent, for example using a manual or automated lamination process or adhesive.

[0050] The upper segment 3 and the lower segment 4 may be rigid, flexible, or semi-flexible, and in some cases may be formed using the same thermoplastic binder material. In some embodiments, for example, the upper segment 3 and the lower segment 4 may comprise the same thermoplastic composite, such as a WPC composite, differing only in the amount and / or type of foaming agent used. In other embodiments, one or more of the binder, fiber, additive, filler, plasticizer, elastomer, etc., may differ in the upper segment 3 and the lower segment 4. For example, in some exemplary embodiments, the upper segment 3 may comprise more than 25 phr of plasticizer, more than 50 phr of plasticizer, or more than 75 phr of plasticizer, while the lower segment 4 may contain almost no plasticizer (e.g., less than 5 phr). In other embodiments, the upper segment 3 may be formed of rubber, DOTP LVT, or other materials different from the material used to form the lower segment 4 of the core layer 2.

[0051] A panel locking system 5, such as a tongue and groove or other latching type locking system, may be formed along the outer edge of the core layer 2. The locking system 5 is preferably formed only along the edge of the lower section 4 (e.g., by milling) because the lower section provides greater compressibility, stiffness, and rigidity compared to the upper section 3 of the core layer. The locking system 5 may include any known locking or fastening mechanism that allows interconnection with other decorative floor panels.

[0052] Due to the lower compressibility of the upper section 3 in the core layer 2, the impact acoustic performance of the decorative floor panel may be improved (e.g., resulting in less noisy footsteps). Additionally, the upper section 3 and lower section 4 may include cavitation, which improves sound transmission reduction in the floor system (e.g., less indoor reflected noise and noise reaching the room below). In some embodiments, the acoustic performance of the decorative floor panel may be further improved by including a plurality of holes 7 that may extend through the top layer 1 and one or more of the upper section 3 and lower section 4 of the core layer. In some exemplary embodiments, the holes 7 may extend from the top of the decorative floor panel to the bottom of the decorative floor panel and may be blind holes. In some instances, the hole 7 may be a through hole. In some embodiments, for example, a plurality of holes 7 may extend through the entire depth of the top layer 1, for example, from the top surface of the top layer 1 through the bottom surface of the top layer 1, including through the coating, abrasion layer, and finish layer. In some instances, the hole 7 may further extend into the upper section (3) and / or lower section (4) of the core layer 2. In some instances, the top layer 1 may not contain the hole 7, and the hole 7 may extend from the upper surface of the upper section 3 toward the lower section 4 of the core layer 2. In other instances, the hole 7 may extend from the top surface of the top layer 1 through the bottom surface of the core layer 2, or in some embodiments, through to the bottom surface of the decorative floor panel (e.g., in some embodiments, which may include a soft, resilient layer beneath the core layer 2).

[0053] The relatively high compressibility of the lower section 4 advantageously prevents severe dents from penetrating into the core layer (which could otherwise damage the decorative floor panel) and also allows the locking system 5 to be milled directly into the lower section 4. The locking system 5 is configured to interconnect the decorative floor panel with a similar locking system on at least one adjacent decorative floor panel. A separate undercoat (not shown) may be attached or positioned below the lower section 4 of the core layer 2 to provide anti-slip properties, comfort, and / or further noise reduction to the decorative floor panel.

[0054] FIG. 2 shows a vertical cross-sectional view of a decorative floor panel according to a second exemplary embodiment. The difference between the exemplary embodiments of FIG. 1 and 2 is that the upper section 3 and the lower section 4 in FIG. 2 may be formed using different manufacturing processes. To illustrate this difference, the upper section 3 in FIG. 2 is further shaded (compared to FIG. 1) to indicate that it is formed as a separate material layer, for example, using a different extrusion and / or calendering process (compared to the lower section 4). In this example, the upper segment 3 may be formed directly on the top surface of the lower segment 4 in the core layer 2, or may be attached to (e.g., using adhesives or bonding, using heat and / or pressure, etc.) the top surface of the lower segment 4 in the core layer 2. Specification 10 / 14 pages 13 CN 121175189 A

[0055] In some exemplary embodiments, the upper segment 3 may be made primarily of a foamed sol having a density, for example, between 700 kg / m³ and 1150 kg / m³, and the lower segment 4 may be made primarily of a plasticizer-free foam core having a density between 800 kg / m³ and 1300 kg / m³. Although in such exemplary embodiments, the two segments may have similar average densities, they are implemented in very different ways. For example, the lower segment 4 may be more packed than the upper segment 3, but has a larger porosity. In some instances, both the upper and lower sections may be based on PVC, but the upper section has a more flexible chemical structure, allowing the upper section 3 to compress more than the lower section 4. In some embodiments, the lower section 4 may have a high porosity, which helps improve acoustic performance, but the lack of plasticizers in the lower section makes its chemical structure more rigid and reduces compressibility. This is preferred because the lower section 4 receives the locking system 5. The inventors’ research has found that for at least some of the tested decorative flooring panels, sound reduction can be improved if the density of the upper section is less than 700 kg / m³, or if the thickness of the upper section is greater than 1.5 mm, but dent resistance may not be acceptable for most flooring applications. However, for some suitable flooring applications, a thickness of up to 2 mm or more for the upper section does not fall outside the scope of this disclosure. Other test samples of decorative flooring panels having the construction shown in Figure 2 were manufactured with an upper section 3 made of PVC resin (such as that used in conventional resilient rigid flooring).Compared to conventional resilient rigid flooring, the upper section 3 in these test samples features a foaming agent incorporated into the mixture prior to extrusion, and the inventors used a very high concentration of plasticizer to make the chemical structure more flexible. The inventors found that the combination of microcavitation and the flexible chemical structure gives the upper section 3 higher compressibility. In some instances, the inventors adjusted the foaming agent from 1.5 phr to 2 phr and the plasticizer dosage from 40 phr to 80 phr, so the compressibility of the upper section remained in the range of 5% to 10%. In some embodiments, the compressibility of the upper section 3 can be between approximately 4% and approximately 20%, and in some exemplary embodiments, between 5% and 8%. In some instances, the inventors maintained a PVC to filler ratio of 1:2 and a density of approximately 1.4 kg / m³, which improved dent resistance compared to samples made using plastisol topcoats. Such highly foamed and highly plasticized resins with this high filler content cannot be achieved using conventional calendering processes, so the inventors used an extrusion process to extrude the upper section 3.

[0056] FIG3 shows the decorative floor panel of FIG1, wherein the compression zone 6 of the top layer 1 and the upper section 3 is recessed, such as due to impacts on the installed decorative floor panel (e.g., due to dropped objects) or due to applied heavy loads (e.g., due to furniture), but due to its relatively high compressibility, the structural integrity of the lower overlay section 4 in the core layer 2 is not affected. In this case, the more compressible upper section 3 can absorb and / or dissipate the energy of the impact to help maintain the structural integrity of the lower overlay section 4 of the core layer 2. However, in this embodiment, under normal loads (such as normal foot traffic, furniture and / or household appliances from above the decorative floor panel), the top layer 1 and the upper section 3 may not be compressed in zone 6.

[0057] FIG4 similarly shows the decorative floor panel of FIG3, which includes the compression zone 6 in the top layer 1 and the upper section 3. Again, due to its greater compressibility compared to the upper section 3, the structural integrity of the lower section 4 in the core layer 2 is not affected. Furthermore, in this exemplary embodiment, the more compressible upper section 3 of the core layer 2 can again absorb and / or dissipate the energy of impacts or heavy loads, helping to maintain the structural integrity of the lower section 4 in the core layer 2. In this illustrative embodiment, the top layer 1 and the upper section 3 can remain uncompressed in zone 6 under normal loads (such as from regular foot traffic, furniture, and / or household appliances). Of course, if a larger load is applied to the surface, the lower section of the core layer will also be compressed. However, the inventors have found that certain combinations of the upper section (3) and the lower section (4) can provide suitable solutions for flooring applications. For example, in an exemplary embodiment, the upper section 3 can be a 0.8 mm thick calendered expanded polystyrene layer with a density of 1050 kg / m³, and the lower section 4 of the core layer 2 can be a 5 mm thick extruded expanded polystyrene PVC core with a density of 950 kg / m³.In this example, the upper segment 3 may have approximately 7% compressibility, and the lower segment 4 may have approximately 3% compressibility. In some embodiments, the two segments of the core layer 2 may be laminated together using a polyurethane adhesive. This exemplary combination of the upper and lower segments conforms to ASTM F3261 (performance requirements for resilient flooring). Specification 11 / 14 pages 14 CN 121175189 A

[0058] FIG5 shows a vertical cross-sectional view of a decorative floor panel according to a third exemplary embodiment. The difference between the exemplary embodiments of FIG1 and 5 is that the lower segment 4 of the core layer 2 in FIG5 is not foamed and preferably substantially free of cavitation or voids. In some cases, the compressibility of the non-foamed lower segment 4 shown in the embodiment of FIG5 may be further improved compared to the compressibility of the foamed lower segment 4 in the embodiment of FIG1. ​​

[0059] FIG6 shows a vertical cross-sectional view of a decorative floor panel according to a fourth exemplary embodiment. Similar to FIG. 5 above, the difference between the exemplary embodiments shown in FIG. 2 and 6 is that the lower segment 4 of the core layer 2 in FIG. 6 is not foamed and preferably substantially free of cavitation or voids. As mentioned above, the compressibility of the non-foamed lower segment 4 shown in the exemplary embodiment of FIG. 6 can be further improved compared to the compressibility of the foamed lower segment 4 shown in the embodiment of FIG. 2.

[0060] FIG. 7 shows a vertical cross-sectional view of a decorative floor panel according to a fifth exemplary embodiment. In this example, the core layer 2 includes an upper segment 3, a middle segment 8, and a lower segment 9. The upper segment 3 of the core layer 2 in FIG. 7 corresponds to the same upper segment 3 that may be used, for example, in the exemplary embodiments of FIG. 1 and 5. Alternatively, the upper segment 3 may be a separate layer adhered or bonded to the top of the middle segment 8, such as the upper segment 3 of the upper segment 4 in the embodiments of FIG. 2 and 6.

[0061] The middle segment 8 corresponds to the previously described lower segment 4. In the example shown in FIG. 7, the middle section 8 is not foamed and therefore corresponds to the lower section 4 shown in the embodiments of FIG. 5 and 6. In an alternative embodiment (not shown), the middle section 8 may be foamed and contain cavitation, such as the lower section 4 in the exemplary embodiments of FIG. 1 and 2. The locking system 5 may be formed along the outer edge of the middle section 8 in the same manner as the locking system 5 in each of the other exemplary embodiments in FIG. 1-6.

[0062] In FIG. 7, the core layer 2 further includes a lower section 9. The lower section 9 can provide further acoustic improvements in reducing noise and providing comfort when a user walks on the decorative floor panel. In some embodiments, the lower section 9 may be formed in the same manner as the upper section 3. As shown in FIG. 7, for example, the lower section 9 may be a foamed layer located at or near the bottom of the core layer 2.In other embodiments, the lower segment 9 may be formed of a different material than the upper segment 3, and in some embodiments, it may be a separately formed layer of material adhered to or bonded to the bottom of the intermediate segment 8. Like the decorative floor panels shown in Figures 1-6, the decorative floor panel in Figure 7 may further include a separate underlayer (not shown) that may be attached or otherwise positioned below the lower segment of the core layer 2 to provide anti-slip properties, comfort, and / or further noise reduction to the decorative floor panel. In some instances, the foaming, density, thickness, and / or material composition of the upper segment 3 and the lower segment 9 may differ from each other and also from the intermediate segment 8. In other instances, the foaming, density, thickness, and / or material composition of the upper segment 3 and the lower segment 9 may be similar to each other but may differ from the intermediate segment 8.

[0063] Figure 8 shows a vertical cross-sectional view of a decorative floor panel according to a sixth exemplary embodiment. Similar to Figures 1 and 2 above, the core layer 2 includes an upper segment 3 and a lower segment 4. However, in this exemplary embodiment, the upper segment 3 of the core layer 2 in FIG8 is not foamed and preferably substantially free of cavitation or voids, but the lower segment 4 includes cavitation or voids. In the embodiments described (such as in FIG8), in order to create an upper segment 3 having lower compressibility or higher compressibility than the lower segment 4, the plasticizer content of the upper segment 3 can be increased up to 80 phr. Because a higher plasticizer ratio can increase the overall production cost, the inventors found that they could limit the thickness of the upper segment to about 0.9 mm and still reduce the level of footstep noise while keeping it within an acceptable cost range for a viable product. In the exemplary embodiment of FIG8, the upper segment 3 does not have cavitation (or is substantially free of cavitation compared to the lower segment 4) in order to prioritize its impact resistance over its acoustic performance (while still achieving acceptable acoustic performance), since high impact resistance may be relatively more important for some commercial applications.

[0064] FIG9 shows a vertical cross-sectional view of a decorative floor panel according to a seventh exemplary embodiment. Similar to FIG. 7, the core layer 2 in FIG. 9 also includes an upper segment 3, a middle segment 8, and a lower segment 9. However, in this example, the upper segment 3 and the lower segment 9 are preferably substantially free of cavitation or voids and can be formed using a material similar to that of the upper segment 3 described above in the exemplary embodiment of FIG. 8. The middle segment 8 in FIG. 9 may contain cavitation and can be formed using the same material (such as foamed thermoplastics) as that of the lower segment 4 described above in conjunction with the exemplary embodiment of FIG. 8. In some embodiments, the upper segment 3 in FIG. 8 and 9 and the lower segment 9 in FIG. 9 can be formed using an extrusion process. Alternatively, these exemplary segments 3 and 9 of the core layer 2 can be formed as separate layers that are adhered to or bonded to the upper segment 4 (FIG. 8) or the middle segment 8 (FIG. 9).The decorative floor panels in Figures 8 and 9 may further include a separate underlayer (not shown) which may be attached or otherwise positioned below the lower section of the core layer 2.

[0065] In some exemplary embodiments in which the core layer 2 includes an upper section 3, a middle section 8, and a lower section 9, as shown in Figures 7 and 9, the lower section 9 may be formed of the same or similar material as the upper section 3 and / or have the same or similar thickness to the upper section 3 to help maintain the construction balance of the thin decorative floor panel. In some exemplary embodiments, the lower section 9 may have a compressibility resistance that is substantially similar to or different (higher or lower) than that of the upper section 3. In some exemplary embodiments, the middle section 8 may have a greater compressibility resistance than both the upper section 3 and the lower section 9 of the core layer 2. In other exemplary embodiments, the middle section 8 may have a greater compressibility resistance than the upper section 3, while the lower section 9 may have a higher, lower, or substantially similar compressibility resistance than the middle layer 8. However, thicker decorative floor panels may not include the lower section 9, for example, as shown in exemplary embodiments such as Figures 1-6 and 8.

[0066] Figure 10 shows a vertical cross-sectional view of a decorative floor panel according to an eighth exemplary embodiment. The difference between the exemplary embodiments of Figures 1 and 10 is that the lower section 4 of the core layer 2 in Figure 10 also includes a honeycomb pattern 10 with voids. While the voids may be hexagonal, as shown in the embodiment of Figure 10, they may alternatively include a generally regular (i.e., substantially periodic) pattern of cavities of any shape and size. For example, the honeycomb pattern may include a generally regular pattern of circular bubbles or other polygons. The honeycomb pattern 10 preferably fills most of the volume of a relatively less compressible section of the core layer 2 (such as the lower section 4 (Figures 1-6) or the middle section 8 (Figure 7)). Therefore, the honeycomb pattern 10 does not need to fill the entire volume, although it may. The honeycomb pattern 10 can be used in the lower section 4 or the middle section 8 with or without foaming. In some embodiments, the honeycomb pattern 10 may be used in the lower segment 4 or the middle segment 8 to provide improved structural strength and / or compressibility, as well as the additional advantage of using less material in the core layer 2. In some instances, the honeycomb pattern voids 10 may extend horizontally (e.g., from one edge to another or from side to side, and not from the top surface to the bottom surface) along at least a portion of the width or length of the core layer 2.

[0067] In some embodiments described herein, the upper segment of the core layer may be foamed and may also include a plasticizer. In yet other example embodiments, the upper segment of the core layer may include a plasticizer and may not be foamed. In example embodiments in which the upper segment of the core layer is not foamed, the upper segment may include more plasticizer than the upper segment would include in other exemplary embodiments in which it is both foamed and includes a plasticizer. In some instances, in any of such embodiments, the amount of plasticizer in the upper segment of the core layer may be at least 50 phr.For example, in some embodiments, the amount of plasticizer in the upper section may be in the range of approximately 60-90 phr. In some embodiments, the amount of plasticizer in the upper section of the core layer may be in the range of approximately 70-80 phr, wherein some non-foamed embodiments of the upper section may include more plasticizer than other embodiments employing a foamed upper section. For example, in some embodiments, the upper section of the core layer may be non-foamed and include 70-80 phr of plasticizer, while in other example embodiments where the upper section is both foamed and includes plasticizer, the upper section may include less than 70 phr of plasticizer.

[0068] In both foamed and non-foamed embodiments of the upper section of the core layer, the upper section may be manufactured as soft as possible to reduce noise (indoor / reflected noise and / or room-to-room / transmission noise) as much as possible, while minimizing indentation or providing an acceptable level of indentation. For example, in some exemplary embodiments, when tested using the test methods described in ASTM 1914, the percentage of residual indentation on the upper section of the core layer may be less than 20%, and in some embodiments, using the Class A test method described on pages 13 / 14 of this specification (CN 121175189), the indentation may be less than 15% or less than 10%. In some embodiments, for a static load of 250 pounds applied to the top of the decorative panel, using the test methods described in ASTM F970, the amount of indentation on the upper section of the core layer may be less than or equal to 0.003 inches. Furthermore, the lower section of the core layer (or, in some embodiments, the middle section) may be manufactured as rigid as possible (e.g., based on surface hardness) to minimize indentation on the upper section of the core layer, while adding as much foam as possible and allowing for continuous reduction (e.g., dissipation, absorption, etc.) of sound transmitted from the upper section of the core layer, thus providing better overall sound reduction throughout the core layer and the entire product.

[0069] FIG11 shows a top view of an exemplary decorative floor panel having a plurality of holes 7 formed in a top layer 1. In this example, the depth of the holes 7 may be substantially the same as the entire depth of the top layer 1. However, in other disclosed embodiments, the plurality of holes 7 may extend deeper or less into the top layer 1, and may be formed, for example, in one or more of the top layer 1 and the upper section 3 and lower section 4 of the core layer 2. For example, in an alternative embodiment, the holes 7 may extend only partially through the top layer 1; in still other embodiments, the holes may extend through the top layer 1 and into at least a portion of the upper section 3 of the core layer 2. When the holes 7 are used in conjunction with some embodiments of a honeycomb structure including voids 10 in the core layer 2 (such as shown in FIG10), the honeycomb voids 10 may have openings larger (at least on average) than the size of the openings of the holes 7. In other instances, the size of the openings of the voids 10 in the core layer 2 may be substantially the same as the size of the openings of the holes 7.In this context, the relative sizes of the openings of the gaps 10 and the holes 7 may correspond to their relative average or approximate diameters or cross-sectional areas.

[0070] Unlike conventional floor panels, the disclosed embodiments provide decorative floor panels that improve the acoustic performance of the floor panel while maintaining sufficient top surface hardness. In this respect, the inventors have generally found that including a large number of small holes 7 in a decorative floor panel provides superior noise performance and acoustic attenuation compared to including a smaller number of larger holes 7 (all other things being equal). For example, in some preferred embodiments, the holes 7 may preferably have a diameter between about 1 mm and about 5 mm, and the distance between the holes is preferably between about 2 mm and about 10 mm.

[0071] The foregoing description is directed to specific exemplary disclosed embodiments of the invention. However, it will be apparent that other modifications and variations can be made to the described embodiments to obtain some or all of their advantages. For example, the decorative articles described herein are described in the context of decorative floor panels, but more generally, they may be wall, floor, or ceiling coverings. Furthermore, as used herein, the terms “approximately,” “about,” “around,” or “substantially” used in relation to values ​​allow for variations of plus or minus 5%, or plus or minus 10%, or plus or minus 20% in the value (including the value itself). Additionally, the ranges of values ​​disclosed herein (such as the range “between” two values) generally include the endpoints of the range.

[0072] Therefore, this description is by way of example only and does not further limit the scope of the embodiments herein. Thus, the appended claims are intended to cover all such variations and modifications that fall within the true spirit and scope of the embodiments incorporated herein.Instruction manual, page 14 / 14, 17 CN 121175189 A, Figure 1; Instruction manual, Figure 1 / 11, page 18 CN 121175189 A, Figure 2; Instruction manual, Figure 2 / 11, page 19 CN 121175189 A, Figure 3; Instruction manual, Figure 3 / 11, page 20 CN 121175189 A, Figure 4; Instruction manual, Figure 4 / 11, page 21 CN 121175189 A, Figure 5; Instruction manual, Figure 5 / 11, page 22 CN 121175189 A, Figure 6; Instruction manual, Figure 6 / 11, page 23 CN 121175189 A, Figure 7; Instruction manual, Figure 7 / 11, page 24 CN 121175189 A, Figure 8; Instruction manual, Figure 8 / 11, page 25 CN 121175189 A, Figure 9; Instruction manual, Figure 9 / 11, page 26 CN 121175189 A, Figure 10 Figure 11, page 27, CN 121175189 A; Figure 11, page 28, CN 121175189 A.

Claims

1. A decorative article comprising: The top layer consists of a finishing layer and a wear-resistant layer; as well as A core layer comprising an upper segment and a lower segment, the upper segment having lower compressibility than the lower segment, and wherein the upper segment comprises a foamed thermoplastic material and a plasticizer. The top layer is positioned above the upper segment of the core layer, and the upper segment of the core layer is positioned above the lower segment of the core layer. The lower section of the core layer includes a locking system configured to interconnect with at least one adjacent decorative element.

2. The decorative article according to claim 1, wherein, The decorative product is a decorative floor panel.

3. The decorative article according to claim 1, wherein, The ratio of the thickness of the upper segment of the core layer to the thickness of the lower segment of the core layer is between approximately 0.2 and approximately 0.

6.

4. The decorative article according to claim 3, wherein, The thickness of the upper section of the core layer is in the range of approximately 1 mm to approximately 4 mm.

5. The decorative article according to claim 1, wherein, The upper section of the core layer has a strength of 1350 to 1700 kg / m³. 3 The density between.

6. The decorative article according to claim 1, wherein, The lower section of the core layer comprises a foamed thermoplastic material.

7. The decorative article according to claim 1, wherein, The upper section of the core layer includes at least 50 phr of plasticizer.

8. The decorative article according to claim 7, wherein, The upper section of the core layer includes at least 75 phr of plasticizer.

9. The decorative article according to claim 1, wherein, The upper section of the core layer is a separate material layer attached to the top surface of the lower section of the core layer.

10. The decorative article according to claim 1, wherein, The compressibility of the lower section of the core layer is approximately twice that of the upper section of the core layer.

11. The decorative article according to claim 1, wherein, The compressibility of the upper section is between approximately 4% and approximately 20%.

12. The decorative article according to claim 11, wherein, The compressibility of the upper section is between 5% and 8%.

13. The decorative article according to claim 1, wherein, The upper section has a Shore D surface hardness of approximately 50.

14. The decorative article according to claim 1, wherein, The lower section has a Shore D surface hardness of approximately 55.

15. The decorative article according to claim 1, wherein, The finishing layer is located less than 0.2 mm above the upper section of the core layer.

16. The decorative article according to claim 1, wherein, The locking system is formed along the outer edge of the lower segment of the core layer.

17. The decorative article according to claim 16, wherein, The locking system is a latch-type locking system.

18. The decorative article according to claim 1, wherein the decorative article further comprises a resilient soft layer beneath the core layer.

19. The decorative article according to claim 1, wherein, The lower section of the core layer includes a honeycomb structure.

20. A decorative article comprising: The top layer consists of a finishing layer and a wear-resistant layer; as well as A core layer comprising an upper segment and a lower segment, the upper segment having lower compressibility than the lower segment, and wherein the upper segment comprises a thermoplastic material and a plasticizer. The top layer is positioned above the upper segment of the core layer, and the upper segment of the core layer is positioned above the lower segment of the core layer. The lower section of the core layer includes a locking system configured to interconnect with at least one adjacent decorative element.

21. The decorative article according to claim 20, wherein, The thermoplastic material includes foamed thermoplastic material.

22. The decorative article according to claim 20, wherein, The upper section of the core layer comprises a plasticizer of approximately 70 to 80 phr.

23. A decorative article comprising: The top layer includes the finishing layer; as well as A core layer comprising an upper section, a middle section, and a lower section, wherein the middle section has greater compressibility than the upper section of the core layer, and wherein the upper section comprises a foamed thermoplastic material and a plasticizer. The top layer is positioned above the upper section of the core layer, the upper section of the core layer is positioned above the middle section of the base layer, and the middle section of the core layer is positioned above the lower section of the core layer. The intermediate section of the base layer includes a locking system configured to interconnect with at least one adjacent decorative element.

24. The decorative article according to claim 23, wherein, The upper section of the core layer includes at least 50 phr of plasticizer.

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