Extruded panels and methods of making same

Abstract

The invention relates to extruded panels and to a method for producing such panels. The invention relates in particular to a floor, ceiling or wall panel produced by extrusion, comprising at least one channel formed by extrusion, tongue and groove coupling profiles on at least two opposite edges of the panel, said coupling profiles being integrated with the core material of the panel.

Description

Technical Field

[0001] The present invention relates to extruded panels and to a method of manufacturing such panels. The invention particularly relates to a floor panel, ceiling panel or wall panel produced by extrusion, comprising at least one channel formed by extrusion, a tongue and groove coupling profile on at least two opposite edges of the panel, wherein the coupling profile is integral with its core material. The invention also relates to a panel covering, such as a floor covering or a wall covering consisting of a plurality of interlocking panels according to the invention. Background Art

[0002] As is known, the paneling industry has been growing significantly over the years. For example, floor panel installation has gained wide acceptance. The installation methods and materials used vary depending on indoor and / or outdoor use. Using wood as a core material for indoor and / or outdoor paneling is more expensive and more difficult to maintain. Using synthetic materials is cheaper, but it leads to a less environmentally friendly manufacturing. In particular, the use of composite materials as a core material for paneling has gained a lot of popularity in recent years, as it is weather-resistant, cost-effective and more environmentally friendly. Some installation techniques are considered to be more complicated, as it is known that floor panels are installed by gluing or nailing them to the subfloor, which also makes it more difficult to remove the installed floor panels. According to the proposed invention, floor panels can be loosely installed on the subfloor or supporting structure, whereby the floor panels are matched to each other by tongue and groove joints. The floor obtained in this way is also called floating floor, which has the advantage that it is not difficult to install and the entire surface can be easily moved, which is usually possible, in order to withstand the expansion and contraction phenomena that may occur due to changes in weather, temperature, humidity, etc. Summary of the invention

[0003] The object of the present invention is to overcome these drawbacks and to provide a lighter, more environmentally friendly and more cost-effective panel having a relatively effective coupling profile that allows interlocking in horizontal and vertical directions. Another object is to provide a panel formed by extrusion, comprising at least one channel in the core of the panel and at least a portion of the coupling profile also formed by extrusion, which allows manufacturing scalability and requires relatively little maintenance, without affecting the strength and quality of the panel.

[0004] To this end, the invention proposes a panel, in particular a floor panel, a ceiling panel or a wall panel, comprising: an extruded core having an upper side and a lower side on opposite sides of the core, wherein the core comprises at least an extruded polymer material, a coupling profile arranged on at least two opposing edges of the core, wherein the coupling profile is preferably integrated with the core, wherein the coupling profile is designed to interlock in horizontal direction and / or vertical direction, preferably in both directions, with a coupling profile of an adjacent panel having a tongue and groove coupling profile, and Therein, the core comprises at least one channel extending in the extrusion direction, wherein the at least one channel is arranged at a distance from the lower side and / or the upper side.

[0005] The panel according to the invention has several advantages. A first advantage is that the weight per square meter of the top surface of the panel is relatively low, resulting in a lightweight panel, which is beneficial from an economic, environmental and logistical point of view. The relatively low weight of the panel is achieved by applying at least one extruded channel extending in the extrusion direction, wherein at least one channel is arranged at a distance from the underside and / or the upper side of the panel, which reduces the amount of material used in the core and thus in the panel.

[0006] Preferably, the channel is located at a distance from at least two panel edges, more preferably, at a distance from the connection profile positioned at the panel edge. In this way, the connection profile will not be weakened by the channel, so the connection profile can be shaped in a relatively strong (unweakened) manner. Preferably, the panel is an elliptical panel, more preferably an elliptical, rectangular panel. Such an elliptical panel generally includes two longitudinal edges and two transverse edges. In the production process of the panel, the extrusion direction is generally (but not necessarily) parallel to the longitudinal edge. The latter allows to form (shape) at least a portion of the connection profile located at the longitudinal edge of the panel during the extrusion process. The connection profile may also be located at the transverse edge (usually the short edge) of the panel. All sides of the panel may be equipped with a connection profile. Preferably, the connection profile located at the opposite panel edge is shaped in a complementary manner to allow the pair of complementary connection profiles of adjacent panels to interact. The panel may be square or have other polygonal shapes, such as triangles, hexagons or octagons or parallelograms.

[0007] Preferably, the method for producing such a panel is achieved by extrusion. This is another advantage of not forming the panel mechanically (e.g., by milling), so that the generation of undesirable dust particles will not be caused during the panel forming process. These dust particles not only pollute the production environment and also pollute the core, and therefore also pollute the panel, but also bring unnecessary health risks to the production workers. In addition, replacing milling with extrusion will also reduce material waste, which is beneficial from an environmental and economic point of view. For panel manufacturers, large-scale production of these panels is also relatively more efficient and more economical. The panel according to the present invention can be used as indoor (interior) panel and / or outdoor (exterior) panel.

[0008] The panels according to the invention are usually elongated, wherein the profile with the connecting profile along the long sides of the panel is formed by extrusion and is formed along the extrusion direction. Therefore, the extrusion direction can also be the longitudinal direction of the panel. The shape of the long sides of the panel is formed during the extrusion process, wherein usually no short sides are formed during the extrusion process. The short sides can be shaped, for example, by milling after extrusion, or can remain unmilled and only cut to the required panel length.

[0009] Horizontal and vertical directions may also refer to directions within a panel plane (for horizontal floor or ceiling panels, for vertical wall panels) and directions perpendicular to this plane (for vertical floor or ceiling panels, for horizontal wall panels).

[0010] The coupling profiles at the edges of the opposing panels are preferably complementary and are usually configured to achieve at least one tongue-and-groove connection. Preferably, at least one pair of coupling profiles of the panels are configured to couple by a tilting or rotational movement. In such a movement, the tongue of a first coupling profile of one panel is placed at an angle in the groove of a second coupling profile of an adjacent panel and then an angular movement is performed to complete the coupling of the two panels. Such coupling systems have been around for a long time in conventional (wood) floors and provide an intuitive coupling method for coupling panels.

[0011] The core according to the present invention may include an extrudable polymer material, wherein, preferably, the core includes a composite material, the composite material including at least one polymer, particularly a thermoplastic material and / or a thermosetting material, and at least one non-polymer material. Examples of such extrudable polymer materials include, but are not limited to, ethylene-vinyl acetate (EVA)--it is a copolymer of ethylene and vinyl acetate, rubber, polyurethane (PU)--particularly thermoplastic polyurethane (TPU), polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyethylene terephthalate (PET), or a mixture thereof. Similarly, in the case of using another thermoplastic material, this material can be applied in the core in a foamed state to reduce density and cost. For example, PS can be in the form of expanded PS (EPS), to further reduce the density of the panel, thereby saving costs and facilitating the processing of the panel. However, it is also conceivable that the thermoplastic material used as the main polymer is a solid polymer (i.e., an unfoamed polymer). Preferably, at least a portion of the polymer used can be formed by recycled thermoplastics, such as recycled PVC and / or recycled TPU and / or recycled PET. It is conceivable that a mixture of virgin and recycled thermoplastic materials is used to form at least a portion of the core. In a preferred embodiment, the core may contain at least 20% of its weight of thermoplastic material, preferably (recycled) thermoplastic material between 20% and 100% of its weight. The weight ratio between virgin thermoplastic material and recycled thermoplastic material is preferably less than 4 (i.e., at least 20% by weight is formed by recycled thermoplastic material). Instead of thermoplastic material, thermosetting polymers such as thermosetting polyurethanes can also be used. The core may include at least one plasticizer to increase the flexibility of the panel. The composite of the core layer preferably includes one or more fillers, wherein these fillers are made of non-polymer materials. Examples of such non-polymer materials include, but are not limited to, talc, chalk, wood, calcium carbonate, titanium dioxide, calcined clay, ceramics, glass particles, carbon particles, silicon particles, (another) mineral filler, (another) natural filler, cellulose-based particles, coconut, Kevlar fiber, nylon, perlite, rock wool, bamboo, sisal, fir, (another) (auxiliary) polymer, such as elastomer and / or latex. It is also conceivable that rubber and / or elastomer parts (particles) are dispersed in the composite material in order to increase flexibility and / or impact resistance at least to a certain extent. The core can (thus) be rigid, semi-flexible or flexible and can thus become a floor covering element. The filler can be formed by fibers, such as glass fibers or synthetic fibers or leather fibers, and / or can be formed by dust-like particles. Here, the term "dust" is understood to mean small dust-like particles (powders), such as bamboo powder, wood powder, cork powder or non-wood powders, such as mineral powder, stone powder, in particular cement, and combinations thereof. The average particle size of the dust is preferably between 14 and 20 microns, more preferably between 16 and 18 microns.This may further increase the strength of the panel and / or the water resistance and / or fire resistance of the panel and / or may reduce the cost price of the panel.

[0012] During the extrusion process, it is conceivable that the core is provided with at least two regions of different composition. For example, such regions can be obtained by coextrusion. Different compositions in different regions may lead to mutually different characteristics, for example in terms of elasticity, color, adhesion, surface smoothness, processability, etc. The purpose is that different compositions in the core layer can lead to a better sound-absorbing effect of the panel, and in combination with the channels extruded therefrom, a better acoustic effect can be achieved in the area where such panel is applied. For example, in indoor and / or outdoor situations, walking sounds (but not limited to) and any other sounds can be better absorbed by the coextruded core composition. For example, the different compositions in different regions may depend on different ratios between polymer materials, in particular thermoplastic materials (such as PVC and / or PET) and non-polymer materials, in particular fillers, more particularly mineral fillers (such as chalk). For this purpose, for example, it is conceivable that the core layer is relatively hard or rigid, while another layer, preferably located below the core layer during normal use, is relatively flexible or soft. It may be beneficial that the coupling profile is coextruded, because the softer side of the core can increase flexibility, so that the stress pressure during the coupling process is less, which may lead to a more durable coupling profile. Alternatively, when possibly extruded, the core may partly consist of another substrate, for example a mineral material such as magnesium oxide, magnesium hydroxide, gypsum, (lightweight) concrete and / or clay; and / or wood or wood-based materials such as HDF or MDF, or any other non-thermoplastic material, may be used as substrate. In a preferred embodiment, the core has an area density of less than 9000 g / m 2 , preferably less than 6000g / m 2 , more preferably about 5000 g / m 2 .

[0013] Preferably, a satisfactory panel comprises at least one or more channels, each of which is surrounded by at least one core material at the top and bottom, wherein the volume of at least one channel preferably accounts for at least 20% of the core volume, more preferably 30%-40% of the core volume. The channel in the present invention may refer to a hollow portion surrounded by a core material, wherein the hollow portion is located between opposite sides including a connecting profile and does not intersect with any connecting profile. This is feasible for maintaining the appropriate rigidity and structural performance of the core, so that the panel is light in weight but still has high functionality and strength, thereby reducing costs.

[0014] Preferably, at least one channel, more preferably each channel is connected to (to) opposite side edges. This results in a channel with an open end face. The channel can not only save weight, but can also be used functionally, for example for drainage and / or for accommodating (electrical) cables and / or wires. Thus, at least one channel can be equipped with at least one cable and / or at least one wire. At least one cable and / or at least one wire can constitute an integral part of the panel and / or can be fixed in at least one channel. It is conceivable that the channel is completely filled with cable material and / or wire material.

[0015] Ideally, when the panel comprises a plurality of channels, one channel may be located next to another channel or on top of each other, while comprising the same or different shapes to each other. In general, a hollow core is one of the most sustainable products in construction and / or installation. It is also conceivable that at least one core groove is filled with at least one solid and / or liquid material. Preferably, this filling material is cheaper than the polymers and / or other ingredients (additives) used in the core. Examples of cheap filling materials are solid wood, sawdust, sawdust, wood fiber, hemp fiber, bamboo and mineral fillers such as chalk (calcium carbonate). By at least partially filling at least one core groove, preferably filling all core grooves, the panel has different properties, such as increasing the noise reduction effect.

[0016] Preferably, the core comprises a plurality of core layers. At least two of these core layers may have different compositions (as described above) and / or may have the same composition. The core layers are stacked one on top of the other. Preferably, this multilayer core is manufactured by coextrusion and / or calendering. Preferably, during the manufacturing process, for example during extrusion and / or calendering, at least one first core layer is provided with a channel substrate, wherein at least one side (upper side and / or lower side) of the first core layer is patterned to define the position, length and width of the channel. In a subsequent step, the patterned side of the first core layer may be covered by at least one second core layer to ultimately define the channel and close (embed) the channel into the core. For example, the bonding of the core layers may be achieved by coextrusion and / or calendering, wherein at least one core layer, typically all core layers, is preferably sufficiently soft (softened) and / or sticky to allow the core layers to bond to each other, typically by melting (therefore without using a separate adhesive) bonding to each other. The second core layer may also be patterned, and may be patterned, for example, by providing a complementary pattern, although it is also conceivable that the second core layer and / or the side of the second core layer facing the first core layer is flat (therefore not patterned). The preferably closed peripheral wall of each channel is in this case defined by a plurality of core layers.If the core consists of a single layer, the preferably closed peripheral wall of each channel is defined by the core material of said single layer.

[0017] Preferably, at least one channel, more preferably each channel has a curved, in particular circular or elliptical cross section, or a polygonal cross section, such as a triangular, square, pentagonal, hexagonal, rhombus, quadrilateral and / or octagonal cross section. At least two channels of the panel can have the same shape and / or mutually different shapes. At least two channels of the panel can have the same size and / or mutually different sizes.

[0018] It is conceivable that the upper side and / or the bottom side of the core comprises an extruded groove or a plurality of substantially parallel extruded grooves, whereby such a surface can, for example, provide a non-slip form suitable for outdoor decks, and / or wherein one or more grooves or other recesses applied in the panel (preferably applied on the bottom side of the panel) can be configured and / or used to cooperate with a separate locking profile and / or a separate locking strip and / or a separate coupling element to fix the panel to a lower support structure, which can, for example, be formed by a frame and / or one or more beams, such as extruded beams made of metal (such as aluminum) and / or thermoplastic material. Each frame and / or each beam preferably (also) comprises one or more locking grooves to allow a separate locking profile and / or a separate locking strip and / or a separate coupling element to be coupled to the frame and / or beam. This allows a separate locking profile and / or a separate locking strip and / or a separate coupling element to mechanically connect one or more panels to a lower support structure, such as a frame and / or one or more beams. One or more separate locking profiles and / or separate locking strips and / or separate coupling elements can constitute part of a panel covering according to the invention. The same applies to the lower supporting structure, if applied, and in this case this is mechanically connected to the panel or panels according to the invention by means of one or more separate locking profiles and / or separate locking strips and / or separate coupling elements.

[0019] Outdoor decks may become slippery and dangerous when wet, icy or snowy, so a non-slip surface may be more suitable to improve safety. Therefore, even when wet, the outdoor deck area composed of the extruded panels can still be entered. For the above reasons, extrusion is the preferred production method, so the substantially elongated grooves are preferably formed by extrusion in the same extrusion direction as the core and / or channel extrusion. It is conceivable that at least a portion of the surface grooves may include at least one non-slip insert, preferably two non-slip inserts. In a preferred embodiment, a decorative pattern and / or color pigment may be applied to at least the upper side of the core.

[0020] In another preferred embodiment, it is conceivable that at least one decorative top structure, in particular a decorative floor layer, a decorative ceiling layer or a decorative wall layer, is directly or indirectly attached to the upper side of the core. Preferably, at least one decorative top structure at least partially covers the upper side of the core and optionally at least partially covers one or more side edges of the core. Preferably, the decorative top structure comprises at least one preferably printed, more preferably digitally printed decorative layer and at least one protective layer covering the decorative layer.

[0021] The decorative layer may include a decorative print or any decorative structure attached directly or indirectly to the decorative side of the core, and at least one transparent wear layer covering the decorative surface as a protective layer. The decorative top structure is preferably formed by a printed thermoplastic or paper film and includes at least one backing layer between the decorative layer and the core layer, wherein the backing layer is preferably made of a vinyl compound. A paint layer or other protective layer may be applied on top of the wear layer. A finishing layer may be applied between the decorative layer and the wear layer. The decorative layer will be visible and will be used to provide an attractive appearance for the panel. To this end, the decorative layer may have a design pattern, such as a wood grain design, a mineral texture design similar to marble, granite or any other natural stone texture, or a color pattern, a color mixture or a monochrome pattern, to name just a few design possibilities. In the panel production process, a customized appearance, usually achieved by digital printing, is also conceivable. The decorative print or any decorative structure may also be formed by an ink layer, preferably a UV-based ink layer, printed directly or indirectly (preferably digitally) on the core.

[0022] Preferably, the panel thickness is between 3 and 30 mm, preferably 4 and 27 mm.

[0023] The panels may comprise coupling profiles, wherein at least one coupling profile, preferably all coupling profiles, is at least partially formed by the core. The panel preferably comprises a pair of first panel edges and an opposite second panel edge, the first panel edge comprising a first coupling profile, the second panel edge comprising a second coupling profile, the second coupling profile being designed to interlock with the first coupling profile of an adjacent panel, typically in a tongue-and-groove connection. Such coupling is preferably such that the coupled panels are locked relative to each other in a horizontal and / or vertical direction, preferably in both directions. The first coupling profile of the first panel edge preferably comprises a lateral tongue extending in a direction substantially parallel to the upper side of the panel, wherein the second coupling profile of the second panel edge preferably comprises a groove or recess for accommodating at least a portion of the lateral tongue of an adjacent panel. The recess is preferably defined by an upper lip and a lower lip, the upper lip comprising a recess formed by extrusion, and the lateral tongue is designed to be locked by an introduction movement in the recess of the lateral tongue and a downward tilting movement around an axis parallel to the first edge, as a result of which a projection on the top side of the lateral tongue will engage with the upper lip, thereby locking the adjacent panels at the first and second edges in the horizontal direction and in the vertical direction. It is conceivable that each first coupling profile is compatible with each second coupling profile and can therefore interact and interlock. It is conceivable that each male coupling profile is compatible with each female coupling profile and can therefore interact and interlock. It is conceivable that at least one coupling profile is compatible with at least two different other coupling profiles of adjacent panels and can therefore interact and interlock. This also applies to the case where the interlocking coupling profiles do not have completely complementary shapes.

[0024] In a preferred embodiment, the at least one first coupling profile comprises: a lateral tongue extending in a direction substantially parallel to a plane defined by the panels, wherein an upper side of the lateral tongue preferably comprises at least one first locking element, such as an upwardly protruding locking element; and wherein at least one second coupling profile comprises: a groove configured to accommodate at least a portion of a lateral tongue of at least one first coupling profile of an adjacent panel, the groove being defined by an upper lip and a lower lip, wherein the lower lip extends beyond the upper lip, and wherein the underside of the upper lip preferably comprises at least one second locking element, such as a downwardly facing recess, which is configured to face the first locking element of an adjacent panel in the coupled state of the panels and preferably cooperates with the first locking element to interlock the panels in a horizontal direction.

[0025] By at least partially inserting a lateral tongue of a panel into a groove of an adjacent panel, a locking effect in the vertical direction is achieved. Preferably, the first and second coupling profiles are configured such that the two panels can be coupled to each other by a rotational movement and / or a translational movement, preferably in a horizontal plane, wherein, in the coupled state: at least a portion of the lateral tongue of a first panel is inserted into a groove of an adjacent second panel, and wherein at least one second locking element of the first panel faces the first locking element of the adjacent panel and preferably cooperates with the first locking element of the adjacent panel to interlock the two panels in the horizontal and vertical direction.

[0026] The lower lip preferably comprises an inner section located directly below the upper lip and a connected outer section extending beyond an outer vertical plane defined by the upper lip, wherein the maximum height of the inner section equals or exceeds the maximum length of the outer section. Thus, the upper surface of the lower lip is preferably substantially planar. However, it is conceivable that said upper surface of the lower lip, preferably the outer section of the lower lip, comprises at least one upward drainage groove. Such a drainage groove (further) contributes to the drainage of water, for example water penetrating between the coupling profiles.

[0027] Preferably, the lower lip of the panel is configured to engage with a stop surface of the second profile of an adjacent panel in the coupled state of the panels, wherein the stop surface is located at a lower level than the lateral tongue. The stop surface typically preferably ensures a minimum distance between the tops of the interlocking panels, which typically results in an open seam at the tops between the interlocking panels, which facilitates the drainage capacity of a covering at least partially formed by the interlocking panels. Preferably, the first coupling profile comprises a first top located above the lateral tongue, wherein the first top preferably extends in a substantially vertical direction, and wherein the outer end of the upper lip defines a second top, wherein the second top preferably extends in a substantially vertical direction, and wherein, in the coupled state of the panels, the second top is configured to face the first top of the adjacent panel. As described above, such an open (top) seam improves the drainage capacity of a covering at least partially formed by the interlocking panels.

[0028] The stop surface is preferably a vertical stop surface. The distal surface of the lower lip is configured to cooperate with the stop surface of another panel, preferably oriented substantially vertically, which generally easily leads to a stable abutment of two substantially vertical surfaces. Preferably, the underside of the panel is provided with a longitudinal cutout portion, which is connected and parallel to the first edge, for accommodating each lower lip in the coupled state of the adjacent panels. The cutout portion is preferably defined in part by the stop surface and in part by a connecting horizontal portion of the underside of the panel.

[0029] Preferably, the first locking element comprises a projection and / or a recess, and wherein the second locking element comprises a projection and / or a recess. The projection is generally adapted to be at least partially accommodated in a recess of an adjacent coupling panel to achieve a locking connection, preferably a vertical locking connection. The curved recess in the upper lip and / or the lower lip is preferably formed by an extrusion method and is substantially parallel to the extrusion direction, so that such a recess is complementary and compatible with the projection on the top side or bottom side of the lateral tenon, and is therefore technically difficult to achieve by milling technology. The projection of another panel arranged adjacently is guided by the curved recess of the panel. Due to its shape, the projection can withstand relatively strong forces without damage. The projection and recess connection plays an important role as a locking element for horizontally interlocking the panel with the adjacent panel, after which the panel and the adjacent panel can be interlocked in the horizontal and vertical directions by all elements of the coupling profile.

[0030] The first locking element is preferably formed by at least one projection and the second locking element is preferably formed by at least one recess to at least partially accommodate the at least one projection. The result of this embodiment is a more solid and therefore stronger lateral tenon. Preferably, the projection and / or the recess preferably have a rounded triangular shape, usually with two right-angled sides connected by a rounded vertex. The curvature of the vertices of the projection and the recess may be the same, wherein preferably, the radius defining the vertices of the projection exceeds the radius defining the vertices of the recess. This makes the projection less sharp and therefore less prone to breakage. An opposite embodiment can also be imagined, in which the first locking element can be formed by at least one recess and the second locking element can be formed by at least one projection to at least partially accommodate the at least one projection. Other combinations of alternative locking elements and / or projections and recesses can also be envisaged as the first locking element and the second locking element.

[0031] Preferably, at least one lower lip is provided with at least one curved side edge, preferably, two curved side edges are provided, as seen from a top view of the lower lip. Such curved side edges make the lower lip generally less susceptible to damage and / or breakage. The lower lip is generally used to support the lateral tenon in the coupled state of adjacent panels. Preferably, in the coupled state of adjacent panels, the lateral tenon is supported by said inner section and said outer section of the lower lip. Preferably, a distal portion of the lower side of the lateral tenon below the first locking element, such as said first locking element, which is preferably formed by at least one protrusion, is at least partially inclined upwards towards the outer end of the lateral tenon. This inclination creates space that facilitates coupling of the coupling profile, in particular facilitates the oblique entry of the lateral tenon into the groove. The outer end of the lateral tenon is preferably substantially vertical, which generally contributes to the robustness of the lateral tenon.

[0032] Preferably, at least one lateral tongue has at least one curved and / or beveled (inclined) side edge, preferably preferably two curved and / or beveled (inclined) side edges seen in a top view of the lateral tongue. These one or more side edges can be used as guide surfaces for aligning the panel relative to the supporting structure.

[0033] At least two first connection profiles, in particular from a cross-sectional view, can be identical. Additionally or alternatively, at least two first connection profiles, in particular from a cross-sectional view, are different from each other. At least two first connection profiles, in particular from a top view, are mirror-symmetrical first connection profiles. In this embodiment, the mirror-symmetrical first connection profiles are preferably separated by an intermediate section, in particular a drainage section, which makes two adjacent first connection profiles look like interrupted larger first connection profiles divided into two smaller first connection profiles. The (imaginary) larger first connection profile can have the same length (from the direction of the first edge) as another (undivided) first connection profile located at the first edge. The same applies to the second connection profile, which can be the same and / or deviated connection profile. At least two second connection profiles, in particular from a top view, can be mirror-symmetrical second connection profiles.

[0034] Preferably, the connecting profile constitutes an integral part of the panel, in particular the core of the panel. More preferably, the connecting profile is at least partially formed by extrusion, preferably simultaneously with at least one layer of the panel, such as the core layer. Thus, the layer and the connecting profile can be made from one piece of material. It is well conceivable that after extrusion, the connecting profile is milled and / or otherwise formed into its final shape (also in a length direction parallel to the first and second side edges).

[0035] Alternatively and / or additionally, the panel may be arranged in combination with a tilting (downward) movement. Such a movement may also be referred to as a rotational movement, wherein a portion of a new panel is inserted into a portion of an already placed and fully inserted panel by means of a tilting movement. In a preferred embodiment, the panel comprises at least one third coupling profile and at least one fourth coupling profile arranged on another pair of opposite sides of the panel, wherein the third coupling profile of the panel and the fourth coupling profile of the other panel are preferably arranged to be coupled by means of a downward tilting movement. Preferably, the third connecting profile comprises: a lateral tongue extending in a direction substantially parallel to the upper side of the core, at least one second downward wing at a certain distance from the lateral tongue, and a second downward groove formed between the lateral tongue and the second downward wing, wherein the fourth connecting profile comprises: a third groove configured to accommodate at least a portion of the lateral tongue of the third connecting profile of an adjacent panel, the third groove being defined by an upper lip and a lower lip, wherein the lower lip is provided with an upward locking element, wherein the third connecting profile and the fourth connecting profile are formed so that two such panels can be connected to each other by a rotational movement, wherein, in the connected state: at least a portion of the lateral tongue of a first panel is inserted into the third groove of an adjacent second panel, and wherein at least a portion of the upward locking element of the second panel is inserted into the second downward groove of the first panel.

[0036] In one embodiment, the panel comprises a first coupling profile and a second coupling profile at least at a first pair of opposite edges, allowing that a plurality of such panels can be coupled to each other, whereby in case of coupling of two such panels these coupling profiles provide locking in a first direction (R1) perpendicular to the plane of the panels and in a second direction (R2) perpendicular to the respective edge and parallel to the plane of the panels, wherein the first coupling profile comprises a lateral tongue, wherein the lateral tongue comprises a front region and a rear region, wherein a top surface of the front region is preferably at least partially inclined downwards in a direction away from the rear region, and wherein a bottom surface and / or a side surface of the rear region of the lateral tongue defines a first contact portion, and wherein the lateral tongue comprises a passivated bottom surface located adjacent to the first contact portion,

[0037] wherein the second coupling profile comprises a recess (or groove) for accommodating at least a portion of a lateral tongue of the other panel, the recess being defined by an upper lip and a lower lip, wherein the lower lip extends beyond the upper lip, and wherein the lower lip is provided with an upwardly protruding shoulder, which shoulder defines a second contact portion, which second contact portion is configured to cooperate, in particular actively cooperate, with the first contact portion of the other panel in the coupled state of the panels, such that the panels exert a force, in particular a tensile force (T1), at least laterally towards each other, wherein the top surface of the lower lip is at least partially curved, in particular smoothly curved, and wherein the at least partially curved top surface of the lower lip and the blunt bottom surface of the lateral tongue are positioned relative to each other such that in the coupled state of the two panels an intermediate space is present near the actively cooperating first and second contact portions, and wherein the lower surface of the upper lip is preferably at least partially inclined and configured to abut at least a portion of the top surface of a front area of ​​the lateral tongue of the other panel. These coupling profiles may be used instead of or in combination with other coupling profiles.

[0038] At least one pair of opposite edges of the panel (usually formed by the third edge and the fourth edge) can be completely free of a joining profile. In this case, these opposite edges are defined by substantially vertical end faces.

[0039] In one embodiment of the panel according to the present invention, at least one pair of connecting profiles comprises a third connecting profile and a fourth connecting profile, the third connecting profile comprising an upward tongue, at least one upward wing at a certain distance from the upward tongue, and an upward groove formed between the upward tongue and the upward wing, wherein the upward groove is suitable for receiving at least a portion of a downward tongue of a second connecting profile of another panel, wherein a side of the upward tongue facing the upward wing is an inner side of the upward tongue, and a side of the upward tongue facing away from the upward wing is an outer side of the upward tongue; wherein the second connecting profile comprises a downward tongue, at least one downward wing at a certain distance from the downward tongue, and a downward groove formed between the downward tongue and the downward wing, wherein the downward groove is suitable for receiving at least a portion of the upward tongue of the third connecting profile of another panel, wherein a side of the downward tongue facing the downward wing is an inner side of the downward tongue, and a side of the downward tongue facing away from the downward wing is an outer side of the downward tongue. Preferably, both the outer side of the downward tongue and the upward wing comprise an upper contact surface close to, located at, adjacent to or towards the top side of the panel, wherein preferably at least one of the contact surfaces extends at least partially vertically, preferably completely vertically, and wherein, in the coupled state of the panels, the upper contact surface of the outer side of the downward tongue of the panel is configured to engage with the upper contact surface of the upward wing of an adjacent panel. Preferably, below the upper contact surface, more preferably adjacent to the upper contact surface, both the downward tongue and the upward wing comprise an inclined contact surface, wherein the inclined contact surface of the downward tongue of the panel is configured to engage with the inclined contact surface of the upward wing of an adjacent panel in the coupled state of the panels, wherein each vertical portion of the upper contact surface and each adjacent inclined surface enclose an angle (α) of between 100 and 175 degrees with each other. Preferably, the downward tongue comprises an outer surface located below the inclined contact surface of the downward tongue when abutting the inclined contact surface, and the upward wing preferably comprises an inner surface located below the inclined contact surface of the upward wing when abutting the inclined contact surface, wherein the outer surface and the inner surface extend substantially parallel and at least partially in a vertical direction; wherein, in the coupled state of adjacent panels, there is a space between at least a part of the outer surface of the panel and at least another part of the inner surface of the adjacent panel. Such panels are usually arranged in combination with a downward movement. Such a movement is also called a pull-down or vertical movement and may mean that a new panel can be pushed into an already placed panel. Such a coupling is also possible when the panels are connected by a compression or shearing movement.

[0040] In addition or alternatively, the panel may include at least one third (preferably elastic) connecting profile and at least one fourth (preferably elastic) connecting profile respectively connected to opposite edges of the core, the third connecting profile comprising a single tongue, at least one upward wing at a distance from the upward tongue and a single upward groove formed between the upward tongue and the upward wing, wherein: at least a part of the side of the upward tongue facing the upward wing extends in the normal direction of the upper side of the core, at least a part of the side of the upward tongue facing the upward wing forms an alignment edge for connecting the third connecting profile to the fourth connecting profile of an adjacent floor panel, and at least a part of the side of the upward tongue facing away from the upward wing is optionally provided with a first locking element, which is substantially rigidly connected to the upward tongue and is suitable for cooperating with an optionally applied second locking element of the fourth connecting profile of the adjacent floor panel. The invention relates to a method for producing a fourth coupling profile comprising a single downward tongue, at least one downward flank at a distance from the downward tongue and a single downward groove formed between the downward tongue and the downward flank, wherein: at least a portion of a side of the downward tongue facing the downward flank extends in a normal direction to the underside of the core, at least a portion of a side of the downward tongue facing away from the downward flank will form an alignment edge for coupling the fourth coupling profile to a third coupling profile of an adjacent floor panel, the downward flank being provided with an optional second locking element which is substantially rigidly connected to the downward flank and is adapted to cooperate with an optionally applied first locking element of the third coupling profile of the adjacent floor panel, wherein the upward groove is adapted to receive at least a portion of the downward tongue of the adjacent panel, and wherein the downward groove is adapted to receive at least a portion of the upward tongue of the adjacent panel. Since the coupling profiles are given a specific form and also adopt a (somewhat) resilient form, substantially complementary formed coupling profiles of adjacent floor panels can be coupled to each other relatively simply but durably and effectively. During the connection of adjacent floor panels, a force will be exerted on one or both connection profiles, whereby one or more connection profiles will be elastically deformed (elastically moved), whereby the volume occupied by the downward groove and / or the upward groove will increase, so that the upward tongue and the downward tongue can be arranged relatively simply in the downward groove and the upward groove, respectively. By subsequently allowing the stressed connection profiles to elastically move back to the original position, a reliable locking connection will be achieved between the two connection profiles and thus the connection between the two floor panels. This locking connection, in which the two connection profiles engage with each other in a relatively reliable manner, will offset the friction between the parts of the connection piece, so that such a connection usually produces relatively little noise. The applied alignment edges, which are often also called chamfers or guide surfaces, here help to hook the two connection profiles together by a substantially linear displacement of the connection profiles relative to each other. The application of interacting locking elements prevents a substantially vertical displacement of the two floor panels relative to each other.Since the first locking element and the second locking element are connected substantially rigidly to the upward tongue and the downward wing, respectively, a relatively durable and secure locking can be achieved, since relatively weak elastic locking parts are not used, in which material fatigue can occur relatively quickly. According to the invention, the locking of the floor panels is achieved by deforming the third coupling profile and / or the fourth coupling profile relative to the core, whereby the locking elements can wrap around each other or engage with each other. Due to the rigid connection to the upward tongue and the downward wing, the locking elements themselves do not deform, or hardly deform. Otherwise, the first locking element can form an integral part of the upward tongue, wherein the first locking element can be formed, for example, by deformation of a protruding (outwardly protruding) or recessed (inwardly protruding) edge of the upward tongue. The second locking element can also form an integral part of the downward tongue, wherein the second locking element can be formed, for example, by deformation of a recessed or protruding edge of the downward wing. The upward groove of the third coupling profile usually has such a form that it is suitable for receiving at least a part of the downward tongue of the fourth coupling profile of the adjacent floor panel in a locking manner. Thus, by restricting the downward tongue of a floor panel in the upward groove of an adjacent floor panel and restricting the upward tongue of an adjacent floor panel in the upward groove of the floor panel, a first locking will be formed, and a second locking will be formed by applying a locking element. A normal is understood to mean a normal vector of a plane, i.e. a vector perpendicular to the plane and therefore originating from the plane. If the upper or lower side of the core is not completely flat, for example because the lower or upper side of the core is (to some extent) in the form of a profile, the plane formed by the upper or lower side of the core can be used as a reference to determine a clear direction of the normal of the upper and lower sides of the core. Since floor panels are usually supported on a flat horizontal surface, the normal direction of the upper side of the core and the lower side of the core will be oriented substantially vertically. In the process of connecting a floor panel to an adjacent floor panel, the specific orientation of the upward tongue facing the side of the upward wing and the downward tongue facing the side of the downward wing provides a first locking mechanism (internal lock). This is because, due to the specific oblique orientation of the tongues towards the walls of the respective flanks, (for example) vertical forces exerted on the coupling are less likely to lead to a disengagement of the co-acting coupling profiles, since the walls of the associated tongues are pressed against each other, which is a considerable constraint to the sliding of the walls of the tongues against each other and the subsequent disengagement of the coupling profiles. Furthermore, at the coupling point of the two floor panels, at a distance from the first locking mechanism, a second locking mechanism (outer lock) is formed by interacting locking elements, which are at a distance from the (inner) walls of the above-mentioned tongues. In the event of a possible failure of one of the locking mechanisms, a fixed coupling between the two floor panels will be maintained as far as possible, which results in a relatively reliable coupling between the two floor panels, thereby preventing an undesired mutual displacement or disengagement of the floor panels as far as possible.Since the floor panel according to the invention will achieve a multiple locking when a floor panel is connected to an adjacent floor panel, a relatively strong, reliable and durable connection between the floor panels can be achieved.

[0041] The invention also relates to a method for producing a decorative panel, in particular a decorative panel according to the invention, comprising the following steps: a. liquefying the polymer core component; b. extruding a liquefied polymer-based core component to form a soft core material; extruding the soft core material simultaneously by an extrusion process forming channels and / or grooves, i. wherein during the extrusion process, at least one channel and / or groove is formed by pressing at least one extrusion die into the soft core material, ii. wherein the at least one channel or groove is arranged at a distance from the lower side and / or upper side, c. Allow the core material provided with the channels and / or grooves of the core to solidify.

[0042] Optionally, the method comprises the following steps: a. liquefying the polymer core component; b. extruding the liquefied polymer-based core component to form a soft core material; i. forming at least one channel in the core material, ii. forming a tongue and groove joint profile at the edge of the core material; c. Allow the core material provided with the channels and / or grooves of the core to solidify.

[0043] In a preferred embodiment, a preferred operation can be performed, wherein during step c), the extruded core is actively cooled, preferably by a cooled liquid or gas or surface. In another preferred embodiment, a further preferred operation can be performed, wherein after step c), a decorative top structure is directly or indirectly applied to the upper side of the core sheet, thereby forming a decorative panel, and at least one transparent wear layer covering the decorative side or decorative pattern is applied to the upper side of the core sheet. Preferably, a further operation can include step d) cutting the solid core sheet or decorative sheet into a plurality of panels.

[0044] Embodiments of the invention are presented in the non-limiting set of clauses presented below.

[0045] 1. A panel, in particular a floor panel, a ceiling panel or a wall panel, comprising: o an extruded core having an upper side and a lower side on opposite sides of the core, wherein the core comprises at least an extruded polymer material, o coupling profiles arranged at at least two opposing edges of the core, wherein the coupling profiles are integrated with the core material, wherein the coupling profiles are designed to interlock with coupling profiles of adjacent panels having coupling profiles to provide locking in horizontal and / or vertical direction, and o wherein the core comprises at least one channel, wherein the at least one channel is arranged at a distance from a lower side and / or an upper side of the core.

[0046] 2. A panel according to claim 1, wherein the core comprises a plurality of core layers, preferably co-extruded core layers, wherein at least two core layers mutually surround at least one channel, preferably each channel, and / or wherein at least two core layers together define the peripheral wall of at least one channel, preferably the peripheral wall of each channel.

[0047] 3. A panel according to any of the preceding clauses, wherein the volume enclosed by at least one channel, preferably the volume enclosed by all channels together, is at least 20%, preferably between 30% and 50%, of the total volume enclosed by the core.

[0048] 4. A panel according to any of the preceding clauses, comprising a plurality of channels, wherein one channel is adjacent to or located on top of another channel, wherein at least one channel has the same or different shape than at least one other channel.

[0049] 5. Panel according to any of the preceding clauses, wherein the at least one channel is arranged at a distance from a side of the core or from the coupling profile.

[0050] 6. A panel according to any of the preceding clauses, wherein the at least one channel is surrounded on the top and bottom, and preferably also on the sides, by at least one of the core materials.

[0051] 7. A panel according to any of the preceding clauses, wherein the extrudable polymer material comprises at least a thermoplastic material and / or a thermosetting material, for example, ethylene vinyl acetate (EVA), which is a copolymer of ethylene and vinyl acetate, rubber, polyurethane (PU), polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC) or a mixture thereof.

[0052] 8. A panel according to any of the preceding clauses, wherein the core is at least partially made of foamed thermoplastic material and / or thermosetting material, preferably of recycled plastic material, wherein the core comprises at least 50% of its weight of thermoplastic material, preferably 50% to 100% of its weight of thermoplastic material.

[0053] 9. The panel according to any of the preceding clauses, wherein the core comprises at least one plasticizer.

[0054] 10. The panel according to any of the preceding clauses, wherein the core comprises at least one polymer material and preferably at least one non-polymer material, such as talc, chalk, glass particles, calcium carbonate (CaCO3) and / or cellulose-based particles.

[0055] 11. A panel according to any of the preceding clauses, wherein the core has an area density of less than 9000 g / m 2 , preferably less than 6000g / m 2 , more preferably about 5000 g / m 2 .

[0056] 12. A panel according to any of the preceding clauses, wherein the panel comprises at least one decorative top structure fixed directly or indirectly to the core, the decorative top structure at least partially covering the upper side of the core and optionally at least partially covering at least one side edge of the core.

[0057] 13. Panel according to clause 12, wherein the decorative top structure comprises at least one preferably printed, more preferably digitally printed decorative layer and at least one protective layer covering the decorative layer.

[0058] 14. Panel according to clause 13, wherein the decorative layer comprises a decoration formed by a layer of ink, preferably a UV based ink, printed directly or indirectly, preferably digitally, on the core.

[0059] 15. The panel according to any of the preceding clauses, wherein the core and / or the upper side of the panel comprises a plurality of parallel extrusion grooves.

[0060] 16. A panel according to any of the preceding clauses, wherein the panel thickness is between 3 and 30 mm, preferably between 4 and 27 mm.

[0061] 17. A panel according to any of the preceding clauses, wherein the panel comprises a pair of first panel edges and an opposing second panel edge, the first panel edge comprising a first coupling profile, the second panel edge comprising a second coupling profile designed to interlock with the first coupling profile of an adjacent panel in a tongue and groove connection, preferably both horizontally and vertically, wherein the pair of opposing edges comprises: o a first edge comprising a lateral tongue extending in a direction substantially parallel to the upper side of the panel, a protrusion on top of the edge of the lateral tongue, o an opposite second edge comprising a recess for receiving at least a part of a lateral tongue of another panel, said recess being defined by an upper lip and a lower lip, said upper lip comprising a recess formed by extrusion, o The lateral tongue is designed to be locked by a movement introducing a recess of the lateral tongue and a tilting movement downwards around an axis parallel to the first edge, whereby a protrusion on the top side of the lateral tongue will engage with the upper lip, locking the adjacent panels at the first and second edges in horizontal and vertical directions.

[0062] 18. A panel according to any of the preceding clauses, wherein the pair of opposing edges comprises: o a first edge comprising a lateral tongue extending in a direction substantially parallel to the upper side of the panel, a protrusion on the bottom of the edge of the lateral tongue, wherein the first downward groove is adapted to receive at least a part of a second upward tongue of a second coupling profile of an adjacent panel, o an opposite second edge comprising a recess for receiving at least a part of a lateral tongue of another panel, said recess being defined by an upper lip and a lower lip, said lower lip comprising a recess formed by extrusion, o The lateral tongue is designed to lock by a movement introduced into the recess of the lateral tongue and an upward tilting movement, so that the protrusion at the bottom of the lateral tongue will engage with the lower lip, locking the adjacent panels at the first and second edges in horizontal and vertical directions.

[0063] 19. Panel according to any of the preceding clauses, wherein at least one coupling profile, preferably all coupling profiles, are at least partially formed by the core.

[0064] 20. A panel according to any of the preceding clauses, wherein the core is formed along an extrusion direction and wherein the channels and / or grooves are formed along the extrusion direction.

[0065] 21. A panel according to any of the preceding clauses, wherein the core comprises a central part and a peripheral part surrounding the central part, wherein the panel edge and the joining profile constitute part of the peripheral part, and wherein the peripheral part is free of channels and / or grooves of the core.

[0066] 22. A method for producing a panel, in particular a floor panel, a ceiling panel or a wall panel, comprising the following steps: a. liquefying the polymer core component; b. extruding the liquefied polymer-based core component to form a soft core material; a. forming at least one channel in the core material at a distance from the lower side and / or upper side of the core material, b. forming a tongue and groove joint profile at the edge of the core material; c. Curing the core material provided with the channels and / or grooves of the core.

[0067] 23. Method according to clause 22, wherein during step c), the extruded core is actively cooled, preferably by a cooled liquid or gas or a surface.

[0068] 24. A method according to clauses 22 and / or 23, wherein after step c), a decorative top structure is applied directly or indirectly to the upper side of the core material to form a decorative sheet, and at least one transparent wear-resistant layer covering the decorative side or decorative pattern is applied to the upper side of the core material.

[0069] 25. The method according to clauses 22-24, further comprising the following steps: d. Cutting the solid core material or decorative sheet into multiple panels. BRIEF DESCRIPTION OF THE DRAWINGS

[0070] Further advantages, features and details of the invention are explained on the basis of preferred embodiments of the invention, with reference to the accompanying drawings, in which:

[0071] Figure 1A and 1B shows a cross-sectional view of a panel according to the invention, which has an extruded groove on the upper side, a decorative layer on the upper side, both with a coupling profile and a channel arranged in the core;

[0072] Figure 2A and 2B shows a cross-sectional view of a panel according to the invention, respectively having an extruded groove on the upper side, having a decorative layer on the upper side, both having a coupling profile and a plurality of channels arranged in a core;

[0073] Figure 3A , 3B 4A and 4B show cross-sectional views of panels according to the invention, respectively with an extruded groove on the upper side, with a decorative layer on the upper side, both with a coupling profile and a plurality of channels arranged in the core, arranged next to identical floor panels in the coupled state;

[0074] Figure 5A and 5B shows a cross-sectional view of a panel according to the invention, which has an extruded groove on the upper side, a decorative layer on the upper side, both with a coupling profile and a plurality of channels arranged in a core, wherein the core is coextruded from two different components;

[0075] Fig. 6A and 6BA cross-section of a panel according to the invention is shown, which has an extruded groove on the upper side and a decorative layer on the upper side, both having a connecting profile and a plurality of channels filled with a filler, the filler being arranged in a core, wherein the core is coextruded from two different components. DETAILED DESCRIPTION

[0076] Figure 1A and 1BA cross section of a single panel 100 according to the invention is shown. This figure allows a more detailed elaboration of the first coupling profile 101 and the second coupling profile 102. The first coupling profile 101 and the second coupling profile 102 are preferably realized by extrusion. At least one first coupling profile 101 comprises a lateral tongue 105. The upper side or the upwardly facing surface of the lateral tongue 105 comprises at least one first locking element 106. In this particular embodiment, the first locking element 106 is formed by an upwardly facing protrusion 106. Preferably, the first locking element 106 extends beyond the average surface height of the lateral tongue 105. Thus, the first locking element can be used as a horizontal locking element. The underside of the panel 100 is provided with a cutout portion 103, which according to this embodiment is connected and parallel to the first edge. The cutout portion is used to allow the first edge to accommodate a portion of the second coupling profile 102, in particular its lower lip 104. The downwardly facing surface of the lateral tongue 208 can be provided with a chamfer, which can allow the panel to tilt downwards into the second coupling profile 102 of the adjacent panel 100. The second coupling profile 102 comprises a groove 110 for accommodating at least a portion of the lateral tongue 105 of the first coupling profile 101. The groove 110 is at least partially defined by a lower lip 104 and an upper lip 108. In the coupled state of the adjacent panels 100, the lower lip 104 can be accommodated by the cut-out portion 103. In this particular embodiment, the downwardly facing surface of the upper lip 108 is provided with a second locking element 109. In this embodiment, the second locking element 109 can be formed by a recess 109. The recess 109 can be formed by extrusion. The second locking element is configured to receive at least a portion of the first locking element 210, wherein the first locking element 106 and the second locking element 109 mutually lock the adjacent panels 100. At least one lower lip 104 can be provided with a recess portion 111, which can be used as a drainage channel when the panel 100 is used as an outdoor panel. The upper surface of the panel 100 can include a plurality of grooves 112 and a protruding area 113. The grooves 112 can be realized by extrusion. The groove 112 may extend over the entire length of the panel 100, or may extend over a portion thereof. While it is envisioned that the groove 112 is substantially horizontal, it is also envisioned that a first end of the groove 112 is lower than an opposite second end of the groove 112. In addition, for outdoor use, at least one through hole may be provided in at least one of the recesses to allow water to drain through the hole. In this regard, the hole may extend through the entire panel 100. It is also envisioned that, for example, Figure 1BAs shown, the panel 100 may include a decorative portion 118, preferably for indoor use. The central portion of the panel 100 may include a channel 116. This can reduce the weight of the panel, thereby saving material and transportation costs. The panel 100 may include different thicknesses, depending on whether it is used outdoors or indoors. Preferably, the outdoor panel 100 is thicker than the indoor panel 100. The panel 100 may include a core 117. In this regard, at least one first connection profile 101 and at least one second connection profile 102 constitute an integral part of the core 117. The core 117 may be at least partially composed of a thermoplastic material, which is selected from: PVC, PET, PP, PS, thermoplastic polyurethane (TPU), PE, in particular MDPE and / or HDPE; and combinations thereof. It is conceivable that each of the first connection profile 101 and the second connection profile 102 includes a first top 114 and a second top 115, respectively. The first top 114 and the second top 115 preferably extend in a vertical direction. The first top portion 114 is located above the lateral tongue 105 of the first coupling profile 101 The second top portion 115 may be formed at least partially, preferably completely, by an outer end of the upper lip 108 .

[0077] Figure 2A and 2B A cross section of a single panel 200 according to the invention is shown. In this preferred non-limiting embodiment, it is shown that the panel 200 may comprise a core of two components, an upper layer 201 of the core and a lower layer 202 of the core. It is conceivable that the core is provided with at least two regions (201 and 202) of different composition, whereby these regions may at least partially consist of a thermoplastic material selected from the group consisting of: PVC, PET, PP, PS, thermoplastic polyurethane (TPU), PE, in particular MDPE and / or HDPE; and combinations thereof. Such regions may be obtained, for example, by coextrusion. It is also conceivable that the panel 200 may comprise a plurality of channels 203, which may also provide the same functionality as a single channel 116, without reducing the strength and rigidity of the panel 200. A turning movement may be performed to insert the lateral tongue 105 into the groove 110.

[0078] Figure 3A and 3BA cross section of a single panel 300 according to the present invention is shown. In this preferred non-limiting embodiment, it shows a coupling state 301 of two adjacent panels 300. For example, when a lateral tenon 302 is at least partially inserted into a groove 304 by a tilting or rotational movement, a protrusion 303 can be received by a recess 305 of an adjacent panel 300. These locking elements can perform interlocking connections in the vertical and horizontal directions of two adjacent panels 300, respectively. As shown, a channel 306 can include a circular shape, which is only an example of a non-limiting shape and / or height and / or width of a channel in the present invention. Panel 300b shows that the panel can include two core layer areas, preferably achieved by extrusion.

[0079] Figure 4A and 4B Other preferred, non-limiting embodiments according to the present invention are shown, wherein the channels 401 may include different shapes, heights and / or widths in one panel 400. More specifically, Figure 4A and 4B Each of the panels shows a central channel located in the center of the core of these panels. The center of each central channel may intersect the center plane of the core. It is also conceivable that the center of each central channel is located at a distance from the center plane of the core, but in which the central channel itself intersects the center plane. The peripheral wall of each central channel consists entirely of core material. In addition, Figure 4A and 4B Each of the panels of the present invention shows a bottom channel located at the bottom side of the core, which can be optionally covered by a separate backing layer, such as a cork layer and / or an EVA layer, as shown. The backing layer is usually glued to the bottom side of the core. For these bottom channels, the peripheral wall of each bottom channel is partially formed by the core material and partially formed by the backing layer material. It is conceivable that the panel according to the present invention has no central channel and only includes eccentric channels, such as the bottom channel. It is also conceivable that the panel according to the present invention has no bottom channel and only includes a central channel. Figure 5A and 5B Other preferred, non-limiting embodiments according to the invention are shown, in which the panel 500 comprises a third connecting profile 501 on one edge and a fourth connecting profile 502 on the opposite edge of the edge comprising the third connecting profile 501. The connecting profiles 501, 502 are configured to allow adjacent panels 500 to interlock by a pull-down or lowering movement, preferably in the horizontal and vertical directions. It can also be seen from the figure that a portion of the channel 503 is located in the upper core layer 504 and another portion is located in the lower core layer 505, whereby this combination can have different compositions and can be achieved by coextrusion. Each channel 503 is located in the upper core layer 504 and the lower core layer 505 is located in the lower core layer 505. Figure 5A5a. The channels 503 are shown as elliptical, but their shape and / or height and / or width are not limited. The elliptical shape is determined in part by the upper core layer 504 and in part by the lower core layer 505. During the lamination process, especially during the calendering process, the alignment of these two layers is usually important for the final formation of the elliptical shape shown in Figure 5a. In Figure 5b, each channel 503 is dome-shaped, wherein the shape of each dome is determined only by the upper core layer 504, and the lower core layer 505 is only used as a (planar) cover layer to close the peripheral wall of the channel 503. Each channel 503 preferably has an open end.

[0080] Fig. 6A and 6B Other preferred, non-limiting embodiments of panels 600a, 600b according to the present invention are shown. Each panel 600a, 600b includes a third connecting profile 601 on one edge and a fourth connecting profile 602 on the opposite edge of the edge including the third connecting profile 601. The connecting profiles 601, 602 are configured to allow adjacent panels 500 to interlock by a pull-down or lowering movement, preferably in the horizontal and vertical directions. Each panel 600a, 600b includes a channel 603 filled with fillers, wherein these fillers include at least (sound and / or impact damping) material. The combination of an upper core layer 604, a lower core layer 605 and multiple channels filled with fillers 603 can be intended to provide better sound insulation while maintaining the quality, rigidity and strength of the panel 600. Each channel 603 has a rectangular cross-section. As Fig. 6A and 6B As shown, the shapes of the channels 603 can vary. Fig. 6A As shown, the shape of the rectangular channel 603 is defined only by the upper core layer 604, wherein the lower core layer 605 serves only as a (planar) covering layer to close the peripheral wall of the channel 603. Figure 6B 6a, the shape of the rectangular channel is determined partly by the upper core layer 604 and partly by the lower core layer 605. During the lamination process, especially during the calendaring process, the alignment of these two layers is usually important for the final rectangular shape as shown in Figure 6a. Each channel 603 preferably has an open end.

[0081] The coupling profiles may also be referred to as coupling profiles or connecting profiles. "Complementary" coupling profiles mean that these coupling profiles can cooperate with each other. However, for this purpose, complementary coupling profiles do not necessarily have to have a complementary form. Locking in a "vertical direction" means locking in a direction perpendicular to the plane of the panel. Locking in a "horizontal direction" means locking in a direction perpendicular to the respective coupling edges of the two panels and parallel to or falling together with the plane defined by the panels. The ordinal numbers used in this document, such as "first", "second", "third" and "fourth", are used for identification purposes only. Therefore, the use of the term "third coupling profile" does not necessarily require the simultaneous presence of a "first coupling profile".

[0082] The invention has been described using detailed embodiments of the invention. It is obvious that the invention is not limited to the working examples shown and described herein, but that many variations are possible within the scope of the appended claims, which will be obvious to a person skilled in the art.

[0083] The verb "to comprise" and its variations as used in this patent disclosure are understood to mean not only "to include", but also the phrases "including", "consisting essentially of", "formed of", and variations thereof.

Claims

1. A panel, in particular a floor panel, a ceiling panel or a wall panel, comprising: o an extruded core having an upper side and a lower side on opposite sides of the core, wherein the core comprises at least an extruded polymer material, o coupling profiles arranged on at least two opposing edges of the core, wherein the coupling profiles are integrated with the core material, wherein the coupling profiles are designed to interlock with coupling profiles of adjacent panels having coupling profiles to provide locking in horizontal and / or vertical direction, and o wherein the core comprises at least one channel, wherein the at least one channel is arranged at a distance from both the lower side and the upper side of the core.

2. The panel according to claim 1, wherein The core comprises a plurality of core layers, preferably coextruded core layers, wherein at least two core layers mutually surround at least one channel, preferably each channel, and / or wherein at least two core layers together define a peripheral wall of at least one channel, preferably each channel.

3. A panel according to any one of the preceding claims, wherein The volume enclosed by at least one channel, preferably the volume enclosed by all channels together, is at least 20%, preferably between 30% and 50%, of the total volume enclosed by the core.

4. A panel according to any one of the preceding claims, comprising a plurality of channels, wherein: One channel is adjacent to or on top of another channel, wherein at least one channel has the same or different shape than at least one other channel.

5. A panel according to any one of the preceding claims, wherein The at least one channel is arranged at a distance from a side of the core or from the coupling profile.

6. A panel according to any one of the preceding claims, wherein The at least one channel is surrounded on the top and bottom, and preferably also on the sides, by at least one of the core materials.

7. A panel according to any one of the preceding claims, wherein The extrudable polymer material includes at least a thermoplastic material and / or a thermosetting material, for example, ethylene vinyl acetate (EVA), which is a copolymer of ethylene and vinyl acetate, rubber, polyurethane (PU), polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polyethylene terephthalate (PET) or a mixture thereof.

8. A panel according to any one of the preceding claims, wherein The core is at least partially made of foamed thermoplastic and / or thermosetting material, preferably of recycled plastic material, wherein the core comprises at least 50% of its weight of thermoplastic material, preferably 50 to 100% of its weight of thermoplastic material.

9. A panel according to any one of the preceding claims, wherein The core includes at least one plasticizer.

10. A panel according to any one of the preceding claims, wherein The core comprises at least one polymer material and at least one non-polymer material, for example, talc, chalk, glass particles, calcium carbonate (CaCO3) and / or cellulose-based particles.

11. A panel according to any one of the preceding claims, wherein The core has an area density of less than 9000 g / m 2 , preferably less than 6000g / m 2 , more preferably about 5000 g / m 2 .

12. A panel according to any one of the preceding claims, wherein The panel comprises at least one decorative top structure fixed directly or indirectly to the core, the at least one decorative top structure at least partially covering the upper side of the core and optionally at least partially covering one side edge of the core.

13. The panel according to claim 12, wherein The decorative top structure comprises at least one preferably printed, more preferably digitally printed, decorative layer and at least one protective layer covering the decorative layer.

14. The panel according to claim 13, wherein The decorative layer comprises a decoration formed by a layer of ink, preferably a UV based ink layer, printed directly or indirectly, preferably digitally, on the core.

15. A panel according to any one of the preceding claims, wherein The core and / or the upper side of the panel comprises a plurality of parallel extrusion grooves.

16. A panel according to any one of the preceding claims, wherein The panel thickness is between 3 and 30 mm, preferably between 4 and 27 mm.

17. A panel according to any one of the preceding claims, wherein The panel comprises a pair of first panel edges and an opposing second panel edge, the first panel edge comprising a first coupling profile, the second panel edge comprising a second coupling profile, the second coupling profile being designed to interlock with the first coupling profile of an adjacent panel in a tongue and groove connection, preferably both in horizontal and vertical direction, wherein the pair of opposing edges comprises: o a first edge comprising a lateral tongue extending in a direction substantially parallel to the upper side of the panel, a protrusion at the top of the edge of the lateral tongue, o an opposite second edge comprising a recess for receiving at least a part of a lateral tongue of another panel, said recess being defined by an upper lip and a lower lip, said upper lip comprising a recess formed by extrusion, o The lateral tongue is designed to be locked by a movement introducing a recess of the lateral tongue and a downward tilting movement around an axis parallel to the first edge, whereby a protrusion on the top side of the lateral tongue will engage with the upper lip, thereby locking the adjacent panels at the first and second edges in horizontal and vertical directions.

18. A panel according to any one of the preceding claims, wherein The panel comprises a second pair of opposing edges consisting of a third panel edge and a fourth panel edge, the third panel edge comprising a third coupling profile, the fourth panel edge comprising a fourth coupling profile, wherein the third coupling profile comprises an upward tongue, at least one upward flank at a distance from the upward tongue and an upward groove formed between the upward tongue and the upward flank, wherein the upward groove is adapted to receive at least a portion of a downward tongue of a second coupling profile of another panel, wherein a side of the upward tongue facing the upward flank is an inner side of the upward tongue and a side of the upward tongue facing away from the upward flank is an outer side of the upward tongue; wherein the fourth coupling profile comprises a downward tongue, at least one downward flank at a distance from the downward tongue and a downward groove formed between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a portion of an upward tongue of a first coupling profile of another panel, wherein a side of the downward tongue facing the downward flank is an inner side of the downward tongue and a side of the downward tongue facing away from the downward flank is an outer side of the downward tongue.

19. A panel according to any one of the preceding claims, wherein At least one coupling profile, preferably all coupling profiles, are at least partially formed by the core.

20. A panel according to any one of the preceding claims, wherein At least one pair of opposing panel edges is completely free of a joining profile.

21. A panel according to any one of the preceding claims, wherein The core is formed along an extrusion direction, and wherein the channels and / or grooves are formed along the extrusion direction.

22. A panel according to any one of the preceding claims, wherein The core comprises a central part and a peripheral part surrounding the central part, wherein the panel edges and the joining profile constitute part of the peripheral part, and wherein the peripheral part is free of channels and / or grooves of the core.

23. A panel covering consisting of a plurality of interlocking panels according to any one of the preceding claims.

24. A method for producing a panel, in particular a floor panel, a ceiling panel or a wall panel, comprising the following steps: a. liquefying the polymer core component; b. extruding the liquefied polymer-based core component to form a soft core material; a. forming at least one channel in the core material at a distance from the lower side and / or upper side of the core material, b. forming a tongue and groove joint profile at the edge of the core material; c. Allow the core material provided with the channels and / or grooves of the core to solidify.

25. The method according to claim 24, wherein: During step c), the extruded core is actively cooled, preferably by a cooled liquid or gas or surface.

26. The method according to claim 24 and / or 25, wherein: After step c), a decorative top structure is applied directly or indirectly to the upper side of the core sheet to form a decorative panel, and at least one transparent wear layer covering the decorative side or decorative pattern is applied to the lower side of the core sheet.

27. The method according to claims 24-26, further comprising the steps of: d. Cutting the solid or decorative sheet into multiple panels.

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