Floor element for forming a floor covering and method of manufacturing a floor element

Abstract

The present application relates to a floor element for forming a floor covering and a method of manufacturing a floor element. A floor element for forming a floor covering comprises a decorative layer made of a ceramic material, an intermediate layer of a resin material having a lower surface permeating the decorative layer, and a support layer arranged below the decorative layer, wherein the support layer comprises an edge provided with a coupling element configured to enable mechanical coupling with a coupling element of an adjacent floor element.

Description

[0001] This application is a divisional application of Chinese invention patent application No. 202080059512.9, filed on February 11, 2020, entitled “Floor element for forming floor cover, floor cover and method for manufacturing floor element” (the corresponding PCT international application application number is PCT / US2020 / 017696).

[0002] Cross-reference to related applications

[0003] This application claims priority to PCT application No. PCT / US2019 / 040083, filed July 1, 2019, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0004] The present invention relates to a floor element for forming a floor cover, a floor cover, and a method for manufacturing the floor element.

[0005] More specifically, the present invention relates to a floor element for forming a floor covering, wherein the floor element includes a decorative layer made of a brittle material, such as natural stone, glass, or sintered ceramic material, such as porcelain, pottery, etc. The decorative layer may be, for example, ceramic tile. Background Technology

[0006] Traditionally, tiles are installed by placing them side-by-side on surfaces such as floors or walls. Typically, an adhesive compound is used to attach the tiles to the surface. The joints between the tiles are then grouted. This bonds the tiles to a rigid surface, such as a concrete subfloor, thereby increasing its impact resistance. This bond with the subfloor, and consequently with the building structure, also results in a significant reduction in walking noise, both within the room where the floor is installed and in the areas beneath it. Tile surfaces are impermeable and hygienic because they can be cleaned very wetly. However, the process of installing tiles with adhesive is labor-intensive and represents a significant portion of the labor involved in typical floor covering installation. Furthermore, this installation technique requires a high level of expertise to achieve a particularly smooth floor cover. Therefore, professional tile installation is often quite expensive due to the time and labor involved.

[0007] To replace existing tile flooring, it is usually necessary to destroy the tiles, regenerate the surface by removing adhesive residue, and then install new flooring. Therefore, removing tile flooring is a laborious and time-consuming operation. This operation also becomes difficult if the purpose of the repair is to replace only one or a few damaged tiles, as replacing one tile preferably does not damage adjacent tiles.

[0008] In recent years, manufacturers have attempted to produce self-installation tile solutions that are easier to install. Examples of these attempts are shown in WO 2004 / 097141 and WO 2008 / 097860. The flooring elements disclosed in those documents can be laid on a surface and mechanically coupled together to form a floor covering without the use of adhesives, thus reducing labor and time during the installation phase. This type of floor covering is referred to as a floating floor covering. Specifically, in these documents, ceramic tiles or natural stone slabs are fixed to a support layer comprising coupling elements configured to achieve coupling with coupling elements of adjacent flooring elements, thereby forming the floor covering.

[0009] On the other hand, because such floor elements are not bonded to a common rigid surface, impact strength is significantly reduced, resulting in significantly reduced fatigue strength. Floating installations may also cause greater walking noise. The joints between tiles as described in WO 2008 / 097860 may be prone to water seepage, especially during wet washing. According to some embodiments of WO 2004 / 097141, grouting can be applied to the available joints between adjacent floor elements, which can result in the impermeability of the corresponding joints.

[0010] To improve the impact resistance of ceramic tiles, US2014 / 349084 recommends a ceramic tile with a composite structure. In this composite tile, a reinforcing layer is arranged between two ceramic layers or between a ceramic layer and a polymer laminate. A fiberglass layer is mentioned as an example of a reinforcing layer. However, the installation of such tiles remains cumbersome. Bonding to a subfloor is required, for example via a substrate with a pressure-sensitive adhesive or quick-setting loop fabric, so that the tile and subfloor are essentially solid to improve impact strength. Furthermore, precise positioning of the tile is difficult.

[0011] WO 2010 / 072704 proposes different types of reinforcing layers, namely steel plates. These steel plates are attached to the back of the tiles or slabs. However, installation is also difficult here. The installation is accomplished by simply placing the tiles on the underlying floor, making precise tile positioning difficult, and the floor covering results in a less-than-smooth surface and a noisy, permeable floor covering.

[0012] The primary objective of this invention is to provide an alternative floor element that, according to several preferred embodiments, addresses one or more problems present in the prior art. Summary of the Invention

[0013] In a first aspect, the present invention provides a floor element for forming a floor covering, the floor element comprising: a decorative layer comprising a ceramic material; an intermediate layer comprising a resin material permeating a lower surface of the decorative layer; and a support layer disposed below the decorative layer, wherein the support layer includes an edge provided with a coupling element configured to achieve mechanical coupling with coupling elements of adjacent floor elements.

[0014] In another aspect, the present invention provides a floor covering comprising a plurality of floor elements as described herein.

[0015] In another aspect, the present invention provides a method for manufacturing a floor element, comprising the steps of: providing a decorative layer made of a ceramic material; providing a support layer; providing a resin material for bonding the decorative layer and the support layer together; and pressing the decorative layer and the support layer together to form a floor element, such that the resin material permeates the decorative layer.

[0016] In another aspect, the present invention provides the use of a resin material for bonding a decorative layer and a support layer made of ceramic material to form a floor element, the resin material having a viscosity of less than 1000 mPas at 20°C.

[0017] In another aspect, the present invention provides a floor element comprising: a decorative layer made of ceramic material, and a support layer disposed beneath the decorative layer, wherein the support layer includes at least two pairs of opposing edges, each opposing edge including a coupling element configured to achieve mechanical coupling with a coupling element of an adjacent floor element, wherein a first coupling element located on a first pair of opposing edges is configured to be coupled to a coupling element of an adjacent floor element by an inclined movement about a horizontal axis parallel to the respective edge, and wherein a second coupling element located on a second pair of opposing edges is configured to be coupled to a coupling element of an adjacent floor element by a downward translational movement of the respective edges toward each other.

[0018] In another aspect, the present invention provides a floor element comprising: a decorative layer having a density of at least 10 kg / sqm, preferably at least 15 kg / sqm, expressed as surface weight; and a support layer disposed below the decorative layer, wherein the support layer includes at least two pairs of opposing edges, each opposing edge including a coupling element configured to achieve mechanical coupling with a coupling element of an adjacent floor element, wherein a first coupling element located on a first pair of opposing edges is configured to be coupled to a coupling element of an adjacent floor element by an inclined movement about a horizontal axis parallel to the respective edge, and wherein a second coupling element located on a second pair of opposing edges is configured to be coupled to a coupling element of an adjacent floor element by a downward translational movement of the respective edges toward each other.

[0019] These and other objects, features and advantages of the present invention will become more apparent when the following specification is read in conjunction with the appended description and drawings. Attached Figure Description

[0020] The following non-limiting and exemplary drawings are provided to illustrate several possible forms of embodiments according to this disclosure.

[0021] Figure 1 A top view of an embodiment of the floor element of the present invention is shown;

[0022] Figure 2 Shown at a larger scale along Figure 1 The cross section of line II-II;

[0023] Figure 3 Shown at a larger scale Figure 2 The view of area F3 shown;

[0024] Figure 4 Shown at a larger scale along Figure 1 The cross section of line IV-IV;

[0025] Figure 5 Shown at a smaller scale including Figure 1 Top plan view of the floor covering with multiple floor elements;

[0026] Figure 6 Shown at a larger scale along Figure 5 The cross section of line VI-VI;

[0027] Figure 7 Shown at a larger scale Figure 6 The view of area F7 shown;

[0028] Figure 8 Shown at a larger scale along Figure 5 The cross section of line VIII-VIII;

[0029] Figure 9 Shown at a larger scale Figure 8 The view of area F9 shown;

[0030] Figure 10 Some steps of a method for manufacturing floor components are shown. Detailed Implementation

[0031] Therefore, according to a first independent aspect, the present invention relates to a floor element for forming a floor covering, wherein the floor element comprises a decorative layer made of ceramic material and a support layer disposed beneath the decorative layer, wherein the support layer comprises an edge provided with coupling elements configured to achieve mechanical coupling with coupling elements of adjacent floor elements, and wherein the floor element comprises an intermediate layer of resin material having a lower surface permeated with the decorative layer. The inventors have discovered that, due to this solution, the impact resistance of the floor element (more particularly, the ceramic decorative layer) is significantly improved, such that even with mechanical locking between these floor elements, the impact strength reaches or even exceeds that of conventional elements installed by adhesives. Furthermore, with the claimed solution, it is possible to improve the impact resistance of the floor element without having to add additional rigid or elastic reinforcing elements, such as rubber layers, fiberglass, or metal plates. In fact, the resin permeating the pores of the decorative layer substantially improves the transmission and dissipation of impact stress through the floor element, such that a smaller portion of the energy is absorbed by the decorative layer, thereby improving its impact resistance. Since it is not necessary to add rigid reinforcing elements, the resulting floor element is lighter and thinner. Furthermore, the resin hinders the propagation of cracks within the decorative layer itself. Additionally, in the event of surface cracks in the decorative layer, the intermediate layer maintains the continuity of the decorative layer itself and is preferably compacted, thereby concealing the visual appearance of the surface cracks.

[0032] The impact strength of a floor can be determined using a steel ball impact test. This test measures impact strength by dropping a steel ball from a height onto a floor element; if the floor element does not break, the height is increased until the steel ball breaks. The steel ball weighs 225.5 grams and has a diameter of 38.1 millimeters (1.5 inches). Impact strength is expressed as the maximum height from which a steel ball can fall onto a floor element without breaking it. The higher the drop height, the higher the impact strength. Impact strength can be expressed in Joules (J), which is the energy of the steel ball when it impacts the surface of the floor element. The inventors have found that conventional floors, such as those made of ceramic floor elements approximately 10 mm thick, directly bonded to the subfloor, typically exhibit an impact strength of 1.68 J to 2.25 J (corresponding to a ball dropped from a height of 762 to 1016 mm), while known floating floors typically exhibit an impact strength below 1.12 J (equivalent to a ball dropped from a height below 508 mm). The inventors have discovered that, thanks to this solution, an impact strength of over 5.62J can be achieved (equivalent to a steel ball falling from a height of over 2540mm).

[0033] According to ASTM C627, the fatigue strength of flooring is determined by the so-called Robinson test. In this test, a three-wheeled trolley rotates around the center of a sample section of tile flooring on top of it. Each wheel has a pole above it along which weights can be stacked. A motor drives the assembly, rotating the trolley at 15 revolutions per minute. The test is conducted according to a loading schedule of 14 different cycles. For each cycle, the schedule specifies the type of wheels to be used (soft rubber, hard rubber, or steel), the amount of weight to be stacked above each wheel, and the total number of trolley revolutions to be performed. After each cycle, the sample flooring section is visually inspected. The test results are used to evaluate the flooring based on the number of cycles passed without failure, indicating the level of service the flooring will achieve:

[0034] - Samples that completed cycles 1 through 3 without failure: "Residential" rating;

[0035] - Samples that completed cycles 1 through 6: "Mild" commercial rating;

[0036] - Samples that completed cycles 1 through 10: "Medium" business rating;

[0037] - Samples that have completed cycles 1 through 12: "Severe" commercial rating;

[0038] - Samples that complete all 14 cycles without failure are designated as “Extra Heavy” commercial rating.

[0039] The inventors have discovered that, due to the use of the intermediate layer according to the invention, the Robinson test can result in passing at least 6 cycles (light commercial rating).

[0040] According to a preferred embodiment of the invention, the decorative layer comprises a ceramic body, for example made of porcelain, red-body ceramic, ceramic, earthenware, or other sintered ceramic powder. Preferably, the decorative layer is a ceramic tile or slab. The term "ceramic tile" includes an element having a substantially flat body composed of a calcined mineral such as clay, and preferably having a calcined decorative top surface, preferably, but not necessarily, based on a glaze. The glaze also has the effect of preventing resin from penetrating the decorative layer to the top surface of the decorative layer and thus affecting the appearance of the floor element.

[0041] However, it should be noted that this first aspect can advantageously be applied to decorative layers made of any kind of material having openings at least at corresponding locations on its lower surface. Examples of such materials can be brittle materials, such as natural stone, concrete, glass, or glass-ceramic materials. The term brittle material is intended to include any material that fractures without significant plastic deformation. In particular, for the purposes of this patent application, the term brittle material refers to a material that, according to a ball impact test, has an impact strength of less than 1.68 J (corresponding to a ball dropped from a height of less than 762 mm) if it is not bonded to a support layer and has no reinforcing elements.

[0042] According to a preferred aspect of the invention, the decorative layer may include openings corresponding at least to its lower surface, which are adapted to allow resin to permeate the decorative layer itself. Indeed, as described above, the inventors have surprisingly discovered that by allowing the resin of the intermediate layer to permeate the pores of the decorative layer, the transfer of impact energy can be significantly improved. Therefore, according to a preferred embodiment of the invention, the decorative layer comprises an apparent porosity of 0.1% to 10%, more preferably 2% to 8%, for example 6%, as determined by ASTM C373. The aforementioned range and values ​​of apparent porosity provide an optimal balance between the inherent mechanical properties of the decorative layer and its resin permeability, thereby optimizing impact strength. In fact, pores in a material, particularly closed pores that cannot be permeated by resin, can represent a weakness in the material itself; therefore, it is preferred that the decorative layer comprise an apparent porosity of less than 15%, preferably less than 10%, as measured by ASTM C373. Furthermore, the decorative layer may preferably have an opening volume of 0.01 cc (cm³) to 1 cc, more preferably 0.10 cc to 0.90 cc, for example 0.60 cc. In this way, the pores are large enough to be filled by the resin, while being small enough not to impair the mechanical properties of the decorative layer. This result is particularly impressive because the apparent porosity range is unique for tiles primarily used for wall or floor coverings in residential facilities, but tiles with apparent porosity are preferred for floor coverings in commercial facilities where traffic is more intense and higher mechanical properties are required.

[0043] Therefore, according to the first preferred possibility, the decorative layer is made of porcelain. Porcelain is a ceramic material obtained by firing a mixture of relatively pure raw materials, including clay, kaolin, quartz, feldspar, calcium carbonate, and / or other mineral raw materials, at a high temperature of, for example, about 1200°C. Porcelain exhibits a very low apparent porosity as measured according to ASTM C373, preferably less than 1%, for example, 0.3%. Porcelain has a volume comprising pores ranging from 0.01 cc (cubic centimeters) to 0.1 cc, more preferably from 0.1 cc to 0.6 cc. This porosity value causes the porcelain material to exhibit relatively high mechanical properties, which can be further enhanced by resin permeation of the decorative layer. In fact, the ceramic tile itself, i.e., when not bonded to the support layer and without resin permeation of the decorative layer, exhibits an impact resistance of 0.73 J, while a floor element comprising a decorative layer made of porcelain, bonded above the support layer by an intermediate layer of resin comprising the lower surface of the permeated decorative layer, can achieve an impact resistance of up to 3.37 J.

[0044] Therefore, according to the second preferred possibility, the decorative layer is made of red-body ceramic. Red-body ceramic is a ceramic material obtained by firing a mixture of raw materials including clay, kaolin, quartz, feldspar, calcium carbonate, and / or other mineral raw materials at a high temperature, for example, about 1150°C. Compared to porcelain, red-body ceramic can be fired at a lower temperature, thus exhibiting higher porosity and water absorption. Furthermore, red-body ceramic can be obtained from a raw material mixture that is cheaper than the raw material mixture required to obtain porcelain. For example, red-body ceramic may include less than 10%, preferably between 2% and 8%, for example 6%, of apparent porosity as measured according to ASTM C373. Red-body ceramic may have an open-cell volume including between 0.10 cc and 0.90 cc, for example 0.60 cc. Typically, red-body ceramic tiles, when not bonded to a support layer and without resin permeation of the decorative layer, exhibit an impact resistance of 0.67 J. However, flooring elements comprising a decorative layer made of red-body ceramic, bonded above the support layer via an intermediate layer including resin permeating the lower surface of the decorative layer, can achieve an impact resistance as high as 5.62 J. It should be noted that the impact resistance of red-body ceramic tiles is lower than that of porcelain ceramic tiles, and the flooring elements comprising red-body ceramic according to the present invention exhibit significantly higher impact resistance than flooring elements comprising porcelain.

[0045] The inventors have discovered that the interaction between the resin and the decorative layer is improved when the decorative layer includes a substantially flat lower surface. The lower surface is the invisible surface (in use) opposite the upper decorative surface of the decorative layer. Typically, the lower surface of a tile includes a back structure, usually formed by ribs or recesses, with a thickness up to 1 mm; however, the inventors have discovered that, in order to apply resin to the lower surface itself, a decorative layer without such a back structure (e.g., without the ribs) is preferably used. Furthermore, according to a preferred embodiment of the invention, the lower surface of the decorative layer (particularly the lower surface of the tile) has no backflow. Backflow is a thin coating mainly comprising a glaze base, which is typically applied unevenly to the lower surface of the tile and functions to prevent material from unfired tiles from adhering to the rollers of the firing kiln. Since backflow comprises a glaze base consisting at least partially of a glass composition, its melting permeates the pores open on the lower surface of the tile during firing, making the lower surface itself impermeable. Therefore, the inventors have discovered that a decorative layer made from a tile having a lower surface without backflow provides better resin permeability to the lower surface of the tile. The reflow may also cover a portion of the lower surface of the decorative layer, less than 20%, preferably 10%, of the lower surface. In this way, the reflow does not completely impermeable the lower surface, thus allowing the resin to penetrate the pores of the decorative layer, while on the other hand, it helps to manufacture the decorative layer and prevents material from unfired ceramic tiles from sticking to the rollers of the firing kiln.

[0046] The decorative layer may have an upper surface including a decoration. This decoration may be provided with various textures, designs, and colors. In a preferred embodiment, the decoration mimics a natural product, such as natural stone or wood. Preferably, the decoration is at least partially formed by a printout. This printout is preferably achieved by digital printing, such as inkjet printing, but screen printing, rotary gravure printing, aniline printing, or offset printing are not excluded. According to a variation, the decoration is at least partially formed by a uniformly colored substrate or a mixture of colored substrates.

[0047] The decorative layer may include a background coating that at least partially covers its upper surface and is adapted to receive decoration on top of it, such as printed material. The background coating may be white, beige, brown, or any color suitable for receiving decoration on top of it. When the decorative layer is made of ceramic material, the background layer preferably includes at least a glaze covering the upper surface of the ceramic body.

[0048] The decorative layer may also include a protective coating that at least partially covers its upper surface and is suitable for placement over the decoration. The protective coating may be transparent or translucent. The protective coating may be used in conjunction with a background coating. When the decorative layer is made of ceramic material, the protective layer is preferably a glaze.

[0049] Preferably, the decorative layer has a thickness of 4 mm to 15 mm, more preferably 6 mm to 12 mm, and more preferably greater than 7 mm, such as 8 mm or 10 mm. The inventors have discovered that satisfactory fatigue behavior can be achieved for relatively thin decorative layers by adding an intermediate layer. Furthermore, it should be noted that the preferred thickness values ​​allow for a good balance between the weight and cost of the material on one side and the mechanical resistance on the other. Generally, higher thickness corresponds to higher weight and cost, as well as higher mechanical resistance. The thickness of the decorative layer itself can be reduced due to the reinforcing effect provided by resin penetration into the lower surface of the decorative layer. Furthermore, the rigidity of the decorative layer inhibits the thermal expansion of the support layer, and this inhibition effect increases with the increase of the decorative layer thickness.

[0050] It should be noted that the decorative layer may include a density expressed as surface weight of at least 10 kg / sqm, preferably 15 kg / sqm, and for example, greater than 19 kg / sqm. A high density of the decorative layer can improve the installation of the floor covering, particularly the vertical locking between floor elements, as described in more detail below. It is also preferred that the decorative layer include a density expressed as surface weight of less than 35 kg / sqm, preferably less than 30 kg / sqm, and for example, less than 25 kg / sqm. In practice, an excessively heavy decorative layer may affect the maneuverability of the floor elements and complicate their packaging and transportation.

[0051] The decorative layer can be made in any shape, such as square, rectangular, or hexagonal. In a preferred embodiment, the floor element is rectangular or rectangular in shape and is preferably provided with a wood grain print depicting wood grain lines that extend integrally in the longitudinal direction of the rectangular decorative layer. The covering element can also include any size, but preferably it has a surface area of ​​less than 1.5 sqm, preferably less than 1 sqm, and more preferably less than 0.4 sqm.

[0052] According to a preferred aspect of the invention, the intermediate layer comprises a resin, such as a thermosetting resin or a thermoplastic resin. Examples of thermosetting resins are epoxy resins, polyurethanes, cyanoacrylates, or acrylic resins. Examples of thermoplastic resins are hot-melt, thermoplastic polyesters, vinyl, etc. Preferably, the resin is a rigid resin. In fact, the inventors have found that rigid resins, rather than flexible resins, improve the transfer of impact energy between layers. In particular, according to a preferred embodiment of the invention, the intermediate layer comprises an epoxy resin. It is also preferred that the epoxy resin is a two-component resin, i.e., a thermosetting resin obtained by curing a mixture of two components (i.e., resin and hardener) at a low temperature (e.g., at room temperature). When the two components of the resin are mixed together, the curing reaction begins, so that curing does not have to be activated by providing external energy (e.g., heat, UV, or EB radiation). The external energy may optionally be provided to accelerate the curing process. According to a preferred aspect of the invention, the resin has a viscosity of less than 1000 mPas, preferably less than 800 mPas, more preferably less than 600 mPas, for example, about 400 mPas at 20°C. The viscosity values ​​expressed in this application refer to dynamic viscosity and can be measured using a torsional rheometer (such as those in the Physica MCR series from Anton Paar, for example). Within the scope of this invention, viscosity refers to the viscosity of the uncured resin, for example, the viscosity of a mixture of two components before curing is complete, i.e., during the so-called pot life. In fact, the inventors have discovered that if the resin is sufficiently fluid, it can penetrate its pores during its application to the back of the decorative layer, greatly improving the bond between the intermediate layer and the decorative layer. In fact, when the resin penetrates the pores of the decorative layer, it essentially forms a “composite polymer-ceramic layer” that significantly improves the impact strength of the flooring element. It should be noted that, according to the preferred solution, the resin is essentially in a liquid state during the manufacturing process of the flooring element. In alternative embodiments, the resin may be in a paste or gel state during the manufacturing process, exhibiting thixotropic behavior to achieve sufficient fluidity to penetrate the pores of the decorative layer under predetermined process conditions (e.g., during the pressing step). According to embodiments of the invention, the intermediate layer may comprise two or more different resins. For example, the intermediate layer may include a first resin for impregnating the pores of the decorative layer and a second resin for bonding the decorative layer and the support layer together. According to the embodiment, the first resin may be a rigid resin for reinforcing the decorative layer, and the second resin may be a soft or elastic resin, for example, that provides a cushioning effect in the event of an impact.

[0053] The inventors have also discovered that, preferably, the resin may be free of fillers, such as mineral fillers. In fact, the inventors have found that the presence of fillers can improve the mechanical properties of the resin itself, and on the other hand, fillers can increase the viscosity of the resin, thereby creating a barrier to the penetration of the decorative layer.

[0054] The resin preferably has a tensile strength of 50 MPa to 90 MPa, more preferably 60 MPa to 80 MPa, for example 75 MPa. It should be noted that the resin preferably has a compressive strength of 90 MPa to 130 MPa, more preferably 100 MPa to 120 MPa, for example 110 MPa. The inventors have found that this strength is sufficient to provide a rigid matrix for the composite polymer-ceramic layer, thereby allowing for the dissipation of impact energy. It should also be noted that the resin can preferably exhibit a hardness value of at least 50 as measured on the Shore D scale.

[0055] Preferably, the resin covers at least a portion of the lower surface of the decorative layer, such as a large portion of the lower surface of the decorative layer, i.e., at least 50%. More preferably, the resin covers 80% or more of the lower surface of the decorative layer, for example, it covers 100% of the lower surface of the decorative layer, so that an impact energy distribution and dissipation effect is achieved for any impact occurring at any point in the decorative layer.

[0056] Preferably, resin is provided on the lower surface of the decorative layer in an amount greater than 150 g / sqm, more preferably greater than 200 g / sqm, for example 220 g / sqm, such that the amount of resin is sufficient to completely penetrate the openings on the lower surface of the decorative layer.

[0057] Preferably, the resin is provided in an amount sufficient to overflow from the openings in the decorative layer so as to serve as an adhesive for the support layer. In other words, it is preferable that the resin partially permeates the openings in the decorative layer and partially covers its lower surface to form an intermediate layer and improve energy transfer. The energy transfer effect is further improved if the support layer is directly attached to the intermediate layer, particularly to the portion of the resin coated on the lower surface of the decorative layer, thereby enabling the intermediate layer to function as an adhesive layer that bonds the decorative layer and the support layer together.

[0058] In addition, the intermediate layer may include reinforcing elements. These reinforcing elements may be embedded in the intermediate layer, for example, embedded in a resin material, or may be a reinforcing layer placed between the intermediate layer and the support layer. The reinforcing elements may include fibers, such as glass fibers, carbon fibers, polymer fibers, such as aramid or polyamide fibers, or ceramic fibers, such as boron or silicate fibers. The fibers may be woven or nonwoven fibers, for example, having fibers arranged in different orientations, and may be in the form of padding, wool, or cloth. The reinforcing elements can be used to further improve the impact resistance of the floor element, particularly in special and unique installations such as raised floors.

[0059] According to an alternative embodiment, the reinforcing element may comprise a metal sheet, such as a steel or aluminum sheet. Preferably, the metal sheet is configured to establish a compressed state within the decorative layer. This significantly improves impact resistance because the decorative layer is in a compressed state, as compression hinders crack propagation and helps to visually conceal surface cracks. To achieve this, the metal sheet is first stretched, for example by mechanical or thermal stretching, and then bonded to the decorative layer while the metal sheet is in a stretched state. Subsequently, the stretching is released by interrupting the mechanical induction or by cooling the metal sheet itself, thereby establishing a compressed state within the decorative layer. For example, in one embodiment, the coefficient of thermal expansion of the metal sheet is higher than that of the decorative layer. Due to this solution, the reinforcing element is heated to a stretched state and then bonded to the decorative layer while still stretched, subsequently cooled to retract and place the decorative layer in a compressed state.

[0060] According to a preferred embodiment of the invention, the support layer is made of a material different from that of the decorative layer. In particular, the support layer is preferably made of a material suitable for providing coupling elements and / or a waterproof material and / or a compressible material.

[0061] The support layer is preferably made of a polymeric material. Polymeric materials have good mechanical properties, as well as relatively low cost and weight. Furthermore, they provide an impermeable and sound-reducing support layer. The statement "preferably made of a polymeric material" does not necessarily mean that the support layer is entirely made of polymeric material. For example, the support layer may include fillers made of polymeric or non-polymeric materials, such as fibers, strands, whiskers, or particles. Furthermore, this term does not necessarily mean that the polymeric material constitutes the majority of the material in the support layer, for example, greater than 50% by weight. The term generally refers to the polymeric material representing the matrix that surrounds and binds the filler together.

[0062] Preferably, the support layer is made of a thermoplastic polymer material. Preferred examples of thermoplastic materials include, for example, PVC (polyvinyl chloride), polypropylene (PP), or polyurethane, more particularly thermoplastic polyurethane. Preferably, the thermoplastic polymer material has a glass transition temperature (Tg) of less than 100°C. Forming the support layer from a material with a relatively low glass transition temperature results in a support layer that is easily compressible at room temperature. Compression is desirable in many ways. For example, possible thermal expansion of the support layer can be partially or completely suppressed by a more rigid or stiffer decorative layer and / or by reinforcing elements that keep the material of the support layer in its original dimensions. Compression may also be important for the design of the coupling elements and can allow for some adaptation to the unevenness of the subfloor, which in turn prevents air pockets between the support layer and the subfloor that could amplify walking noise.

[0063] Among thermoplastic materials, PVC is the preferred choice for the support layer due to the balance between processability, physical and mechanical properties, and cost. Furthermore, the inventors have discovered that PVC has a good affinity with resins, particularly epoxy resins, making it possible to form a very good bond and interfacial phase between the support layer and the intermediate layer. This interfacial phase improves the transfer of impact energy between the layers of the floor element, thereby increasing its impact strength. In addition, the inventors have discovered that due to the interaction between PVC and resins, particularly epoxy resins, any delamination effect between the support layer and the intermediate layer can be reduced or avoided, resulting in improved fatigue resistance of the floor element. In fact, because the aforementioned good interaction prevents delamination between the decorative layer and the support, the floor element retains its mechanical properties substantially unaffected even after prolonged use, thus exhibiting good fatigue strength.

[0064] In a preferred embodiment, the support layer is made of rigid or flexible PVC, wherein the rigid PVC includes less than 15 phr of plasticizer, and the flexible PVC includes 15 phr or more, preferably greater than 20 phr or greater than 25 phr of plasticizer. In the context of this specification, the term "rigid" means that the individual support layer bends less than 10 cm / m under its own weight, and more preferably less than 5 cm / m, while "flexible" means that the individual support layer bends greater than 10 cm / m under its own weight. The support layer may also include filler materials, such as mineral particles, such as chalk and / or calcium carbonate. The filler can be included in the support layer in relatively high amounts, for example, greater than 30 wt% or greater than 60 wt%. The filler increases the weight of the support layer and makes it very effective in eliminating or reducing the transmission of walking noise to the area below. Rigid PVC including filler is also called SPC (solid polymer composite). The filler content should preferably be limited to less than 70 wt%, for example less than 50 wt%, so as not to unduly increase the brittleness of the support layer. Rigid PVC provides a support layer with good dimensional stability when exposed to temperature changes. In other words, the expansion of the support layer is limited when exposed to high temperatures, thus providing good stability to the floor. Preferably, the coefficient of thermal expansion of rigid PVC is less than 85 μm / m / ℃, more preferably less than 60 μm / m / ℃, for example, 50 μm / m / ℃. For example, the coefficient of thermal expansion of the support layer, particularly when it is made of rigid PVC, ranges from 20 μm / m / ℃ to 85 μm / m / ℃, preferably from 40 μm / m / ℃ to 60 μm / m / ℃. Support layers made of flexible PVC have lower dimensional stability but are more easily compressed, and therefore their tendency to expand can be at least partially suppressed by the decorative layer and / or intermediate layer.

[0065] The inventors have discovered that good results in terms of impact strength can be obtained by using a support layer made of a rigid polymer material (preferably PVC). Therefore, according to a preferred embodiment, the support layer is made of a rigid polymer material (preferably PVC) that may include a flexural modulus of 1.5 GPa to 3.5 GPa, for example, about 2.6 GPa. The support layer may also include a flexural strength of 60 MPa to 90 MPa, for example, about 76 MPa. Furthermore, the support layer may include a compressive strength between 40 MPa and 70 MPa, for example, about 56 MPa. In fact, the inventors have discovered that the rigidity of the support layer helps absorb impact energy, thereby improving impact strength.

[0066] According to alternative embodiments, the support layer made of flexible PVC or any other material (thermoplastic or non-thermoplastic) can be designed to compensate for dimensional changes due to temperature variations. For example, the support layer may be formed from multiple separate elements, such as strips, or may include grooves separating adjacent portions of the support layer, thereby allowing said portions to expand without affecting the overall stability of the floor. The grooves preferably open toward the lower surface of the support layer.

[0067] Furthermore, the support layer preferably has a thickness ranging from 2 mm to 7 mm, preferably less than 6 mm, and more preferably about 4 mm or less. A thinner support layer provides lower cost and higher thermal stability, particularly because the thermal expansion of a thinner support layer can be more effectively suppressed by the rigidity of the support layer. For example, a preferred embodiment of the invention provides a support layer made of rigid PVC, exhibiting a thickness of 4 mm, thus providing a good solution in terms of thermal stability, noise reduction, low weight, and low cost. Also as mentioned above, the inventors have found that the rigidity of the decorative layer helps to suppress the thermal expansion of the support layer, and the rigidity of the layer depends on its thickness. Therefore, according to a preferred embodiment, the thickness of the decorative layer is equal to or greater than the thickness of the support layer; preferably, the thickness of the decorative layer is at least 1 times the thickness of the support layer, preferably 1.5 times, and more preferably 2 times.

[0068] The thickness of the flooring elements is less than 20 mm, preferably 18 mm or less, more preferably 13 mm or less. This results in relatively thin flooring elements, reducing the impact of the flooring on the environment, especially in the case of repairing existing flooring. Furthermore, this method limits the surface weight of the flooring elements, making packaging, transportation, and installation easier. For example, the surface weight of the flooring elements is at least 18 kg / sqm, preferably at least 21 kg / sqm. For example, in a preferred embodiment where the decorative layer is made of ceramic and is 8.5 mm thick, and the support layer is made of PVC and is 4 mm thick, the surface weight of the flooring elements is approximately 24 kg / sqm. Therefore, a good balance is achieved between the economy of transportation and packaging and the ease of installation. In fact, a weight exceeding the stated limit can help with the coupling between two flooring elements, particularly improving their vertical locking.

[0069] According to a preferred embodiment of the invention, the floor element comprises: a ceramic decorative layer, preferably made of porcelain or red-body ceramic; a support layer made of rigid PVC; and an intermediate layer comprising resin permeating the lower surface of the decorative layer. Preferably, the ceramic decorative layer has a thickness of 6 mm to 12 mm, more preferably 8 mm. Preferably, the support layer has a thickness of less than 6 mm, more preferably 4 mm. This embodiment provides a floor element with particularly effective thermal stability, making the floor covering unaffected by temperature variations in the room. Furthermore, this effect is achieved by a floor element with a thickness of less than 13 mm. This value is relatively low, and it offers advantages in terms of packaging, cost, and maneuverability.

[0070] As previously described, the support layer includes edges with coupling elements configured to achieve mechanical coupling with coupling elements of adjacent floor elements. The term "mechanical coupling" includes allowing adjacent floor elements to couple with each other without the need for adhesives or the like. Mechanical coupling can be achieved by including shaped edge profiles comprising coupling elements, which are primarily male and female components that mate with each other. It should be noted that, preferably, the coupling elements are configured such that the mechanical coupling results in locking between the edges in the vertical direction and / or one or more horizontal directions.

[0071] Preferably, the coupling element comprises at least one male component and at least one female component, wherein, in the connected state of two such floor elements, the male and female components are already engaged with each other. The male and female components are preferably at least partially formed in the support layer. For example, the male and / or female components may be entirely formed in the support layer. The female components engage with each other in the connected state of two similar floor elements to create mechanical coupling between corresponding edges, preferably resulting in locking between the edges in the vertical direction and / or one or more horizontal directions.

[0072] As used herein, the terms “horizontal” and “vertical” are used in relation to floor coverings mounted on a surface that is generally considered horizontal. Therefore, when used for a single floor element as a substantially flat element having a main plane, the terms “horizontal” and “vertical” are considered equivalent to the terms “parallel to the main plane of the floor element / installed floor element” and “perpendicular to the main plane of the floor element / installed floor element,” respectively.

[0073] Furthermore, in the coupled state of two adjacent floor elements, the coupling elements cooperate and preferably form a locking surface that restricts the relative movement of the floor elements in the vertical direction and / or one or more horizontal directions. Preferably, in the coupled state of two adjacent floor elements, a first locking surface is formed to restrict the relative movement of the floor elements in a direction perpendicular to the coupling edge and in a substantially horizontal plane. Furthermore, in the coupled state, a second locking surface is formed to restrict the relative movement of the floor elements in the substantially vertical direction. Due to this solution, the floor elements can be installed smoothly without unacceptable height differences between adjacent floor elements. Furthermore, the floor elements are securely coupled to each other to improve the fatigue behavior of the floor covering. Additionally, by restricting the relative movement of the floor elements, the step noise effect can be reduced, i.e., the noise generated at each step can be reduced.

[0074] According to a preferred embodiment of the invention, the male and female components may be disposed substantially along the entire length of the respective edges, for example, substantially defining the respective edges. For example, according to this embodiment, the male and female components may be substantially shaped as tongues and grooves extending substantially through the entire length of the respective opposing edges. Preferably, the male component is positioned at a first edge of the floor element, and at least the female component is positioned at a second opposing edge of the floor element.

[0075] Alternatively, the male and female components may extend over a finite length portion of the associated edge, wherein this finite length is less than the entire length of the associated edge itself, preferably less than half the length of the associated edge. According to this possibility, the edge preferably includes portions without the male and female components. The geometry for the coupling components according to this alternative embodiment includes mating male and female components that are dovetail-shaped in the top plan view, or male and female components that resemble the connection of a jigsaw puzzle in the top plan view.

[0076] In some implementations, the coupling elements are configured such that a pre-tensioned state is established between the coupling elements in the coupled state. In other words, the coupling elements are configured such that their elastic deformation in the coupled state applies opposing reaction forces. Due to this solution, the coupling between the floor elements is strengthened, and the coupling itself contributes to the waterproofing of the floor covering.

[0077] According to a preferred embodiment of the invention, the coupling elements are configured such that, in the coupled state, the coupling is not pre-tensioned, simplifying the coupling and requiring less force from the operator. In other words, in the coupled state, the coupling elements are in an undeformed state. Furthermore, even without deformation, coupling movement of the coupling elements, i.e., relative movement between the mechanically coupled coupling elements, also occurs. For example, in some embodiments, a gap is established between the coupling elements in the coupled state, allowing minute movement between the coupling elements in the vertical and / or horizontal directions. For example, the size of the male component on a plane orthogonal to the corresponding edge is equal to or slightly smaller than the size of the female component on the same plane.

[0078] The coupling elements are configured to allow coupling to be achieved through movement of one floor element relative to another adjacent floor element. This movement can be, for example, translation in a vertical downward direction, translation in a horizontal direction perpendicular to the edge, or tilting about a horizontal axis parallel to the edge. This corresponding movement then preferably results in the aforementioned male and female components of the adjacent floor elements engaging with each other.

[0079] Therefore, the coupling element can be interpreted according to several different possibilities, two of which will be briefly described below.

[0080] According to a first possibility, the coupling elements are configured to couple to each other by tilting movement about a horizontal axis parallel to the edge. According to this first possibility, it is also preferred that the coupling elements are configured to couple by translational movement in the horizontal direction (e.g., perpendicular to the edge). According to the first possibility, the male and female components are respectively formed as a tenon and a groove, wherein the tenon extends outward in the horizontal direction beyond its respective edge, and the groove extends inward in the horizontal direction relative to the respective edge. As described above, the tenon and groove are configured such that, in the coupled state of the tenon and groove, a first locking surface and a second locking surface are formed to restrict relative movement of the floor element in the vertical and horizontal directions, wherein the horizontal direction is perpendicular to the edge. According to a preferred embodiment, the tenon includes a horizontally extending lip and a downwardly extending protrusion. Thus, in this embodiment, the groove has a horizontal recess for receiving the lip of the tenon and an upwardly oriented hollow portion for receiving the protrusion of the tenon, such that the tenon can engage in the groove. Preferably, in the coupled state, the tenon is fitted into the groove, creating a horizontal non-operating space between the end of the tenon (particularly the end of its lip) and the bottom of the groove (particularly the bottom of its recess). Also preferably, in the coupled state, the tenon is fitted into the groove, creating a vertical non-operating space between the lower surface of the tenon (particularly the lower surface of its lip) and the groove (particularly its recess). This solution provides a tenon with a lip narrower than the groove, improving the tilting movement for coupling the floor element. Also preferably, in the coupled state, the downwardly projecting protrusion of the tenon contacts the hollow portion of the groove, and the upper surface of the tenon contacts the groove. In particular, it is preferred that the lower surface of the tenon corresponds only to the protrusion contacting the groove. This interaction provides a second contact surface, while simplifying coupling by tilting movement, since the lower contact surface corresponds only to the protrusion of the tenon and not to its lip formation. In other words, the lip has more space within the tenon for performing tilting movements.

[0081] Furthermore, according to this preferred embodiment of the first possibility, a gap is formed in the coupled state of the tenon and the groove. This gap allows for minute movement in the vertical and / or horizontal directions (preferably the horizontal direction). This gap allows the tenon and the groove to couple to each other without deformation.

[0082] This results in a significant reduction in the force applied by the operator attempting to install the floor components. This is particularly important because the weight of the decorative layer, while complicating the installation process on the one hand, can also contribute to the locking between the floor components on the other. Therefore, a slightly looser coupling due to the gap is allowed, which helps improve ease of installation. Preferably, the gap is greater than 0.01 mm, more preferably greater than 0.03 mm. Furthermore, the gap is preferably less than 0.10 mm, for example less than 0.08 mm.

[0083] According to a second possibility, the coupling element is configured to be coupled by translational movement in a downward direction (e.g., vertical direction). According to this second possibility, the coupling element includes an upwardly pointing lower hook-shaped member located on one edge and a downwardly pointing upper hook-shaped member located on the opposite edge. The lower hook-shaped member defines an upwardly pointing cavity forming a female member, while the upper hook-shaped member defines a downwardly pointing lip forming a male member. Once in the coupled position, the downwardly pointing lip and the upwardly pointing cavity form a first locking surface for restricting relative movement in the horizontal direction (e.g., perpendicular to the edge). Preferably, the upper hook-shaped member and the lower hook-shaped member, more preferably the lip and the cavity respectively, are configured such that, in the coupled state, the second locking surface is formed to restrict relative movement of the floor elements in the vertical direction. In particular, the upper hook-shaped member and the lower hook-shaped member are configured such that two sets of the second locking surfaces are formed, for example, on opposite sides of the male and female members. Preferably, both the upper and lower hook-shaped components include undercut portions, such that in the coupled state, the first locking surface and / or the second locking surface are formed to restrict the relative movement of the floor elements. Furthermore, the coupling elements according to the second possibility are configured to deform during coupling movement. Preferably, the lower hook-shaped component includes a flexible rod portion configured to deform by disengaging the upper and lower hook-shaped components, such that the undercut portions can be coupled through said deformation.

[0084] It should be noted that the floor element may include the same coupling element on all its edges, i.e., according to either the first or second possibility. According to a preferred embodiment of the invention, the floor element may include coupling elements of different shapes or sizes on different edges. For example, the floor element may include coupling elements according to the first possibility on the first pair of opposite edges (e.g., the long edges in the case of a rectangular floor element), and coupling elements according to the second possibility on the second pair of opposite edges (e.g., the short edges). In other words, a rectangular floor element may include coupling elements adapted for coupling via tilting movement on the long edges and coupling elements adapted for coupling via translational movement in the downward direction on the short edges. Due to this solution, the coupling between floor elements is significantly simplified. In fact, due to the tilting movement, such as that provided by tongues and grooves, the long edges of the floor element are easily aligned, thus simplifying positioning and providing a strong coupling between the long edges in both the vertical and horizontal directions, while the short edges can be easily coupled via translational movement in the downward direction, a direct result of the coupling between the long edges. This is particularly advantageous in the case of heavy-duty decorative layers. In fact, once coupled according to the first possibility of coupling elements (e.g., tongue and groove on the long side), it is sufficient to position the floor element horizontally to achieve mechanical coupling according to the second possibility of coupling elements, such as on the short side, without requiring hammering or striking the floor element itself. This also occurs when the coupling elements according to the second possibility deform during coupling, as the weight of the decorative layer may be sufficient to cause such deformation.

[0085] Preferably, the support layer has a shape substantially corresponding to the decorative layer; however, more preferably, the support layer has one or more portions extending beyond the decorative layer. The support layer may also include one or more recesses extending beneath the decorative layer. The support layer is preferably a continuous element, wherein it preferably covers a substantial portion, i.e., at least 50%, of the lower surface of the decorative layer. For example, the support layer covers 80% or more of the lower surface of the decorative layer. More preferably, the support layer completely covers at least the entire lower surface of the decorative layer (i.e., covers 100% of the lower surface), and in some embodiments may extend beyond the lower surface of the decorative layer. Alternatively, the decorative layer may at least partially cover the upper surface of the support layer, preferably a substantial portion, e.g., greater than 50%, preferably greater than 80%, e.g., 90% or more. According to a different embodiment, the support layer comprises a plurality of separate, adjacent support layer portions, in which case the plurality of support layer portions preferably cover at least 50% of the lower surface, or even 80% or more thereof.

[0086] Preferably, the support layer is attached to the decorative layer such that it extends beyond at least one edge of the decorative layer, for example, at least two edges of the decorative layer, preferably a subsequent edge of the decorative layer, and more preferably beyond all edges of the decorative layer. In particular, according to a preferred embodiment, the decorative layer is mounted on the support layer in a manner centered on the upper surface of the support layer, for example, each upper edge of the support layer extends beyond the edge of the decorative layer by the same predetermined distance. Alternatively, the decorative layer may be mounted on the support layer at a position offset relative to the upper surface of the support layer, such that the predetermined distance between the upper edge of the support layer and the edge of the decorative layer varies from edge to edge of the decorative layer. The predetermined distance is at least 0.5 mm, more preferably 0.75 mm, for example, 1 mm or 1.5 mm.

[0087] Floor elements can include any size, although preferably, they have a surface area of ​​less than 1.5 sqm, more preferably less than 1 sqm, and more preferably less than 0.4 sqm. For example, floor elements, particularly decorative layers, may have edges with a maximum length of less than 1.5 m, preferably less than 0.9 m. In practice, floor elements are used to lay on subfloors that may have irregularities (e.g., depressions or protrusions), which can affect the installation of the floor covering, the impact resistance of the floor elements, and fatigue resistance. For floor elements with a reduced area, the impact of such irregularities and the likelihood of encountering them are reduced. Furthermore, decorative layers, especially those made of ceramic materials, can be slightly curved, thus mitigating the same problems that may arise due to irregularities in the subfloor. The larger the sides of the decorative layer, the greater the curvature, making it preferable for both the floor elements and decorative layers to have a reduced surface area.

[0088] According to a preferred embodiment of the invention, in the coupled state of two floor elements, there is preferably an intermediate distance between the respective upper edges of adjacent floor elements. Preferably, the decorative layer is mounted on the support layer such that when the floor elements are coupled, the intermediate distance exists between the edges of adjacent decorative layers, while the edges of the underlying support layer are coupled to each other by available coupling elements. This solution allows for slight dimensional variations in the decorative layers of adjacent tiles. When the decorative layer is formed of one or more tiles, both unmodified and modified tiles can be selected, with unmodified tiles being preferred because they are cheaper than modified tiles. Even when modified tiles are selected, in the case of unmodified tiles, an intermediate distance of at least 1.5 mm, for example, about 3 mm or more, is preferred. Generally, for fragile decorative layers, it is best to prevent direct contact between the edges of the decorative layers of adjacent floor elements to minimize the risk of edge breakage during installation or use of the floor covering. Preventing direct contact between the edges of the decorative layers also prevents squeaking noise when walking on the floor. Furthermore, some decorative layers and / or support layers may expand or contract due to thermal changes. The available intermediate distance prevents this expansion and contraction from affecting the stability of the floor. For example, the predetermined distance between the edge of the decorative layer and the upper edge of the support layer is the same on all edges of the decorative layer, and is preferably half the intermediate distance between the corresponding upper edges of adjacent floor elements in a coupled state. This solution is particularly preferred if uncorrected tiles are used, as it simplifies the positioning of tiles that may be slightly different in size on a support layer of the same size.

[0089] The intermediate distance or gap between the decorative layers of adjacent floor elements can be further adjusted in several possible ways.

[0090] According to the first possibility, the intermediate distance between the floor elements can be filled with grout, thereby providing an impermeable floor cover. Polymer-based and / or cement-based grouts are preferably used. The grout can be flexible or rigid. Flexible grouts can be, for example, silicone-based grouts, while rigid grouts can be, for example, epoxy-based or cement-based grouts. Epoxy-based and silicone-based grouts are examples of polymer grouts. Other examples of polymer grouts are polyurethane-based or acrylic-based grouts.

[0091] In the second possibility, the decorative layer may be at least partially, preferably completely, surrounded by a gasket, such that in the coupled state of two adjacent floor elements, the gasket is compressed by the decorative layer of the adjacent floor elements to form a substantially waterproof connection between the floor elements.

[0092] It should be noted that the inventive concept is formed by the floor element comprising an intermediate layer of resin material having a lower surface permeated with a decorative layer, independent of the presence of a support layer, and particularly independent of the presence of a support layer comprising an edge having coupling elements configured to achieve mechanical coupling with coupling elements of adjacent floor elements. Therefore, according to a second independent aspect, the present invention relates to a floor element for forming a floor covering, wherein the floor element comprises a first decorative layer made of ceramic material and a second layer disposed beneath the decorative layer, wherein the second layer comprises a resin material permeated with the lower surface of the decorative layer. According to this second independent aspect of the invention, the floor element may optionally include a third support layer disposed beneath the second layer. Furthermore, optionally, the third support layer may include one or more of the features of the support layer described above with respect to the first independent aspect. The decorative layer and the intermediate layer may also include one or more of the features described above with respect to the first independent aspect.

[0093] As an example, the floor element according to the second independent aspect can be made of a pressure-sensitive adhesive layer, a quick-adhesive ring-shaped fabric layer (e.g., The floor element can be installed on the subfloor. For example, the floor element may include a pressure-sensitive adhesive layer, such as a double-adhesive layer covered by a cover sheet, placed beneath the second layer to be peeled off before the floor element is installed on the subfloor. Alternatively, the floor element may also be installed on a pressure-sensitive adhesive pad layer. As another example, the floor element according to the second independent aspect can be installed using a quick-adhesive ring-shaped fabric layer (e.g., The floor element can be installed on the subfloor. In this case, the floor element may include a third support layer comprising rings and hooks of fabric adapted to interlock with the padding of the subfloor. Furthermore, for example, according to the second independent aspect, the floor element can be installed on the subfloor via a magnetic device. In this case, the floor element may include a third support layer comprising a magnetic and / or ferromagnetic material adapted to interact with the magnetic and / or ferromagnetic padding of the subfloor.

[0094] It should be noted that the fact that resin materials can be used to form floor coverings including, for example, decorative layers made of ceramic materials, and that the resin permeates the lower surface of the decorative layer, forms the inventive concept, regardless of other characteristics of the floor element, such as the nature of the decorative layer and the presence of the support layer. Therefore, according to the third independent aspect, the present invention relates to the use of resin materials for bonding a decorative layer and a support layer made of ceramic materials to form a floor element. The resin material may include one or more of the features of the support layer described above with respect to the first independent aspect. Furthermore, the decorative layer and the support layer may include one or more of the features described above with respect to the first independent aspect.

[0095] According to a fourth independent aspect of the invention, a floor covering comprising a plurality of adjacent floor elements is provided, wherein each floor element comprises a decorative layer of ceramic material and a support layer disposed beneath the decorative layer, wherein the floor covering comprises a combination of the following features: at least one floor element comprises an intermediate layer having a resin material permeating the lower surface of the decorative layer; the floor element comprises a coupling element configured to achieve coupling with coupling elements of adjacent floor elements; the floor covering comprises a grout filling the intermediate distance between the decorative layers separating the floor elements. Preferably, the floor element is separated from the lower surface (e.g., the subfloor), i.e., it is not bonded to the lower surface by adhesives or mechanical means. Due to this solution, a floor covering consisting of floor elements installed without adhesives is provided, exhibiting satisfactory high impact and fatigue strength and being completely impermeable. Through the second aspect, the inventors finally provide a solution to a long-standing need in the field of ceramic flooring. It provides an easy-to-install ceramic tile floor with good impact strength and water resistance. The floor elements of the first aspect and their preferred embodiments can be used to form a floor covering according to the third aspect of the invention.

[0096] According to a preferred embodiment of the invention, the floor covering includes a sublayer disposed beneath the floor elements, configured to serve as a moisture barrier. This solution may prevent mold formation beneath the floor elements. In conjunction with or as an alternative to this solution, the sublayer may be configured to serve as a noise-reducing layer, thereby reducing noise generated by steps on the floor.

[0097] The present invention also relates to a method for manufacturing floor elements, such as the floor element of the present invention. Therefore, according to a fifth independent aspect of the invention, a method for manufacturing a floor element is provided, comprising the steps of: providing a decorative layer made of a ceramic material; providing a support layer; providing a resin material for bonding the decorative layer and the support layer together; and pressing the layers together to form a floor element such that the resin material permeates the ceramic layer. Thus, a method is provided that allows the manufacture of floor elements installed on a subfloor without the use of glue or adhesives, and the method exhibits associated impact resistance and fatigue resistance. Furthermore, the method allows for the manufacture of highly resistant floor elements in a simple and efficient manner. In fact, since rigid reinforcing elements are not necessarily required, the method includes a reduced number of steps, making it relatively fast, and it can be performed with relatively simple equipment. The resulting floor element preferably exhibits the characteristics of the aforementioned floor element of the present invention.

[0098] The steps of providing a decorative layer may include brushing and / or roughening the lower surface of the decorative layer. The purpose of the brushing and / or roughening steps is to prepare the lower surface of the decorative layer for penetration by a resin material. For example, in the case where the decorative layer is made of a ceramic material, the brushing and / or roughening steps aim to remove backflow and / or the structure of the lower surface of the decorative layer. In this way, any decorative layer can be used to manufacture flooring elements without having to manufacture a specific decorative layer for the flooring element, such as not having to manufacture tiles without backflow and without a structure on the lower surface.

[0099] As already described, the support layer may include edges provided with coupling elements. Therefore, according to a preferred embodiment of the invention, the step of providing the support layer may include providing a support layer including edges provided with coupling elements, i.e., providing the coupling elements in the support layer during a separate process. Alternatively, a method for manufacturing a floor element may include the step of providing coupling elements in the edges of the support layer. The step of providing coupling elements may include milling, molding, or other techniques. Furthermore, the step of providing coupling elements may be performed before or after the step of placing the decorative layer over the support layer, for example, before the step of providing the resin or after the step of pressing.

[0100] The step of providing the resin includes applying uncured resin to at least one surface of the decorative layer and / or the support layer. The resin material can be provided by rolling, spraying, curtain coating, or other techniques. According to an embodiment of the invention, the resin material is applied to the upper surface of the support layer. According to an alternative embodiment, the resin material is applied during multiple intermediate steps, for example, a first amount of resin is applied to the upper surface of the support layer in a first intermediate step, and a second amount of resin is applied to the lower surface of the decorative layer in a second intermediate step. This solution is particularly preferred for manufacturing floor elements in which the intermediate layer includes reinforcing elements, such as fibers. In practice, a larger amount of resin may be required in this case, and multiple steps for providing the resin may be ideal to ensure proper bonding between layers, embedding of reinforcing elements, and penetration of the decorative layer.

[0101] When the resin is a two-component resin (e.g., a two-component epoxy resin), the step of providing the resin may include a step of mixing its components. This mixing step may be performed during (i.e., simultaneously with) the step of applying the uncured resin, or shortly before the step of applying the uncured resin. In practice, the curing of the resin is typically activated by mixing its components, thus increasing the viscosity of the resin. Therefore, it is preferable to delay the onset of the curing reaction as much as possible to allow the resin to spread more easily onto the surface of the layer and to improve the penetration of the decorative layer. For example, according to a preferred embodiment of the invention, the resin is applied by spraying, and the components are mixed during spraying, for example, substantially corresponding to the nozzle of a spraying device.

[0102] Preferably, during the pressing step, a pressure of at least 350 kg / sqm, more preferably at least 370 kg / sqm, is applied to the layer. These values ​​have been found to be optimal for allowing the resin to penetrate the decorative layer. Furthermore, these values ​​have been found to be optimal for allowing the resin to achieve 100% coverage of the lower surface of the decorative layer, since in some embodiments, the resin is applied according to a pattern and then spread during the pressing step. Additionally, the inventors have found that extending the pressing time by maintaining the pressure can improve the penetration of the decorative layer, for example, potentially achieving a greater penetration depth. Therefore, according to a preferred aspect of the invention, during the pressing step, the pressure is maintained for a pressing time greater than 1 second, preferably greater than 10 seconds, for example, 30 seconds. It has been found that, when the resin is applied according to a pattern, this pressing time is optimal for allowing the resin to achieve a satisfactory coverage of the lower surface of the decorative layer, preferably a majority of the lower surface, and preferably complete (100%) coverage of the lower surface. Furthermore, especially in the case of resins made of epoxy resin, the pressing time is sufficient to allow the resin to begin to cure, so that the decorative layer and the support layer are at least partially attached to each other, and to prevent slippage between the layers during transport of the flooring element after pressing.

[0103] It should be noted that while 100% resin coverage of the lower surface of the decorative layer may be a desirable achievement, it is also important to prevent or minimize resin overflow from the edges of the decorative layer itself, and more preferably to prevent or minimize overflow on the coupling elements. In fact, if resin overflows from the coupling elements, the coupling between the floor elements may be adversely affected. Several measures can be employed to prevent such undesirable overflow. According to a preferred measure, the decorative layer and / or support layer may include one or more grooves, each opening on the lower or top surface, adapted to collect a portion of the resin. When the grooves are located on the decorative layer, they are implemented near the edges of the decorative layer itself. When the grooves are located on the decorative layer, and when the decorative layer is located on the support layer, they may be implemented in a portion of the upper surface intended to be covered by the decorative layer, for example, near the edge of the decorative layer. In this case, preferably, the grooves are parallel to the edges of the decorative layer. Alternatively or additionally, the grooves may exist in a portion of the upper surface extending beyond the edges of the decorative layer. Preferably, the grooves are parallel to the edges of the decorative layer. Preferably, the grooves extend continuously along the edges.

[0104] The pressing step can be performed in any suitable manner to apply pressure to the decorative layer and / or support layer to facilitate resin penetration into the decorative layer. Therefore, according to an embodiment of the invention, the pressing step can be a static pressing step, wherein the layers enter the die of a static press such that they are subjected to a predetermined pressure by the press punch. This allows the pressure to be maintained for a predetermined pressing time to improve the permeability of the decorative layer. According to an alternative embodiment, the pressing step can be a lamination step, wherein the layers enter lamination equipment, for example, under a lamination roller or belt, or between a pair of lamination rollers, such that they are subjected to a predetermined pressure. Since lamination is a continuous process, it is possible to accelerate the overall manufacturing method while applying sufficient pressure to the layers to penetrate the decorative layer. During lamination, the pressing time is a function of the layer's advance speed, and therefore the advance speed can be adjusted to accelerate the process while achieving sufficient pressing time.

[0105] Preferably, the method includes the step of storing the flooring element for a period of time to allow the resin to at least partially cure before packaging, shipping, and / or use in floor coverings. Preferably, the storage time allows the resin to cure at least 70%, preferably 85%, and more preferably completely. For example, the storage time is at least 0.5 hours, preferably more than 1 hour, such as 2 hours.

[0106] It should also be noted that the features of the floor element, including coupling elements according to a first possibility on a first pair of opposite edges and coupling elements according to a second possibility on a second pair of opposite edges, form an independent inventive concept independent of other features of the floor element. Therefore, according to a sixth independent aspect, the present invention relates to a floor element comprising a decorative layer made of ceramic material and a support layer disposed beneath the decorative layer, wherein the support layer comprises at least two pairs of opposite edges, each pair of opposite edges comprising coupling elements configured to achieve mechanical coupling with coupling elements of adjacent floor elements, wherein a first coupling element at a first pair of opposite edges is configured to be coupled to a coupling element of an adjacent floor element by an oblique movement about a horizontal axis parallel to the respective edge, and wherein a second coupling element at a second pair of opposite edges is configured to be coupled to a coupling element of an adjacent floor element by a downward translational movement of the respective edges toward each other. This combination of different types of coupling elements can be particularly advantageous for heavy-duty decorative layers (such as ceramic stone, etc.). In fact, once the first coupling element is coupled, it is sufficient to position the floor element horizontally to achieve the mechanical connection of the second coupling element, without requiring hammering or striking the floor element itself. This also applies if the second coupling element deforms during coupling, as the weight of the decorative layer may be sufficient to cause such deformation. Once the first coupling element is connected, since no further force is required, the user may have the impression that the floor element can be simply dropped off to complete the coupling. It should be noted that the floor element according to the sixth independent aspect may include one or more of the features described with respect to the first independent aspect.

[0107] It should be noted that within the scope of this sixth independent aspect, the preferred embodiment includes a decorative layer made of ceramic; however, it should be noted that this sixth aspect can advantageously apply decorative layers made of any kind of relatively heavy material, such as natural stone, quartz, artificial stone, concrete, glass, or glass-ceramic materials. It should also be noted that this sixth aspect can advantageously apply decorative layers having a density expressed as surface weight of at least 10 kg / sqm, preferably greater than 15 kg / sqm, for example greater than 19 kg / sqm, regardless of the material forming the decorative layer.

[0108] The inventors have also discovered that if the first coupling elements are connected with a gap (e.g., a horizontal gap) in the coupled state, the coupling of the floor elements according to the sixth independent aspect is further simplified. In fact, while the weight of the decorative layer simplifies the coupling of the second coupling elements once the first coupling elements are coupled, it also complicates the coupling of the first coupling elements, and particularly the maneuverability of the floor elements. Therefore, the gap facilitates the coupling at the first pair of edges. This effect is further enhanced if the gap is greater than 0.01 mm, preferably greater than 0.03 mm. Furthermore, the gap is preferably less than 0.10 mm, for example, less than 0.08 mm. In particular, this effect is further enhanced if the gap allows the first coupling elements to couple to each other without deformation.

[0109] It should also be noted that the idea of ​​including a support layer made of rigid PVC to improve the thermal stability of the floor element constitutes an independent inventive concept, independent of the presence of other features of the floor element itself, particularly the presence of an intermediate layer on the lower surface of the permeable decorative layer. Therefore, according to the seventh independent aspect, the present invention relates to a floor element comprising a decorative layer made of ceramic material and a support layer disposed beneath this decorative layer, characterized in that the support layer is made of rigid PVC. It should be noted that the floor element according to the seventh independent aspect may include one or more of the features described with respect to the first independent aspect or any other aspect of the invention.

[0110] It should be noted that the grooves for collecting resin form the inventive concept, regardless of the presence of other features of the flooring element. Therefore, according to the eighth independent aspect, the present invention relates to a flooring element comprising a decorative layer, a support layer, and an intermediate layer disposed between the decorative layer and the support layer, wherein the intermediate layer comprises resin, characterized in that the decorative layer and / or the support layer comprises one or more grooves adapted to collect a portion of the resin. It should be noted that the flooring element according to this eighth independent aspect may include one or more of the features described with respect to any other aspect of the invention.

[0111] To better illustrate the features of the invention, several preferred embodiments are described below as examples without any limiting features, with reference to the accompanying drawings, wherein:

[0112] Figure 1 A top view of an embodiment of the floor element of the present invention is shown;

[0113] Figure 2 Shown at a larger scale along Figure 1 The cross section of line II-II;

[0114] Figure 3 Shown at a larger scale Figure 2 The view of area F3 shown;

[0115] Figure 4 Shown at a larger scale along Figure 1 The cross section of line IV-IV;

[0116] Figure 5 Shown at a smaller scale including Figure 1 Top plan view of the floor covering with multiple floor elements;

[0117] Figure 6 Shown at a larger scale along Figure 5 The cross section of line VI-VI;

[0118] Figure 7 Shown at a larger scale Figure 6 The view of area F7 shown;

[0119] Figure 8 Shown at a larger scale along Figure 5 The cross section of line VIII-VIII;

[0120] Figure 9 Shown at a larger scale Figure 8 The view of area F9 shown;

[0121] Figure 10 Some steps of a method for manufacturing floor components are shown.

[0122] Figure 1 A top view of an embodiment of the floor element 1 according to the present invention is shown. The floor element 1 includes a decorative layer 2 disposed above a support layer 3.

[0123] As shown in the figure, the floor element 1 comprises a rectangular elongated shape. Preferably, the floor element 1 comprises a surface area of ​​less than 1.5 sqm, more preferably less than 1 sqm, and more preferably less than 0.4 sqm. For example, the decorative layer 2 comprises an edge having a maximum length L of less than 1.5 m, preferably less than 0.9 m.

[0124] Decorative layer 1 has an upper surface 4 including decoration 5. Decoration 5 can be provided with various textures, designs, and colors. In the illustrated example, the decoration simulates a wood grain and flaked wood pattern. Preferably, decoration 5 is at least partially formed by print 6. Preferably, print 6 is achieved by digital printing (e.g., inkjet printing), although screen printing, rotary gravure printing, aniline printing, or offset printing are not excluded.

[0125] Figure 2 Shown at a larger scale along Figure 1The cross-section of line II-II. According to the example shown, decorative layer 2 includes a body 7 made of ceramic material, such as red body ceramic or porcelain.

[0126] Decorative layer 2 includes a background coating 8 that at least partially covers the upper surface of the body 7, and may include, for example, at least one glaze. The background coating 8 is adapted to receive decoration 5 on top of it, for example, to receive print 6 on top of it. The background coating 8 may be white, beige, brown, or any color suitable for receiving decoration 7 on top of it.

[0127] Decorative layer 2 also includes a protective coating 9 that at least partially covers the upper surface of the body 7, such as including at least one glaze. The protective coating 9 is adapted to be placed over the decoration 5 and is transparent or translucent.

[0128] Figure 2 It is also shown that the decorative layer 2 has a thickness Tl of 4 mm to 15 mm, for example 6 mm, preferably greater than 7 mm, for example 8 mm or 10 mm.

[0129] According to this example, the support layer 3 is made of a polymer material, preferably a thermoplastic material, such as PVC. In a preferred embodiment, the support layer is made of rigid PVC. In the context of this specification, "rigid" means that the support layer bends individually under its own weight by less than 10 cm / m, and more preferably less than 5 cm / m. The support layer 3 may also include a large amount of filler material, such as chalk or calcium carbonate, for example, more than 30 wt% or more than 60 wt% of such filler material.

[0130] Furthermore, according to a preferred embodiment, the support layer 3 is made of rigid PVC, which may have a flexural modulus of 1.5 GPa to 3.5 GPa, for example, approximately 2.6 GPa. The support layer 3 may also include a flexural strength of 60 MPa to 90 MPa, for example, approximately 76 MPa. Additionally, the support layer 3 may include a compressive strength between 40 MPa and 70 MPa, for example, approximately 56 MPa. Preferably, the support layer 3 has a coefficient of thermal expansion of 20 μm / m / ℃ to 85 μm / m / ℃, more preferably 40 μm / m / ℃ to 60 μm / m / ℃.

[0131] In addition, the support layer 3 preferably has a thickness T2 of 2 mm to 7 mm, preferably less than 6 mm, more preferably about 4 mm or less.

[0132] Figure 2 The support layer 3 is also shown to include a longitudinal edge 10, which is provided with first coupling elements 11, 12, configured to achieve mechanical coupling with coupling elements 11, 12 of adjacent floor elements 1. In the illustrated example, coupling elements 11, 12 include a male and a female component disposed on opposite longitudinal edges 10.

[0133] The first coupling elements 11, 12 of the longitudinal edge 10 are configured to couple to each other by tilting motion about a horizontal axis parallel to the longitudinal edge 10. The male and female components are respectively formed in the form of a tenon 11 and a groove 12, wherein the tenon 11 extends outward in the horizontal direction X beyond its respective longitudinal edge 10, and the groove 12 extends inward in the horizontal direction relative to the respective longitudinal edge 10.

[0134] The support layer 3 extends beyond the longitudinal edge 26 of the decorative layer 2. In this example, the support layer 3 includes an upper longitudinal edge 27 extending beyond the longitudinal edge 26 of the decorative layer 2 at a distance D1. The distance D1 is equal on both opposite longitudinal edges 26 of the decorative layer 2.

[0135] Figure 2 The floor element 1 is also shown to include an intermediate layer 13 disposed between a decorative layer 2 and a support layer 3. The intermediate layer 13 comprises a resin material, such as a thermosetting resin or a thermoplastic resin. Examples of thermosetting resins are epoxy resins, polyurethanes, cyanoacrylates, or acrylic resins. Examples of thermoplastic resins are hot-melt, thermoplastic polyesters, vinyl, etc. Preferably, the resin is a rigid resin. In particular, according to a preferred embodiment of the invention, the intermediate layer comprises an epoxy resin. It is also preferred that the epoxy resin is a two-component resin, i.e., a thermosetting resin obtained by curing a mixture of two components (i.e., resin and hardener) at a low temperature (e.g., at room temperature).

[0136] The resin preferably has a tensile strength of 50 MPa to 90 MPa, more preferably 60 MPa to 80 MPa, for example 75 MPa. Furthermore, the resin preferably has a compressive strength of 90 MPa to 130 MPa, more preferably 100 MPa to 120 MPa, for example 110 MPa. It is also preferred that the resin exhibits a hardness value of at least 50 measured on the Shore D scale.

[0137] As shown in the figure, the intermediate layer 13 covers 100% of the lower surface of the decorative layer 2. Resin is provided on the lower surface of the decorative layer 2 in an amount greater than 150 g / sqm, more preferably greater than 200 g / sqm, for example 220 g / sqm.

[0138] exist Figure 2 In the example shown, the intermediate layer 13 is in direct contact with the upper surface of the support layer 3, so that the adhesive used as the decorative layer 2 and the support layer 3 is applied.

[0139] exist Figure 2In one embodiment, the support layer 3 includes a groove 50 adapted to collect a portion of the resin from the intermediate layer 13 in case it overflows the edge 26 of the decorative layer 2, thereby preventing the resin from overflowing onto the coupling elements 11, 12. In this embodiment, the groove 50 is provided in the portion of the support layer 3 that extends beyond the edge 26 of the decorative layer 2. Furthermore, the groove 50 extends parallel to and continuous with the edge 26 of the decorative layer 2. For simplicity, the groove 50 is not shown in the other figures of this application, but it may be present in any embodiment described herein, for example, it may be present at a location also corresponding to the short edge of the floor element 1.

[0140] Figure 3 Shown at a larger scale Figure 2 The view of area F3 shown. Figure 3 As shown, the decorative layer 2, more specifically its body 7, includes openings 14 on its lower surface that are adapted for resin penetration by the decorative layer 2 itself.

[0141] Therefore, according to a preferred embodiment of the invention, the decorative layer 2 comprises an apparent porosity of 0.1% to 10%, more preferably 2% to 8%, for example 6%, as determined by ASTM C373. Furthermore, the decorative layer may preferably have a volume comprising openings 14 of 0.01 cc (cubic centimeters) to 1 cc, preferably 0.10 cc to 0.90 cc, for example 0.60 cc.

[0142] Therefore, in order to properly flow into the opening 14, the resin has a viscosity of less than 1000 mPas, preferably less than 800 mPas, more preferably less than 600 mPas, and for example, about 400 mPas at 20°C. Within the scope of this invention, viscosity refers to the viscosity of the uncured resin, for example, the viscosity of a mixture of two components before curing is complete, i.e., during the so-called pot life.

[0143] Figure 4 Shown at a larger scale along Figure 1 The cross-section of line IV-IV. According to this embodiment, the support layer 3 includes a lateral edge 15, on which second coupling elements 16, 17 are provided, the second coupling elements being configured to achieve mechanical coupling with the second coupling elements 16, 17 of the adjacent floor element 1.

[0144] In the illustrated example, the second coupling elements 16, 17 differ from the first coupling elements 11, 12 of the longitudinal edge 10. The second coupling elements 16, 17 of the transverse edge 15 are configured to be coupled to each other by a translational movement along a substantially vertical direction. In the illustrated example, the second coupling elements 16, 17 are configured to be coupled by a translational movement in the downward (e.g., vertical) direction Y.

[0145] The support layer 3 extends beyond the lateral edge 28 of the decorative layer 2. In this example, the support layer 3 includes an upper lateral edge 29 extending beyond the lateral edge 28 of the decorative layer 2 at a distance D2. The distance D2 is equal on both opposite edges 28 of the decorative layer 2. Furthermore, in the preferred embodiment, the distance D2 is equal to the distance D1. For example, the distances D1 and D2 are greater than 0.5 mm, preferably greater than 0.75 mm, for example, 1.5 mm.

[0146] Figure 5 It is a top plan view of a floor cover 18 including multiple floor elements 1, which are joined along the longitudinal edge 10 by first coupling elements 11, 12 and along the transverse edge 15 by second coupling elements 16, 17.

[0147] Figure 6 Shown at a larger scale along Figure 5 The cross-section of line VI-VI. The floor covering 18 includes grout 19 filling the intermediate distance I that separates the decorative layer 2 of the floor element 1. According to the example shown, the intermediate distance I is twice the distance D1 between the upper edge of the support layer 3 and the edge of the decorative layer 3.

[0148] Grout 19 is preferably made of a polymer material. Grout 19 can be flexible or rigid. Flexible grout 19 can be, for example, a silicone-based grout, while rigid grout can be, for example, an epoxy-based grout or a cement-based grout. Other examples of polymer grouts are polyurethane-based and acrylic-based grouts.

[0149] Figure 6 A cross-section of the mechanical coupling between the first coupling elements 11 and 12 along a plane transverse to the longitudinal edge 10 is also shown. By means of Figure 7 The mechanical coupling between the first coupling elements 11 and 12 is described in detail.

[0150] Figure 7 Shown at a larger scale Figure 6 The view shown is for area F7. Figure 7 In the example shown, the tenon 11 includes a horizontally extending lip 20 and a downwardly extending protrusion 21. The groove 12 has a horizontal recess 22 for receiving the lip 20 of the tenon 11 and an upwardly oriented hollow portion 23 for receiving the protrusion 21 of the tenon 11, such that the tenon 11 can be fitted into the groove 12.

[0151] exist Figure 7 In the coupled state shown, the upper edges 27 of the support layers 3 are in contact with each other, thereby forming a first set of first locking surfaces 24, which restrict the relative movement of the floor elements 1 in the horizontal direction X perpendicular to the longitudinal edges 10 of the coupling.

[0152] Figure 7 It is also shown that, in the coupled state, the lip 20 is received by the recess 22. The upper surface of the flange 20 contacts the upper wall of the recess 22, thereby forming a first set of second locking surfaces 25, which are configured to restrict the relative movement of the floor element 1 in the substantially vertical direction Y. It should be noted that a horizontal non-operating space S1 is established between the end of the flange 20 and the bottom of the recess 22. Furthermore, a vertical non-operating space S2 is established between the lower surface of the lip 20 and the recess 22.

[0153] The downwardly extending protrusion 21 of the tenon 11 is received by the hollow portion 23 of the groove 12. The lower surface of the downwardly extending protrusion 21 contacts the hollow portion 23, thereby forming a second set of second locking surfaces 25. In other words, the lower surface of the tenon 16 only corresponds to the contact of the downwardly extending protrusion 21 with the groove 12.

[0154] exist Figure 7 In the coupled state, a horizontal gap P is formed between the protruding protrusion 21 and the hollow portion 23, which allows the tenon 11 to move slightly horizontally into the groove 12. The gap P and the slight horizontal movement are limited by a set of first contact surfaces that can be formed between the protruding protrusion 21 and the hollow portion 23.

[0155] Preferably, the gap P is greater than 0.01 mm, more preferably greater than 0.03 mm. Furthermore, the gap P is preferably less than 0.10 mm, for example less than 0.08 mm.

[0156] It should be noted that in the coupled state, the tenon 11 and the groove 12 are in an undeformed state. Furthermore, the entire tilting movement of the coupling between the tenon 11 and the groove 12 is allowed to occur without deformation of the first coupling elements 11 and 12. In fact, the coupling between the tenon 11 and the groove 12 is significantly simplified due to the gap P and the non-operating spaces SL and S2.

[0157] Figure 8 Shown at a larger scale along Figure 5 The cross section of line VIII-VIII. Figure 8 The mechanical coupling between the second coupling elements 16 and 17 is shown in a cross-section along the plane transverse to the transverse edge 15. By means of Figure 9 The mechanical coupling between the second coupling elements 16 and 17 is described in detail.

[0158] Figure 9 Shown at a larger scale Figure 8 The view of area F9 shown.

[0159] The second coupling elements 16, 17 include a downwardly pointing upper hook-shaped member 16 located on one lateral edge 15 and an upwardly pointing lower hook-shaped member 17 located on the opposite edge 15. The lower hook-shaped member 17 defines an upwardly pointing cavity forming a female member, while the upper hook-shaped member 16 defines a downwardly pointing lip forming a male member.

[0160] Once in the coupled position, the downward-pointing lip and the upward-pointing cavity form a first locking surface 24 to restrict the relative movement of the floor element 1 in the horizontal direction Z perpendicular to the lateral edge 15.

[0161] Furthermore, both the upper hook-shaped member 16 and the lower hook-shaped member 17 include undercut portions 30, such that in the coupled state, a second locking surface 25 is formed to restrict the relative movement of the floor elements 1 in the vertical direction Y. More specifically, for example, two sets of the second locking surfaces 25 are formed on opposite sides of the male and female members.

[0162] Preferably, the lower hook-shaped member 17 includes a flexible rod portion 31 configured to deform by disengaging the upper hook-shaped member 16 from the lower hook-shaped member 17, such that the undercut portion 30 may be coupled through the deformation.

[0163] Figure 10 Some steps of a method for manufacturing flooring elements are shown. The method includes a first step S1 of providing a decorative layer 2. In step S1, the decorative layer 2 is provided to a resin application station 40, wherein an uncured resin material R is provided, for example, according to a pattern, to the lower surface of the decorative layer 2. The uncured resin R preferably has a viscosity of less than 1000 mPas, preferably less than 800 mPas, more preferably less than 600 mPas, and for example, about 400 mPas at 20°C. It should be noted that in the resin application station 40, the decorative layer is positioned with the upper surface of the decorative element 6 facing downwards.

[0164] Then, in step S2, the decorative layer 2 is transported to the placement station 41 in which the support layer 3 is disposed. The support layer 2 is placed below the lower surface decorative layer 3, thereby forming a semi-finished interlayer 42. Preferably, in the placement station 41, the decorative layer 2 and the support layer 2 are properly centered relative to each other.

[0165] Next, in step S3, the semi-finished interlayer 42 is transported to the pressing station 43, where layers 2 and 3 are pressed together to form floor element 1, allowing the resin material to penetrate the pores of the ceramic material in decorative layer 2 and form intermediate layer 13. Preferably, the pressure is maintained for a pressing time of at least 1 second, preferably 30 seconds, so that the uncured resin R can flow and cover at least 80%, preferably 100%, of the lower surface of decorative layer 2. Furthermore, the pressing time is necessary for the uncured resin R to penetrate decorative layer 2. Preferably, during step S4, a pressure of at least 350 kg / sqm is applied to the layers.

[0166] Then, in step S4, the pressed floor element 1 is transported to storage station 44, where it is stored for a predetermined storage time to allow the resin R to continue curing before packaging, transportation, and / or use in floor coverings. Preferably, the storage time is such that it allows the resin R to cure at least 70%, preferably 85%, and more preferably completely. For example, the storage time is at least 0.5 hours, preferably greater than 1 hour, such as 2 hours.

[0167] This invention is by no means limited to the embodiments described above, but can be implemented with various modifications without departing from the scope of the invention. While several possible embodiments have been disclosed above, the embodiments of the invention are not limited thereto. These exemplary embodiments are not intended to be exhaustive or unnecessarily limiting of the scope of the invention, but have been selected and described to explain the principles of the invention and enable others skilled in the art to practice it. In fact, various modifications to the invention will become apparent to those skilled in the art from the foregoing description, in addition to those described herein. Such modifications are intended to fall within the scope of the appended claims.

Claims

1. A floor element for forming a floor covering, the floor element comprising: The decorative layer is made of a brittle material; A support layer is disposed below the decorative layer, wherein the support layer includes an edge provided with a coupling element configured to achieve mechanical coupling with a coupling element of an adjacent floor element, and wherein the floor element includes an intermediate reinforcing layer having a resin material permeating the lower surface of the decorative layer, wherein the intermediate reinforcing layer is an adhesive layer that bonds the decorative layer and the support layer together.

2. The floor element according to claim 1, wherein, The decorative layer includes ceramic tiles.

3. The floor element according to claim 1 or 2, wherein, The resin material includes epoxy resin.

4. The floor element according to claim 1 or 2, wherein, The resin material has a viscosity of less than 1000 mPas at 20°C.

5. The floor element according to claim 1 or 2, wherein, The intermediate reinforcing layer covers 80% or more of the lower surface of the decorative layer.

6. The floor element according to claim 1 or 2, wherein, The intermediate reinforcing layer comprises a resin content of at least 150 g / sqm.

7. The floor element according to claim 1 or 2, wherein, The support layer comprises rigid PVC.

8. The floor element according to claim 7, wherein, The support layer comprises more than 30 wt% filler.

9. The floor element according to claim 1 or 2, wherein, The support layer has a flexural modulus of 1.5 GPa to 3.5 GPa.

10. A floor element for forming a floor covering, the floor element comprising: The decorative layer is made of a brittle material; A support layer is disposed below the decorative layer, wherein the support layer includes an edge provided with coupling elements, the coupling elements being configured to achieve mechanical coupling with coupling elements of adjacent floor elements, and wherein the floor elements include an intermediate reinforcing layer having a resin material permeating the lower surface of the decorative layer, wherein the coupling elements are configured such that a gap is established between the coupled coupling elements in the coupled state.

11. A method for manufacturing a floor element, comprising the following steps: Provide a decorative layer made of brittle material; Provide a support layer; A resin material is provided for bonding the decorative layer and the support layer together; The decorative layer and the support layer are pressed together to form the floor element, such that the resin material permeates the decorative layer.

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