Panel element, method of forming panel element, and extrusion device

Abstract

The present invention relates to a panel element (100), such as a floor panel, a wall panel, a ceiling panel or a deck panel. The panel element (100) comprises: a first substrate (102) made of a synthetic composite material (102a) comprising at least 20% by weight of mineral material; and a second substrate (104) made of a spacer material (104a) embedded or recessed in the first substrate (102). The bulk density of the spacer material (104a) is lower than the bulk density of the synthetic composite material (102a). The panel element (100) comprises at least two opposing side edge portions (103) formed solely by the first substrate (102). A method (300) of forming a panel element (100) and an extrusion device (200) configured to form a panel element (100) are also provided.

Description

Technical Field

[0001] The present invention generally relates to a panel element, such as a floor panel, a wall panel, a ceiling panel, or a deck panel, a method of forming a panel element, and an extrusion device configured to form a panel element. Background Art

[0002] Panel elements or panels of various types, shapes and materials are used in a variety of applications, such as in the construction industry. For example, such panels are used in floors, ceilings and walls of buildings. In addition, panels are used for facades and roofs.

[0003] Panels used in the construction industry are used for different purposes and therefore have different properties. Some panels are used for decorative purposes, while others are used for technical purposes. Decorative interior panels may be simple from a technical point of view, but must meet high demands in terms of aesthetics. Roof panels, on the other hand, often have to withstand adverse weather conditions and therefore must meet high technical standards. However, the visual appearance of a roof panel is often not as important as its technical capabilities in terms of weather protection and durability.

[0004] However, when it comes to panels for floors and walls in wet rooms, for example, high technical and aesthetic requirements come into play simultaneously. Wooden panels are often attractive, but have poor wear and water resistance. Therefore, wooden floors are often not suitable for rooms subject to high wear and tear and wet rooms. Correspondingly, wooden wall panels or ceiling panels are often also not suitable for the same types of spaces.

[0005] Several panels with customized appearance and high technical capabilities have been proposed. An example of a high technical capability panel is the so-called SPC (Stone Plastic Composite) panel. Such panels are usually manufactured by extrusion. SPC panels are often used for flooring, the so-called SPC flooring. SPC flooring is based on a new generation of materials, which can replace traditional floor covering materials such as laminate flooring, wooden flooring and stone flooring.

[0006] Another example of a high-tech panel is the so-called WPC (Wood Plastic Composite) panel. Such panels are usually made by extrusion. WPC panels are similar to SPC panels in many ways, but are usually slightly lighter due to the fact that WPC panels contain foamed PVC. WPC panels are similar to SPC panels that are usually used for flooring. Such flooring is then called WPC flooring. Both SPC and WPC flooring are collectively referred to as resilient flooring. Other examples of resilient flooring are LVT or PVC floor coverings, natural linoleum, rubber, polyurethane, synthetic polymers, modular multilayer products, flooring.

[0007] Both SPC and WPC based panels are wear-resistant and waterproof, but they have other disadvantages. The main disadvantage lies in the high density of the materials used. Especially with SPC based panels, the panels can quickly become very heavy. This problem is also evident with WPC based panels. The fact that heavier materials are used in SPC and WPC panels leads to high transportation costs as well as high material costs. In addition, the panels usually have to be made to a certain thickness in order to meet requirements related to failure, bending stiffness and handling. This in turn can lead to panels becoming unnecessarily heavy. The panels can be made thinner to make them lighter. However, if the panels are made thinner, the locking system must be made smaller and therefore weaker. In addition, the risk of making the panels thinner is that they will be perceived as less strong and / or of lower quality.

[0008] Therefore, it has been proposed to remove material from the back side of the panel to reduce the weight of the panel in use. However, this process is very time consuming and generates a lot of waste material, which must be recycled in order not to waste it.

[0009] Another method is to extrude the panel material so that longitudinal voids are formed during the extrusion process. This method can make manufacturing cumbersome, making it difficult to accurately control the thickness and overall surface smoothness of the panels produced.

[0010] Another approach proposed in US 11,149,441 B2 is to reduce the weight of the panel by patterning the back side of the panel to form voids. This approach makes manufacturing cumbersome, making it difficult to accurately control the thickness of the produced panel. In addition, the structural integrity and stiffness of the panel may also be negatively affected, for example resulting in undesirable warping of the panel. Summary of the invention

[0011] In view of the above, an object of the present invention is to provide an improved panel element (such as a floor panel, wall panel, ceiling panel or deck panel), an improved method of forming a panel element, and an improved extrusion device configured to form a panel element.

[0012] Another object is to provide such a panel element having a reduced weight.

[0013] Another object is to provide such a panel element having a reduced weight to volume ratio.

[0014] Another object is to provide such a panel element having increased structural integrity relative to its weight.

[0015] Another object is to provide such a panel element having increased strength relative to its weight.

[0016] Another object is to provide a more environmentally friendly panel element.

[0017] Another object is to provide such a panel element which requires less material during manufacture.

[0018] Another object is to provide such a method and an extrusion device for forming a panel element which simplifies the panel element production.

[0019] Another object is to provide such a method and an extrusion device for forming a panel element which enable the production of panel elements of a high technical standard.

[0020] It is also an object to provide a panel element having a cost-effective structure, a method for forming a panel element having a cost-effective structure, and a cost-effective extrusion device.

[0021] In order to achieve at least one of the above objects and other objects that will become apparent from the following description, according to the inventive concept, there is provided a panel element having the features defined in claim 1, a method of forming a panel element according to claim 10, and an extrusion device according to claim 15. Preferred variants of the inventive concept will become apparent from the dependent claims.

[0022] More specifically, according to a first aspect, there is provided a panel element, such as a floor panel, a wall panel, a ceiling panel or a deck panel, comprising: a first substrate, the first substrate being made of a synthetic composite material, the synthetic composite material comprising at least 20 weight % of a mineral material, and a second substrate, the second substrate being made of a spacer material, the spacer material being embedded or recessed in the first substrate, wherein the bulk density of the spacer material is lower than the bulk density of the synthetic composite material, wherein the panel element comprises at least two opposite side edge portions formed only by the first substrate.

[0023] An improved panel element is thereby provided.

[0024] The panel element comprises a first substrate and a second substrate, wherein the second substrate is embedded or recessed in the first substrate.

[0025] The first substrate is made of a synthetic composite material comprising at least 20% by weight of a mineral material. The first substrate may be made of a thermoplastic material combined with a mineral material. The first substrate may be made of a thermosetting material combined with a mineral material. The mineral material may be from the ground or ground rock.

[0026] The first substrate may be made of CaCO3 combined with PVC. The first substrate may be made of CaCO3 combined with PVC and additives. CaCO3 may be provided in powder form.

[0027] Therefore, the first substrate can be regarded as a filled synthetic composite material.

[0028] The second substrate is made of a distance material. It should be noted that in the context of the present application, the term "distance material" may be any type of material that is included in a panel element and contributes to the overall structural integrity and / or strength of the panel element, or any type of material that is included in a panel element and contributes to the structural integrity of the panel element during its formation. Thus, the distance material of the second substrate may be used as a core material for the synthetic composite material of the first substrate when forming the panel. Thus, the distance material of the second substrate may contribute to the structural integrity of the panel element during its formation.

[0029] The spacer material of the second substrate is embedded or recessed in the first substrate.

[0030] When the second substrate is "embedded" in the first substrate, a majority of the combined surface area of ​​all outer surfaces of the second substrate is in contact with the first substrate. In other words, when the second substrate is embedded in the first substrate, the second substrate is typically substantially surrounded by the first substrate.

[0031] When the second substrate is "recessed" in the first substrate, a significant portion of the outer surface of the second substrate is exposed and therefore visible from the outside of the panel element. In other words, when the second substrate is recessed in the first substrate, a majority of the outer surface of the second substrate is typically surrounded by the first substrate, while a significant portion of at least one outer surface is exposed. In addition, when the second substrate is recessed in the first substrate, portions of multiple outer surfaces of the second substrate may be exposed and therefore visible from the outside of the panel element. For example, a major surface and a portion of the thickness of the second substrate may be in contact with the first substrate. A portion of the thickness of the second substrate may extend all the way to the edge of the panel element, so that the side edge surfaces of the panel element are formed by the first substrate and the second substrate together.

[0032] The bulk density of the spacer material is lower than the bulk density of the composite material. Therefore, the overall density of the matrix material is lower than the overall density of the composite material. However, the spacer material may include a material having a relatively high density as long as its bulk density is lower than the bulk density of the composite material.

[0033] The spacer material may be a light material. The spacer material may be a non-dense material. The spacer material may be a porous material.

[0034] The panel element comprises at least two opposing side edge portions formed only by the first substrate. The at least two opposing side edge portions formed only by the first substrate may be directly opposing. The at least two opposing side edge portions formed only by the first substrate may be indirectly opposing. The at least two opposing side edge portions formed only by the first substrate may be arranged on opposing side edges of the panel element, for example, in a staggered arrangement, such that the at least two opposing side edge portions formed only by the first substrate are indirectly opposing each other.

[0035] Thus, at least two portions of opposing edges of the panel element are typically formed only by the first substrate. Side edge portions formed only by the first substrate may extend along the entire edge of the panel element. Side edge portions formed only by the first substrate may extend along a portion of the edge of the panel element. Such side edge portions may be distributed along the edge of the panel element. Side edge portions formed only by the first substrate may extend along a major portion of the edge of the panel element. Side edge portions formed only by the first substrate may extend along a smaller portion of the edge of the panel element.

[0036] The side edge portion formed only by the first substrate may extend over the entire thickness or height of the panel element. In other words, the entire thickness of the side edge surface of the panel element may be occupied by the first substrate.

[0037] The side edge portion formed only by the first substrate may extend over a portion of the thickness of the panel element. In other words, a first portion of the thickness of the side edge surface of the panel element may be occupied by the first substrate, and thus a second portion of the thickness of the side edge surface may be occupied by the second substrate. In yet other words, the side edge surface of the panel element may be formed by both the first substrate and the second substrate.

[0038] The side edge portions formed only by the first substrate may include small portions of support material for connecting discrete spacer material elements, each spacer material element forming the second substrate or part of the second substrate forming a panel element.

[0039] The panel element may include a top coating. Such a top coating may be arranged on a side of the panel that is visible after mounting the panel element, such as the top side. The top coating may have wear resistant properties. The top coating may have UV (ultraviolet) protection properties.

[0040] The panel element may include a decorative top coating. Such a top coating may be disposed on a side of the panel that is visible after the panel is installed, such as the top side or the front side. The decorative top coating may have a decorative feature. The decorative top coating may resemble the appearance of a natural material, such as wood or stone.

[0041] The panel element may include a bottom coating. Such a bottom coating may be arranged on a side of the panel that is not visible after the panel is installed, such as the bottom side or the back side. The bottom coating may have sound attenuating properties. The bottom coating may have insulating properties.

[0042] The bulk density of the spacer material can be less than 2000 kg / m 3 , preferably less than 1000 kg / m 3 , which has the advantage that the panel element can be made lighter. The panel element can be lighter than a panel element formed only of the synthetic composite material.

[0043] The thickness of the spacer material may be 1 mm to 30 mm, preferably 1 mm to 8 mm.

[0044] The thickness of the spacer material may be 20%-80%, preferably 30%-70% of the total thickness of the panel element.

[0045] The width of at least two opposite side edge portions formed only by the first substrate may be 10 mm-25 mm, preferably 15 mm-20 mm, which has the advantage that the side edge portions may contribute to the overall strength of the panel element and / or the side edge portions may be used to provide a reliable connection or transition with an adjacent panel. 50%-100%, preferably 60%-98% of the height of at least two opposite side edge portions formed only by the first substrate may be formed by the first substrate, which has the advantage that the overall material consumption of the panel may be further reduced.

[0046] When the second substrate is embedded in the first substrate, the first substrate may form a top layer and a bottom layer, wherein the second substrate is arranged between the top layer and the bottom layer, which has the advantage that a strong and lightweight panel element may be formed. The fact that the first substrate may form a top layer and a bottom layer, wherein the second substrate is arranged between the top layer and the bottom layer, may cause the panel element to exhibit improved bending stiffness and / or torsional stiffness.

[0047] 45%-100%, preferably 60%-95% of the top and bottom layers may be supported by the second substrate, which has the advantage that a lightweight and strong panel element may be provided.

[0048] The thickness of the top layer may be 0.5 mm to 15 mm, preferably 1 mm to 10 mm.

[0049] The thickness of the bottom layer may be 1 mm-10 mm, preferably 1.5 mm-6 mm.

[0050] The top layer may be patterned and / or contoured.

[0051] A portion of the second substrate may be exposed at a side edge of the panel element, which has the advantage that the position of the second substrate relative to the first substrate can be visually determined.

[0052] Corresponding portions of the second substrate may be exposed at edge regions of opposite side edges of the panel element, with the advantage that the position of the second substrate relative to the first substrate may be visually determined while affecting the strength of the panel element to a limited extent.

[0053] The corresponding part of the second substrate can be exposed at the corner area of ​​the opposite side edge of the panel element, which has the advantage that the position of the second substrate relative to the first substrate can be determined visually, while affecting the strength of the panel element within a limited range. This exposed part of the second substrate can be exposed at the side edge surface of the panel element. Therefore, the exposed part of the second substrate can be visible from the side of the panel element. This exposed part of the second substrate can be exposed at the top surface of the panel element. Therefore, the exposed part of the second substrate can be visible from the top side of the panel element. When this exposed part of the second substrate is exposed on the top surface of the panel element, the exposed part of the second substrate can be advantageously used to synchronize the application position of the top coating and / or the decorative top coating. Therefore, this top coating and / or the decorative top coating can include an opening or a similar structure, which is configured to be applied at a position corresponding to the exposed part of the second substrate. By providing an opening or a similar structure in this top coating and / or the decorative top coating, the synchronization error between the panel element and the top coating and / or the decorative top coating can be detected.

[0054] Such an exposed portion of the second substrate may be exposed on the bottom surface of the panel element. Therefore, the exposed portion of the second substrate may be visible from the bottom side of the panel element. When such an exposed portion of the second substrate is exposed at the bottom surface of the panel element, the exposed portion of the second substrate may be advantageously used to synchronize the application position of the bottom coating. Therefore, such a bottom coating may include an opening or a similar structure, which is configured to be applied at a position corresponding to the exposed portion of the second substrate. By providing an opening or a similar structure in such a bottom coating, a synchronization error between the panel element and the bottom coating may be detected.

[0055] The corresponding exposed portion of the second substrate may include features configured to be inspected by an optical inspection process.

[0056] Features configured to be detected by an optical detection process may include color, shape, pattern, relief, or a combination thereof.

[0057] The spacer material of the second substrate may include a material selected from the group consisting of: honeycomb material, polymer foam, multiple hollow tube segments extending in parallel, glass foam, metal-containing foam, fiber-reinforced polymer material, closed-cell PVC foam, EPS (expanded polystyrene) or EPP (expanded polypropylene), a material including cavities, a material including cavities of different geometries, a free-flowing powder consisting of thin-walled hollow glass microspheres, and a paperboard material, which has the advantage of providing a strong and lightweight panel element. Other advantageous properties that can be achieved by the material include sound attenuation properties, insulation properties, and hardening properties.

[0058] The spacing material of the second substrate may include an open-cell material provided with a top layer and a bottom layer for closing the cell structure of the open-cell material. By providing a top layer and a bottom layer for closing the cell structure of the open-cell material, the material of the first substrate may be prevented or blocked from entering the cells of the cell structure of the open-cell material. This facilitates the ability to manufacture the panel element in a controlled manner such that the properties of the spacing material are not affected by the synthetic composite material of the first substrate.

[0059] The spacing material of the second substrate may include a honeycomb material provided with a top layer and a bottom layer for closing a pore structure of the honeycomb material.

[0060] When the second substrate is embedded in the first substrate, the spacer material may be provided with a channel extending in a normal direction to a major surface of the panel, wherein the first substrate may extend through the channel, which has the advantage of making the panel stronger. The fact that the first substrate may extend through the channel of the second substrate enables portions of the first substrate arranged on opposite sides of the second substrate to be interconnected through the channel of the second substrate, thereby providing a stronger panel element that is less prone to delamination.

[0061] At least two opposing side edge portions may comprise complementary coupling members configured to couple adjacent panel elements to each other, with the advantage that a panel element assembly comprising a plurality of panel elements may be formed in a simple manner. Such a panel element assembly may be formed without the use of any tools. Such a panel element assembly may form a floor, a wall or a ceiling. Such a panel element assembly may form a deck. Such a panel element assembly may form a plurality of connected panel assembly parts, such as a plurality of walls.

[0062] Furthermore, when the panel elements are complemented using complementary connecting members configured to connect adjacent panel elements to each other, the complementary connecting members can be made stronger compared to conventional panel elements without any spacing material because at least two opposing side edge portions can be made thicker without significantly increasing the weight and / or material consumption of the panel.

[0063] The complementary coupling member may be machined from the material of the first substrate, which has the advantage that a strong and reliable coupling member may be formed integrally with the first substrate.

[0064] The complementary coupling member may be machined from the material of the first substrate and the second substrate, which has the advantage that a strong and reliable coupling member may be formed integrally with the first substrate and the second substrate.

[0065] According to another aspect of the present invention, there is provided a method for forming a panel element, such as a floor panel, a wall panel, a ceiling panel or a deck panel, the method comprising: providing a first extrusion stream of a synthetic composite material, the synthetic composite material comprising at least 20 weight % of a mineral material, providing a second extrusion stream of the synthetic composite material, providing a spacer material, applying the first extrusion stream and the second extrusion stream from opposite sides of the spacer material so that the first extrusion stream and the second extrusion stream form a first substrate, the first substrate being embedded with or recessed with the spacer material forming the second substrate, thereby forming a panel element comprising at least two opposite side edge portions formed only by the first substrate.

[0066] An improved method of forming a panel element is thereby provided.

[0067] Details and advantages of this aspect of the invention are generally similar to those of the previous aspect of the invention, to which reference is made.

[0068] However, in summary, the method forms a panel element by providing a first extrusion stream and a second extrusion stream of a synthetic composite material (the synthetic composite material includes at least 20% by weight of a mineral material) and applying the first extrusion stream and the second extrusion stream from opposite sides of a spacer material. Typically, the application is performed by one or more extruders in such a way that the first extrusion stream and the second extrusion stream form a first substrate, which is embedded or recessed with a spacer material forming a second substrate, thereby forming a panel element. In addition, the application is performed in such a way that the formed panel element includes at least two opposite side edge portions formed only by the first substrate.

[0069] Therefore, when forming a panel element, in which the first extrusion stream and the second extrusion stream form a first substrate, which is embedded with a spacer material forming a second substrate, the first extrusion stream and the second extrusion stream are typically applied over the entire width of two opposite sides of the spacer material, or over most of the width of two opposite sides of the spacer material.

[0070] On the other hand, when forming a panel element, wherein the first extrusion stream and the second extrusion stream form a first substrate embedded with a spacer material forming a second substrate, one of the first extrusion stream and the second extrusion stream (typically the first extrusion stream) is typically applied over the entire width of one opposite side of the spacer material, while the other of the first extrusion stream and the second extrusion stream (typically the second extrusion stream) is typically applied over a portion of the other opposite side of the spacer material (such as, an opposite edge portion).

[0071] The spacer material can be provided in a reel form or a sheet form and can be fed to an application point where a first extrusion stream and a second extrusion stream are applied from opposite sides of the spacer material, with the advantage that panel elements can be formed continuously at a single location. By providing the spacer material in a reel form and feeding the spacer material to an application point where a first extrusion stream and a second extrusion stream are applied from opposite sides of the spacer material, an extended web or substrate comprising a plurality of panel elements can be formed continuously. This extended web can then be separated into individual panel elements. By providing the spacer material in a reel form, simplified handling and storage of the spacer material can be achieved. By providing the spacer material in a sheet form and feeding the spacer material to an application point where a first extrusion stream and a second extrusion stream are applied from opposite sides of the spacer material, the size, shape and quantity of the panel elements formed simultaneously can be advantageously controlled. One sheet of spacer material can correspond to one panel element. One sheet of spacer material can correspond to a plurality of panel elements.

[0072] The spacer material can be fed through an extrusion die by feeding the spacer material between a first nozzle of the extrusion die and a second nozzle of the extrusion die, wherein a first extrusion stream and a second extrusion stream are applied from opposite sides of the spacer material in the extrusion die, the first nozzle being configured to provide the first extrusion stream and the second nozzle being configured to provide the second extrusion stream, which has the advantage that panel elements can be continuously formed at a single location.

[0073] The first nozzle may include a plurality of nozzle elements, wherein each nozzle element may be configured to be individually controlled so that the amount of the first extrusion stream provided to the extrusion die varies across the width of the extrusion die, and / or wherein the second nozzle may include a plurality of nozzle elements, wherein each nozzle element may be configured to be individually controlled so that the amount of the second extrusion stream provided to the extrusion die varies across the width of the extrusion die. This has the advantage that the amount and / or distribution of the synthetic composite material in the first extrusion stream provided to the extrusion die may vary across the width of the extrusion die, and therefore across the width of the panel element being formed. This also has the advantage that the amount and / or distribution of the synthetic composite material in the second extrusion stream provided to the extrusion die may vary across the width of the extrusion die, and therefore across the width of the panel element being formed. Thus, the amount and / or distribution of the synthetic composite material may be controlled on either of the opposite sides of the panel element so that the spacer material of the second substrate is embedded or recessed in the first substrate made of the synthetic composite material.

[0074] The first nozzle may include a plurality of nozzle elements. The plurality of nozzle elements of the first nozzle may have different sizes and / or different shapes. That is, the plurality of nozzle elements of the first nozzle may include at least two nozzle elements having different sizes and / or shapes.

[0075] The second nozzle may include a plurality of nozzle elements. The plurality of nozzle elements of the second nozzle may have different sizes and / or different shapes. That is, the plurality of nozzle elements of the second nozzle may include at least two nozzle elements having different sizes and / or shapes.

[0076] This has the advantage that the amount and / or distribution of the synthetic composite material in the first extrusion stream provided to the extrusion die can be varied across the width of the extrusion die, and therefore across the width of the panel element being formed. This also has the advantage that the amount and / or distribution of the synthetic composite material in the second extrusion stream provided to the extrusion die can be varied across the width of the extrusion die, and therefore across the width of the panel element being formed.

[0077] The first extrusion stream can be provided by more than one extruder, and / or the second extrusion stream can be provided by more than one extruder, so that the first substrate of the panel element can include more than one material on the same side and / or different sides thereof, with the advantage that the properties of the panel element can be adjusted to meet specific needs.

[0078] The spacer material can be provided in roll form and can be fed to a first application point, where a first extrusion stream can be applied from a first side of the spacer material, and the spacer material can be fed to a second application point, where a second extrusion stream can be applied from a second side of the spacer material, the second side of the spacer material being opposite to the first side of the spacer material, with the advantage that the first substrate can be formed continuously at different physical locations.

[0079] The first extrusion stream may come from a first extruder and the second extrusion stream may come from a second extruder, such that the first substrate of the panel element may include different materials on different sides thereof.

[0080] The plurality of panel elements may be formed in a continuous process and / or in a parallel process, which has the advantage that the plurality of panel elements may be formed in a simple manner. The plurality of panel elements may be formed sequentially. The plurality of panel elements may be formed in parallel. The plurality of panel elements may be formed sequentially and in parallel.

[0081] The spacer material may be provided in the form of a plurality of discrete spacer material elements connected by a support material, with the advantage that individual panel elements each comprising a single spacer material element may be formed when a first extrusion stream and a second extrusion stream are applied from opposite sides of the spacer material.

[0082] The support material may include threads connecting adjacent discrete spacer material elements.

[0083] The support material may include thread-like members connecting adjacent discrete spacer material elements.

[0084] The support material may include a network connecting adjacent discrete spacer material elements.

[0085] The support material may be integrally formed with the discrete spacing material elements.

[0086] The method may further include: performing a thickness control operation on the panel element, which has the advantage that the final thickness of the formed panel element can be accurately controlled.

[0087] The thickness control operation may include feeding the panel element through a roller gap formed between two thickness control rollers, which has the advantage that the thickness of the formed panel element can be controlled while the panel element is continuously formed. In addition, by feeding the panel element through the roller gap formed between the two thickness control rollers, the lamination between the first substrate and the second substrate can be improved. Therefore, by feeding the panel element through the roller gap formed between the two thickness control rollers, the first substrate and the second substrate can be firmly pressed together, so that the respective substrates are more firmly bonded to each other. Delamination of the first substrate and the second substrate can thereby be prevented.

[0088] The two thickness control rollers may be heated, which has the advantage that the thickness can be accurately controlled by locally softening the resulting composite material of the first substrate.

[0089] According to another aspect of the present invention, an extrusion device is provided, which is configured to form a panel element according to the first aspect, and the device includes: a first extrusion nozzle, the first extrusion nozzle is configured to provide a first extrusion flow of a synthetic composite material, a second extrusion nozzle, the second extrusion nozzle is configured to provide a second extrusion flow of a synthetic composite material, and a space formed between the first extrusion nozzle and the second extrusion nozzle, the space is configured to receive a spacing material, so that the first extrusion flow and the second extrusion flow are applied from opposite sides of the spacing material, so that the first extrusion flow and the second extrusion flow form a first substrate, the first substrate is embedded with or recessed with the spacing material forming the second substrate, thereby forming a panel element, the panel element includes at least two opposite side edge portions formed only by the first substrate.

[0090] There is thereby provided an improved extrusion apparatus configured to form a panel element.

[0091] Details and advantages of this aspect of the invention are substantially similar to those of the previous aspects of the invention, to which reference is made.

[0092] In general, unless otherwise expressly defined herein, all terms used in the claims should be interpreted according to their ordinary meaning in the technical field. Unless otherwise expressly stated, all references to "a / an / the [element, device, part, means, step, etc.]" should be interpreted openly as referring to at least one instance of the element, device, part, means, step, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0093] The above and other objects, features and advantages of the present invention will be better understood through the following illustrative and non-limiting detailed description of preferred variations of the inventive concept, with reference to the accompanying drawings, in which like reference numerals will be used for similar elements, wherein:

[0094] Figure 1 A cross-sectional perspective view conceptually illustrates a panel element in which a second substrate is embedded in a first substrate.

[0095] Figure 2a A cross-sectional perspective view conceptually shows a panel element in which a second substrate is recessed in a first substrate.

[0096] Figure 2b A cross-sectional perspective view conceptually showing different panel elements with a second substrate recessed within a first substrate.

[0097] Figure 3 A cross-sectional perspective view conceptually illustrates a panel element in which a second substrate is embedded in a first substrate.

[0098] Figure 4 A cross-sectional perspective view conceptually illustrates a panel element in which a second substrate is embedded in a first substrate.

[0099] Figure 5 A cross-sectional perspective view of a panel element provided with a coupling member is conceptually shown.

[0100] Figure 6 A cross-sectional view of a panel element provided with a coupling member, a top coating, and a bottom coating is conceptually shown.

[0101] Figure 7 A cross-sectional perspective view of a panel element provided with relief features is conceptually shown.

[0102] Figure 8a A perspective view of a floor panel is conceptually shown.

[0103] Figure 8b Perspective views of different floor panels are conceptually shown.

[0104] Fig. 9 A perspective view of a wall panel or ceiling panel is conceptually shown.

[0105] Fig.10 A perspective view of an extrusion device is conceptually shown.

[0106] Fig.11 Conceptually shows Fig.10 A partial cross-sectional perspective view of an extrusion device.

[0107] Fig.12 A perspective view of a spacer material is conceptually shown.

[0108] Fig.13 is a block diagram of a method for forming a panel element. DETAILED DESCRIPTION

[0109] The inventive concept will be described more fully below with reference to the accompanying drawings, in which preferred variations of the inventive concept are shown. However, the inventive concept may be embodied in a variety of different forms and should not be construed as limited to the variations described herein; rather, these variations are provided for comprehensiveness and completeness and fully convey the scope of the inventive concept to the skilled person. Throughout the description, the same reference numerals represent the same elements.

[0110] Will refer to Figure 1 and Figure 2aA panel element 100 is described, such as a floor panel, a wall panel, a ceiling panel or a deck panel.

[0111] Figure 1 and Figure 2a The panel elements 100 each have a first substrate 102 made of a synthetic composite material 102a. The synthetic composite material 102a contains at least 20% by weight of a mineral material or at least 20% by weight of a mineral material. More specifically, Figure 1 and Figure 2a The synthetic composite material 102a of the illustrated panel element 100 is made of CaCO powder combined with PVC. Additives can be used to advantageously adjust the properties of the first substrate 102. The amount of mineral material of the first substrate 102 can vary greatly. The content of mineral material of the first substrate 102 is at least 20% by weight. However, the content of mineral material of the first substrate 102 can account for as much as 90% by weight.

[0112] Figure 1 and Figure 2a The panel elements 100 each have a second substrate 104 made of a spacer material 104a. The bulk density of the spacer material 104a is lower than the bulk density of the composite material 102a of the first substrate 102. Figure 1 and Figure 2a In the illustrated panel element 100, the spacer material 104a used is a honeycomb material.

[0113] in addition, Figure 1 and Figure 2a The panel elements 100 each have two opposite side edge portions 103 formed only of the first substrate 102 .

[0114] exist Figure 1 In the panel element 100, the second substrate 104 is embedded in the first substrate 102. That is, Figure 1 As shown, the first substrate 102 surrounds the second substrate 104. Therefore, the first substrate 102 forms a top layer 106 and a bottom layer 108, and the second substrate 104 is arranged between the top layer 106 and the bottom layer 108. The thickness of the top layer 106 and the bottom layer 108 are equal. Figure 1 As shown, the first substrate 102 forms two opposite side edge portions 103 .

[0115] On the other hand, Figure 2a In the panel element 100, the second substrate 104 is recessed in the first substrate 102. That is, Figure 1 As shown, Figure 2a The first substrate 102 is mainly arranged above the second substrate 104. However, the first substrate 102 extends downward on the side portion of the second substrate 104, thereby forming two opposite side edge portions 103. Figure 2a In the panel element 100 of FIG. 1 , the spacer material 104a forming the second substrate 104 is exposed on the lower side of the panel element 100. The spacer material 104a forming the second substrate 104 is usually exposed on the side that is not visible after the panel element 100 is mounted. The spacer material 104a forming the second substrate 104 is usually exposed on the back side of the panel element 100.

[0116] exist Figure 1 and Figure 2a In the illustrated panel element 100, the width of the two opposite side edge portions 103 formed only by the first substrate 102 is 17 mm. Generally, the width of the two opposite side edge portions 103 formed only by the first substrate 102 may be 10 mm to 25 mm, preferably 15 mm to 20 mm.

[0117] like Figure 1 As shown, the major extensions of the top layer 106 and the bottom layer 108 may be supported by the second substrate 104. Figure 1 In the embodiment shown in FIG. 1 , approximately 80% of the extended portions of the top layer 106 and the bottom layer 108 are supported by the second substrate 104 . Figure 1 The thickness of the top layer 106 and bottom layer 108 of the panel element is about 2 mm. Other thicknesses may also be used to advantage.

[0118] In fact, when forming the panel element 100 in which the second substrate 104 is embedded in the first substrate, 45%-90%, preferably 60%-80% of the top layer 106 and the bottom layer 108 may be supported by the second substrate 104. The expanded hole portions of the top layer 106 and the bottom layer 108 may generally correspond to the opposite side edge portions 103. However, the thickness of the top layer 106 and the bottom layer 108 may vary to suit different needs.

[0119] Similarly, if Figure 2a As shown, the main extension of the first substrate 102 is supported by the second substrate 104. Figure 2a In the embodiment, about 80% of the first substrate is supported by the second substrate 104. Figure 1 The thickness of the portion 102b of the panel element supported by the second substrate 104 is about 2 mm.

[0120] In fact, when forming the panel element 100 in which the second substrate 104 is recessed in the first substrate, 45%-90%, preferably 60%-80% of the first substrate can be supported by the second substrate 104. The expanded hole portion of the first substrate generally corresponds to the opposite side edge portion 103. Figure 1 The thickness of the portion 102b supported by the second substrate 104 of the panel element 100 may vary to suit different needs.

[0121] The spacing material 104a of the second substrate 104 of the panel element 100 according to the present inventive concept can be changed to a large extent. By changing the spacing material 104a of the second substrate 104, various properties of the panel element 100 can be adjusted.

[0122] For example, the weight of panel element 100 may be reduced by utilizing spacer material 104a that exhibits a low bulk density.

[0123] For example, the rigidity of the panel element 100 may be enhanced by using a spacer material 104a exhibiting high rigidity.

[0124] For example, the structural integrity of the panel element 100 may be enhanced by utilizing a spacer material 104a that is securely bonded to the resultant composite material 102a of the first substrate 102 .

[0125] Examples of suitable spacer materials 104 a for the second substrate 104 include, but are not limited to, honeycomb materials, polymer foams, a plurality of hollow tube segments extending in parallel, glass foams, metal comprising foams, fiber reinforced polymer materials, closed-cell PVC foams, EPS (expanded polystyrene) or EPP (expanded polypropylene), materials comprising cavities, materials comprising cavities of varying geometries, free-flowing powders comprised of thin-walled hollow glass microspheres, and paperboard materials.

[0126] All of the materials used for the spacer material 104a have a relative humidity of less than 2000 kg / m 3 However, preferably, the material used for the spacer material 104a has a bulk density of less than 1000 kg / m 3 Several materials used for the spacer material 104a have significantly lower bulk densities.

[0127] The materials used for the spacer material 104a may be combined to achieve properties that the materials cannot provide when used alone.

[0128] For example, the hollow tube may be embedded in a polymer form to provide the spacing material 104a.

[0129] As a few non-limiting examples, by utilizing the described materials for the spacing material 104a of the second substrate 104, the overall properties may also be enhanced in terms of sound attenuation and insulation.

[0130] For free-flowing powders composed of thin-walled hollow glass microspheres (such as Glass Bubbles material manufactured by 3M™), they provide additional and / or other outstanding advantages, such as improved fire resistance, reduced need for adhesives or resins, and reduced cooling time during panel manufacturing, thereby increasing manufacturing rates and reducing the risk of panel warping during manufacturing.

[0131] The various materials used for the spacer material 104a of the second substrate 104 are so-called open-cell materials, in which the accessible holes or cavities of the material form the exterior of the material. An example of an open-cell material is a conventional honeycomb material. In a conventional honeycomb material, the generally hexagonal cavities of the honeycomb material can be accessible from the exterior of the material. In order to make such honeycomb materials and other open-cell materials more robust, and also to prevent material from entering the cavity or pores, such open-cell materials can be provided with a top layer 104t and a bottom layer 104b to close the pore structure of the open-cell material.

[0132] As mentioned above, Figure 1 and Figure 2a The spacing material 104a of the second substrate 104 of the panel element 100 is a honeycomb material. However, it should be noted that it is also possible to Figure 1 and Figure 2a Other spacer materials may be advantageously utilized in the panel element 100. Figure 1 and Figure 2a The honeycomb material of the spacer material 104a of the second substrate 104 of the panel element 100 has been provided with a top layer 104t and a bottom layer 104b for closing the pore structure of the open-cell honeycomb material.

[0133] Therefore, when the formation Figure 1 2 , the top layer 104 t and the bottom layer 104 b of the honeycomb spacer material 104 prevent the synthetic composite material 102 a of the first substrate 102 from entering the open cavities of the honeycomb spacer material 104 .

[0134] Additionally, the top layer 104 t and the bottom layer 104 b of the spacer material 104 help to improve the overall strength and dimensional stability of the spacer material 104 .

[0135] Now turn to Figure 2b A panel element 100 is conceptually depicted herein. Figure 2b The panel element 100 and Figure 2a The panel element 100 is similar. Figure 2b The panel element 100 has a first substrate 102 made of a synthetic composite material 102a, and Figure 2a The second substrate 104 made of a spacer material 104a is recessed in the first substrate 102. Figure 2b The overall composition and materials used in the panel elements are combined with the above Figure 2a The overall components and materials described are similar. Therefore, to avoid unnecessary repetition, these details will not be repeated.

[0136] like Figure 2b As shown, Figure 2b The first substrate 102 is mainly arranged above the second substrate 104. However, Figure 2b The second substrate 104 in the embodiment has an overall stepped shape. The stepped shape of the second substrate 104 is combined with the shape of the first substrate 102 so that the upper portion of the second substrate 104 is recessed in the first substrate 102, while the lower portion of the second substrate 104 is arranged below the first substrate 102 so that the lower portion of the second substrate 104 is exposed at the side edge portion of the substrate 100. Figure 2b As shown, the lateral side edge surface of the panel element 100 is formed by the first substrate 102 and the second substrate 104. More specifically, the upper portion of the lateral side edge surface of the panel element 100 is formed by the first substrate 102, and the lower portion of the lateral side edge surface of the panel element 100 is formed by the second substrate 104.

[0137] Therefore, the first substrate 102 extends downward onto the side portions of the second substrate 104, thereby forming two opposite side edge portions 103 formed only by the first substrate 102. Figure 2b In the panel element 100 , the spacer material 104 a forming the second substrate 104 is exposed on the lower side of the panel element 100 and on the side edges of the panel element 100 .

[0138] Now turn to Figure 3 A panel element 100 is conceptually depicted herein. Figure 3 The panel element 100 and Figure 1 The panel element 100 is similar. Figure 3 The panel element 100 has a first substrate 102 made of a synthetic composite material 102a, and Figure 1 The panel element 100 is similar to the panel element 100. The first substrate 102 is embedded with a second substrate 104 made of a spacer material 104a. Figure 3 The overall composition and materials used in the panel elements are combined with the above Figure 1 The overall components and materials described are similar. Therefore, to avoid unnecessary repetition, these details will not be repeated.

[0139] Figure 3 The spacing material 104a of the second substrate 104 of the panel element 100 is made of a honeycomb material. However, it should be noted that Figure 3Other spacer materials are advantageously used in the panel element 100. Therefore, the spacer material 104a of the second substrate 104 is made of an open-porous material. Figure 3 In the embodiment, the spacer material 104a is provided with a plurality of channels 104c, and the plurality of channels 104c extend along the normal direction N of the main surface of the panel 100. Figure 3 As shown, the first substrate 102 extends through the channel 104 .

[0140] exist Figure 3 In the panel element 100 shown, the channels 104c are formed by opening certain cavities in the honeycomb material, which are originally provided with a top layer 104t and a bottom layer 104b, as described above in conjunction with Figure 1 and Figure 2a As described. This opening can be achieved by penetrating the top layer 104t and the bottom layer 104b. Alternatively, the materials forming the top layer 104t and the bottom layer 104b can be provided with openings at regular distances. Other principles for forming the channel 104c can be advantageously used.

[0141] The channels 104c help improve the overall strength of the panel element 100 by connecting the top layer 106 and the bottom layer 108 of the first substrate 102 through the corresponding channels 104c. That is, the first substrate 102 extends through the channels 104c, thereby connecting the top layer 106 and the bottom layer 108 of the first substrate 102.

[0142] Furthermore, the fact that the first substrate 102 extends through the channel 104c, connecting the top layer 106 and the bottom layer 108 of the first substrate 102, counteracts or prevents Figure 3 The panel element 100 includes a first substrate 102 and a second substrate 104 which are layered.

[0143] Alternatively or additionally, one or more outer surfaces of the spacer material 104a of the second substrate 104 may be patterned to increase bonding between the spacer material 104a of the second substrate 104 and the composite material 102a of the first substrate 102. Delamination of the first and second substrates 102, 104 may thereby be counteracted.

[0144] Now turn to Figure 4 A panel element 100 is conceptually depicted herein. Figure 4 The panel element 100 is similar to Figure 1 The panel element 100. Figure 4 The panel element 100 has a first substrate 102 made of a synthetic composite material 102a, similar to Figure 1 The panel element 100. The first substrate 102 is embedded with a second substrate 104 made of a spacer material 104a.

[0145] exist Figure 4 In the embodiment, the spacer material 104a of the second substrate is made of a polymer foam material. The polymer foam material forming the spacer material 104a has a closed cell structure. Therefore, Figure 4 The spacer material 104a does not have any top layer and bottom layer for closing the pore structure of the spacer material 104a.

[0146] Figure 4 The first substrate 102 of the embodiment of the present invention forms a top layer 106 and a bottom layer 108, and the second substrate 104 is arranged between the top layer 106 and the bottom layer 108. The top layer 106 and the bottom layer 108 have different thicknesses. The top layer 106 of the first substrate 102 is thicker than the bottom layer 108 of the first substrate 102. By making the top layer 106 of the first substrate 102 thicker than the bottom layer 108 of the first substrate 102, improved wear resistance can be achieved while still providing a strong panel element 100.

[0147] like Figure 4 As shown, the second substrate 104 made of the spacer material 104a in the form of a polymer foam material may advantageously be formed shortly before being included in the panel element 100. Such a second substrate 104 made of the spacer material 104a in the form of a polymer foam material may advantageously be formed in an extrusion process immediately before forming the panel element 100. Such a second substrate 104 formed in an extrusion process immediately before forming the panel element 100 may be cooled so that the structural integrity of the second substrate 104 is sufficient for the second substrate 104 to withstand the forces to which it is subjected during forming the panel element 100. Therefore, such a second substrate 104 formed in an extrusion process immediately before forming the panel element 100 may not be fully cured during forming the panel element 100.

[0148] Now turn to Figure 5 A panel element 100 is conceptually depicted herein. Figure 5 The panel element 100 is formed after subsequent processing of two opposite side edge portions 103. Figure 1 Therefore, Figure 5 The panel element 100 and Figure 1 In other words, Figure 5 The overall composition and materials used in the panel elements are combined with the above Figure 1 The overall composition and materials described are the same. Therefore, to avoid unnecessary repetition, these details will not be repeated.

[0149] However, Figure 5The panel element 100 has been provided with complementary coupling members 103a, 103b. The complementary coupling members 103a, 103b are configured to couple adjacent panel elements 100 to each other. The complementary coupling members 103a, 103b include a male coupling member 103a and a female coupling member 103b. The complementary coupling members 103a, 103b are processed from the material of the first substrate 102. More specifically, the complementary coupling members 103a, 103b are processed from the material of the two opposite side edge portions 103 of the first substrate 102. The complementary coupling members 103a, 103b are processed from the material of the first substrate 102, along the Figure 3 The complementary coupling members 103a, 103b are machined from the material of the first substrate 102 by using a milling cutter. The male coupling member 103a is machined from the material of the first substrate 102 by using a first milling cutter. The female coupling member 103b is machined from the material of the first substrate 102 by using a different second milling cutter. Other techniques may be advantageously used to form the complementary coupling members 103a, 103b. Other shapes and designs of the complementary coupling members 103a, 103b may be advantageously used.

[0150] Thus, a panel element assembly can be formed by connecting a plurality of panel elements 100 to each other using complementary coupling members 103a, 103b of the respective panels used in the panel element assembly. Such a panel element assembly can be formed by connecting a plurality of panel elements 100 to each other without using any tools. This means that a plurality of panel elements can form, for example, a floor, ceiling, wall panel assembly or a deck panel assembly.

[0151] Now turn to Figure 6 A panel element 100 is conceptually depicted herein. Figure 6 The panel element 100 is after a subsequent process of applying a top coating 110 and a bottom coating 112 to the panel element 100. Figure 1 and Figure 5 Therefore, Figure 6 The panel element 100 and Figure 1 and Figure 5 In other words, Figure 6 The overall composition and materials used in the panel elements are combined with the above Figure 1 and Figure 5 The overall composition and materials described are very similar. Therefore, to avoid unnecessary repetition, these details will not be repeated.

[0152] Figure 6The top coating 110 has a variety of uses. The top coating 110 has wear-resistant properties. The top coating 110 also has aesthetic uses. Therefore, the appearance of the top coating 110 is similar to that of a wooden floor. Therefore, the top coating can be said to be a decorative top coating 110. Such a top coating 110 can have other appearances. Such a top coating 110 can resemble stone. Such a top coating 110 can have a color. Such a top coating 110 can be patterned, and the like.

[0153] Further coatings having UV (ultraviolet) protection properties may advantageously be applied to the top coating.Alternatively or additionally, a UV protectant may be included in the top coating 110 .

[0154] The bottom coating 112 is a polymer foam layer. When the panel element 100 is used for flooring, this polymer foam layer can reduce the noise generated when walking. This polymer foam layer can increase the insulating properties of the panel element 100. Other types of bottom coatings can be used to meet specific needs.

[0155] like Figure 6 As shown, the panel element 100 includes a portion of a support material 208a for connecting the spacer material 104a of the second substrate 104 to an adjacent element of the spacer material during manufacture of the panel element 100. Figure 10-12 The manufacture of the support material 208a and the panel element 100 is described in more detail. Therefore, please refer to the following.

[0156] Now turn to Figure 7 A panel element 100 is conceptually depicted herein. Figure 7 The panel element 100 is similar to Figure 2a The panel element 100. Figure 7 The panel element 100 has a first substrate 102 made of a synthetic composite material 102a, similar to Figure 2a The panel element 100. The first substrate 102 is embedded with a second substrate 104 made of a spacer material 104a. Figure 7 The overall composition and materials used in the panel elements are similar to those in the above combination Figure 2a Therefore, to avoid unnecessary repetition, these details will not be repeated.

[0157] like Figure 7 As shown, the top surface of the panel element 100 is provided with relief features 114 . Figure 7 The embossed feature 114 of the panel 100 may be a decorative feature. Figure 7 The relief features 114 of the panel 100 may help increase the strength of the panel element 100 . Figure 7The embossed features 114 of the panel 100 are integrally formed with the first substrate 102. Thus, the embossed features 114 are formed by the composite material 102a of the first substrate 103. Figure 7 The panel element 100 is similar to a plurality of profiled wooden panels arranged side by side.

[0158] exist Figure 7 In the embodiment, the longitudinal edges of the panel elements 100 are not provided with any coupling members. However, the longitudinal edges may be connected to the longitudinal edges of other panel elements 100 in any manner, for example by gluing.

[0159] Now also refer to Figure 8a , here conceptually depicts the above combination Figure 1 and Figure 6 A panel element 100 of the type described. Figure 8a The panel elements are floor panels similar to wooden floor panels. Figure 8a As shown, the top coating 110 resembles the appearance of a wooden surface. At a lower portion of the longitudinal edge of the panel element 100, the female coupling member 103b is visible. At an upper portion of the longitudinal edge of the panel element 100, the male coupling member 103a is visible.

[0160] Now also refer to Figure 8b , here conceptually depicts the above combination Figure 2b A panel element 100 of the type described. Figure 8a Similar to the panel element 100, Figure 8b The panel element is a floor similar to a wooden floor. Figure 8b The floor is combined with the above Figure 2b Panel elements of the type described are manufactured and formed. Figure 8b As shown, the top coating 110 resembles the appearance of a wooden surface. At a lower portion of the longitudinal edge of the panel element 100, the female coupling member 103b is visible. At an upper portion of the longitudinal edge of the panel element 100, the male coupling member 103a is visible.

[0161] like Figure 8b As shown, the spacer material 104a is exposed at the lateral side edge surfaces of the panel element 100 and at the lateral side edge surfaces of the panel element 100. The spacer material 104a is also exposed at the lower side of the panel element 100. Figure 8bAs shown, the lateral side edge surface and the lateral side edge surface of the panel element 100 are formed by the first substrate 102 and the second substrate 104. More specifically, the upper portion of the lateral side edge surface and the lateral side edge surface of the panel element 100 is formed by the first substrate 102. Correspondingly, the lower portion of the lateral side edge surface and the lateral side edge surface of the panel element 100 is formed by the second substrate 104.

[0162] In addition, as mentioned above Figure 2b As described, the second substrate 104 is recessed in the first substrate 102. Therefore, the first substrate 102 extends downward onto the side portions of the second substrate 104, thereby forming two opposite side edge portions 103 formed only by the first substrate 102.

[0163] Now also refer to Fig. 9 , here conceptually depicts the above combination Figure 2a and Figure 7 A panel element 100 of the type described. Fig. 9 The panel elements are wall panels similar to multiple profiled wood siding panels. Fig. 9 As shown, the top surface of the panel element is provided with seven longitudinally extending relief features 114 so that the top surface of the panel element resembles the appearance of seven parallel extending profiled wood siding boards. At the lower portion of the longitudinal edge of the panel element 100, the female coupling member 103b is visible.

[0164] Other embodiments of a panel element, such as a floor panel, a wall panel, a ceiling panel, or a deck panel, may include a first substrate made of a free-flowing powder composed of thin-walled hollow glass microspheres, wherein the panel element includes at least two opposing side edge portions formed only by the first substrate. That is, in such an embodiment, the panel element is made only of a first substrate having a low bulk density, such as glass bubbles manufactured by 3M™. In such a panel element, each of the at least two opposing side edge portions formed by the low bulk density first substrate may have a width of 10 mm-25 mm, preferably 15 mm-20 mm, similar to the above in conjunction with Figures 1 to 9 The example shown. In addition, in such an embodiment, at least two opposing side edge portions may include complementary coupling members configured to couple adjacent panel elements to each other. In addition, the complementary coupling members may be processed from a material of the first substrate of low bulk density. Such panel elements provide additional and / or other outstanding advantages, such as improved fire resistance, reduced need for adhesives or resins, and reduced cooling time during panel manufacturing, thereby increasing manufacturing rates and reducing the risk of panel warping during manufacturing.

[0165] Now turn to Fig.10 and Fig.11 . Here is a conceptual depiction of the above combination Figures 1 to 9 An extrusion device 200 for a panel element 100 of the type described will be mainly referred to below. Fig.10 and Fig.11 The extrusion apparatus 200 and its operation are described. Fig.10 is a general overview of the extrusion device 200, and Fig.11 is a partial cross-sectional view of a portion of the extrusion device 200, more clearly showing how the extrusion device 200 is used to form the above bond during the extrusion process. Figures 1 to 9 A panel element 100 of the type described.

[0166] The extrusion device 200 is provided with a first extrusion nozzle 202 configured to provide a first extrusion flow EF1 of a resultant composite material 102 a for forming the first substrate 102 .

[0167] The extrusion device 200 is provided with a second extrusion nozzle 204 configured to provide a second extrusion flow EF2 for forming a resultant composite material 102 a of the first substrate 102 .

[0168] A space 206 is formed between the first extrusion nozzle 202 and the second extrusion nozzle 204. Fig.11 As best shown, space 206 is configured to receive Fig.10 and Fig.11 The right hand side of the feed is fed to the spacing material 104a in the space 206. Fig.11 As shown by the middle arrows, when the spacer material 104a is fed through the space 206, the first extrusion flow EF1 and the second extrusion flow EF2 are applied from opposite sides of the spacer material 104a.

[0169] The synthetic composite material 102a is typically heated to above its glass transition temperature when it is fed with the first extrusion flow EF1 and the second extrusion flow EF2 and applied to opposite sides of the spacer material 104a. The synthetic composite material 102a is typically then cooled to harden and form the first substrate 102. The relevant temperatures of the first extrusion flow EF1 and the second extrusion flow EF2 depend on the composition of the synthetic composite material 102a being processed (at hand). Such temperatures are well known in the art and are typically specified by the supplier of the synthetic composite material 102a.

[0170] Thus, the first extrusion stream and the second extrusion stream will form a combined Figures 1 to 9 A first substrate 102 of the type described is simultaneously applied from opposite sides of the spacing material 104a that is fed into and through the space 206 .

[0171] Depending on the design and / or control of the first extrusion nozzle 202 and the second extrusion nozzle 204 , the first substrate 102 being formed will be embedded or recessed in the spacing material 104 a forming the second substrate 104 .

[0172] The first extrusion nozzle 202 and the second extrusion nozzle 204 are designed so that the formed panel elements 100 each have at least two opposite side edge portions 103 formed only of the first substrate 102 .

[0173] like Fig.11 As best shown, the spacer material 104a can be provided in a roll form 208. Thus, the spacer material 104a is typically provided on the roll 208. Alternatively, the spacer material 104a can be provided as a discrete element 104f, such as Fig.11 206 and 207. The spacer material 104a is typically fed from the reel 208 to an application point AP where the first extrusion stream EF1 and the second extrusion stream EF2 are applied from opposite sides of the spacer material 104a. The application point AP is the point in the extrusion apparatus 200 shown where the first extrusion stream EF1 and the second extrusion stream EF2 leave their respective extrusion nozzles 202, 206 and are applied from opposite sides of the spacer material 104a.

[0174] In other words, the spacer material 104a is typically fed through the extrusion die 210, where a first extrusion flow EF1 and a second extrusion flow EF2 are applied from opposite sides of the spacer material 104a by feeding the spacer material between the first nozzle 202 of the extrusion die 210 and the second nozzle 204 of the extrusion die 210. As described above, the first nozzle 202 of the extrusion die 210 is typically configured to provide the first extrusion flow EF1, and the second nozzle 204 of the extrusion die 210 is typically configured to provide the second extrusion flow EF2.

[0175] The illustrated first nozzle 202 includes a plurality of nozzle elements. The plurality of nozzle elements of the first nozzle 202 are distributed over the width of the extrusion die 210, ie, over the width of the spacer material 104a fed through the gap 206.

[0176] Accordingly, the second nozzle 204 is shown to include a plurality of nozzle elements. The plurality of nozzle elements of the second nozzle 204 are distributed over the width of the extrusion die 210 , ie, over the width of the spacer material 104 a fed through the gap 206 .

[0177] The nozzle elements of the first nozzle 202 and the second nozzle 204 may be individually controlled.

[0178] Because the nozzle elements of the first nozzle 202 may be individually controlled, the amount of first extrusion flow EF1 provided to the extrusion die 210 and, therefore, the spacer material 104a may vary across the width of the extrusion die 210 and, therefore, the spacer material 104a.

[0179] Accordingly, since the nozzle elements of the second nozzle 204 can be individually controlled, the amount of the second extrusion flow EF2 provided to the extrusion die 210 and, therefore, to the spacer material 104a can vary across the width of the extrusion die 210, and, therefore, across the width of the spacer material 104a at opposite sides of the spacer material 104a.

[0180] Therefore, through each nozzle element of the first nozzle 202 and the second nozzle 204 , the formation manner of the first substrate 102 may be controlled.

[0181] Therefore, the spacing material 104a forming the second substrate 104 can be selectively embedded in the first substrate 102 formed by the first extrusion flow EF1 and the second extrusion flow EF2 by controlling the respective nozzle elements of the first nozzle 202 and the second nozzle 204. This can generally be achieved by providing the first extrusion flow EF1 and the second extrusion flow EF2 over the entire width of the spacing material 104a fed through the gap 206 of the extrusion die 210.

[0182] Similarly, the spacing material 104a forming the second substrate 104 can be selectively recessed in the first substrate 102 formed by the first extrusion flow EF1 and the second extrusion flow EF2 by controlling the respective nozzle elements of the first nozzle 202 and the second nozzle 204. This can typically be achieved by providing the first extrusion flow EF1 over the entire width of the spacing material 104a fed through the gap 206 of the extrusion die 210, while providing the second extrusion flow EF2 only at certain points of the width of the spacing material 104a, such as points near the edge of the spacing material 104a.

[0183] exist Fig.10 and Fig.11 , depicts how the first extrusion stream EF1 and the second extrusion stream EF2 are fed from the same extruder 212. However, the first extrusion stream EF1 and the second extrusion stream EF2 may be fed from different extruders. With this arrangement, different materials may be applied from different sides of the spacer material 104a. For example, a less delicate or lower cost material may be used on the back side of the panel element 100 being formed.

[0184] exist Fig.10 and Fig.11, it is depicted how the first extrusion flow EF1 and the second extrusion flow EF2 are applied to the spacer material 104a at the application point AP. However, the spacer material may alternatively be fed to a first application point, where the first extrusion flow EF1 is applied from a first side of the spacer material 104a, and a second application point, where the second extrusion flow EF2 is applied from a second side of the spacer material opposite to the first side of the spacer material. Thus, the first application point and the second application point may be spaced apart in the feeding direction of the spacer material 104a.

[0185] For example, the spacer material 104a can be a material selected from the group consisting of: a honeycomb material, a polymer foam, a plurality of hollow tube segments extending in parallel, a glass foam, a metal-containing foam, a fiber-reinforced polymer material, a closed-cell PVC foam, EPS (expanded polystyrene) or EPP (expanded polypropylene), a material including cavities, a material including cavities of different geometries, a free-flowing powder composed of thin-walled hollow glass microspheres, and a cardboard material.

[0186] After applying the first extrusion flow EF1 and the second extrusion flow EF2 from opposite sides of the spacer material 104a, the one or more panel elements 100 thus formed can be subjected to a thickness control operation. Such a thickness control operation can include feeding the one or more panel elements 100 through a nip 214a formed between two thickness control rollers 214. The nip 214a will then typically have a certain width, which will correspond to the desired final thickness of the one or more panel elements 100 being formed. Therefore, the one or more panel elements 100 formed can be pressed by the thickness control rollers 214 while being fed through the nip 214a formed between the thickness control rollers 214. When feeding the one or more panel elements 100 through the nip 214a formed between the two thickness control rollers 214, the one or more panel elements 100 are typically subjected to high compressive pressure. Such compressive pressure can apply a force equivalent to several tons to the one or more panel elements 100 being fed through the nip 214a. The thickness control roller 214 may be heated to facilitate the thickness control operation by maintaining the one or more panel elements 100 at a temperature that causes the resultant composite material 102a to be hot enough to have a viscosity suitable for the thickness control operation.

[0187] As can be seen above, a plurality of panel elements 100 may be formed in a continuous process of feeding the spacer material 104a through the gap 206 of the extrusion die 210 and simultaneously applying the first extrusion flow EF1 and the second extrusion flow EF2 from opposite sides of the spacer material 104a.

[0188] To accomplish this, the roll 208 of spacer material may include spacer material 204a for a plurality of panel elements 100 sequentially disposed on the roll 208 .

[0189] However, multiple panel elements 100 may be advantageously formed in a parallel process of feeding the spacer material 104a through the gap 206 of the extrusion die 210 and simultaneously applying the first extrusion flow EF1 and the second extrusion flow EF2 from opposite sides of the spacer material 104a.

[0190] To accomplish this, the roll 208 of spacing material may include spacing material 204a for a plurality of panel elements 100 arranged in parallel on the roll 208. Fig.11 2, which depicts the spacing material 104a of a spool 208 being provided in the form of a plurality of discrete spacing material elements 104e that are disposed side-by-side and sequentially within the spool 208.

[0191] The plurality of discrete spacing material elements 104e of the reel 208 may be interconnected by support material 208a, such as Fig.11 208. The support material 208a may be formed integrally with the discrete spacing material elements 104e of the reel 208. The support material 208a may be formed from a web connecting the spacing material elements 104e of the reel 208. The support material 208a may be formed from a thread connecting the spacing material elements 104e of the reel 208.

[0192] When a plurality of panel elements 100 are formed in a continuous process and / or a parallel process, the formed panel elements are separated from each other to form the upper bonding Figures 1 to 9 A single panel element 100 of the type described.

[0193] like Fig.11 As best shown, multiple panel elements 100 may be formed serially and in parallel. This means that a web 216 or substrate 216 exiting the extrusion die 210 may include multiple panel elements 100 arranged serially and in parallel within the web 216.

[0194] In order to form the above combination Figures 1 to 9 Individual panel elements 100 of the type described are typically cut at locations between discrete spacing material elements 104e included in the web 216. That is, the web 216 may be cut along a longitudinal direction L (i.e., a feed direction) of the web 216 and / or along a transverse direction T of the web 216 to form individual panel elements 100.

[0195] Cutting the web 216 may include sawing, milling, laser cutting, and waterjet cutting, as a few non-limiting examples.

[0196] Now turn to Fig.12 . In order to facilitate cutting the stencil 216 at the correct location and thus keep track of the location of the stencil 216 to be cut, the spacer material 104a can be formed so that portions 104d of the spacer material 104a are exposed at opposite side edges of the panel element 100 or the stencil 216. Alternatively or additionally, the spacer material 104a can be exposed at an edge region of the top side of the panel element 100 being formed. Alternatively or additionally, the spacer material 104a can be exposed at a region of the bottom side of the panel element 100 being formed. Alternatively or additionally, the spacer material 104a can be exposed at corner regions of at least some of the panel element 100 being formed. That is, the spacer material 104a can be formed so that certain portions 104d or features 104d of the spacer material 104a are exposed after the stencil 216 is formed. In fact, such certain features 104d of the spacer material 104a can generally be exposed at the longitudinal edges of the stencil 216. However, such certain features 104d of the spacing material 104a may also be exposed at the top side of the panel element 100 and / or at the bottom side of the panel element 100 . Fig.12 The spacer material 104a is Fig.11 The types shown in . Fig.12 As shown, the depicted spacing material 104a includes four discrete spacing material elements 104e arranged side by side. In addition, a plurality of discrete spacing material elements 104e are arranged sequentially on the reel 208. For simplicity, Fig.12 The scroll 208 is omitted. Fig.12 The spacer material 104a of the embodiment includes certain portions 104d or features 104d in the form of protrusions 104d, which will become visible at the longitudinal edges of the web 216 after the web 216 is formed. Such certain features 104d can be detected during optical inspection so that the position of the discrete spacer material elements 104e of the spacer material 104a relative to the web 216 can be determined.

[0197] By making Fig.12The portions 104d or features 104d of the second substrate 104 are shaped slightly differently, so that the portions 104d or features 104d become visible at the top side of the stencil 216 after the stencil 216 is formed. The portions 104d or features 104d can then be used to synchronously apply a top coating 110, such as a decorative top coating 110. To this end, the top coating 110 (such as a decorative top coating 110) can be provided with a hole structure that is configured to be synchronously applied with the portions 104d or features 104d of the second substrate 104. In this way, errors in applying the top coating 110 can also be detected in the synchronization as deviations, offsets, or similar metrics. If the portions 104d or features 104d are visible on the top side of the stencil 216 after the stencil 216 is formed, such portions 104d or features 104d are typically removed in a subsequent processing step so that such portions 104d or features 104d are not visible in the final product. For example, if a floor panel is manufactured, certain portions 104d or features 104d may be removed when milling the complementary coupling members 103a, 103b.

[0198] By making Fig.12 By forming certain portions 104d or features 104d in the second substrate 104 slightly differently, the portions 104d or features 104d may become visible at the bottom side of the stencil 216 after the stencil 216 is formed. Certain portions 104d or features 104d may then be used to synchronously apply a bottom coating 112, such as a sound attenuating bottom coating 110. To this end, the bottom coating 112 may be provided with a hole structure that is configured to be synchronously applied with certain portions 104d or features 104d of the second substrate 104. In this way, errors in applying the bottom coating 112 may also be detected in the synchronization as deviations, offsets, or similar measures.

[0199] The spacing material 104a may include a pattern, such as a hole pattern, configured for feeding the spacing material 104a in a feeding direction in the manner of a toothed drive or wheel.

[0200] In the formation of Fig.12 After the spacer material 104a is formed on the screen 216, generally in the transverse direction T of the screen 216 and along the Fig.12 The mesh 216 is cut by a line that coincides with the transverse cutting line TC of the spacer material 104a. Generally, a plurality of cutting lines TC are repeated along the transverse direction T of the mesh 216.

[0201] Accordingly, in forming Fig.12 After the spacer material 104a is formed on the mesh 216, generally in the longitudinal direction L of the mesh 216 and along the Fig.12The longitudinal cutting lines LC of the spacer material 104a coincide with the lines cutting the stencil 216. However, a single panel element 100 may occupy the entire width of the stencil 216.

[0202] Therefore, by following the Fig.12 The line cutting screen 216 in which the transverse cutting line TC and the longitudinal cutting line LC of the spacer material 104a overlap each other can form a combined Figures 1 to 9 Thus, when the individual panel elements 100 are separated by cutting, the cuts will typically be located between the discrete spacer material elements 104e, so that the individual panel elements 100 have at least two opposing side edge portions 103 formed only by the first substrate 102. Such opposing side edge portions 103 may include cut-through portions of the support material 208a.

[0203] Another embodiment of an extrusion device configured to form a panel element may include: a first extrusion nozzle configured to provide a first extrusion stream of a composite material; and a second extrusion nozzle configured to provide a second extrusion stream of a spacer material. The second extrusion stream of the spacer material may be disposed along the entire width of the panel or may be centered on the panel so that at least two opposing side edge portions may still be formed solely from the first substrate.

[0204] That is, instead of providing the spacer material 104a in the form of a roll, the spacer material 104a can be provided via a second extrusion nozzle. When the spacer material is in the form of, for example, a free-flowing powder consisting of thin-walled hollow glass microspheres mixed with a binder or resin, this embodiment provides additional advantages, such as simplifying the manufacturing process.

[0205] Another embodiment of an extrusion device configured to form a panel element may include: a first extrusion nozzle, the first extrusion nozzle is configured to provide a first extrusion flow of a synthetic composite material; a second extrusion nozzle, the second extrusion nozzle is configured to provide a second extrusion flow of a synthetic composite material; a third extrusion nozzle, the third extrusion nozzle is configured to provide a third extrusion flow of a spacing material; and a space formed between the first extrusion nozzle and the second extrusion nozzle, the space being configured to receive the spacing material so that the first extrusion flow and the second extrusion flow are applied from opposite sides of the spacing material so that the first extrusion flow and the second extrusion flow form a first substrate, the first substrate being embedded or recessed with the spacing material forming the second substrate, thereby forming a panel element, the panel element including at least two opposite side edge portions formed only by the first substrate.

[0206] Alternatively, the second extrusion nozzle may be configured to provide a second extrusion stream of another synthetic composite material, which may be a synthetic composite material having other mechanical properties, such as density or stiffness.

[0207] That is, instead of providing the spacer material 104a in the form of a roll, the spacer material 104a can be provided through a third extrusion nozzle disposed between the first extrusion nozzle and the second extrusion nozzle. When the spacer material is in the form of, for example, a free-flowing powder composed of thin-walled hollow glass microspheres mixed with a binder or resin, this embodiment provides additional advantages, such as simplifying the manufacturing process.

[0208] Now refer to Fig.13 A method 300 of forming a panel element 100, such as a floor panel, a wall panel, a ceiling panel, or a deck panel, is described.

[0209] In a first step 302 of the method 300 , a first extruded flow EF1 of a synthetic composite material 102a is provided, the synthetic composite material 102a comprising at least 20% by weight of a mineral material.

[0210] In a second step 304 of the method 300, a second extruded flow EF2 of the resultant composite material 102a is provided.

[0211] In a third step 306 of the method 300 , a spacer material 104 a is provided.

[0212] In the fourth step 308 of method 300, a first extrusion flow EF1 and a second extrusion flow EF2 are applied from opposite sides of the spacer material 104a so that the first extrusion flow EF1 and the second extrusion flow EF2 form a first substrate 102, wherein the first substrate 102 is embedded with or recessed with the spacer material 104a forming the second substrate 104, thereby forming a panel element 100, wherein the panel element 100 includes at least two opposite side edge portions 103 formed only by the first substrate 102.

[0213] The method 300 may further include performing 310 a thickness control operation on the panel element 100 .

[0214] Another embodiment of a method for forming a panel element (such as a floor panel, wall panel, ceiling panel, or deck panel) may include: providing a first extrusion stream of a synthetic composite material, the synthetic composite material including at least 20% by weight of a mineral material; providing a second extrusion stream of the synthetic composite material; and providing a third extrusion stream of a spacer material. The first extrusion stream and the second extrusion stream are applied from opposite sides of the spacer material so that the first extrusion stream and the second extrusion stream form a first substrate, the first substrate being embedded or recessed with the spacer material forming the second substrate, thereby forming a panel element, the panel element including at least two opposing side edge portions formed only by the first substrate. When the spacer material is in the form of, for example, a free-flowing powder, the free-flowing powder being composed of thin-walled hollow glass microspheres mixed with a binder or resin, this embodiment provides additional advantages, such as simplifying the manufacturing process.

[0215] Another embodiment of a method for forming a panel element, such as a floor panel, a wall panel, a ceiling panel, or a deck panel, may include providing a first extruded stream of a synthetic composite material, the synthetic composite material comprising at least 20% by weight of a mineral material; providing a second extruded stream of another synthetic composite material having a different density, such as a synthetic composite material mixed with a free-flowing powder composed of thin-walled hollow glass microspheres. The second extruded stream of material may be disposed along the entire width of the panel, or may be disposed centrally on the panel, such that at least two opposing side edge portions may still be formed solely from the first substrate.

[0216] Although the drawings may show a specific order of method steps, the order of the steps may be different from the order depicted. In addition, two or more steps may be performed simultaneously or partially simultaneously. This change will depend on the selected software and hardware systems and the designer's choice. All such variations are within the scope of the present disclosure. In addition, even if the inventive concept has been described with reference to its specific exemplary variations, many different changes, modifications, etc. will become apparent to those skilled in the art. By studying the drawings, the disclosure, and the accompanying claims, those skilled in the art can understand and implement changes to the disclosed variations when practicing the claimed invention. In addition, in the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "one" or "an" does not exclude plural numbers.

[0217] Furthermore, it will be clear that the inventive concept is not limited to the variants shown. Therefore, numerous modifications and variations are conceivable within the scope of the invention as defined by the appended claims.

[0218] Itemized List of Exemplary Embodiments

[0219] IEE1. A panel element, such as a floor panel, a wall panel, a ceiling panel or a deck panel, comprising:

[0220] a first substrate made of a synthetic composite material comprising at least 20% by weight of a mineral material, and

[0221] a second substrate, the second substrate being made of a spacer material, the spacer material being embedded or recessed in the first substrate,

[0222] wherein the bulk density of the spacer material is lower than the bulk density of the synthetic composite material,

[0223] The panel element includes at least two opposite side edge portions formed only by the first substrate.

[0224] IEE2. A panel element according to IEE1, wherein the bulk density of the spacer material is less than 2000 kg / m 3 , preferably less than 1000 kg / m 3 .

[0225] IEE3. The panel element according to IEE1 or IEE2, wherein the width of each of at least two opposite side edge portions formed only by the first substrate is 10 mm-25 mm, preferably 15 mm-20 mm.

[0226] IEE4. A panel element according to any one of the aforementioned IEEs, wherein when the second substrate is embedded in the first substrate, the first substrate forms a top layer and a bottom layer, and the second substrate is arranged between the top layer and the bottom layer.

[0227] IEE5. A panel element according to IEE4, wherein 45%-100%, preferably 60%-95%, of the top layer and the bottom layer are supported by the second substrate.

[0228] IEE6. A panel element according to any one of the aforementioned IEEs, wherein a portion of the second substrate is exposed at a side edge of the panel element.

[0229] IEE7. A panel element according to any one of the aforementioned IEEs, wherein the spacing material of the second substrate comprises a material selected from the group consisting of: honeycomb materials, polymer foams, multiple hollow tube segments extending in parallel, glass foams, metal-containing foams, fiber-reinforced polymer materials, closed-cell PVC foams, EPS (expanded polystyrene) or EPP (expanded polypropylene), materials comprising cavities, materials comprising cavities of different geometries, free-flowing powders composed of thin-walled hollow glass microspheres, and cardboard materials.

[0230] IEE8. A panel element according to any one of the aforementioned IEEs, wherein the spacing material of the second substrate comprises an open-porous material, and the open-porous material is provided with a top layer and a bottom layer for closing the pore structure of the open-porous material.

[0231] IEE9. A panel element according to any one of the aforementioned IEEs, wherein when the second substrate is embedded in the first substrate, the spacer material is provided with a channel extending in a normal direction of a major surface of the panel, wherein the first substrate extends through the channel.

[0232] IEE10. A panel element according to any one of the preceding IEEs, wherein the at least two opposing side edge portions comprise complementary coupling members configured to couple adjacent panel elements to each other.

[0233] IEE11. A panel element according to IEE10, wherein the complementary connecting member is processed from the material of the first substrate.

[0234] IEE12. A method of forming a panel element, such as a floor panel, a wall panel, a ceiling panel or a deck panel, the method comprising:

[0235] providing a first extruded stream of a synthetic composite material comprising at least 20% by weight of a mineral material,

[0236] providing a second extruded stream of the synthetic composite material,

[0237] Provide spacer material,

[0238] The first extrusion stream and the second extrusion stream are applied from opposite sides of the spacer material so that the first extrusion stream and the second extrusion stream form a first substrate, and the first substrate is embedded or recessed with the spacer material forming the second substrate, thereby forming a panel element, and the panel element includes at least two opposite side edge portions formed only by the first substrate.

[0239] IEE13. A method according to IEE12, wherein the spacer material is provided in a roll form or a sheet form and is fed to an application point where the first extrusion stream and the second extrusion stream are applied from opposite sides of the spacer material.

[0240] IEE14. A method according to IEE12 or IEE13, wherein the spacing material is fed through the extrusion die by feeding the spacing material between a first nozzle of the extrusion die and a second nozzle of the extrusion die, the first extrusion stream and the second extrusion stream are applied from opposite sides of the spacing material in the extrusion die, the first nozzle is configured to provide the first extrusion stream, and the second nozzle is configured to provide the second extrusion stream.

[0241] IEE15. A method according to IEE14, wherein the first nozzle comprises a plurality of nozzle elements, each of which is configured to be individually controlled so that the amount of the first extrusion flow provided to the extrusion die varies over the width of the extrusion die, and / or wherein the second nozzle comprises a plurality of nozzle elements, each of which is configured to be individually controlled so that the amount of the second extrusion flow provided to the extrusion die varies over the width of the extrusion die.

[0242] IEE16. A method according to IEE12, wherein the spacer material is provided in the form of a roll and is fed to a first application point, at which the first extrusion flow is applied from a first side of the spacer material, and the spacer material is fed to a second application point, at which the second extrusion flow is applied from a second side of the spacer material, the second side of the spacer material being opposite to the first side of the spacer material.

[0243] IEE17. The method according to any one of IEE12 to IEE16, wherein a plurality of panel elements (100) are formed in a continuous process and / or a parallel process.

[0244] IEE18. A method according to any one of IEE12 to IEE17, wherein the spacing material is provided in the form of a plurality of discrete spacing material elements, and the plurality of discrete spacing material elements are connected by a supporting material.

[0245] IEE19. The method according to any one of IEE12 to IEE18, further comprising:

[0246] A thickness control operation is performed on the panel element.

[0247] IEE20. A method according to IEE19, wherein the thickness control operation comprises feeding the panel element through a roller gap formed between two thickness control rollers.

[0248] IEE21. An extrusion device, the extrusion device being configured to form a panel element according to any one of IEE1 to IEE11, the device comprising:

[0249] a first extrusion nozzle configured to provide a first extrusion stream of a synthetic composite material,

[0250] a second extrusion nozzle configured to provide a second extrusion stream of the composite material, and

[0251] A space is formed between the first extrusion nozzle and the second extrusion nozzle, and the space is configured to receive a spacer material so that the first extrusion stream and the second extrusion stream are applied from opposite sides of the spacer material so that the first extrusion stream and the second extrusion stream form a first substrate, and the first substrate is embedded or recessed with the spacer material forming the second substrate, thereby forming the panel element, and the panel element includes at least two opposite side edge portions formed only by the first substrate.

[0252] IEE22. A panel element, such as a floor panel, a wall panel, a ceiling panel or a deck panel, comprising:

[0253] a first substrate, the first substrate being made of a free-flowing powder, the free-flowing powder being composed of thin-walled hollow glass microspheres,

[0254] The panel element includes at least two opposite side edge portions formed by the first substrate.

[0255] The at least two opposing side edge portions may be formed of only the first substrate.

[0256] IEE23. A panel element according to IEE22, wherein a width of each of at least two opposite side edge portions formed by the first substrate is 10 mm-25 mm, preferably 15 mm-20 mm.

[0257] IEE24. A panel element according to any one of IEE22 to IEE23, wherein the at least two opposing side edge portions comprise complementary coupling members configured to couple adjacent panel elements to each other.

[0258] IEE25. A panel element according to IEE24, wherein the complementary connecting member is processed from the material of the first substrate.

[0259] IEE26. A method of forming a panel element, such as a floor panel, a wall panel, a ceiling panel or a deck panel, the method comprising:

[0260] providing a first extruded stream of a synthetic composite material comprising at least 20% by weight of a mineral material,

[0261] providing a second extrusion stream of the synthetic composite material,

[0262] providing a third extrusion stream of spacer material,

[0263] The first extrusion stream and the second extrusion stream are applied from opposite sides of the spacer material so that the first extrusion stream and the second extrusion stream form a first substrate, and the first substrate is embedded or recessed with the spacer material forming the second substrate, thereby forming the panel element, and the panel element includes at least two opposite side edge portions formed only by the first substrate.

[0264] IEE27. A method of forming a panel element, such as a floor panel, a wall panel, a ceiling panel or a deck panel, the method comprising:

[0265] providing a first extruded stream of a synthetic composite material comprising at least 20% by weight of a mineral material, and

[0266] A second extrusion stream of material having a different density is provided. The second extrusion stream of material may include a material selected from the group consisting of: polymer foam, synthetic composite foam, glass foam, metal-containing foam, fiber-reinforced polymer material, closed-cell PVC foam, EPS (expanded polystyrene) or EPP (expanded polypropylene), material including cavities, material including cavities of different geometries, free-flowing powder consisting of thin-walled and hollow glass microspheres.

[0267] The method may include forming a panel element including at least two opposing side edge portions formed only from the first substrate.

[0268] IEE28. An extrusion device configured to form a panel element, the device comprising:

[0269] a first extrusion nozzle configured to provide a first extrusion stream of a synthetic composite material,

[0270] a second extrusion nozzle configured to provide a second extrusion stream of the synthetic composite material,

[0271] a third extrusion nozzle configured to provide a third extrusion stream of spacer material, and

[0272] A space is formed between the first extrusion nozzle and the second extrusion nozzle, and the space is configured to receive the spacer material so that the first extrusion stream and the second extrusion stream are applied from opposite sides of the spacer material, so that the first extrusion stream and the second extrusion stream form a first substrate, and the first substrate is embedded or recessed with the spacer material forming the second substrate, thereby forming the panel element, and the panel element includes at least two opposite side edge portions formed only by the first substrate.

Claims

1. A panel element (100), such as a floor panel, a wall panel, a ceiling panel or a deck panel, comprising: a first substrate (102) made of a synthetic composite material (102a) comprising at least 20% by weight of a mineral material, and a second substrate (104), the second substrate being made of a spacer material (104a), the spacer material being embedded or recessed in the first substrate (102), wherein the bulk density of the spacer material (104a) is lower than the bulk density of the synthetic composite material (102a), The panel element (100) comprises at least two opposite side edge portions (103) formed only by the first substrate (102).

2. The panel element (100) according to claim 1, wherein the bulk density of the spacer material (104a) is less than 2000 kg / m 3 , preferably less than 1000 kg / m 3 .

3. The panel element (100) according to claim 1 or 2, wherein the width of each of the at least two opposite side edge portions (103) formed only by the first substrate (102) is 10 mm-25 mm, preferably 15 mm-20 mm.

4. A panel element (100) according to any one of the preceding claims, wherein when the second substrate (104) is embedded in the first substrate (102), the first substrate (102) forms a top layer (106) and a bottom layer (108), and the second substrate (104) is arranged between the top layer and the bottom layer.

5. The panel element (100) according to any one of the preceding claims, wherein a portion (104b) of the second substrate (104) is exposed at a side edge of the panel element (100).

6. A panel element (100) according to any of the preceding claims, wherein the spacer material (104a) of the second substrate (104) comprises a material selected from the group consisting of: honeycomb materials, polymer foams, a plurality of hollow tube segments extending in parallel, glass foams, metal-containing foams, fiber-reinforced polymer materials, closed-cell PVC foams, EPS (expanded polystyrene) or EPP (expanded polypropylene), materials comprising cavities, materials comprising cavities of different geometries, free-flowing powders consisting of thin-walled hollow glass microspheres, and paperboard materials.

7. The panel element (100) according to any one of the preceding claims, wherein the spacing material (104a) of the second substrate (104) comprises an open-porous material, the open-porous material being provided with a top layer (104t) and a bottom layer (104b) for closing a pore structure of the open-porous material.

8. A panel element (100) according to any one of the preceding claims, wherein when the second substrate (104) is embedded in the first substrate (102), the spacer material (104a) is provided with a channel (104c) extending in a normal direction to a major surface of the panel (100), wherein the first substrate (102) extends through the channel (104c).

9. A panel element (100) according to any one of the preceding claims, wherein the at least two opposing side edge portions (103) comprise complementary coupling members (103a, 103b) configured to couple adjacent panel elements (100) to each other.

10. A method (300) of forming a panel element (100), such as a floor panel, a wall panel, a ceiling panel or a deck panel, the method (300) comprising: providing (302) a first extruded stream (EF1) of a synthetic composite material (102a), the synthetic composite material comprising at least 20% by weight of a mineral material, providing (304) a second extruded flow (EF2) of the synthetic composite material (102a), providing (306) a spacer material (104a), The first extrusion flow (EF1) and the second extrusion flow (EF2) are applied (308) from opposite sides of the spacing material (104a) so that the first extrusion flow and the second extrusion flow (EF1, EF2) form a first substrate (102), and the first substrate is embedded or recessed with the spacing material (104a) forming the second substrate (104), thereby forming the panel element (100) including at least two opposite side edge portions (103) formed only by the first substrate (102).

11. The method (300) of claim 10, wherein the spacer material (104a) is provided in roll form (208) or sheet form (104f) and is fed to an application point (AP) where the first and second extrusion flows (EF1, EF2) are applied from opposite sides of the spacer material (104a).

12. The method (300) according to claim 10 or 11, wherein a plurality of panel elements (100) are formed in a continuous process and / or in a parallel process.

13. The method (100) according to any one of claims 10 to 12, wherein the spacer material (104a) is provided in the form of a plurality of discrete spacer material elements (104e), the plurality of discrete spacer material elements being connected by a support material (208a).

14. The method (300) according to any one of claims 10 to 13, further comprising: A thickness control operation is performed (310) on the panel element (100).

15. An extrusion device (200) configured to form a panel element (100) according to any one of claims 1 to 9, the device (200) comprising: a first extrusion nozzle (202) configured to provide a first extrusion flow (EF1) of a composite material (102a), a second extrusion nozzle (204) configured to provide a second extrusion flow (EF2) of the composite material (102a), and A space (206) is formed between the first extrusion nozzle (202) and the second extrusion nozzle (204), and the space (206) is configured to receive a spacer material (104a), so that the first extrusion flow and the second extrusion flow (EF1, EF2) are applied from opposite sides of the spacer material (104a), so that the first extrusion flow and the second extrusion flow (EF1, EF2) form a first substrate (102), and the first substrate is embedded or recessed with the spacer material (104a) forming the second substrate (104), thereby forming the panel element (100) including at least two opposite side edge portions (103) formed only by the first substrate (102).

Images