Flooring board and method of manufacturing such flooring board

Abstract

The invention relates to a floorboard comprising a decorative surface layer applied to a substrate, wherein the substrate is optionally a MDF or HDF material at its side edges. The invention also relates to a floorboard covering consisting of a plurality of floorboards according to the invention. The invention also relates to a method of manufacturing such a floorboard according to the invention.

Description

Technical Field

[0001] This invention relates to decorative panels, such as flooring panels or flooring panels, and methods of manufacturing such decorative panels, such as flooring panels. More specifically, this invention relates to a type of flooring panel comprising a single-piece or multi-piece substrate at least partially composed of a wood-based material, particularly a substrate composed of MDF or HDF (medium-density fiberboard or high-density fiberboard), and the flooring panel having a decorative surface layer as a top layer, such as precast parquet flooring or veneer parquet flooring, wherein the top layer is typically made of wood, or, for example, laminated flooring panels, which typically have a top layer based on a synthetic material. Background Technology

[0002] Such flooring panels are known to be used to form floating floor coverings. In this case, the flooring panels are joined together at their side edges during installation, either by conventional tongue and groove joints, which may be glued together, or by mechanical couplings used to lock the floor panels together, for example, in both the horizontal and vertical directions.

[0003] To this end, WO 97 / 47834, particularly the embodiment shown in Figure 23 of that document, discloses a flooring panel comprising a substrate and a decorative surface layer, wherein the substrate is provided with connecting members at at least two opposite edges, enabling a plurality of such flooring panels to be connected to each other, thereby locking the flooring panels in a first direction perpendicular to the plane of the flooring panel and in a second direction perpendicular to the respective edges and parallel to the plane of the flooring panel in a connected state, wherein the connecting member comprises a tongue and a groove, wherein the groove is located between an upper lip and a lower lip, wherein the lower lip extends beyond the upper lip, and wherein the connecting member further comprises a locking portion for achieving locking in the second direction, the locking portion being formed at least by contact portions, wherein in the connected state of two such flooring panels, the contact portions are capable of engaging with each other, wherein one of these contact portions is located above the lower lip such that the contact portion is at least partially located outside the upper lip, and wherein two of the contact portions are arranged such that the flooring panels are pressed against each other laterally by tension in the connected state. The tension, also known as “pretension,” achieves the effect that the floor panels are adjacent to each other on their visible upper sides when joined, and that when these floor panels are forced to separate from each other for any reason, there is a reaction force that forces the floor panels to move back toward each other.

[0004] However, the connecting components cannot be integrated into ceramic tiles, stone tiles, and / or other rigid tiles. For this purpose, it is known to glue ceramic tiles to a substrate, wherein the substrate is provided with connecting components, as shown in Figure 23 of WO 97 / 47834. However, the application of these so-called "corner-embedded" connecting components leads to installation difficulties because the relatively thick decorative tiles on top of the substrate hinder the corner-embedded connection process. To solve this problem, the size of the tiles glued to the top of the substrate is reduced, which results in wider grout lines between the ceramic tiles of the interconnected floorboards. However, this solution is considered less aesthetically pleasing by consumers. Summary of the Invention

[0005] The first objective of this invention is to provide an interlocking floor slab with decorative bricks on top, which allows for easy installation and the formation of relatively narrow grout lines.

[0006] A second object of the present invention is to provide a wood-based, particularly MDF or HDF-based, decorative panel, especially a flooring panel, which has improved water resistance.

[0007] A third object of the present invention is to provide an improved decorative panel, particularly a flooring panel, comprising an MDF or HDF substrate, and designed to minimize the effect of moisture on the decorative panel.

[0008] A fourth object of the present invention is to provide an improved method for manufacturing wood-based, particularly MDF or HDF-based, decorative panels, especially flooring panels, which have improved water resistance.

[0009] The fifth objective of this invention is to provide an improved decorative panel, particularly a flooring panel, that can counteract the risk of squeaking noise.

[0010] At least one of these objectives can be achieved by providing a flooring material comprising:

[0011] A substrate having side edges, and optionally a decorative surface layer applied to the substrate.

[0012] At least one side edge and its opposite side edge together form a first pair of opposing side edges of the substrate; wherein the first pair of opposing side edges optionally includes a mechanical first connecting member and a second connecting member, the first connecting member and the second connecting member allowing the flooring board to be connected to a similar flooring board at the respective side edge, preferably by a downward angular movement, such that, in the connected state, the flooring board and the other flooring board are locked in both a vertical direction perpendicular to the board plane defined by the interconnected flooring boards and a horizontal direction parallel to the board plane.

[0013] The optional first connecting component includes a lateral tenon, wherein the lateral tenon includes a front section, a rear section, and a middle section located between the front section and the rear section.

[0014] Preferably, the bottom surface and / or side surface of the front section of the lateral tenon are at least partially curved, wherein the bottom surface of the front section defines a front-downward tenon contact portion.

[0015] Preferably, the top surface of the front section of the lateral tenon is at least partially inclined downward in a direction away from the middle and rear sections, wherein the top surface of the front section preferably defines a front upward tenon contact portion.

[0016] Preferably, the bottom surface of the middle section of the lateral tenon defines a lower intermediate contact portion, which is located between adjacent non-functional portions of the middle section of the lateral tenon.

[0017] Preferably, the bottom surface and / or side surface of the rear section of the lateral tenon is at least partially inclined upward in a direction away from the middle section and the front section, wherein the inclined portion of the bottom surface and / or side surface of the rear section preferably defines a rear downward tenon contact portion.

[0018] Preferably, the rear section is configured to accommodate an upwardly projecting locking element of a second connecting member of another floor panel.

[0019] The optional second connecting component includes a recess for receiving at least a portion of a lateral tongue of another floorboard, the recess being defined by an upper lip and a lower lip, wherein the lower lip extends beyond the upper lip, wherein the lower lip preferably includes a front section, a rear section, and a middle section located between the front and rear sections, wherein the upper lip is located above and connected to the front section of the lower lip, and wherein the lower lip is provided with an upwardly projecting locking element located in the rear section of the lower lip.

[0020] Preferably, the bottom surface and / or side surface of the front segment of the lower lip are at least partially curved, wherein the bottom surface of the front segment of the lower lip defines a front portion that contacts the upper lip.

[0021] Preferably, the bottom surface of the upper lip slopes downward at least partially in a direction away from the middle and rear sections of the lower lip, wherein the bottom surface of the front section preferably defines a front portion that contacts the lower lip.

[0022] Preferably, the top surface of the middle segment of the lower lip defines a middle upper lip contact portion, which is located between adjacent non-functional portions of the middle segment of the lower lip.

[0023] Preferably, the top surface and / or side surface of the rear segment of the lower lip are at least partially inclined upwards in a direction away from the middle and front segments of the lower lip, wherein the inclined portion of the top surface and / or side surface of the rear segment preferably defines a rear-upward lip contact portion, and wherein, preferably, the top surface and / or side surface of the rear segment of the lower lip partially defines the upwardly projecting locking element.

[0024] In the case of adjacent floorboards being joined, the lateral tongue and lower lip optionally define at least three spaced-apart lower contact areas, wherein:

[0025] The front lower contact area is defined by the synergistic effect between the front downward tenon contact portion of the flooring board and the front upward lip contact portion of the other flooring board.

[0026] The lower middle contact area is defined by the synergistic effect between the downward middle tongue contact portion of the flooring board and the upward middle lip contact portion of the other flooring board, and

[0027] The rear lower contact area is defined by the synergistic effect between the downward tongue contact portion of the rear of the flooring board and the upward lip contact portion of the rear of another flooring board.

[0028] Furthermore, in the connected state of adjacent floorboards, the lateral tongue and upper lip optionally define at least two spaced-apart upper contact areas, wherein:

[0029] The first upper contact area is preferably defined by the synergistic effect between the upward tongue contact portion of the front part of the flooring board and the downward lip contact portion of the front part of another flooring board.

[0030] The second upper contact area is preferably defined by the synergistic effect between the top side surface of the first connecting member of the flooring sheet and the side surface of the upper lip of the other flooring sheet, wherein the side surface of the upper lip is located above the front lower lip contact portion.

[0031] The decorative surface layer is preferably substantially rigid, wherein the thickness of the decorative surface layer is preferably at least 4 mm, and wherein the height of the side surface of the upper lip and / or the height of the upper lip at its distal end is preferably less than 1 mm.

[0032] One aspect of the invention is that the flooring slab includes a (modified) "corner-embedded" connection member that allows the flooring slab to be easily joined and disjointed relative to another flooring slab, while the insertion angle (installation angle) is reduced due to the lateral tongue being positioned at a relatively high position. This allows the decorative surface layer (decorative tile) to be positioned closer to the edges of the first and / or second connection members. The latter allows for the formation of a relatively narrow grout line, particularly a grout line with a width of 1 mm or less. Preferably, the height of the side surface of the upper lip and / or the height of the upper lip at its distal end is less than 20% of the substrate thickness, preferably less than 15% of the substrate thickness. For example, in the case of a substrate thickness of 6 mm, the height of the upper lip at its distal end is preferably less than 0.9 mm. This limited upper lip height allows the lateral tongue to be positioned at a relatively high position relative to embodiments where the height of the lateral tongue relative to the side surface is at least 1 mm. As described above, when a relatively thick decorative surface layer is applied to the top of the substrate, for example, at least 1 mm thick, such as at least 2, 3, 4, 5, 6, 7, 8, 9, or 10 mm, this higher position of the lateral tenon can be advantageous. Preferably, the decorative surface layer is at least 4 mm, more preferably at least 5 mm, and most preferably at least 6 mm, for example, 7 mm. This relatively thick decorative surface layer, also known as decorative tile, protects the vulnerable side edges of the substrate, making the stability of these vulnerable side edges less critical, thus allowing the lateral tenon to be positioned at a relatively high position.

[0033] As described above, this relatively high positioning of the lateral tongue is advantageous for the connection of floorboards because it reduces the insertion angle, for example, to an insertion angle of 3 to 10 degrees, rather than a significantly larger one. Here, the upper side of the second upper contact area preferably defines the point of rotation during the connection of the floorboards, where the maximum rotation angle (insertion angle) during connection is determined by the thickness of the decorative surface layer and is between 3 and 10 degrees. The insertion angle is particularly limited when a relatively thick decorative surface layer of at least 4 mm is applied because the decorative surface layers come into contact with each other during the cornering motion, thus limiting the insertion angle. The relatively high positioning of the lateral tongue is advantageous, especially for these embodiments. For the same reason, the distance between the top surface of the substrate and the front lower contact area can preferably be less than 4 mm. The ratio between (i) the (vertical) distance between the top surface of the substrate and the front lower contact area and (ii) the (vertical) height of the decorative surface layer is between 0.3 and 1. This facilitates the smooth insertion of the lateral tongue of a floorboard into the recess of an adjacent floorboard, even with a limited insertion angle, particularly when a relatively thick decorative surface layer (greater than 1 mm, typically greater than 4 mm) is applied. It is conceivable that the thickness of the decorative surface layer is equal to or even greater than the thickness of the substrate. For example, the substrate thickness could be 6 mm, while the decorative surface layer on top could have a thickness of 7 mm. Regardless of the thickness of the decorative surface layer, it is preferably a rigid decorative surface layer. The decorative surface layer is at least partially made of at least one material selected from the group consisting of: ceramic, stone, concrete, mineral ceramics, glass, mosaic, granite, limestone, metal, cork, marble, linoleum, wood, and carpet. In the case of rigid bricks, such as ceramic bricks, stone bricks, glass bricks, etc., one or more side edges of the rigid brick can extend in a direction perpendicular to the plane defined by the brick. Therefore, the brick can be provided with regular, straight, upright side edges. However, it is also conceivable that one or more side edges of the rigid brick are inclined relative to the plane defined by the brick. For example, the sloping or beveled edge may form an angle between 15 and 75 degrees with the brick plane, including the endpoints, preferably between 30 and 60 degrees. The sloping edge may be planar, curved, or have other shapes. It is conceivable that opposite side edges of the decorative bricks extend parallel to each other, or that these opposite side edges form an angle between each other, for example, between 15 and 90 degrees. Adjacent bricks of interconnected flooring slabs may form a grout line extending vertically and / or obliquely relative to the plane defined by the bricks. The width of the grout line may be constant or may vary in the upward direction, i.e., away from the substrate, for example, by increasing. The latter results in the grout line having a diverging (V-shaped) cross-section in the upward direction.By employing a beveled edge, wider or narrower grout lines can be formed, and / or the minimum grout line width between adjacent, preferably interconnected, floorboards can be reduced, and / or a smaller insertion angle can be allowed to connect the connecting parts of adjacent floorboards (compared to the case of using a conventional vertical side edge orientation). From a top view, the decorative tile applied to the top of the substrate can be smaller than the substrate. This allows one or more peripheral portions of the top surface of the substrate to be uncovered by the tile. The latter facilitates the formation of a grout line between adjacent, preferably interconnected, floorboards. When the grout line is optionally filled with grout (mortar), and / or when a decorative tile with a beveled edge is applied on top, the exposed (uncovered) portion of the top surface of the substrate can be concealed; the decorative tile with the beveled edge can cover the exposed portion, thus making the exposed portion of the top surface of the substrate no longer visible. Preferably, the decorative tile can be attached to the distal side edge of the upper lip, while the decorative tile is positioned spaced apart from the distal side edge of the lateral tongue (or vice versa). This results in the joints formed between the floorboards being aligned with and / or connected to the decorative tiles, thus being eccentrically positioned relative to the grout line to be formed. This reduces the vulnerability of at least one side edge of the substrate before installation.

[0034] The decorative top structure can be adhered to the substrate using at least one adhesive layer, particularly a flexible adhesive layer. This flexibility of the adhesive layer helps accommodate any differences in thermal expansion or contraction between the substrate and the top layer (decorative surface layer); the top layer is preferably the aforementioned rigid layer / brick, which is at least partially made of at least one material selected from the group consisting of ceramics, stone, steel, concrete, mineral ceramics, glass, mosaic, granite, limestone, and marble. The adhesive layer can include water-based adhesives with a viscosity of less than 50 Pa·s at room temperature (as the application temperature), or hot-melt adhesives, such as polyurethane (PU) hot-melt adhesives with a viscosity of less than 10 Pa·s at a temperature between 120 and 180 °C, and / or one or more polyurethane adhesives, one or more modified silane adhesives, one or more epoxy-based adhesives, one or more acrylic adhesives, one or more latex-based adhesives, one or more silicone adhesives, one or more hybrid polymer adhesives, and combinations of two or more of these adhesives. These viscosity ranges allow for effective application and penetration of the adhesive. Therefore, the adhesive layer can penetrate into the substrate and / or the decorative top layer, thereby enhancing the bond strength between the layers. A flexible adhesive layer is preferred. This flexibility is particularly important when the substrate and top layer have different coefficients of thermal expansion or different responses to humidity changes. By using a flexible adhesive layer, the panel can accommodate these differences without creating stress or potential separation between the layers. In some embodiments, the adhesive layer is a hot-melt adhesive layer. Hot-melt adhesives offer several advantages in this application. They can be applied and cured quickly, thus accelerating the manufacturing process. They typically also provide strong initial adhesion, which helps hold the layers together during subsequent manufacturing processes. Hot-melt adhesives can be formulated to remain flexible after cooling, which aligns with the requirement for a flexible adhesive layer in this panel design.

[0035] As defined above, the substrate is generally relatively waterproof, and since the substrate is attached to a top layer that is also generally waterproof, it is strongly preferred that the coefficients of moisture expansion (CME) of the two layers be on the same order of magnitude, and / or preferably matched. If the CMEs of the two layers differ significantly, the panel itself is prone to delamination or damage. Expansion characteristics (linear expansion and contraction within the panel plane) and swelling characteristics (thickness swelling and contraction in the direction perpendicular to the panel plane) are generally key parameters for the dimensional stability of each individual layer and the panel itself. Linear expansion values ​​are generally significantly smaller than thickness swelling values. In particular, linear expansion is considered a control factor when evaluating the behavior of each individual layer and the panel itself when exposed to moisture. The hygroscopic linear expansion of each individual panel layer within the panel plane is of practical importance for forming durable and stable floor or wall coverings using these panels. Flexible adhesives are preferably used to compensate for differences in CME.

[0036] The rigid, preferably ceramic, top layer is generally unaffected, or virtually unaffected, by expansion or contraction caused by changes in humidity in the immediate environment. Therefore, the CME of the top layer is typically zero or very close to zero. Advantageously, the substrate has a linear coefficient of humidity expansion of less than 0.015% per 1% change in substrate humidity. This means that, with a change in substrate moisture content, typically increasing by 1%, the expansion of the substrate in the panel plane is less than 0.15 mm per meter of substrate length. Preferably, the substrate has a first linear coefficient of humidity expansion, and the top layer has a second linear coefficient of humidity expansion, wherein the difference between the first and second linear coefficients is less than 0.015% per 1% change in humidity. Preferably, the substrate has a linear coefficient of shrinkage of less than 0.025% per 1% change in substrate humidity. This means that, with a change in substrate moisture content, typically decreasing by 1%, the shrinkage (water loss) of the substrate in the panel plane is less than 0.25 mm per meter of substrate length. Preferably, the substrate has a first linear humidity shrinkage coefficient, and the top layer has a second linear humidity shrinkage coefficient, wherein the difference between the first linear humidity shrinkage coefficient and the second linear humidity shrinkage coefficient is less than 0.025% per 1% humidity change.

[0037] In a preferred embodiment, the substrate has a thickness swelling coefficient of less than 0.6% per 1% change in substrate moisture content. This means that, with a change in substrate moisture content, typically increasing by 1%, the expansion of the substrate in the direction perpendicular to the panel plane is less than 0.0006 mm per millimeter of substrate thickness. Preferably, the substrate has a first thickness swelling coefficient, and the top layer has a second thickness swelling coefficient, wherein the difference between the first and second thickness swelling coefficients is less than 0.6% per 1% change in moisture content. Preferably, the substrate has a thickness shrinkage coefficient of less than 0.5% per 1% change in substrate moisture content. This means that, with a change in substrate moisture content, typically decreasing by 1%, the reduction in substrate thickness is less than 0.0005 mm per millimeter of substrate thickness. Preferably, the substrate has a first thickness shrinkage coefficient, and the top layer has a second thickness shrinkage coefficient, wherein the difference between the first and second thickness shrinkage coefficients is less than 0.5% per 1% change in moisture content. For both the top layer and the substrate, moisture expansion can be determined by applying the test described in ISO 10545. The aforementioned humidity-related properties ensure that the panel remains stable and flat under varying humidity conditions, thereby reducing the risk of warping, separation, or gap formation.

[0038] Generally, in flooring panels according to the invention, it is conceivable that a decorative surface layer (only) partially covers the top surface of the substrate, wherein at least one side edge of the substrate, preferably at least a first side edge, is not covered by the decorative surface layer. These one or more uncovered portions of the substrate can, for example, be used to form one or more bevels and / or one or more joint lines, wherein it is also conceivable that said one or more bevels are formed by partially removing a portion of the decorative surface layer. Preferably, one side edge is not covered by the decorative surface layer, while the opposite side edge is covered by the decorative surface layer. From a manufacturing point of view, this is generally preferred. Furthermore, in this way, the seams formed between panels are eccentrically positioned relative to the side edges of the joint lines or bevels, and therefore are less likely to be in direct line of sight; this is aesthetically attractive, especially when bevels (chamfers) are used.

[0039] The side surface and / or distal end of the upper lip can be straight, curved, stepped, or have other shapes. While the height of the side surface and / or the height of the upper lip at its distal end is preferably less than 1 mm, this is not excluded if the height is at least 1 mm. Preferably, the side surface of the upper lip includes a generally vertical top section and a bottom section below the top section, preferably at least partially sloping, wherein at least a portion of the top section is configured to cooperate with the top side surface of the first connecting member to define a second upper contact area, wherein the bottom section of the side surface is positioned inward relative to the top section of the side surface. Here, the bottom section may be provided with at least one cut-out portion to form a space. Preferably, the height of the bottom section is greater than the height of the top section. This provides sufficient stability to the surface, thereby significantly reducing the risk of breakage during connection and use. The preferred height of at least 1 mm is particularly advantageous when the decorative surface layer is relatively thin, for example, less than 1 mm, because in this case, the decorative surface layer does not significantly obscure or protect the substrate from breakage at the side edges.

[0040] For the aforementioned type of flooring, it has been found that undesirable sounds, particularly creaking noises, may occasionally occur when people walk on floor coverings made of such panels. Typically, these floor panels are installed on a resilient, compressible subfloor, which can be pre-installed or prefabricated beneath the panel and can serve various purposes, such as noise reduction, heat insulation, leveling the subfloor, and forming a vapor barrier. Therefore, when walking on such floor coverings, slight movements occur between the panels, mostly tilting relative to each other, which can generate noise due to friction between the connecting parts. Furthermore, due to changes in external loads, the connecting parts themselves may also deform, potentially causing the same noise when the floor covering is stepped on.

[0041] Furthermore, the aforementioned connecting mechanism aims to achieve a balance between the position-selective contact portions and the gaps or spaces formed between said contact portions, which are defined as non-functional portions. Here, employing no fewer than five contact portions and four intermediate gaps or spaces ensures that the connecting members are securely and firmly positioned in the connected state of adjacent floorboards, thereby achieving a secure and reliable connection. This connection is intended to be a backlash-free connection, wherein the connecting members are fixed and locked to each other in the connected state. This fixation prevents the connecting members of the two interconnected floorboards from shifting relative to each other at the height of the contact portions. Minor mutual movement is prevented when the floor covering composed of the interconnected floorboards is stepped on. Since most of this noise is generated at the height of the contact portions, this mutual fixation between the floorboards also results in a significant reduction in the risk of generating such noise, or even completely preventing it. Therefore, the profile of the connecting members is designed to reduce the risk of such undesirable noise even without the application of a sliding agent; however, this does not preclude the application of a sliding agent to the connecting members of the floor panel according to the invention.

[0042] Further embodiments of the flooring material according to the invention are given below. As a preliminary note, it should be noted that the flooring material according to the invention can also be applied to walls or ceilings, and / or can form part of furniture coverings, and is therefore also referred to and considered as wall paneling, wall paneling, ceiling paneling, ceiling paneling, furniture paneling, or furniture paneling. Therefore, in the following disclosure, the term "flooring material" is used interchangeably with these equivalent terms used for alternative applications, and can be generally referred to as decorative paneling, optionally laminated decorative paneling. Since the (flooring) material typically has a decorative surface layer on top of its substrate, the (flooring) material can be referred to as decorative (flooring) material.

[0043] In a preferred embodiment, the height level of the intermediate lower contact area lies between the lower height level of the front lower contact area and the higher height level of the rear lower contact area. In a more preferred embodiment, the height level of the intermediate lower contact area lies between the height levels of the front lower contact areas and the height levels of the rear lower contact areas. This forms a stepped lower contact area. This allows the front portion of the lateral tenon to be designed more robustly, thereby reducing the vulnerability and fragility of the lateral tenon during insertion into the recess and in the connected state. The more robust front portion of the lateral tenon also allows for the absorption of greater (clamping) forces. The stepped lower contact area also allows for the design of the lower lip, particularly the middle and rear sections, to be relatively robust, thereby reducing the vulnerability and fragility of these sections. Furthermore, the more robust middle section provides the desired dimensional and morphological stability to stably support the lateral tenon; this helps prevent squeaking noise when loads are applied to the connected components, even if the loads are applied in a direction perpendicular to the plane defined by the floor panel.

[0044] Preferably, at least a portion of the upper lip contact portion and at least a portion of the lower tenon contact portion are planar, collectively defining a planar lower contact area. This planar contact area ensures that the upper lip contact portion and the lower tenon contact portion maintain continuous engagement when adjacent floorboards are joined. Furthermore, by employing a planar lower contact area, the contact surface area can be predefined relatively accurately; this accuracy is generally higher than, for example, using a curved lower contact area, as curved contact surfaces can be more sensitive to tolerance variations during manufacturing, potentially leading to cavities and / or reduced contact surface area, and increasing the likelihood of squeaking noise when a load is applied to the connecting components. However, this does not preclude the use or adoption of a lower contact area with a shape different from a planar one. Preferably, at least a portion of the upper lip contact portion and at least a portion of the lower tenon contact portion are planar and extend horizontally, collectively defining a substantially horizontal planar lower contact area. This orientation results in the lower contact area not, or practically not, contributing to the application of force or pressure in a direction parallel to the plane defined by the floorboards. Therefore, the rear lower contact area defined by the synergistic action between the downward tongue contact portion of the floorboard and the rear upward lip contact portion and / or upwardly projecting locking element of the other floorboard will generate a force or pressure (if any) for pushing the floorboards closer together in the coupled state to close the joint formed between the floorboards. Preferably, the rear lower contact area may be inclined, for example, inclined in a curved manner and / or inclined in a planar manner.

[0045] The lower middle contact area is preferably larger than the front contact area, more preferably at least 1.5 times the size of the front contact area. A relatively large lower middle contact area provides reliable support for the critical portion of the lateral tenon, thereby reducing the risk of noise generation. A relatively small front contact area, due to lower friction during connection, facilitates the insertion of the (front) portion of the lateral tenon into the recess.

[0046] The middle lower contact area is preferably smaller than the rear lower contact area, preferably at most half the size of the rear lower contact area. As mentioned above, the rear lower contact area typically plays a crucial role in maintaining the closure of the joint formed between interconnected floorboards. By employing a relatively large rear lower contact area, joint closure can be ensured more reliably. For the same reason, the front lower contact area is preferably smaller than the rear contact area, more preferably at most one-third the size of the rear contact area. The height of the front lower contact area is less than the height of the rear lower contact area, preferably at most one-tenth the height of the rear lower contact area. In most embodiments, this also means that the rear lower contact area (relative to the plane defined by the floorboards) is steeper than the front lower contact area. Preferably, the rear lower contact area is larger than the sum of the front lower contact area and the middle lower contact area (i.e., the total). This provides and ensures sufficient locking between adjacent floorboards in the horizontal direction, while also ensuring sufficient and stable (triple) support for the lateral tongues in the connected state of adjacent floorboards.

[0047] Preferably, the width of each non-functional portion of the middle section of the lower lip is greater than the width of the middle portion contacting the upper lip, preferably at least twice as wide. This means that the middle lower contact area is closer to the rear lower contact area than the front lower contact area. This positioning of the middle lower contact area further helps to ensure a stable and fixed connection between the connecting components in the connected state. In the middle and rear sections, the effective support surface in the vertical direction (perpendicular to the plane defined by the floor slab) is preferably achieved by a combination of the horizontal projection of the middle lower contact area, which is preferably horizontal and preferably planar, and the horizontal projection of the rear lower contact area, which is generally inclined. Preferably, the horizontal projection of the rear lower contact area is greater than the horizontal projection of the middle lower contact area. The horizontal projection of the front lower contact area is preferably smaller than the horizontal projection of the middle lower contact area. The horizontal projection of the contact area refers to the horizontal projection of the contact area in a plane parallel to the plane defined by the floor slab.

[0048] The non-functional portion of the middle section of the lower lip, located between the front upper lip contact portion and the middle upper lip contact portion, is preferably a bent non-functional portion, more preferably a single-bent non-functional portion (i.e., a non-functional portion with a single bend), and / or includes at least one concave portion. The non-functional portion of the middle section of the lower lip, located between the front upper lip contact portion and the middle upper lip contact portion, preferably has an upper surface that slopes downward toward the front upper lip contact portion, the sloped upper surface connecting to the middle upper lip contact portion. This allows the middle lower contact area to be positioned at a higher height than the front lower contact area, achieving a (gradually) increasing thickness of the lower lip in the rearward direction, and / or allowing the lateral tenon to have a relatively stable front. The non-functional portion of the middle section of the lower lip, located between the front upper lip contact portion and the middle upper lip contact portion, preferably has a horizontal upper surface spaced apart from both the front and middle upper lip contact portions by a distance. The non-functional portion of the middle section of the lower lip is preferably configured as a guiding surface and a sliding surface to facilitate smooth and / or sliding insertion of the lateral tenon into the recess. The embodiments described in this paragraph help to facilitate smooth insertion of the lateral tenon into the recess.

[0049] The non-functional portion of the middle section of the lower lip, located between the front upper lip contact portion and the middle upper lip contact portion, and / or the front lower contact area, preferably defines the lowest point (deepest point) or lowest region (deepest region) of the lower lip.

[0050] Preferably, the non-functional portion of the middle section of the lower lip, located between the middle upper lip contact portion and the rear upper lip contact portion, is a bent non-functional portion, more preferably a single-bent non-functional portion (i.e., a non-functional portion with a single bend), and / or includes at least one concave portion. Preferably, the non-functional portion of the middle section of the lower lip, located between the middle upper lip contact portion and the rear upper lip contact portion, is provided with an upper surface that slopes upwards in a direction away from the middle upper lip contact portion, the sloped upper surface connecting to the rear upper lip contact portion. This allows the rear lower contact area to be positioned at a higher height than each of the front and middle lower contact areas. Preferably, the non-functional portion of the middle section of the lower lip and the non-functional portion of the middle section of the lateral tongue segment include mutually offset horizontal surfaces (parallel to the plane defined by the floorboard), these horizontal surfaces preferably (viewed from the vertical direction) partially overlapping each other. This allows for the formation of a relatively open / wide front intermediate gap, particularly forming a substantially rhomboid front intermediate gap.

[0051] Preferably, the non-functional portion of the middle section of the lower lip, located between the front upper lip contact portion and the middle upper lip contact portion, includes an inclined surface connected to the front downward tenon contact portion of the lateral tenon; and the inclined surface of the non-functional portion of the lower lip and the inclined top surface of the front section of the lateral tenon together define the downwardly inclined front section of the lateral tenon and / or the downwardly inclined center line of the front section of the lateral tenon. This downwardly inclined orientation facilitates the insertion of the floorboards and thereby facilitates their connection (and disconnection).

[0052] Preferably, the inclined top surface of the front section of the lateral tenon and the inclined bottom surface of the upper lip form an angle with each other, preferably greater than 0 degrees and less than or equal to 5 degrees. Preferably, the inclined bottom surface of the upper lip is steeper (more inclined) than the inclined top surface of the front section of the lateral tenon. This positions the first upper contact area closer to the end portion of the front section of the lateral tenon. This generally benefits the stability of the floorboards in the connected state.

[0053] The non-functional portion of the middle section of the lower lip, located between the middle upper lip contact portion and the rear upper lip contact portion, preferably has a horizontal upper surface portion connected to the middle upper lip contact portion, and preferably integrally formed and / or coplanar with the middle upper lip contact portion. This simplifies the design of the lower lip and facilitates its manufacturing.

[0054] The non-functional portion of the middle section of the lower lip, located between the middle upper lip contact portion and the rear upper lip contact portion, is preferably positioned at a higher height level than the non-functional portion of the middle section of the lower lip, located between the middle upper lip contact portion and the front upper lip contact portion. This allows for the use of the aforementioned stepped lower contact area while maintaining the stability of the connecting components, particularly the lower lip, as much as possible.

[0055] The non-functional portion of the middle section of the lower lip, located between the front and middle upper lip contact portions, is preferably configured to form a front intermediate gap with the non-functional portion of the middle section of the lateral tenon, located between the front and middle lower tenon contact portions. Similarly, the non-functional portion of the middle section of the lower lip, located between the middle and rear upper lip contact portions, is preferably configured to form a middle rear gap with the non-functional portion of the middle section of the lateral tenon, located between the middle and rear lower tenon contact portions. Preferably, the cross-section of the front intermediate gap is larger than the cross-section of the middle rear gap, at least twice as large. This provides more space for the lateral tenon during insertion into the recess, thus facilitating the connection process.

[0056] The non-functional portion of the middle section of the lateral tenon, located between the front downward tenon contact portion and the middle downward tenon contact portion, is preferably a bent non-functional portion, more preferably a single bent non-functional portion (i.e., a non-functional portion with a single bend), and / or includes at least one concave portion. This creates a space at the bottom surface of the middle section of the lateral tenon to ensure that the lateral tenon can smoothly insert into the concave portion.

[0057] The non-functional portion of the middle section of the lateral tenon, located between the front downward tenon contact portion and the middle downward tenon contact portion, preferably includes a horizontal lower surface portion that connects to the middle downward tenon contact portion and is preferably integrally formed and / or coplanar with the middle downward tenon contact portion. This simplifies the design of the lateral tenon and thus facilitates its manufacture.

[0058] The non-functional portion of the middle part of the lateral tenon, located between the front downward tenon contact portion and the middle downward tenon contact portion, preferably includes a lower surface portion that slopes downward in a direction away from the middle downward tenon contact portion. This sloped surface portion is located between the middle downward tenon contact portion and the front downward tenon contact portion, and is preferably spaced apart from both. As described above, this feature creates a space on the bottom side of the lateral tenon, thereby facilitating the insertion of the lateral tenon into the recess during the joining of the two floorboards.

[0059] The non-functional portion of the middle section of the lateral tenon located between the middle downward tenon contact portion and the rear d downward tenon contact portion preferably includes a lower surface portion that slopes upward in a direction away from the middle downward tenon contact portion. Preferably, this upwardly sloped lower surface portion is at least partially configured to cooperate with the lower lip to define the front lower contact area.

[0060] The non-functional portion of the middle section of the lateral tenon, located between the middle downward tenon contact portion and the rear downward tenon contact portion, is preferably a bent non-functional portion, more preferably a single bent non-functional portion (i.e., a non-functional portion with a single bend), and / or includes at least one concave portion. This more or less immediately creates a space below the lateral tenon to realize the non-functional portion in that location.

[0061] The non-functional portions and gaps formed therebetween are intentionally formed and positioned to prevent the connecting parts from working together in these locations, thereby forcing, prompting and allowing only the desired contact to occur at at least five predetermined contact areas of the flooring in the connected state.

[0062] The second upper contact area preferably defines a vertical plane (VP), through which the front lower contact area is traversed. The vertical plane (VP) preferably divides the concave region into an inner region surrounded by an upper lip and a lower lip, and an opposing outer region, wherein the front lower contact area is at least partially, preferably entirely, located in the outer region. It is conceivable and generally preferred that the portion of the front lower contact area located in the outer region is larger than, if any, the portion of the front lower contact area located in the inner region, preferably at least twice as large. It is also conceivable that the front lower contact area is entirely located in the outer region.

[0063] The width of the lower lip preferably exceeds the thickness of the substrate. It is even conceivable, and more preferably, that the width of a portion of the lower lip located in the outer region preferably exceeds the thickness of the substrate. While this results in more significant material loss during the molding of the connecting parts, this relatively long lower lip allows the contact area to be properly positioned, and / or allows the contact area to be designed to be large enough to achieve a stable, secure, and noiseless connection between the connecting parts. Similarly, in a preferred embodiment, the maximum width of the lateral tongue exceeds the thickness of the substrate.

[0064] Preferably, the side surface of the lower lip connected to the upper lip includes at least one non-functional portion, such that, in the connected state of adjacent floorboards, at least one lower front gap is formed between the lateral tenon and the non-functional portion of the lower lip. This prevents the end portion of the lateral tenon, i.e., the nose tip, from contacting the lower lip. Preferably, the side surface of the upper lip (preferably connected to the lower lip) includes at least one non-functional portion, such that, in the connected state of adjacent floorboards, at least one upper front gap is formed between the lateral tenon and the non-functional portion of the upper lip. The upper front gap is preferably located between a first upper contact area and a second upper contact area. Preferably, the second upper contact area defines a vertical plane (VP), through which the front lower contact area is traversed, and wherein the upper front gap is located on both sides of the vertical plane.

[0065] The top surface of the first connecting member of the flooring material and the side surface of the upper lip above the front-to-lower lip contact portion are preferably configured to form a tapered space that gradually narrows upwards. This tapered space is preferably located above the upper front gap, and it positions the second upper contact area on the upper surface of the substrate. The angle formed by the top surface of the first connecting member of the flooring material and the side surface of the upper lip above the front-to-lower lip contact portion can be small, and preferably less than 10 degrees, preferably between 4 and 6 degrees, for example, 5 degrees. It is conceivable that one or both of the top side surface of the first connecting member of the flooring panel and the side surface of the upper lip above the front lower lip contact portion are vertically oriented (perpendicular to the plane defined by the flooring panel); however, it is also conceivable that at least one of the top side surface of the first connecting member of the flooring panel and the side surface of the upper lip above the front lower lip contact portion is slightly inclined relative to the vertical plane (VP) defined by the joint of the flooring panel (which is perpendicular to the (horizontal) plane defined by the flooring panel itself), wherein the inclination is preferably less than 10 degrees.

[0066] Preferably, a concave transition portion, particularly a non-functional concave portion, is provided between the top surface of the first connecting member and the lateral tenon.

[0067] The floorboards are preferably configured such that the upwardly projecting locking element, particularly the rear upper lip contact portion, applies a horizontal force to the lateral tongue of the other floorboard when adjacent floorboards are joined, thereby causing the second upper contact area to actively close and / or causing the top side surface of the first connecting member to apply a horizontal force to the side surface of the upper lip. This results in an actively closed joint between the interconnected floorboards. Preferably, at least a portion of this horizontal (closing) force is generated by a horizontal force (component) applied from the rear upper lip contact portion of the first floorboard to the rear lower tongue contact portion of the second floorboard, i.e., at the location of the rear lower contact area.

[0068] Preferably, the rear lower contact area, the rear downward tenon contact portion, and the rear upward lip contact portion are all inclined and preferably extend parallel to each other, wherein the inclination angle between the board plane and each of the rear downward tenon contact portion and the rear upward lip contact portion is between 45 and 60 degrees and includes the endpoints. This inclination preferably extends upwards along the front section away from the lateral tenon and away from the upper lip, respectively. An inclination angle less than 45 degrees may affect the desired horizontal locking effect (within the plane defined by the floorboards) and fail to effectively prevent the interconnected floorboards from moving apart. An inclination angle greater than 60 degrees generally hinders the smooth insertion of the lateral tenon into the recess.

[0069] The rear section of the lateral tenon preferably has a receiving space for accommodating an upwardly projecting locking element of another floorboard, wherein the width of the receiving space exceeds the width of the upwardly projecting locking element, such that, in the connected state of the interconnected floorboards, there is a lower end gap between the distal end of the upwardly projecting element and the lower surface of the first connecting member. This lower end gap also facilitates a smooth connection between the lateral tenon and the recess. Preferably, the lower surface of the first connecting member is connected to the rear section of the lateral tenon via a preferably continuously curved transition, wherein the curved transition preferably has a constant radius and / or a variable radius between 0.5 and 1 cm. This rounded (curved) transition significantly reduces the risk of cracking in the first connecting member during the insertion of the lateral tenon of one floorboard into the recess of an adjacent floorboard.

[0070] The lower surface of the first connecting member preferably includes a planar, preferably at least partially substantially vertical surface portion, which is connected via a first curved transition portion to a higher, preferably planar, preferably inclined, downward-facing surface portion. Preferably, the higher, downward-facing surface portion is connected via a second curved transition portion to a rear downward tenon contact portion. Preferably, at least a portion of the first curved transition portion is located below at least a portion of the second curved transition portion.

[0071] At the second contact area, at least one edge of the preferred substrate, and more preferably at least one edge of the flooring itself, is recessed and / or chamfered to form a bevel or filler line. The upper portions of the two opposite side edges of the flooring can be lowered, recessed, or chamfered, which allows for the formation of, for example, V-grooves (V-shaped bevels) and / or U-shaped filler lines in the joined state of the flooring. This one or more recessed edges can be achieved, for example, by removing material from the side edges, and / or, if the substrate is made of a partially compressible material (e.g., MDF or HDF), by (compressing) the side edges.

[0072] The front lower contact area is preferably at least partially curved. This is generally advantageous because the bottom surface of the front section of the lateral tenon is typically curved or rounded to facilitate smooth insertion of the lateral tenon into the recess of another floorboard. The front lower contact area may be defined by the synergistic effect between the curved front downward tenon contact portion of the floorboard and the planar and / or inclined (non-curved) front upward lip contact portion. Additionally or alternatively, the front lower contact area may be defined by the synergistic effect between the front downward tenon contact portion of the floorboard and the upwardly projecting ridge of the upward lip contact portion. Preferably, the front lower contact area is inclined upward in a direction toward the front upward tenon contact portion. Thus, the front lower contact area may form part of the tip (and / or front section) of the lateral tenon. The front downward lip contact portion preferably defines the deepest point of the lateral tenon.

[0073] The decorative surface layer preferably comprises multiple sublayers, including a decorative printed layer and at least one translucent or transparent protective layer covering the decorative printed layer, wherein the at least one protective layer (e.g., abrasion-resistant layer) preferably comprises an embossed structure, which is preferably at least partially aligned with the decorative printed layer. The decorative printed layer preferably comprises a carrier film, such as a paper film or polymer film, on which the decorative image is printed. The thickness of the decorative surface layer can be less than 0.75 mm, or even less than 0.5 mm. It is also conceivable that the decorative printed layer is printed directly onto the substrate and / or printed onto another layer, such as a primer layer already applied to the substrate and / or preferably a white base coat. The decorative printed layer can be formed from at least one or more paper layers treated with a thermosetting resin; or from at least one or more wood veneer layers. In the case where the surface layer is at least partially formed from one or more paper layers, it preferably involves so-called DPL (Direct Pressure Laminate) panels, wherein these paper layers are impregnated with a thermosetting resin, such as a melamine-based resin. This is generally preferred when the substrate is at least partially composed of MDF or HDF.

[0074] In a preferred embodiment, the substrate includes a second pair of opposing side edges, wherein each pair of opposing side edges also includes a first connecting member and a second connecting member, respectively. This can form a so-called corner-to-corner flooring, wherein each pair of side edges, particularly the short and long sides in the case of a long flooring, is configured to be connected to another flooring by a downward cornering movement (rotational movement). However, it is also conceivable that the substrate includes a second pair of opposing side edges, wherein each pair of opposing side edges also includes a third connecting member and a fourth connecting member, which allow the flooring to be connected to a similar flooring at the respective side edge by a descending movement or a horizontal displacement movement, such that, in the connected state, the flooring and the other flooring are locked in a vertical direction perpendicular to the plane defined by the interconnected flooring and in a horizontal direction parallel to the plane. Here, it is conceivable that one of the third and fourth connecting members is the same as the second connecting member. In the case of polygonal flooring panels with four sides, such as rectangular or parallelogram flooring panels, this will produce three different types of connection profiles, specifically an in-hole type (i.e., the second connection member) and two different protruding types (i.e., the first connection member and the third (or fourth) connection member).

[0075] In a preferred embodiment, the third connecting member includes: an upward tenon, at least one upward wing spaced apart from the upward tenon, and an upward groove formed between the upward tenon and the upward wing, wherein the upward groove is adapted to receive at least a portion of the downward tenon of the fourth connecting profile of the adjacent panel, and preferably also includes at least one first locking element, which is preferably disposed on the distal side of the upward tenon away from the upward wing; and wherein the fourth connecting member includes: a downward tenon, at least one downward wing spaced apart from the downward tenon, and a downward groove formed between the downward tenon and the downward wing, wherein the downward groove is adapted to receive at least a portion of the upward tenon of the third connecting member of the adjacent floor panel, and preferably also includes at least one second locking element, which is adapted to cooperate with the first locking element of the adjacent panel, and the second locking element is preferably disposed at the downward wing.

[0076] Preferably, the first locking element includes a protrusion and / or a recess, and the second locking element includes a protrusion and / or a recess. The protrusion is generally adapted to be at least partially received in the recess of an adjacent connecting floor panel to achieve a locking connection, preferably a vertical locking connection. It is also conceivable that the first and second locking elements are not formed by a protrusion-recess combination, but rather by a combination of another synergistic shaped surface and / or a high-friction contact surface.

[0077] In the above embodiments, it is conceivable that the third and fourth connecting members are configured such that a pre-tension exists in the connected state, which forces the connected floorboards to face each other at their respective edges. This is preferably achieved by applying overlapping profiles of the third and fourth connecting members, particularly by applying overlapping profiles of the downward tenon and the upward groove and / or the upward tenon and the downward groove. This "pre-tension" between adjacent floorboards in the connected state can also similarly exist between the first and second connecting members. Therefore, at least one pair of connecting members is configured to apply one or more forces to each other in the connected state of adjacent floorboards, thereby actively causing the floorboards to face each other.

[0078] The mechanical connecting components can be entirely implemented from the substrate. It is also conceivable that at least a portion of at least one connecting component is formed from a separate piece attached to the substrate. More specifically, it is conceivable that at least one connecting component, such as a third connecting component, includes at least one locking strip configured to cooperate with a locking groove of an adjacent fourth connecting component of another floorboard. For example, the locking strip can be received in a channel or groove structure in an upward flank, while the locking groove can, for example, be located distal to a downward tenon. The locking strip is typically at least partially made of an elastic polymer and can, for example, be composed of different segments pivotally connected to each other. The locking strip, in its unloaded state, preferably extends beyond the vertical plane defined by the third and fourth connecting components in the connected state. During connection, the distal end of the locking strip typically deforms toward the vertical plane and, in the connected state, typically returns at least partially to or toward its initial position. Thus, the locking strip can be considered a separate insert that elastically moves inward and subsequently outward during downward movement when the two floorboards are connected to capture and lock the adjacent connecting components.

[0079] Optionally, the upper edges of the first pair and / or second pair of opposing side edges form a lowered edge surface. This can be used to achieve (micro)bevels and / or filler lines. As previously mentioned, this can be achieved by cutting or milling, or by (compressing) the side edges to locally shape and lower one or more of the edges. The latter may result in an increase in density at the lowered edge surface. Especially when the substrate and / or side edges are at least partially composed of a moisture-sensitive material (e.g., MDF or HDF), this increase in local density can significantly improve the water-repellent barrier properties at the edges.

[0080] In the case of a substrate based on / including MDF or HDF, the MDF or HDF material preferably has an average density greater than 600 kg / m³, and includes higher density regions at least near the decorative surface layer, wherein the higher density regions have a density of 900 kg / m³ or higher. Preferably, the MDF or HDF substrate has a density that varies substantially parabolically from the bottom to the top surface, with the highest density regions in the top and bottom portions of the substrate, and lower density regions in the central portion of the substrate. Preferably, melamine resin is infiltrated into the top portion of the substrate. The higher density regions, the melamine resin infiltration, and the pressed side edges allow the substrate to be relatively watertight (waterproof) in that location.

[0081] For MDF / HDF materials, it is preferable to use MDF / HDF materials comprising wood fibers bonded by urea-formaldehyde (UF) glue, melamine-formaldehyde (MUF) and / or polymeric methylene diphenyl diisocyanate (PMDI). Preferably, the substrate and / or the MDF / HDF material of the substrate includes at least one formaldehyde scavenger to reduce formaldehyde release from the substrate. In this regard, an aqueous solution of urea (40% or 45% solids content) is used in most cases. Additionally or alternatively, reagents such as sodium metabisulfite (Na2S2O5), ammonium bisulfite ((NH4)HSO3), or ammonium phosphate may also be used. By using MUF-based glue, the MDF / HDF composition can be made more water-resistant (more moisture-resistant), wherein the melamine content is about 12–23%, particularly 12–15%. Based on dry wood, the glue content is in the range of 12–13% by weight.

[0082] The MDF or HDF material comprises wood fibers bonded together with an adhesive, which is preferably substantially formaldehyde-free due to the toxicity and volatility of formaldehyde. This can be achieved, for example, by using PMDI as the adhesive. However, since most commercially available isocyanates are derived from petrochemicals, PMDI may still pose problems in the future. Therefore, one or more bio-based adhesives are becoming increasingly preferred in MDF or HDF substrates. Bio-based adhesives used for MDF or HDF substrates are preferably derived from at least one of proteins, cottonseed, soybean, lignin, and tannins.

[0083] The main appeal of using tannins in MDF or HDF lies in their similarity to formaldehyde, phenol, and resorcinol in terms of reactivity and cross-linking chemistry. Preferably, condensed tannins are used, which are polyphenolic materials and typically include oligoflavonoid structures derived primarily from the heartwood or bark of various tree species.

[0084] Lignin is commonly found in lignocellulosic materials, such as wood and agricultural residues. Typically, it is a high-molecular-weight polymer based on aromatic phenylpropane units, existing in a dense, cross-linked structure. Lignin, mixed with other major types of polymer chains present in the lignocellulosic structure, acts as a glue binding cellulose and hemicellulose chains together, thereby providing increased rigidity to the structure and greater microbial resistance to the cell wall.

[0085] The MDF or HDF material is preferably made flame-retardant by adding at least one flame retardant to the MDF or HDF, such as monoammonium phosphate and diammonium phosphate, boric acid and / or borax. Typically, these flame retardants are used in combination with MUF adhesives, preferably with MUF adhesives containing 15–18% melamine by weight.

[0086] In a preferred embodiment, this MDF or HDF material (or other substrate material) includes, in addition to wood fibers, or optionally instead of wood fibers, fibers and / or particles of at least one non-wood material. The non-wood material is preferably selected from the group consisting of: paper, cork, bamboo, hemp, hemp cloth, flax, jute, sisal, coconut fiber, palm fiber, banana fiber, plant fibers, cotton, felt, and (synthetic and / or natural) leather. Therefore, the non-wood material is preferably (also) a natural material. Many of these fibers, such as bamboo fiber, palm fiber, and / or coconut fiber, have improved water resistance compared to wood fibers, which generally results in a relatively water-resistant substrate. Coconut fiber is typically derived from immature coconuts and is a natural fiber extracted from the coconut shell. The coconut is soaked in hot seawater, and the fibers are then removed from the shell by combing and crushing, a process similar to that of jute fiber. Typically, individual fiber cells are narrow and hollow, with thick walls made of cellulose, and each cell is about 0.8–1.2 mm long and about 10–20 μm in diameter. Coconut fiber, due to its relatively high lignin content, is relatively elastic, durable, and rot-resistant, and is therefore preferably incorporated into the substrate and / or one or more other paneling layers of the decorative panels according to the invention. Bamboo, particularly Andong bamboo (Gigantochloa pseudoarundinacea), Betung bamboo (Dendrocalamus asper), Sembilang bamboo (D. giganteus), and Kuning bamboo (B. vulgaris var striata), also has a relatively high lignin content, at least 25% of the weight of the bamboo material. Bamboo possesses natural moisture resistance due to the presence of a substance called "bamboo kun," an antimicrobial agent that helps resist moisture-related problems such as rot and decay. Therefore, bamboo is generally more resistant to water damage than wood, making it preferable to incorporate bamboo materials, particularly bamboo fibers, into the substrate (and / or one or more other layers) of decorative panels. The substrate may be completely free of wood fibers, especially when using one or more of the aforementioned alternative (non-wood) fibers and / or one or more alternative fillers. Such alternative fillers are preferably at least one additive selected from the group consisting of: talc, chalk, wood, calcium carbonate, titanium dioxide, calcined clay, porcelain, glass particles, glass fibers, carbon particles, silicon particles, another mineral filler, rice, textile fibers (e.g., cotton fibers), and another natural filler.

[0087] Preferably, the central portion of the substrate, particularly the MDF or HDF substrate, is more porous than the top and / or bottom portions of the substrate. This means the central portion can absorb more liquid material than the top and / or bottom portions. If the liquid is moisture (water), it can cause various undesirable effects, such as edge curling or premature wear. To reduce or even eliminate this risk and make the MDF or HDF substrate more water-resistant (more waterproof), preferably, at least one side edge of the substrate and / or flooring material itself is treated with at least one waterproof barrier agent, wherein the waterproof barrier agent is preferably water-impermeable and / or moisture-proof.

[0088] Preferably, the waterproof barrier agent is at least partially impregnated into the at least one side edge, wherein the waterproof barrier agent is preferably selected from the group consisting of at least one (polymeric) MDI (methylene diphenyl diisocyanate), at least one epoxy resin, at least one fluorinated copolymer, acetic anhydride, shellac, linseed oil, or combinations thereof. Shellac is a natural biocompatible polymer, which is a mixture of polyester and monoester that is insoluble in water but soluble in ethanol or ether. For example, shellac can be dissolved in 95% alcohol to prepare a shellac solution with a concentration of 10-20% by weight. Like linseed oil, shellac can improve the stability of MDF or HDF. Both agents exhibit good permeability in MDF and HDF materials, and the coefficient of thermal expansion of wood in the tangential and radial directions is significantly reduced, which improves the dimensional stability of the wood and thus improves the dimensional stability of the MDF or HDF material itself. The penetration depth of the impregnated waterproof barrier agent is preferably less than 10 mm, and more preferably between 3 and 10 mm. Before and / or during impregnation, the substrate and / or side edges to be treated may be heated to open or enlarge the pores in the substrate, thereby facilitating impregnation and allowing for deeper impregnation. The temperature to which the substrate and / or side edges to be treated are heated may vary, but is preferably between 30 and 100°C. When only the top portion of the substrate (above its centerline) is treated, a generally parabolic impregnation depth profile can be observed, which is partly due to the lower permeability (fewer pores) of the upper part of the top portion. The impregnation depth is preferably between 10% and 100% relative to the thickness of the substrate, or between 20% and 75%.

[0089] Additionally or alternatively, it is conceivable that the waterproof barrier agent is at least partially coated onto the at least one side edge, wherein the waterproof barrier agent is preferably selected from the group consisting of nano-clay, micron-clay, microcrystalline wax, polytetrafluoroethylene (Teflon), or combinations thereof. It may, for example, involve particles of bentonite clay or amorphous silica. Preferably, the particles of such a coating agent have an average particle size of less than 100 micrometers, and more preferably less than 30 micrometers.

[0090] Additionally or alternatively, the waterproof barrier agent is a superabsorbent material, preferably comprising sodium polyacrylate (SPA) crystals. The term "superabsorbent material" refers to a water-swellable, water-insoluble organic or inorganic material, including superabsorbent polymers and compositions thereof, which, under most favorable conditions, can absorb at least about 10 times, at least about 15 times, or at least about 25 times its weight in an aqueous solution containing 0.9% by weight of sodium chloride.

[0091] At least one side edge of the substrate can be treated with at least two different waterproofing barrier agents. Here, the at least two different waterproofing barrier agents can be of different types, preferably selected from the group consisting of impregnating agents, coatings, and superabsorbents. It is also conceivable to use at least two waterproofing barrier agents of the same type, such as two or more coatings. In the latter case, the at least two different waterproofing barrier agents are preferably laminated on the side edge. This multilayer coating can be used to ensure that the most moisture-sensitive parts of the side edge are completely covered by the waterproofing barrier agent. Optionally, a primer layer can be applied to the side edge before applying one or more waterproofing barrier-based coatings.

[0092] Preferably, the concentration of the waterproof barrier agent in the top portion of the side edge is lower than the concentration of the waterproof barrier agent in the lower portion located below the top portion. Therefore, the concentration of the waterproof barrier agent can vary along the thickness direction of the substrate. Preferably, the impregnation depth profile is parabolic and / or droplet-shaped.

[0093] In a preferred embodiment, the top portion of at least one side edge of the substrate is treated with at least one waterproof barrier agent, while the bottom portion of the side edge is free of the waterproof barrier agent. Since the top portion is the most critical part of the substrate's side edge, as water (moisture) typically seeps from the top surface of the flooring into the joints (junctions) of adjacent, preferably interconnected, flooring panels, it is preferable to treat this portion with a waterproof barrier agent. To save materials and costs, the bottom portion may remain free of the waterproof barrier agent.

[0094] The waterproof barrier agent can be sprayed onto the substrate portion to be treated. Spraying is preferred because it allows for the application of more liquid. Alternatively or additionally, the waterproof barrier agent can be applied to the substrate portion to be treated. The waterproof barrier agent can be applied by roller coating, for example, using at least one transfer roller. This transfer roller is rotatable about its axis and can apply the waterproof barrier agent to side edges and / or bevels and / or other portions of the substrate to be treated with the waterproof barrier agent. For example, the transfer roller can pick up the waterproof barrier agent by rotating it in a bath containing the waterproof barrier agent. Alternatively or additionally, the waterproof barrier agent can be applied using vacuum techniques, such as those described in DE9202976U.

[0095] It is conceivable to print, preferably digitally print, at least a portion of the waterproof barrier onto the side edges and / or bevels and / or other portions of the substrate to be treated with the waterproof barrier. This allows for precise positioning of the waterproof barrier onto the substrate. This allows for complete coverage of the desired location on the substrate with the waterproof barrier, while the remaining portions, where the waterproof barrier is not needed, remain free of it. Furthermore, printing the waterproof barrier reduces waste. In the case of printing, the waterproof barrier forms a component of the ink composition used for printing. Thus, in this embodiment, the ink composition for printing the waterproof barrier includes at least one waterproof barrier and / or is formed from at least one printable waterproof barrier. The ink composition may include at least one colorant, such as a pigment, to provide color to the ink composition, which can be used for localized coloring of the substrate, for example, at one or more bevels (cissors) and / or caulking lines of the substrate. In this way, the desired color can be imparted to the bevels and / or caulking lines during manufacturing, and this color remains visible in the final decorative flooring. Optionally, after applying / printing the preferably colored ink composition, the ink composition can be covered with at least one protective coating, preferably transparent or translucent. It is conceivable that a water-repellent barrier applied to the bevel and / or any other portion of the substrate can be configured to act as a coating, particularly a water-impermeable coating, optionally set in a selected color. Preferably, the protective coating is water-impermeable. A portion of the protective coating can be applied to the (substantially vertical) sides of the substrate to similarly cover and thus protect the side edges (corners) of the bevel. The protective coating can be applied in a liquid state and subsequently cured, preferably UV cured. Optionally, the protective coating is applied to the printed ink composition while the ink composition is still at least partially liquid, and then, during the curing step, the ink composition and the protective coating are at least partially cured together. It is also conceivable that the protective coating is applied in a liquid state to the printed ink composition while the ink composition is in a dry and / or cured state, and then, during the curing step, the protective coating is at least partially cured. It is conceivable that an ink composition for printing a waterproof barrier agent onto a substrate, particularly onto one or more beveled edges of the substrate, is configured to serve as a primer layer to promote and / or improve the adhesion of the at least one protective coating applied thereon. Alternatively or additionally, the coating may be applied not in a liquid state, but in a solid state, for example, by transfer printing.

[0096] As described above, the flooring material has a lowered edge region located in the top surface on at least one pair of edges, which is preferably in the form of a straight or curved bevel (chamfer). Preferably, the bevel is a so-called pressed bevel, more preferably obtained during the same pressing operation as applying a decorative surface layer to the substrate. During the pressing operation and / or during bevel formation, the bevel may be at least partially covered by the decorative surface layer, or may not be covered by the decorative surface layer. The latter embodiment allows for effective impregnation of the bevel and also allows for different appearances to be given to the bevel, such as different colors. Pressed bevels also have the additional advantage that the density increases during the pressing operation, which in itself generally improves the moisture resistance of the bevel; and the moisture resistance of the bevel is further increased and improved by further treating the bevel with at least one water-repellent barrier agent and optionally at least one protective coating.

[0097] Preferably, at least one waterproof barrier agent is selected from the group consisting of: polyurea, polyurethane, at least one silicone, particularly at least one organopolysiloxane (silicone), hydrophobic polymers having aliphatic hydrocarbon groups (preferably having 6 to 34 carbon atoms), at least one acrylate, at least one alkyd resin, alkyd resin modified with polyurethane, alkyd resin modified with fluorine, epoxy resin (e.g., fluorinated epoxy resin), styrene-butadiene copolymer, and combinations of two or more of these waterproof barrier agents. When using acyl compounds, they can be, for example, acrylates, methacrylates, fluorinated acrylates, fluorinated methacrylates, fluorinated acrylate copolymers, (per)fluoroalkyl (meth)acrylates or (per)fluoroalkyl (meth)acrylate copolymers, styrene acrylates, polyurethane acrylates, when (per)fluoroalkyl (meth)acrylates or (per)fluoroalkyl (meth)acrylate copolymers are used. If fluorinated side chains are used, they preferably include four, five, or six carbon atoms containing fluorine atoms, and / or preferably at least some of the fluorinated side groups are based on perfluorobutane sulfonic acid.

[0098] Typically, waterproofing barrier agents are applied in a liquid and / or solvent-based state. The solvent preferably comprises at least one component selected from the group consisting of: water, ethylene glycol ether, propylene glycol methyl ether, propylene glycol methyl ether acetate, hydrocarbons, preferably aliphatic hydrocarbons and / or isomers, butyl acetate, propyl acetate—for example, 3-methoxy-3-methyl-1-butyl acetate (MMB-AC) or 1-methoxy-propyl acetate (MPA), diesters, ethylene glycol diether, benzoate esters, and / or tetramethoxy ether. For safety reasons, the solvent preferably has a flash point above 30°C, more preferably above 35°C, even more preferably above 55°C, and most preferably above 60°C.

[0099] Additionally or alternatively, the waterproof barrier preferably comprises at least one hydrophobic polymer, at least one hydrophobic polycarbodiimide, and / or at least one hydrophobic polyurethane or at least one hydrophobic acrylate polymer. Preferably, the hydrophobic polymer comprises an aliphatic hydrocarbon group, preferably having 6 to 40 carbon atoms. Preferably, the hydrocarbon group comprises at least 8 carbon atoms, even more preferably at least 10 carbon atoms, and most preferably at least 12 carbon atoms. Also preferably, the hydrocarbon group comprises at most 30 carbon atoms, even more preferably at most 28 carbon atoms, and most preferably at most 26 carbon atoms. Thus, the hydrocarbon group can, for example, comprise 12 carbon atoms, 16 carbon atoms, such as hexadecyl (C16H33), 18 carbon atoms, such as octadecyl (C18H37), or 22 carbon atoms. A type of hydrophobic polymer comprising at least one, two, or more aliphatic hydrocarbon groups, wherein these aliphatic hydrocarbon groups preferably comprise 6 to 40 carbon atoms, can be used. Therefore, for example, hydrophobic polycarbodiimide having only at least one, two, or more aliphatic hydrocarbon groups can be used. Various types of hydrophobic polymers can also be used, such as mixtures including hydrophobic polycarbodiimide and hydrophobic acrylate polymers. The hydrocarbon group can also be referred to by the term "hydrocarbon group". Aliphatic hydrocarbon groups refer to non-aromatic hydrocarbon groups. Preferably, a hydrocarbon group refers to a group having only hydrogen (H) and carbon (C). However, halogenated hydrocarbon groups may also be present, such as halogenated hydrocarbon groups having one, two, or more fluorine atoms. At least one hydrocarbon chain can be a straight chain. At least one hydrocarbon chain can be branched. If used, the aliphatic hydrocarbon group can be a cyclic aliphatic hydrocarbon group (alicyclic hydrocarbon group).

[0100] When at least one hydrophobic polymer is used as a waterproof barrier agent or as part of said waterproof barrier agent, the hydrophobic polymer is preferably selected from the group consisting of: hydrophobic polyurethane, hydrophobic acrylate, hydrophobic vinyl acetate, hydrophobic alkyd resin, hydrophobic methacrylate, hydrophobic polyester resin, hydrophobic hybrid alkyd-acrylic resin, hydrophobic hybrid polyurethane-acrylic resin, long-oil-content low-viscosity alkyd resin based on dry vegetable fatty acids, hydrophobic polycarbodiimide, or hydrophobic polyvinyl alcohol. The hydrophobic polymer can be a hydrophobic polymer composed of 3 to 10 units. The aliphatic hydrocarbon group can form part of an acrylate group or a methacrylate group. It is conceivable that the hydrophobic polymer is a hydrophobic polyurethane comprising 2 to 12 acrylate groups and / or methacrylate groups, wherein each of these acrylate groups and / or methacrylate groups comprises an aliphatic hydrocarbon group, which may be the same or different from each other, and preferably has 2 to 40 carbon atoms, wherein preferably at least one of these aliphatic hydrocarbon groups comprises at least 8 carbon atoms. The hydrophobic polymer may be fluorine-free. Preferably, the hydrophobic polymer constitutes part of a mixture that is completely free of fluorine atoms. Alternatively, the mixture may include a limited amount of fluorine, for example, less than 1 wt% fluorine, preferably less than 0.5 wt%, more preferably less than 0.1 wt%, or even less than 0.01 wt%. Fluorine may be present in the form of an organic or inorganic fluorinated compound. The hydrophobic polymer may be a silicon-containing compound, such as a siloxane, silicone, or silane, for example an organosilane, such as a silane comprising, for example, hexadecyl and / or alkoxysilanes. The hydrophobic polymer may be a hydrophobic polycarbodiimide obtained by a carbodiimide reaction (i.e., a reaction forming (N=C=N) groups), the carbodiimide reaction being carried out by a carbodiimide reaction mixture comprising at least one oligomer, wherein the oligomer comprises at least one (usually one) isocyanate end group and at least two repeating units, each of the at least two repeating units having at least one (usually one) hydrocarbon group comprising at least 4 carbon atoms (and in some embodiments, up to 60 or up to 30 carbon atoms). The hydrophobic polycarbodiimide can be obtained by carbodiimide reaction of a reaction mixture comprising 4,4'-methylenebis(phenyl isocyanate) and acrylate oligomers in a molar ratio of 2:1 to 10:1; the acrylate oligomers are prepared by reacting an oligomer reaction mixture containing mercaptoethanol and octadecyl acrylate in a molar ratio of 1:4 to 1:20, or by reacting an oligomer reaction mixture comprising mercaptoethanol and the reaction product of octadecyl isocyanate and 2-hydroxyethyl(meth)acrylate, or the reaction product of octadecyl isocyanate and 2-isocyanate ethyl(meth)acrylate, wherein mercaptoethanol and the reaction product are converted in a molar ratio of 1:4 to 1:20.It is conceivable that the hydrophobic polycarbodiimide is obtained by the dehydrogenation and desulfurization reaction of urea (e.g., thiourea) and / or by the carbodiimide reaction of isocyanates. Here, "oligomer" preferably refers to a compound having at least 2 and at most 20 repeating units. According to one embodiment, the oligomer has 3 to 15 repeating units. According to another embodiment, the oligomer has 4 to 15 repeating units. In some embodiments, the oligomer has an average molecular weight of up to 50,000 g / mol. These oligomers may also be referred to as polymers, such as short polymers.

[0101] One type of hydrophobic polymer having an aliphatic hydrocarbon group having 6 to 40 carbon atoms can be used. However, two or more types of hydrophobic polymers can also be used, each having at least one aliphatic hydrocarbon group having 6 to 40 carbon atoms. Therefore, for example, a combination of two or more hydrophobic polymers selected from the following can be used: hydrophobic polyurethanes, hydrophobic acrylates, hydrophobic vinyl acetate, hydrophobic alkyd resins, hydrophobic silicon-containing compounds, hydrophobic methacrylates, hydrophobic polyester resins, hydrophobic hybrid alkyd-acrylic resins, hydrophobic polycarbodiimides, or hydrophobic hybrid polyurethane-acrylic resins. Two or more hydrophobic polymers of the same type but different from each other can also be used. Therefore, hydrophobic polyurethanes comprising different hydrocarbon groups can be used.

[0102] After the hydrophobic polymer is applied to the decorative panel, the aforementioned aliphatic hydrocarbon groups or groups of aliphatic hydrocarbon groups of the hydrophobic polymer are preferably oriented away from the panel, for example, outwardly, and thus ensure the water-repellent / water-resistant properties of the decorative panel. The more carbon atoms included in the aliphatic hydrocarbon groups, the stronger the water-repellent properties. These hydrophobic polymers ensure that water cannot pass through the seams between panels and / or ensure that water cannot penetrate into the porous components of the panel. The water-repellent / water-resistant properties are obtained without the need for fluorine atoms. These aliphatic hydrocarbon groups have no negative impact on the environment or human health. Therefore, they are not persistent in the environment and do not cause bioaccumulation. Hydrophobic polymers comprising one or more aliphatic hydrocarbon groups having 8, 12, 16, 18, or 22 carbon atoms have good moldability. The hydrophobic polymer can be directly or indirectly bonded to the decorative panel, for example, bonded to the edge of the decorative panel or some other surface. In one specific embodiment, the aliphatic hydrocarbon groups are linear aliphatic hydrocarbon chains, preferably having the formula CnH2n+1, where n is 6 to 40. These linear hydrocarbon chains are typically oriented linearly away from the decorative panel orientation, thus providing excellent water repellency without, for example, causing steric hindrance between the multiple aliphatic hydrocarbon chains. In this way, the amount of hydrophobic polymer used to achieve the desired water resistance / repellency can be limited. In one specific embodiment, the hydrophobic polymer comprises two or more of the aforementioned linear aliphatic hydrocarbon chains, wherein these linear aliphatic hydrocarbon chains may be the same or different from each other. In a highly preferred embodiment, the hydrophobic polymer is fluorine-free. In a highly preferred embodiment, paraffin wax, such as paraffin beeswax, is also present in the mixture, and preferably the mass ratio of (hydrophobic polymer, such as polycarbodiimide + paraffin) to (the aforementioned polymer selected from alkyd resins, acrylate resins, polyurethane-modified polyesters, silanes, siloxanes, or mixtures thereof) is 10:90 to 90:10, preferably 70:30 to 95:5. Preferably, the hydrophobic polymer constitutes part of a solvent-based mixture, or alternatively, part of a water-based mixture.

[0103] Optionally, the waterproof barrier agent includes one or more additives, such as those selected from surfactants, antifreeze agents, coagulants, solubilizers, emulsifiers or stabilizers, desiccants, catalysts, colorants, and microbial agents (antimicrobial agents) targeting one or more microorganisms.

[0104] In a preferred embodiment, the waterproof barrier agent comprises a mixture of MDI (diphenylmethane diisocyanate) and at least one fluorinated copolymer. Preferably, less than 20 parts of the fluorinated copolymer, or even less than 10 parts or less than 5 parts of the fluorinated copolymer, are applied relative to every 100 parts of MDI. The fluorinated copolymer tends to fill areas of the MDF / HDF that are not treated with MDI. According to a variant of this particular embodiment, a waterproof barrier agent comprising primarily MDI and possibly a solvent is first applied, followed by an impregnating agent comprising primarily a fluorinated copolymer and possibly a solvent, wherein the fluorinated copolymer is preferably present at a dosage of less than 20 parts per 100 parts of solvent. According to this variant, the subsequent treatment is able to better fill areas that are not treated with MDI because the subsequent treatment is more effectively attracted to these areas after the MDI has already been at least partially impregnated into the MDF / HDF material. The solvent may include, for example, butyl acetate or propyl acetate, such as 3-methoxy-3-methyl-i-butyl acetate (MMBAC) or 1-methoxy-propyl acetate (MPA), diesters, ethylene glycol diethers, such as dipropylene glycol dimethyl ether, benzoates, diphenylmethane or diphenylethane, such as butyl diphenylmethane and / or butyl diphenylethane, or tetramethoxy ethers. It has been found that the use of non-aqueous solvents causes the waterproofing barrier to penetrate deeper into the side edges of the flooring substrate. The solvents listed above also have high flash points, making them safe for use in industrial environments. Acetone or ethyl acetate may also be used when flash point is considered less important.

[0105] As described above, it is conceivable that the waterproofing barrier agent comprises at least one superabsorbent material. Preferably, the superabsorbent material comprises sodium polyacrylate (SPA) crystals. These crystals can be very small, for example, having an average particle size of less than 150 micrometers, preferably less than 100 micrometers, in the unswollen state, such that they hardly interfere with the bonding geometry, such as a bonding geometry with mechanically connected parts. Preferably, the average particle size is 5 micrometers or larger, preventing it from entering the gaps between the fibers of the MDF / HDF material. According to another example, the absorbent material particles can involve bentonite clay, amorphous silica, or bleaching clay particles, such as palygorskite and / or attapulgite. Preferably, the superabsorbent material can be applied in a separate step from the application of at least one waterproofing barrier agent, for example, with an impregnating agent. This proves particularly advantageous when the impregnating agent is MDI, as the superabsorbent material, especially SPA, tends to increase the viscosity of the MDI-SPA mixture, thereby resulting in shallower penetration of the impregnating agent. Preferably, the superabsorbent material, such as the SPA crystals described above, is applied in the form of a liquid dispersion, or by a powder coating or spreading operation.

[0106] In another preferred embodiment, at least one side edge of the substrate, such as a first side edge, is provided with a first reactant, and at least one other side edge of the substrate, such as a second side edge, is provided with a second reactant, wherein the first and second reactants are configured to react with each other upon contact during and / or after the joining of adjacent floorboards, thereby forming a waterproof barrier between the floorboards. The first reactant may, for example, comprise at least one isocyanate, and the second reactant may, for example, comprise at least one polyol and / or at least one polyfunctional amine. This allows the formation of a waterproof barrier during and / or after the joining of adjacent floorboards. The waterproof barrier formed by chemical reaction in this way can also result in additional fixation of the interconnected floorboards, as the waterproof barrier can also act as an adhesive, for example. Compared to solvent-based waterproof barriers, this multi-component (reactive) approach, also known as 2K, can have significant advantages, such as relatively low energy costs, relatively short processing times, relatively low (or even no) volatile organic compound (VOC) content, and availability of high-quality chemicals.

[0107] In another preferred embodiment, at least one side edge of the substrate, such as a first side edge and / or a second side edge, preferably each side edge of the substrate, is provided with a waterproof coating. This coating can be or include at least one coating selected from the group consisting of: silicone coatings, epoxy coatings, rubber coatings, acrylic coatings, polyurea coatings, polyurethane coatings, particularly thermosetting polyurethane coatings, and hydrophobic coatings. The coating can be a chemical reaction product formed directly on the side edge after the application of the chemical reactants required to form the coating. For example, in the case of a polyurea coating, the coating is preferably prepared by a chemical reaction between an isocyanate component and a resin blend component, which preferably occurs at least partially when applied to the side edge. This reaction is typically carried out using specialized spraying equipment, allowing for rapid and seamless application. Here, the isocyanate component is typically a diisocyanate, which is a compound containing two isocyanate functional groups. Common examples include diphenylmethane diisocyanate (MDI) and hexamethylene diisocyanate (HDI).

[0108] The resin blend component consists of a combination of amine-terminated or hydroxyl-terminated components. These components react with isocyanates to form polyurea polymers. In the case of thermosetting polyurethane coatings, the reactants used to form such coatings include polyols, isocyanates, and crosslinking agents. Polyols are compounds having hydroxyl (OH) groups, isocyanates have isocyanate (NCO) groups, and crosslinking agents typically contain multiple functional groups, such as hydroxyl or amine groups. Polyols and isocyanates are mixed to form a prepolymer. This mixture can be further combined with a crosslinking agent. The reaction between the polyol and isocyanate results in the formation of urethane bonds and a three-dimensional network of crosslinked polyurethane, leading to the thermosetting behavior of the coating. In the case of coatings formed by chemical reactions, it is conceivable to premix the two (or more) components (reactants) before applying them to the side edges, or to apply them substantially simultaneously to the side edges. Depending on the components used and / or the application method, the surface of the coating can be relatively smooth or relatively rough. A smooth coating surface generally facilitates the bonding process of adjacent decorative panels at their side edges, which is usually preferred. A rougher coating surface may also be preferred where opposing and typically joined coatings applied to the interlocking side edges of different floorboards are intended to form a waterproof barrier and / or waterproof labyrinth between the coatings to prevent water penetration into the joints formed between the interconnected floorboards. The impermeable coating may cover the entire side edge or only a portion thereof. Additionally or alternatively, the impermeable coating may at least partially cover the bevel and / or caulking line of at least one side edge and / or the bevel and / or caulking line connected to at least one side edge. Additionally or alternatively, the impermeable coating may cover another portion of the substrate (different from the side edge).

[0109] In a preferred embodiment, at least one side edge of the substrate and / or at least one connecting member is treated at least partially with at least one anti-friction material, which preferably comprises magnesium oxide and / or hydrated magnesium silicate, and may be formed from and / or comprise serpentine (powder), for example. The serpentine powder is derived from the crushing and grinding of natural diagenetic serpentine minerals. The ideal formula for serpentine is Mg6(Si4O10)(OH)8, wherein it should be noted that derivatives, such as Mg5.82Al0.02Fe0.05Ca0.01K0.07Mn0.01(Si4.21O10.36)(OH)8, may also be used. Optionally, in other alternative serpentines, the aluminum and / or iron and / or calcium and / or potassium and / or manganese portions may be omitted, and / or the molar ratios of the aforementioned referenced atoms (or oxides) may differ. This anti-friction material allows the coefficient of friction to be adjusted to a desired level, particularly facilitating the connection of connecting members of adjacent floorboards and preventing damage to the connecting members during connection. This friction-reducing substance acts as a lubricant. Optionally, it can also act as a waterproof barrier.

[0110] Additionally or alternatively, it is preferred that at least one exposed portion of the (MDF / HDF) substrate surface, preferably a side surface, is a heat-treated surface, particularly a laser-treated surface and / or an ironed surface, and / or has a heat-treated skin, particularly an ironed skin. This can be achieved, for example, by heating an iron, for instance, at a temperature of about 180°C, which can press against at least one side edge and / or at least one bevel of the substrate for a short time, typically 1 to 8 seconds. This heat treatment locally seals pores or other openings in the substrate surface and typically eliminates fiber bulging simultaneously. This results in a sealed, particularly airtight, surface of the substrate after ironing, making water penetration more difficult or even impossible. Additionally or alternatively, a laser can be used to locally alter the structure and / or chemical composition of the skin of the treated substrate surface, producing a sealing (and / or scorching) effect that further hinders moisture penetration.

[0111] In addition to locally (location-selectively) heat-treating the MDF / HDF substrate as described above, it is also conceivable to heat-treat the entire substrate before attaching the decorative surface layer. For this purpose, the substrate can be compressed for a short time, typically 5 to 10 minutes, using a preferred hydraulic press, during which time the substrate undergoes heat treatment, typically at a temperature between 170 and 250°C. Above 250°C, the urea-formaldehyde adhesive optionally used in the MDF / HDF substrate may degrade, which is undesirable. This method significantly improves the dimensional stability and water resistance (moisture resistance) of the MDF, particularly when the substrate is heat-treated at approximately 225°C for about 10 minutes (after sheet fabrication and before the application of the decorative surface layer).

[0112] In a preferred embodiment, the top and / or bottom sections of the substrate comprise melamine, and the central section (viewed vertically from the substrate) preferably does not contain melamine. Preferably, if beveled edges are used in the substrate, these beveled edges do not contain melamine. Preferably, the top section of the substrate comprises melamine in its central portion and a waterproof barrier in its peripheral edge portion, preferably at the location of one or more beveled edges. The waterproof barrier can form an interface with the melamine within the substrate. In the case of a rectangular panel, and viewed from a top view, the top section of the substrate will include a circumferential edge with a waterproof barrier surrounding the central portion containing melamine. Melamine also contributes to the waterproofness of the substrate and generally also improves the mechanical properties and / or dimensional stability of the substrate.

[0113] The flooring panels according to the invention typically have a rectangular or parallelogram shape (viewed from top view). Preferably, the flooring panels are elongated, although square panels are also conceivable.

[0114] Preferably, the substrate is at least partially made of at least one MDF (or HDF) layer, wherein a majority of the wood fibers of the MDF material are oriented (aligned). This can be achieved, for example, by applying an electric field and / or by physical manipulation during substrate manufacturing. MDF or HDF substrates achieving fiber orientation are known in themselves and are generally abbreviated as oriented MDF or oriented HDF. In MDF (and HDF), the fiber orientation is primarily horizontal, having an in-plane orientation. These in-plane orientations can be random or partially aligned. Since wood fibers tend to swell in the transverse direction rather than the longitudinal direction when absorbing moisture, for elongated substrates (and elongated floorboards), it is preferable that a pair of long edges, preferably a pair of long edges provided with a first connecting member and a second connecting member, extend in a direction substantially perpendicular to the average or dominant fiber orientation. This is advantageous because when these edges come into contact with water, the swelling of the long edges will be reduced due to the greater length of the fibers oriented along the edges. Since the long edges of the floorboard are generally most prone to visible swelling due to their length, this orientation of the long edges relative to the average or dominant fiber orientation is preferred. Preferably, the in-plane fiber orientation is such that the fiber portion extending in the x-direction (ax) and the fiber portion extending in the y-direction (ay) have a ratio ax:ay > 1, where x represents the x-direction, which is preferably perpendicular to a pair of side edges, particularly the pair of long side edges, and where y represents the y-direction, which is preferably perpendicular to another pair of side edges, particularly the pair of short side edges. Preferably, the fiber portion extending in the transverse direction (z-direction or vertical direction) (az) is significantly smaller than the in-plane oriented fiber portion. Preferably, az is smaller than ay (and therefore also preferably smaller than ax).

[0115] In a preferred embodiment, the substrate comprises multiple substrate layers. Different substrate layers may have different material compositions. It is conceivable that at least two substrate layers have the same composition. In the case of an MDF (or HDF)-based substrate, it is preferable that the substrate comprises at least two MDF-based substrate layers and at least one intermediate layer located between adjacent MDF-based substrate layers. The intermediate layer is preferably a reinforcing layer. This reinforcing layer preferably has an open structure (mesh or grid structure) to allow an adhesive, such as UF adhesive, to chemically bond (glu) adjacent MDF-based substrate layers through the reinforcing layer. The reinforcing layer may, for example, be a mesh, a woven layer, or a nonwoven layer. The intermediate layer may, for example, consist at least in part of at least one of the following materials: metals, such as aluminum and / or stainless steel; rubber; synthetic materials; glass, especially glass fiber; carbon, especially carbon fiber; flax; natural materials; textiles, especially natural fibers; and / or graphite. Preferably, at least one intermediate layer, particularly the reinforcing layer, is embedded in an epoxy resin or other resin prior to the manufacture of the substrate. This allows for better bonding between the intermediate layer and adjacent substrate layers. Preferably, at least one reinforcing layer is located in the upper half of the substrate thickness. More preferably, at least one reinforcing layer is disposed at a position equal to 10 to 40% of the substrate thickness from the upper side of the substrate. Preferably, the substrate comprises a top, preferably MDF-based, substrate layer, and a bottom, preferably MDF-based, substrate layer, and optionally a central, preferably MDF-based, substrate layer. Preferably, the thickness of the top substrate layer (which may be, for example, 2 to 4 mm) is less than the sum of the thicknesses of one or more substrate layers located below the top substrate layer. The reinforcing layer will strengthen the substrate and can prevent the substrate from deforming upwards when absorbing moisture. It is conceivable that at least one side of the top substrate layer is treated with at least one waterproofing barrier. It is conceivable, and even preferably, that one or more substrate layers located below the substrate layer, preferably MDF-based, are not treated with a waterproofing barrier. This not only saves on waterproofing barrier, but also generally, treating only the upper substrate layer is sufficient to adequately waterproof adjacent, preferably interconnected, floorboards. Even if excessive water seeps through the seams (joints) between adjacent, preferably interconnected, floorboards and comes into contact with the underlying MDF-based substrate layer, the swelling that may occur at one or more edges of the underlying substrate layer will primarily occur in the in-plane direction (i.e., within the plane defined by the floorboards) due to the presence of at least one reinforcing layer above it. This swelling is typically not visible on the top surface of the floorboards, and furthermore, in-plane swelling can further close and even seal the joints formed between adjacent floorboards, thereby creating an additional waterproof barrier between them. Therefore, by applying at least one reinforcing layer, the direction of swelling of the underlying substrate layer can be controlled to some extent, and usually sufficiently.It is advantageous to allow the side edge portions of the flooring panels to swell in opposite directions, naturally forming an additional waterproof barrier between adjacent flooring panels. This can be achieved, in addition to or instead of using at least one reinforcement, by treating a portion of the side edge of the substrate with at least one waterproof barrier agent, while leaving at least one untreated strip within said portion. Upon contact with water, the treated portion of said portion does not actually swell, while the untreated portion may swell and form an additional waterproof barrier between adjacent flooring panels. The portion may be vertical, but may also be of other shapes, wherein, for example, the untreated portion of said portion is inclined and / or extends further relative to the treated portion. This allows control over the swelling direction of the untreated portion of the substrate side edge to form said waterproof barrier between adjacent flooring panels. The formation of this waterproof barrier due to the localized swelling of the substrate material can be combined with the application of one or more superabsorbent materials, wherein said superabsorbent material may be applied, for example, to at least a portion of the untreated portion of at least one side edge of the substrate.

[0116] In a preferred embodiment, at least one backing layer, particularly a (anti)balancing layer and / or a sound-insulating layer, is applied to the bottom surface of the substrate. This backing layer may be a synthetic layer, such as one composed of a thermoplastic material, and / or may comprise a sheet of paper impregnated with a thermosetting resin. Other backing layers may also be applied, such as cork-based backing layers or rubber backing layers.

[0117] As broadly noted above, the substrate may include MDF or HDF. However, additionally or alternatively, the substrate may include one or more other materials. The substrate may, for example, include magnesium oxide (MgO) or other mineral-based materials. One or more edges of the substrate, which is at least partially composed of one or more of these materials, may also be treated with one or more waterproofing agents. Examples of other mineral-based substrates include, for example, gypsum-based substrates, cement-based substrates, etc. Additionally or alternatively, it is conceivable that the substrate is at least partially composed of at least one polymer, particularly a thermoplastic material selected from the group consisting of polypropylene (PP), polyurethane (PU), thermoplastic polyurethane (TPU), polystyrene (PS), polyethylene (PE), polyvinyl chloride (PVC), at least one polyester, or mixtures thereof. When at least one polyester is used in the core layer, the polyester is preferably a homopolymer polyester, such as polyethylene terephthalate (PET) or polyethylene furanyl dicarboxylate (PEF), and / or a copolymer polyester, such as polyethylene furanyl dicarboxylate (PEFT) or polyethylene terephthalate-ethylene glycol modified PETG, polylactic acid (PLA), and / or polyvinyl butyral (PVB). PET is a homopolymer polyester made from terephthalic acid and ethylene glycol. PEF is also a homopolymer polyester derived from furanyl dicarboxylate and ethylene glycol. Due to its bio-based origin, it is considered a more sustainable alternative to PET. PEFT is a copolymer polyester made by copolymerizing furanyl dicarboxylate, terephthalic acid, and ethylene glycol. PETG is a copolymer polyester. It is modified by adding a diol, such as cyclohexanediol (CHDM), which provides higher transparency and durability compared to standard PET. Due to the relatively high temperature resistance of polyester, the use of one or more polyesters in the panels according to the invention may be advantageous and superior to PVC and various other thermoplastic polymers. Unlike PVC and various other thermoplastic polymers, polyester is suitable for withstanding temperatures above 200 degrees Celsius. When using one or more of these thermoplastic materials to manufacture the substrate, the thermoplastic material can be virgin, recycled, or a mixture thereof.

[0118] The total thickness of the substrate can vary, wherein the thickness is preferably between 5 and 12 mm, and more preferably between 6.5 and 9.5 mm.

[0119] As described above, the flooring material according to the present invention can be used as and / or can be constructed as wall panel and / or ceiling panel and / or furniture panel.

[0120] The present invention also relates to a floor covering comprising a plurality of floor panels according to the invention, preferably interconnected.

[0121] The present invention also relates to a method for manufacturing flooring panels according to the present invention, comprising the following steps:

[0122] A. Provide a substrate, wherein the substrate optionally comprises MDF and / or HDF materials and / or wood.

[0123] B. A decorative surface layer is directly or indirectly attached to the top of the substrate, wherein the decorative surface optionally comprises multiple sublayers;

[0124] C. Optionally, at least the edges of the first substrate and the second substrate are formed to create a first connecting member and a second connecting member, respectively.

[0125] D. Wherein at least one edge, preferably at least one side edge, of the substrate is treated with at least one waterproof barrier agent, wherein the waterproof barrier agent is preferably impermeable to water and / or moisture-repellent, and / or wherein at least a portion of at least one edge, preferably at least one side edge, of the substrate is subjected to a heat-burning or ironing step to at least partially burn the edge.

[0126] Various embodiments of the method have been described above and will be described below.

[0127] Terms and Conditions

[0128] Further embodiments of the invention are described in the following non-limiting provisions.

[0129] 1. A decorative panel, such as a flooring panel, comprising:

[0130] A substrate having side edges, and optionally, a decorative surface layer applied to the substrate.

[0131] At least one side edge, together with its opposite side edge, forms a first pair of opposing side edges of the substrate; wherein the first pair of opposing side edges optionally includes a mechanical first connecting member and a second connecting member, the first connecting member and the second connecting member allowing the flooring panel to be connected to a similar flooring panel at the respective side edge, preferably by means of a downward angular movement, such that, in the connected state, the flooring panel and the other flooring panel are locked in both a vertical direction perpendicular to the panel plane defined by the interconnected flooring panels and a horizontal direction parallel to the panel plane.

[0132] The optional first connecting component includes a lateral tenon, wherein the lateral tenon includes a front section, a rear section, and a middle section located between the front section and the rear section.

[0133] The bottom surface and / or side surface of the front section of the lateral tenon is at least partially curved, wherein the bottom surface of the front section defines a forward-downward tenon contact portion.

[0134] The top surface of the front section of the lateral tenon is at least partially inclined downward in a direction away from the middle and rear sections, wherein the top surface of the front section defines a front upward tenon contact portion.

[0135] The bottom surface of the middle section of the lateral tenon defines a lower intermediate contact portion, which is located between adjacent non-functional portions of the middle section of the lateral tenon.

[0136] The bottom surface and / or side surface of the rear section of the lateral tenon is at least partially inclined upward in a direction away from the middle section and the front section, wherein the inclined portion of the bottom surface and / or side surface of the rear section defines a rear-down tenon contact portion.

[0137] The rear section is configured to accommodate an upwardly projecting locking element of a second connecting component of another floor panel.

[0138] The optional second connecting component includes a recess for receiving at least a portion of a lateral tongue of another floorboard, the recess being defined by an upper lip and a lower lip, wherein the lower lip extends beyond the upper lip, wherein the lower lip includes a front section, a rear section, and a middle section located between the front and rear sections, wherein the upper lip is located above and connected to the front section of the lower lip, and wherein the lower lip is provided with an upwardly projecting locking element located in the rear section of the lower lip.

[0139] The bottom surface and / or side surface of the front segment of the lower lip are at least partially curved, wherein the bottom surface of the front segment of the lower lip defines a front portion that contacts the upper lip.

[0140] The bottom surface of the upper lip slopes downward at least partially in a direction away from the middle and rear segments of the lower lip, wherein the bottom surface of the front segment defines a front portion that contacts the lower lip.

[0141] The top surface of the middle segment of the lower lip defines a middle-upper lip contact portion, which is located between adjacent non-functional portions of the middle segment of the lower lip.

[0142] The top and / or side surfaces of the rear segment of the lower lip are at least partially inclined upwards in a direction away from the middle and front segments of the lower lip, wherein the inclined portions of the top and / or side surfaces of the rear segment define a rear-to-upper lip contact portion, and wherein the top and / or side surfaces of the rear segment of the lower lip partially define the upwardly projecting locking element.

[0143] In the case of adjacent floorboards being joined, the lateral tongue and lower lip optionally define at least three spaced-apart lower contact areas, wherein:

[0144] The lower front contact area is defined by the synergistic effect between the downward tongue contact portion of the front of the flooring board and the upward lip contact portion of the front of the other flooring board.

[0145] The lower middle contact area is defined by the synergistic effect between the downward middle tongue contact portion of the flooring board and the upward middle lip contact portion of the other flooring board, and

[0146] The rear lower contact area is defined by the synergistic effect between the rear downward tongue contact portion of the flooring material and the rear upward lip contact portion of another flooring material.

[0147] Furthermore, in the connected state of adjacent floorboards, the lateral tongue and upper lip optionally define at least two spaced-apart upper contact areas, wherein:

[0148] The first upper contact area is defined by the synergistic effect between the upward tongue contact portion of the front part of the flooring board and the downward lip contact portion of the front part of the other flooring board.

[0149] The second upper contact area is defined by the synergistic effect between the top side surface of the first connecting member of the flooring material and the side surface of the upper lip of the other flooring material, the side surface of the upper lip being located above the front lower lip contact portion, and

[0150] The decorative surface layer is preferably substantially rigid, and / or the thickness of the decorative surface layer is preferably at least 4 mm, and / or the height of the side surface of the upper lip and / or the height of the upper lip at its distal end is preferably less than 1 mm and / or less than 20% of the thickness of the substrate.

[0151] 2. The decorative panel according to Clause 1, wherein the rear lower contact area is greater than the sum of the front lower contact area and the middle lower contact area.

[0152] 3. The decorative panel according to Clause 1 or 2, wherein the middle upper lip contact portion and the middle lower tenon contact portion are both planar and together define a planar middle lower contact area.

[0153] 4. The decorative panel according to Clause 3, wherein the middle upper lip contact portion and the middle lower tenon contact portion are both planar and extend in a horizontal direction, and together define a horizontal planar lower contact area.

[0154] 5. The decorative panel according to any one of the preceding clauses, wherein the middle lower contact area is larger than the front lower contact area, preferably at least 1.5 times larger.

[0155] 6. The decorative panel according to any one of the preceding clauses, wherein the lower middle contact area is smaller than the rear contact area, preferably at most 1 / 2.

[0156] 7. The decorative panel according to any one of the preceding clauses, wherein the lower front contact area is smaller than the rear contact area, preferably at most 1 / 3.

[0157] 8. The decorative panel according to any one of the preceding clauses, wherein the height of the lower front contact area is less than the height of the lower rear contact area, preferably at most 1 / 10.

[0158] 9. The decorative panel according to any one of the preceding clauses, wherein the width of each of the non-functional portions of the middle segment of the lower lip is greater than the width of the middle portion that contacts the upper lip, preferably at least twice as wide.

[0159] 10. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is a bent non-functional portion, preferably a single bent non-functional portion, and / or includes at least one concave portion located between the front upper lip contact portion and the middle upper lip contact portion, and / or wherein the non-functional portion of the middle section of the lateral tenon is a bent non-functional portion, preferably a single bent non-functional portion, and / or includes at least one concave portion located between the front lower tenon contact portion and the middle lower tenon contact portion.

[0160] 11. The decorative panel according to Clause 10, wherein the non-functional portion of the middle section of the lower lip, and wherein the non-functional portion of the middle section of the lateral tenon comprises mutually offset horizontal surfaces that, when viewed from the vertical direction, partially overlap each other.

[0161] 12. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip includes an inclined surface connected to the front portion of the lateral tenon that contacts the lower lip portion, the non-functional portion being located between the front portion and the middle portion of the upper lip, and wherein the inclined surface of the non-functional portion of the middle section of the lower lip and the inclined top surface of the front section of the lateral tenon together define the downwardly inclined front section of the lateral tenon.

[0162] 13. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is a bent non-functional portion, and / or includes at least one concave portion located between the middle upper lip contact portion and the rear upper lip contact portion, and / or wherein the non-functional portion of the middle section of the lateral tenon is a bent non-functional portion and / or includes at least one concave portion located between the middle lower tenon contact portion and the rear lower tenon contact portion.

[0163] 14. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is provided with an upper surface that slopes downward toward the front upper lip contact portion, the non-functional portion being located between the front upper lip contact portion and the middle upper lip contact portion, the sloped upper surface being connected to the middle upper lip contact portion.

[0164] 15. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is provided with a horizontal upper surface, the non-functional portion being located between the front upper lip contact portion and the middle upper lip contact portion, the horizontal upper surface being spaced apart from both the front upper lip contact portion and the middle upper lip contact portion.

[0165] 16. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle segment of the lower lip defines the lowest point or lowest region of the lower lip, the non-functional portion being located between the front upper lip contact portion and the middle upper lip contact portion.

[0166] 17. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is a bent non-functional portion, and / or includes at least one concave portion located between the middle upper lip contact portion and the rear upper lip contact portion.

[0167] 18. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is provided with an upper surface that is inclined upward in a direction away from the middle upper lip contact portion, the non-functional portion being located between the middle upper lip contact portion and the rear upper lip contact portion, the inclined upper surface being connected to the rear upper lip contact portion.

[0168] 19. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is provided with a horizontal upper surface portion, the non-functional portion being located between the middle upper lip contact portion and the rear upper lip contact portion, the horizontal upper surface portion being connected to the middle upper lip contact portion and preferably integrally formed with the middle upper lip contact portion.

[0169] 20. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is located at a higher height level than the non-functional portion of the middle section of the lower lip, the former being located between the middle upper lip contact portion and the rear upper lip contact portion, and the latter being located between the middle upper lip contact portion and the front upper lip contact portion.

[0170] 21. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is configured to form a front intermediate gap, preferably a generally rhomboid front intermediate gap, together with the non-functional portion of the middle section of the lateral tenon, the non-functional portion of the middle section of the lower lip being located between the front upper lip contact portion and the middle upper lip contact portion, and the non-functional portion of the middle section of the lateral tenon being located between the front lower tenon contact portion and the middle lower tenon contact portion.

[0171] 22. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is configured to form a middle rear gap together with the non-functional portion of the middle section of the lateral tenon, the non-functional portion of the middle section of the lower lip being located between the middle upper lip contact portion and the rear upper lip contact portion, and the non-functional portion of the middle section of the lateral tenon being located between the middle lower tenon contact portion and the rear lower tenon contact portion.

[0172] 23. The decorative panel according to Clauses 21 and 22, wherein the cross-section of the front intermediate gap is larger than the cross-section of the intermediate rear gap by at least twice.

[0173] 24. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lower lip is larger than the middle downward tenon contact portion, preferably at least twice the size, and the non-functional portion is located between the middle upward lip contact portion and the rear upward lip contact portion.

[0174] 25. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lateral tenon is a bent non-functional portion and / or includes at least one concave portion, the non-functional portion being located between the front downward tenon contact portion and the middle downward tenon contact portion.

[0175] 26. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lateral tenon includes a horizontal lower surface portion, the non-functional portion being located between the front downward tenon contact portion and the middle downward tenon contact portion, the horizontal lower surface portion being connected to the middle downward tenon contact portion and preferably integrally formed with the middle downward tenon contact portion.

[0176] 27. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lateral tenon includes a lower surface portion that slopes downward in a direction away from the intermediate downward tenon contact portion, the non-functional portion being located between the front downward tenon contact portion and the intermediate downward tenon contact portion, and the sloped surface portion being located between the intermediate downward tenon contact portion and the front downward tenon contact portion, and preferably spaced apart from both.

[0177] 28. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle section of the lateral tenon includes a lower surface portion that slopes upward in a direction away from the intermediate downward tenon contact portion, the non-functional portion being located between the intermediate downward tenon contact portion and the rear downward tenon contact portion.

[0178] 29. The decorative panel according to any one of the preceding clauses, wherein the non-functional portion of the middle of the lateral tenon is a bent non-functional portion and / or includes at least one concave portion, the non-functional portion being located between the middle downward tenon contact portion and the rear downward tenon contact portion.

[0179] 30. The decorative panel according to any one of the preceding clauses, wherein the side surface of the lower lip connected to the upper lip includes at least one non-functional portion, such that in the connected state of adjacent decorative panels, at least one lower front gap is formed between the lateral tenon and the non-functional portion of the lower lip, and / or wherein the side surface of the upper lip includes at least one non-functional portion, such that in the connected state of adjacent decorative panels, at least one upper front gap is formed between the lateral tenon and the non-functional portion of the upper lip.

[0180] 31. The decorative panel according to Clause 30, wherein the second upper contact area defines a vertical plane (VP), wherein the front lower contact area is intersected by the vertical plane, and wherein the upper front gap is located on both sides of the vertical plane.

[0181] 32. The decorative panel according to any one of the preceding clauses, wherein the second upper contact area defines a vertical plane (VP), wherein the front lower contact area is intersected by the vertical plane.

[0182] 33. The decorative panel according to Clause 32, wherein the vertical plane (VP) divides the recess into an inner region enclosed by the upper lip and the lower lip and an opposing outer region, wherein the front lower contact area is at least partially, preferably entirely, located in the outer region, or wherein the portion of the front lower contact area located in the outer region is larger than the portion of the front lower contact area located in the inner region, preferably at least twice as large.

[0183] 34. The decorative panel according to any one of the preceding clauses, wherein the width of the lower lip exceeds the thickness of the substrate.

[0184] 35. The decorative panel according to clauses 33 and 34, wherein the width of a portion of the lower lip located in the outer region exceeds the thickness of the substrate.

[0185] 36. The decorative panel according to any one of the preceding clauses, wherein a concave curved transition portion, particularly a non-functional portion of the concave curve, is provided between the top side surface of the first connecting member and the lateral tenon.

[0186] 37. The decorative panel according to any one of the preceding clauses, wherein the maximum width of the lateral tenon exceeds the thickness of the substrate.

[0187] 38. The decorative panel according to any one of the preceding clauses, wherein the side surface of the lower lip connected to the upper lip includes at least one non-functional portion, such that in the connected state of adjacent decorative panels, at least one lower front gap is formed between the lateral tenon and the non-functional portion of the lower lip.

[0188] 39. The decorative panel according to any one of the preceding clauses, wherein the side surface of the upper lip, preferably connected to the side surface of the lower lip, includes at least one non-functional portion, such that in the connected state of adjacent decorative panels, at least one upper front gap is formed between the lateral tenon and the non-functional portion of the upper lip.

[0189] 40. The decorative panel according to Clause 39, wherein the upper front gap is located between the first upper contact area and the second upper contact area.

[0190] 41. The decorative panel according to any one of the preceding clauses, wherein the top side surface of the first connecting member of the decorative panel and the side surface of the upper lip located above the front lower lip contact portion are configured to mutually enclose an upwardly narrowing conical space, the conical space preferably located above the upper front gap, and the conical space such that the second upper contact area is located on the upper surface of the substrate.

[0191] 42. The decorative panel according to any one of the preceding clauses, wherein the decorative panel is configured such that the upwardly projecting locking element, in particular the rear upper lip contact portion, applies a horizontal force to the lateral tenon of the other decorative panel in the connected state of adjacent decorative panels, thereby causing the second upper contact area to actively close, and / or causing the top side surface of the first connecting member to apply a horizontal force to the side surface of the upper lip.

[0192] 43. The decorative panel according to any one of the preceding clauses, wherein, at the rear lower contact area, the rear downward tenon contact portion and the rear upward lip contact portion are both inclined and preferably extend in parallel, wherein the angle of inclination between the panel plane and each of the rear downward tenon contact portion and the rear upward lip contact portion is between 45 degrees and 60 degrees and includes the endpoints.

[0193] 44. The decorative panel according to any one of the preceding clauses, wherein the rear section of the lateral tenon is provided with a receiving space for receiving an upwardly projecting locking element of another decorative panel, wherein the width of the receiving space exceeds the width of the upwardly projecting locking element, such that, in the connected state of the interconnected decorative panels, there is a lower end gap between the distal end of the upwardly projecting element and the lower surface of the first connecting member.

[0194] 45. The decorative panel according to Clause 44, wherein the lower surface of the first connecting member is connected to the rear section of the lateral tenon via at least one, preferably continuous, curved transition, wherein the curved transition preferably has a radius between 0.5 and 1 cm.

[0195] 46. ​​The decorative panel according to Clause 38, wherein the lower surface of the first connecting member includes a planar, preferably vertical surface portion connected via a first curved transition to a higher, preferably planar, inclined surface portion, the higher surface portion connected via a second curved transition to a rear-down tenon contact portion, wherein the first curved transition is preferably located below the second curved transition.

[0196] 47. The decorative panel according to any one of the preceding clauses, wherein at the second upper contact area, at least one edge of the substrate, and preferably at least one edge of the decorative panel itself, is recessed and / or chamfered to form a bevel or filler line.

[0197] 48. The decorative panel according to any one of the preceding clauses, wherein the lower front contact area is a curved contact area.

[0198] 49. The decorative panel according to any one of the preceding clauses, wherein the lower front contact area is inclined upward in the direction toward the upper front tenon contact portion.

[0199] 50. The decorative panel according to any one of the preceding clauses, wherein the front portion contacts the lower lip portion, defining the deepest point of the lateral tenon.

[0200] 51. The decorative panel according to any one of the preceding clauses, wherein the inclined top surface of the front section of the lateral tenon and the inclined bottom surface of the upper lip form an angle with each other, preferably greater than 0 degrees and less than or equal to 5 degrees.

[0201] 52. The decorative panel according to any one of the preceding clauses, wherein the lower front contact area is defined by the synergistic effect between the curved, downward tenon contact portion of the decorative panel and the flat, upward lip contact portion of another decorative panel.

[0202] 53. The decorative panel according to any one of the preceding clauses, wherein the side surface of the upper lip includes a generally vertical top section and a bottom section located below the top section, preferably at least partially inclined, wherein at least a portion of the top section is configured to cooperate with the top side surface of the first connecting member to define a second upper contact area, wherein the bottom section of the side surface is positioned inward relative to the top section of the side surface.

[0203] 54. The decorative panel according to Clause 53, wherein the height of the side surface is at least 1 mm, and wherein the height of the bottom section is preferably greater than the height of the top section.

[0204] 55. The decorative panel according to Clause 54, wherein the height of the side surface is less than 1 mm, and wherein the height of the bottom section is preferably less than the height of the top section.

[0205] 56. The decorative panel according to any one of the preceding clauses, wherein the distance between the top surface of the substrate and the lower front contact area is less than 4 mm.

[0206] 57. The decorative panel according to any one of the preceding clauses, wherein (i) the ratio between the distance between the top surface of the substrate and the front lower contact area and (ii) the height of the decorative surface layer is between 0.3 and 1.

[0207] 58. The decorative panel according to any one of the preceding clauses, wherein the thickness of the decorative surface layer is at least 5 mm, and / or wherein the thickness of the decorative surface layer is at least the thickness of the substrate.

[0208] 59. The decorative panel according to any one of the preceding clauses, wherein the decorative surface layer is a rigid decorative surface layer.

[0209] 60. The decorative panel according to any one of the preceding clauses, wherein the decorative surface layer is made at least in part of at least one material selected from the group consisting of: ceramics, stone, concrete, mineral ceramics, glass, mosaic, granite, limestone, marble, linoleum, and carpet.

[0210] 61. The decorative panel according to any one of the preceding clauses, wherein the upper side of the second upper contact area defines a point of rotation during the connection of the decorative panel, wherein the maximum angle of rotation during the connection is determined by the thickness of the decorative surface layer and is between 3 and 10 degrees.

[0211] 62. A decorative panel according to any one of the preceding clauses, wherein the decorative surface layer partially covers the top surface of the substrate, wherein at least one side edge of the substrate, preferably at least a first side edge, is not covered by the decorative surface layer.

[0212] 63. The decorative panel according to any one of the preceding clauses, wherein, in the connected state of adjacent decorative panels, adjacent decorative surface layers are positioned spaced apart from each other, preferably with a spacing of less than 1.1 mm, to form one or more caulking lines.

[0213] 64. The decorative panel according to any one of the preceding clauses, wherein the decorative surface layer comprises a plurality of sub-layers, the plurality of sub-layers comprising a decorative printed layer and at least one translucent or transparent protective layer covering the decorative printed layer, wherein the at least one protective layer preferably comprises an embossed structure, the embossed structure preferably being at least partially aligned with the decorative printed layer.

[0214] 65. The decorative panel according to Clause 64, wherein the decorative printed layer comprises a carrier film, such as a paper film or a polymer film, onto which the decorative image is printed.

[0215] 66. The decorative panel according to clause 64 or 65, wherein the decorative printed layer is formed of at least one or more paper layers treated with a thermosetting resin; or is formed of at least one or more wood veneer layers.

[0216] 67. The decorative panel according to any one of the preceding clauses, wherein the substrate includes a second pair of opposing side edges, wherein the second pair of opposing side edges also respectively include a first connecting member and a second connecting member.

[0217] 68. A decorative panel according to any one of the preceding clauses, wherein the substrate includes a second pair of opposing side edges, wherein the second pair of opposing side edges also respectively include a third connecting member and a fourth connecting member, the third connecting member and the fourth connecting member allowing the decorative panel to be connected to a similar decorative panel at the respective side edges by a descending movement or a horizontal displacement movement, such that, in the connected state, the decorative panel and the other decorative panel are locked in a vertical direction perpendicular to the panel plane defined by the interconnected decorative panels and in a horizontal direction parallel to the panel plane.

[0218] 69. The decorative panel according to any one of the preceding clauses, wherein one of the third and fourth connecting parts is the same as the second connecting part.

[0219] 70. The decorative panel according to any one of the preceding clauses, wherein at least one pair of connecting members are configured to apply force to each other in the connected state of adjacent decorative panels, thereby actively causing the decorative panels to move toward each other.

[0220] 71. The decorative panel according to any one of the preceding clauses, wherein the mechanical connection component is entirely made of the substrate.

[0221] 72. The decorative panel according to any one of the preceding clauses, wherein the upper edges of the opposite side edges of the first pair and / or the second pair are formed with a lowered edge surface.

[0222] 73. The decorative panel according to any one of the preceding clauses, wherein the substrate comprises MDF and / or HDF materials and / or wood-based materials.

[0223] 74. The decorative panel according to Clause 73, wherein the MDF or HDF material has an average density greater than 600 kg per cubic meter, and includes at least a region of higher density near the decorative surface layer, wherein the region of higher density has a density of 900 kg per cubic meter or higher.

[0224] 75. The decorative panel material according to clause 73 or 74, wherein the MDF or HDF material comprises wood fibers bonded by urea-formaldehyde resin or melamine-urea-formaldehyde resin.

[0225] 76. The decorative panel material according to clause 73 or 74, wherein the MDF or HDF material comprises wood fibers bonded together by an adhesive that is substantially formaldehyde-free.

[0226] 77. The decorative panel according to any one of the preceding clauses, wherein the central section of the substrate is more porous than the top section and / or bottom section of the substrate.

[0227] 78. The decorative panel according to any one of the preceding clauses, wherein at least one side edge of the substrate is treated with at least one waterproof barrier agent, wherein the waterproof barrier agent is preferably impermeable and / or moisture-proof.

[0228] 79. The decorative panel according to Clause 78, wherein the waterproof barrier agent is at least partially impregnated into the at least one side edge, wherein the waterproof barrier agent is preferably selected from the group consisting of at least one MDI (methylene diphenyl diisocyanate), at least one epoxy resin, at least one fluorinated copolymer acetic anhydride, shellac, or combinations thereof.

[0229] 80. The decorative panel according to clause 78 or 79, wherein the waterproof barrier is at least partially applied to the at least one side edge, wherein the waterproof barrier is preferably selected from the group consisting of: nano clay, micron clay, micro wax, polytetrafluoroethylene, or combinations thereof.

[0230] 81. The decorative panel according to any one of clauses 78-80, wherein the waterproof barrier is a superabsorbent material, preferably comprising sodium polyacrylate (SPA) crystals.

[0231] 82. A decorative panel according to any one of clauses 78-81, wherein at least one side edge of the substrate is treated with at least two different waterproof barrier agents.

[0232] 83. The decorative panel according to Clause 82, wherein the at least two different waterproof barrier agents are different types of waterproof barrier agents, preferably selected from the group consisting of: impregnating agents, coatings, and superabsorbents.

[0233] 84. The decorative panel according to clause 82 or 83, wherein the at least two different waterproof barrier agents form a laminated coating on the side edges.

[0234] 85. The decorative panel according to any one of clauses 78-84, wherein the concentration of the waterproof barrier in the top section of the side edge is lower than the concentration of the waterproof barrier in the lower section located below the top section.

[0235] 86. The decorative panel according to any one of clauses 78-85, wherein the concentration of the waterproof barrier agent varies in the thickness direction of the substrate.

[0236] 87. The decorative panel according to any one of clauses 78-86, wherein the top section of at least one side edge of the substrate is treated with at least one waterproof barrier agent, and the bottom section of the side edge is free of the waterproof barrier agent.

[0237] 88. The decorative panel according to any one of clauses 78-87, wherein the maximum penetration depth of the waterproof barrier agent into the substrate is 3 to 10 mm.

[0238] 89. The decorative panel according to any one of clauses 78-88, wherein the top section of the side edge is provided with a bevel, preferably a pressed bevel.

[0239] 90. The decorative panel according to Clause 89, wherein the beveled surface is provided with a waterproof bevel coating, said waterproof bevel coating preferably applied after the side edges have been treated with said at least one waterproof barrier agent.

[0240] 91. The decorative panel according to Clause 90, wherein the impermeable coating is applied to and / or adhered to a beveled surface impregnated with a waterproof barrier agent.

[0241] 92. The decorative panel according to clause 90 or 91, wherein the entire beveled surface is impregnated with at least one waterproof barrier agent.

[0242] 93. The decorative panel according to any one of clauses 90-92, wherein the impermeable bevel coating is formed at least in part by the waterproof barrier agent.

[0243] 94. The decorative panel according to any one of clauses 90-93, wherein the impermeable bevel coating is formed at least in part by the waterproof barrier agent and is provided with at least one colorant, particularly a pigment.

[0244] 95. A decorative panel according to any one of Clauses 78-94, wherein the top and / or bottom sections of the substrate comprise melamine, and wherein the center section is preferably melamine-free.

[0245] 96. The decorative panel according to any one of Clauses 78-95, wherein at least one waterproof barrier agent is selected from the group consisting of polyurea, polyurethane and / or at least one silicone, particularly at least one organopolysiloxane.

[0246] 97. A decorative panel according to any one of the preceding clauses, wherein at least one side edge, such as a first side edge, of the substrate is provided with a first reactant, and at least one other side edge, such as a second side edge, of the substrate is provided with a second reactant, wherein the first reactant and the second reactant are configured to react with each other when they come into contact during or after the connection of the side edges of adjacent decorative panels, thereby forming a waterproof barrier between the decorative panels.

[0247] 98. The decorative panel according to any one of the preceding clauses, wherein at least one side edge of the substrate is provided with at least one first reactant and at least one second reactant, wherein the first reactant and the second reactant are configured to react with each other when in contact, thereby forming a waterproof barrier on and / or within the at least one said edge.

[0248] 99. The decorative panel according to Clause 86, wherein the first reactant comprises at least one isocyanate, and wherein the second reactant comprises at least one polyol and / or at least one polyfunctional amine.

[0249] 100. A decorative panel according to any one of the preceding clauses, wherein at least one side edge of the substrate is treated with a friction-reducing substance, said substance preferably comprising magnesium oxide and / or hydrated magnesium silicate.

[0250] 101. The decorative panel according to any one of the preceding clauses, wherein at least one edge, particularly the side edge, of the substrate is treated with at least one antimicrobial agent, preferably with at least one waterproof barrier agent having antimicrobial properties.

[0251] 102. The decorative panel according to any one of the preceding clauses, wherein at least a portion of the exposed substrate surface, preferably a portion of the side surface, is a heat-burned surface, particularly an ironed surface, and / or is provided with a heat-burned skin, particularly an ironed skin.

[0252] 103. The decorative panel according to any one of the preceding clauses, wherein the decorative panel has a rectangular or parallelogram shape, and wherein the decorative panel is preferably elongated.

[0253] 104. The decorative panel according to any one of the preceding clauses, wherein at least one backing layer, particularly a balancing layer and / or a sound-insulating layer, is applied to the bottom surface of the substrate.

[0254] 105. The decorative panel according to any one of the preceding clauses, wherein the decorative panel is used as and / or constructed as a wall panel, and / or ceiling panel, and / or furniture panel.

[0255] 106. A decorative panel covering comprising a plurality of decorative panels according to any of the preceding clauses, wherein the decorative panels are preferably interconnected.

[0256] 107. A method for manufacturing decorative panels according to any one of clauses 1-106, comprising the following steps:

[0257] A. Provide a substrate, wherein the substrate optionally comprises MDF and / or HDF materials and / or wood.

[0258] B. Attaching a decorative surface layer directly or indirectly to the top of the substrate, wherein the decorative surface optionally comprises a plurality of sublayers;

[0259] C. Optionally, at least the edges of the first substrate and the second substrate are formed to create a first connecting member and a second connecting member, respectively.

[0260] D. At least one edge, preferably at least one side edge, of the said substrate is treated with at least one waterproof barrier agent, wherein the waterproof barrier agent is preferably impermeable and / or moisture-proof, and / or at least a portion of at least one edge, preferably at least one side edge, of the said substrate is subjected to a heat-burning or ironing step to at least partially burn the edge. Attached Figure Description

[0261] The present invention will be further illustrated by means of several illustrative examples and with reference to the accompanying non-limiting drawings, wherein:

[0262] Figure 1 The flooring material according to the present invention is shown schematically;

[0263] Figure 2 Schematic illustration along Figure 1 The transverse section of the corresponding side edge intercepted by line AA in the middle;

[0264] Figure 3 The cross-section schematically illustrates the following based on Figure 2 The side edges of the flooring panels are in a connected state;

[0265] Figure 4 The cross-section schematically illustrates the method for connecting according to... Figure 2 and Figure 3 Methods for the side edges of flooring panels;

[0266] Figure 5The cross-section schematically illustrates the following based on Figure 2 The side edges of the flooring material are treated with a waterproof barrier agent;

[0267] Figure 6 Schematic illustration along Figure 1 The longitudinal section of the corresponding side edge intercepted by line BB in the middle;

[0268] Figure 7 The longitudinal section schematically illustrates the data based on... Figure 6 The side edges of the flooring panels are in a connected state;

[0269] Figure 8 Schematic illustration along Figure 1 The second embodiment of the longitudinal section in which the corresponding side edges of line BB are in a connected state;

[0270] Figure 9 Schematic illustration along Figure 1 The third embodiment of the longitudinal section in which the corresponding side edges of line BB are in a connected state;

[0271] Figure 10 A method for producing flooring panels according to the invention is illustrated schematically;

[0272] Figure 11 Another embodiment of a method for producing flooring panels according to the invention is illustrated schematically;

[0273] Figure 12 An embodiment of the substrate composition of the flooring material according to the present invention is illustrated schematically;

[0274] Figure 13a and Figure 13b An enlarged view of the side edge of the substrate material of the flooring board according to the present invention is shown schematically;

[0275] Figure 14 schematically shown Figure 3 Enlarged view of the rectangular area in the image; and

[0276] Figure 15 The flooring covering according to the invention is shown schematically.

[0277] In these figures, similar reference numerals correspond to similar or equivalent elements or features. Detailed Implementation

[0278] Figure 1A flooring panel 1 according to the present invention is schematically shown. The flooring panel 1 includes a substrate 2 or a core layer. On the upper side of the substrate 2, the flooring panel 1 includes a decorative surface layer 7. The flooring panel 1 shown has a basic rectangular shape; however, other shapes are also conceivable. The flooring panel 1 has a length extending longitudinally along line BB and a width extending laterally along line AA. Thus, the plane of the flooring panel is determined by the combination of lines AA and BB. The flooring panel 1 includes four side edges 3, 4, 5, and 6. A first pair of opposing side edges 3, 4 are formed by a first side edge 3 and a second side edge 4 opposite thereto. The first side edge 3 is provided with a first connecting member 30, and the second side edge 4 is provided with a second connecting member 40. The first connecting member 30 and the second connecting member 40 allow similar flooring panels to be joined at the respective side edges 3, 4. The flooring panel 1 also includes a second pair of opposing side edges 5, 6 formed by a third side edge 5 and a fourth side edge 6 opposite thereto. The third side edge 5 is provided with a third connecting member 70, and the fourth side edge 6 is provided with a fourth connecting member 60. The third connecting component 70 and the fourth connecting component 60 allow similar floor panels to be connected at their respective side edges 5 and 6.

[0279] Figure 2 Schematic illustration along Figure 1 The transverse cross-sections of the corresponding side edges 3 and 4 are taken by line AA. The flooring slab 1 shown includes a substrate 2, which includes an upper side 2a or top surface and a lower side 2b or bottom surface. A decorative surface layer 7 is directly or indirectly attached to the upper side 2a of the substrate 2. The decorative surface layer 7 may have a laminated structure, for example including a printed layer and / or at least one protective (top) layer covering the printed layer and / or the decorative surface layer 7. The flooring slab 1 may also include a backing layer 5, which is directly or indirectly attached to the lower side 2b of the substrate 2. The thickness of the substrate 2 may be adjustable, for example by increasing or decreasing the thickness H of the substrate 2 of the flooring slab 1. Figure 2 The left side shows a cross-sectional view of the first connecting member 30 at the first side edge 3. The right side shows a cross-sectional view of the second connecting member 40 at the second side edge 4.

[0280] The first connecting member 30 includes a lateral tenon 31 and a top surface 56. The top surface 56 is located above the lateral tenon 31. The top surface 56 may be substantially planar. In the illustrated embodiment, the top surface 56 extends in a substantially vertical direction. Between the top surface 56 and the lateral tenon 31, the illustrated first connecting member 30 includes a recess 24. The illustrated recess 24 forms a transition between the top surface 56 and the lateral tenon 31. The illustrated recess 24 is curved, particularly circular. The lateral tenon 31 includes a front segment 31a, a rear segment 31c, and a middle segment 31b located between the front segment 31a and the rear segment 31c. The illustrated distribution of the different portions 31a-31c of the lateral tenon 31 can be moved in the lateral direction of the lateral tenon 31. It is conceivable that the different portions 31a-31c overlap, particularly the front segment 31a and / or the rear segment 31c overlap with the middle segment 31b.

[0281] The front section 31a includes a bottom surface 33 and a side surface 34. In the illustrated embodiment, the side surface 34 is at least partially curved. Preferably, the radius of the curved portion of the side surface 34 is greater than the radius of the recess 24. The bottom surface 33 defines a forward downward tenon contact portion 32. The front section 31a of the lateral tenon 31 also includes a top surface 35. The top surface 35 is at least partially inclined downward in a direction away from the middle section 31b and the rear section 31c. The top surface 35 further defines a forward upward tenon contact portion 36.

[0282] The middle section 31b includes a bottom surface 29. The bottom surface 29 defines a middle downward tenon contact portion 37, which is located between adjacent non-functional portions 38a, 38b of the middle section 31b of the lateral tenon 31. The middle downward tenon contact portion 37 is at least partially planar, preferably substantially planar, and may extend in the horizontal direction or the transverse direction of the lateral tenon 31. The adjacent non-functional portions 38a, 38b are at least partially inclined upward in a direction away from the front section 31a. Preferably, the first upward non-functional portion 38a is inclined upward toward the middle downward tenon contact portion 37. In the illustrated embodiment, the middle downward tenon contact portion 37 and at least a portion of the first adjacent non-functional portion 38a form a first angle θ. The first angle θ may be between 5 and 15 degrees, preferably 10 to 15 degrees, and more preferably 12 degrees. Preferably, the second upward non-functional portion 38b is inclined upward in a direction away from the middle section 31b or in a direction away from the middle downward contact portion 37. In the illustrated embodiment, the middle downward tenon contact portion 37 and at least a portion of the second adjacent non-functional portion 38b form a second angle γ. The second angle γ can be between 5 and 15 degrees, preferably 8 to 12 degrees, and more preferably 10 degrees. The illustrated second non-functional portion 38b also includes a bent portion 38b'.

[0283] The rear section 31c includes a bottom surface 28 and a side surface 27. The bottom surface 28 of the rear section 31c is at least partially inclined upward in a direction away from the middle section 31b and the front section 31a. The inclined portion of the bottom surface 28 defines a rear downward tenon contact portion 39. In another embodiment, it is contemplated that the side surface 27 of the rear section 31c is also at least partially inclined upward in a direction away from the middle section 31b and the front section 31a. The rear section 31c also includes a receiving space 26 configured to receive an upwardly projecting locking element 41 of a second connecting member 40 of another floor panel. Preferably, the bottom surface 28 and / or the (lower) side surface 27 include curved transitions 25. In the illustrated embodiment, the receiving space 26 is provided with two curved transitions 25. In the illustrated embodiment, the curved transitions 25 are circular. However, the curved transitions 25 can have different shapes. The curved transitions 25 can have the same radius. However, it is also contemplated that the radii of the curved transitions 25 are different from each other. The (lower) side surface 27 may include a lowest side surface 27a that is at least partially inclined downward in a direction away from the middle section 31b and the front section 31a. It is conceivable that the lowest side surface 27a is located outside the rear section 31c of the lateral tenon 31.

[0284] The second connecting member 40 includes a recess 42 configured to receive at least a portion of a lateral tongue 31 of another floor panel. The recess 42 is defined by an upper lip 43 and a lower lip 44. In the illustrated embodiment, the second connecting member 40 includes a transition portion 57 located between a bottom surface 58 and a side surface 55 of the upper lip 43. The illustrated transition portion 57 includes two portions 57a and 57b. The first transition portion 57a ​​is at least partially inclined upwards in a direction toward the middle section 44b and / or the rear section 44c of the lower lip 44. The second transition portion 57b extends in a substantially vertical direction. The lower lip 44 extends beyond the upper lip 43. The lower lip 44 includes a front section 44a, a rear section 44c, and a middle section 44b located between the front section 44a and the rear section 44c. The upper lip 43 is located above and connected to the front section 44a of the lower lip 44. The lower lip 44 is provided with an upwardly projecting locking element 41 located in the rear segment 44c of the lower lip 44. The illustrated distribution of the different portions 44a-44c of the lower lip 44 is movable in the lateral direction of the lower lip 44. It is conceivable that the different portions 44a-44c overlap, particularly the front segment 44a and / or the rear segment 44c overlap with the middle segment 44b.

[0285] The front section 44a of the lower lip 44 includes a bottom surface 46 and a side surface 45. In the illustrated embodiment, the side surface 45 is at least partially curved. However, it is contemplated that the bottom surface 46 is also at least partially curved. The bottom surface 46 of the front section 44a defines a front upper lip contact portion 47. The upper lip 43 of the illustrated embodiment also includes a bottom surface 58. The bottom surface 58 is at least partially located in the region defined by the front section 44a of the lower lip 44. The bottom surface 58 slopes downward in a direction away from the middle section 44b and rear section 44c of the lower lip 44. The bottom surface 58 of the front section 44a defines a front lower lip contact portion 54. Between the side surface 45 and the bottom surface 58, the front section 44a includes a curved transition portion 59. The shape of the curved transition portion 59 is preferably at least partially complementary to the curved transition portion between the side surface 34 and the top surface 35 of the lateral tongue 31 of another flooring panel.

[0286] The middle segment 44b of the lower lip 44 includes a top surface 48. The top surface 48 defines a middle upward lip contact portion 49. The middle upward lip contact portion 49 is located between adjacent non-functional portions 50a, 50b of the middle segment 44b of the lower lip 44. It is conceivable that the middle upward lip contact portion 49 is substantially planar, wherein the middle upward lip contact portion 49 extends in a horizontal direction or in a transverse direction of the second connecting member 40. Optionally, the top surface 48 is substantially planar, wherein the top surface 48 extends substantially in a horizontal direction or in a transverse direction of the second connecting member 40. In the illustrated embodiment, the first adjacent non-functional portion 50a is at least partially inclined upward in a direction away from the front segment 44a. Preferably, the first upward non-functional portion 50a is inclined upward toward the middle upward lip contact portion 49. In the illustrated embodiment, the middle upward lip contact portion 49 and the first adjacent non-functional portion 50a (at least a portion) form an angle σ. The angle σ can be between 10 and 35 degrees, preferably 20 to 30 degrees, and more preferably 25 degrees.

[0287] The rear segment 44c of the lower lip 44 includes a side surface 52 and a top surface 51. In the illustrated embodiment, the side surface 52 is at least partially inclined upward in a direction away from the middle segment 44b and the front segment 44a of the lower lip 44. The inclined portion of the side surface 52 defines a rear upper lip contact portion 53. In the illustrated embodiment, the top surface 51 of the lower lip 44 is at least partially inclined downward in a direction away from the middle segment 44b and the front segment 44a of the lower lip 44. The top surface 51 and / or the side surface 52 of the rear segment 44c of the lower lip 44 partially define an upwardly projecting locking element 41.

[0288] Figure 2Further shown, the front sections 31a and 44a of the lateral tenon 31 and the lower lip 44 are smaller than the middle sections 31b and 41b and / or the rear sections 31c and 44c of the lateral tenon 31 and the lower lip 44, respectively. However, it is conceivable that the different portions 31a-31c of the lateral tenon 31 and / or the different portions 44a-44c of the lower lip 44 have substantially the same dimensions. The top side surface 56 of the third connecting member 30 has a length D1. The side surface 55 of the upper lip 43 of the fourth connecting member 40 has a length D2. Preferably, the length D1 of the top side surface 56 is substantially equal to the length D2 of the side surface 55. In another embodiment, the lateral tenon can be moved upward toward the upper side 2a of the substrate 2. Therefore, the length D1 of the top side surface 56 can be reduced. Optionally, the dimensions of the lateral tenon 31 can be adjusted. The thickness of the lateral tenon 31 can be adjusted, preferably the thickness of the lateral tenon 31 in the height direction, which can cause a change in the length D1. For example, the thickness of the lateral tenon 31 can be increased in height, resulting in a decrease in length D1. Furthermore, the recess 42 and / or the lower lip 44 can be moved upward toward the upper side 2a of the substrate 2. Therefore, the length D2 of the side surface 55 can be reduced.

[0289] Figure 3 The cross-section schematically illustrates the following based on Figure 2 The corresponding side edges of the floor panels 1a and 1b are in a connected state. The floor panels 1a and 1b each include a substrate 2, the thickness of which can be adjusted at the upper side 2a by a thickness T, for example 4-6 mm, and / or at the lower side 2b by a thickness H, for example 4-10 mm. In the connected state, the lateral tongue 31 of the first connecting member 30 is at least partially received in the recess 42 of the second connecting member 40. Furthermore, the upwardly projecting locking element 41 is at least partially received in the receiving space 26 of the third connecting member 30.

[0290] In the shown connection state of adjacent floorboards 1a and 1b, the lateral tongue 31 and the lower lip 44 define mutually spaced lower contact areas CZf, CZm, and CZr.

[0291] The lower front contact area CZf is defined by the synergistic action between the lower front tenon contact portion 32 of the first floorboard 1a and the upper front lip contact portion 47 of the other floorboard 1b. The lower front contact area CZf is at least partially, preferably entirely, located in the front section 31a of the lateral tenon 31, and / or at least partially, preferably entirely, located in the front section 44a of the lower lip 44.

[0292] The lower intermediate contact area CZm is defined by the synergistic action between the lower intermediate tenon contact portion 37 of the first floorboard 1a and the upper intermediate intermediate lip contact portion 49 of the other floorboard 1b. The lower intermediate contact area CZm is at least partially, preferably entirely, located in the middle section 31b of the lateral tenon 31, and / or at least partially, preferably entirely, located in the middle section 44b of the lower lip 44. At the lower intermediate contact area CZm, the lower intermediate tenon contact portion 37 of the first floorboard 1a can be configured to apply a vertical force FV to the upper intermediate intermediate lip contact portion 49 of the other floorboard 1b. Optionally, the lower intermediate tenon contact portion 37 of the first floorboard 1a can be configured to apply a force to the upper intermediate intermediate lip contact portion 49 of the other floorboard 1b, wherein the force includes a horizontal component and / or a vertical component. It is conceivable that the magnitude of such horizontal and / or vertical components of the force can depend on the size and / or shape of the lower intermediate contact area CZm.

[0293] The rear lower contact area CZr is defined by the synergistic action between the rear downward tenon contact portion 39 of the first floorboard 1a and the rear upward lip contact portion 53 of the other floorboard 1b. The rear lower contact area CZr is at least partially, preferably entirely, located in the rear section 31c of the lateral tenon 31, and / or at least partially, preferably entirely, located in the rear section 44c of the lower lip 44. In the illustrated embodiment, the upwardly projecting locking element 41, particularly the rear upward lip contact portion 35, is configured to apply a horizontal force FH to the lateral tenon 31 of the other floorboard 1b. This can cause the second upper contact area CZU2 to actively close, and / or this can cause the top side surface 56 of the first connecting member 30 to apply a horizontal force FH to the side surface 55 of the upward lip 43. The upwardly projecting locking element 41 may be at least partially oversized relative to the receiving space 26 of the other floorboard 1b. Preferably, at least a portion of the inclined portion 52 of the top surface 53 and / or side surface 52 of the rear segment 44c of the lower lip 44 is excessively large relative to at least a portion of the bottom surface 28 of the rear segment 31c of the lateral tongue 31 of the other floorboard 1a. Furthermore, at the rear lower contact area CZr in the illustrated embodiment, both the rear downward tongue contact portion 39 and the rear upward lip contact portion 53 are inclined, particularly extending parallel to each other. An inclination angle φ can be defined between the board plane BP and each of the rear downward tongue contact portion 39 and the rear upward lip contact portion 53, wherein the board plane BP extends substantially parallel to the horizontal direction of the respective floorboards 1a, 1b. The inclination angle φ can be between 45 and 60 degrees and includes the endpoints, preferably wherein the inclination angle φ is 50 degrees.

[0294] In the illustrated embodiment, the front lower contact area CZf is smaller than the middle lower contact area CZm and / or the rear lower contact area CZr. In the illustrated embodiment, the rear lower contact area CZr is larger than the middle lower contact area CZm and the front lower contact area CZf. In the illustrated embodiment, the front lower contact area CZf is at least partially located at a lower position than the middle lower contact area CZm and / or the rear lower contact area CZr, or located closer to the lower side 2b of the substrate 2. Preferably, the rear lower contact area CZr is located at a higher position than the middle lower contact area CZm and / or the rear lower contact area CZr, or located closer to the upper side 2a of the substrate 2. The illustrated dimensions and / or positions of the front lower contact area CZf, the middle lower contact area CZm, and the rear lower contact area CZr are provided as illustrative examples in the illustrated embodiment. In another embodiment, the dimensions and / or positions of the contact areas CZf, CZm, and / or CZr may differ (slightly) from the illustrated figures.

[0295] In the connection state shown for adjacent floorboards 1a and 1b, the lateral tongue 31 and the upper lip 43 define the upper contact areas CZU1 and CZU2.

[0296] The first upper contact area CZU1 is defined by the synergistic action between the front upward tenon contact portion 36 of the first floorboard 1a and the front downward lip contact portion 54 of the other floorboard 1b. At the first upper contact area CZU1, the front upward tenon contact portion 36 and the front downward lip contact portion 54 can be configured to apply a vertical force FV to each other. Optionally, the front upward tenon contact portion 36 and the front downward lip contact portion 54 can be configured to apply a force to each other, which includes a horizontal component and / or a vertical component. It is conceivable that the magnitude of such horizontal and / or vertical components of the force can depend on the size and / or shape of the first upper contact area CZU1.

[0297] The second upper contact area CZU2 is defined by the synergistic effect between the top side surface 56 of the first connecting member 30 of the first flooring slab 1a and the side surface 55 of the upper lip 43 of the other flooring slab 1b, the side surface 55 being located above the front lower lip contact portion 54. In the illustrated embodiment, the second upper contact area CZU2 defines a vertical plane VP. The illustrated vertical plane VP extends vertically at least between the top side surface 56 of the first connecting member 30 and the side surface 55 of the upper lip 43. The illustrated vertical plane VP extends substantially vertically relative to the slab plane BP. In the illustrated embodiment, the front lower contact area CZf is intersected by the vertical plane VP. The vertical plane VP of the illustrated embodiment divides the recess 42 into an inner region Ai and an outer region Ao. The inner region Ai is surrounded by the upper lip 43 and the lower lip 44. The outer region Ao is located opposite the inner region Ai. In the illustrated embodiment, the portion of the front lower contact area CZf in the outer region Ao is larger than the portion of the front lower contact area CZf in the inner region Ai.

[0298] The dimensions of different contact areas CZr, CZm, CZf, and CZU1 may depend on the dimensions or lengths of the corresponding contact portions, and / or on the degree of complementarity of the shapes and / or lengths of the corresponding surfaces of the lower lip 44 and the lateral tenon 31. For example, the first upper contact area CZU1 may depend on the dimensions or lengths of the forward-upward tenon contact portion 36 and / or the dimensions or lengths of the forward-downward lip contact portion 54. The dimensions or lengths of the first upper contact area CZU1 may also depend on the degree of complementarity of the shapes and / or lengths of the top surface 35 of the front segment 31a of the lateral tenon 31 and the bottom surface 58 of the upper lip 43. The dimensions of the second contact area CZU2 may depend on the dimensions or lengths of the top side surface 56 of the first connecting member 30 and / or the dimensions or lengths of the side surface 55 of the upper lip 43 of the second connecting member 40. The size or length of the second upper contact area CZU2 may also depend on the complementarity of the shape and / or length of the top side surface 56 of the first connecting member 30 and / or the size or length of the side surface 55 of the upper lip 43 of the second connecting member 40.

[0299] In the connection state shown for adjacent floorboards 1a and 1b, the lower lip 44 of the second connecting component 40 and the lateral tongue 31 of the first connecting component form different gaps GLF, GFM, GMR, and GLE.

[0300] The lower front gap GLF is formed between the lateral tenon 31 and the non-functional portion 60 of the side surface 45 of the lower lip 44. Preferably, the lower front gap GLF is located in the inner region of the vertical plane VP. Preferably, the length of the lower front gap GLF is greater than the width of the lower front gap GLF. Optionally, the distance between the side surface 34 of the front segment 31a of the lateral tenon 31 and the non-functional portion 60 of the side surface 45 of the lower lip is less than the (shortest) distance between the front lower contact area CZf and the first upper contact area CZU1.

[0301] The front-middle gap GFM is formed between the first non-functional portion 50a of the lower lip 44 and the first non-functional portion 38a of the lateral tenon 31, wherein the first non-functional portion 50a is located between the front upper lip contact portion 47 and the middle upper lip contact portion 49, and wherein the first non-functional portion 38a is located between the front lower tenon contact portion 32 and the middle lower tenon contact portion 37. The shape of the front-middle gap GFM is determined by the shape of the first non-functional portions 50a and 38a. In the illustrated embodiment, the front-middle gap GFM is substantially kite-shaped or substantially rhomboid. However, other shapes are conceivable. Preferably, the length of the front-middle gap GFM is greater than the height of the front-middle gap GFM. Optionally, the distance between the first non-functional portions 50a and 38a is less than the (shortest) distance between the front lower contact area CZf and the middle lower contact area CZm. Preferably, the front-middle gap GFM is located in the outer region AO of the vertical plane VP.

[0302] The center-rear gap GMR is formed between the second non-functional portion 50b of the lower lip 44 and the second non-functional portion 38b of the lateral tenon 31, wherein the second non-functional portion 50b is located between the middle upper lip contact portion 49 and the rear upper lip contact portion 53, and wherein the second non-functional portion 38b is located between the middle lower tenon contact portion 37 and the rear lower tenon contact portion 39. Preferably, the length of the center-rear gap GMR is greater than the height of the center-rear gap GMR. Optionally, the distance between the second non-functional portions 50b and 38b is less than the (shortest) distance between the middle lower contact area CZm and the rear lower contact area CZr. In the illustrated embodiment, the front center gap GFM is greater than, preferably at least twice, the center-rear gap GMR.

[0303] The lower end gap GLE exists between the distal end 62 of the upwardly projecting locking element 41 of the second connecting member 40 and the (lower) side surface 27 and / or the lowest side surface 27a of the first connecting member 30. The width of the receiving space 26 exceeds the width of the upwardly projecting locking element 41, thereby providing the lower end gap GLE.

[0304] In the illustrated connection state of adjacent floorboards 1a and 1b, the side surface 55 of the upper lip 43 and the lateral tenon 31 mutually enclose an upper front gap GUF. Specifically, the upper front gap GUF is formed between at least one non-functional portion 61 of the side surface 55 of the upper lip 43 and the lateral tenon 31, and more particularly between the non-functional portion 61 and the recess 24 of the lateral tenon 31. Preferably, the upper front gap GUF extends between a first upper contact area CZU1 and a second upper contact area CZU2. In the illustrated embodiment, the upper front gap GUF intersects with a vertical plane VP defined by the second upper contact area CZU2. It is conceivable that the vertical plane VP of the illustrated embodiment divides the upper front gap GUF into an inner region Ai and an outer region Ao. The inner region Ai of the upper front gap GUF in the illustrated embodiment has a different shape than the outer region Ao of the upper front gap GUF. The outer region Ao of the upper front gap GUF in the illustrated embodiment is substantially curved. However, the outer region Ao can have another shape.

[0305] In the illustrated connection state, the connected floor panels 1a and 1b mutually enclose a conical space 63. The conical space 63 is located above the upper front gap GUF. In the illustrated embodiment, the conical space 63 is relatively small; however, in another embodiment, the conical space, or the area or volume covered by the conical space, can be larger. The conical space 63 is enclosed by the top side surface 56 of the first connecting member 30 and the side surface 55 of the upper lip 43. In the illustrated embodiment, the conical space 63 narrows in the upward direction or in the direction towards the upper side 2a of the substrate 2. The conical space 63 can cause the second upper contact area CZU2 to be located on the upper surface or upper side 2a of the substrate 2. Optionally, the vertical plane VP intersects the conical space 63, preferably wherein the vertical plane VP substantially divides the conical space 63 in two.

[0306] Figure 4 This schematically illustrates the invention and its relation to Figure 2 and Figure 3 The method of connecting the side edges 3 and 4 of the corresponding floor panels 1a and 1b shown. Each floor panel 1a and 1b includes a substrate 2 having an upper side 2a and a lower side 2b. A decorative surface layer 6 is attached directly or indirectly to the upper side 2a of the substrate 2. The thickness of the decorative surface layer Td can be at least the thickness of the substrate Ts, and optionally, the thickness of the decorative surface layer Td exceeds the thickness of the substrate Ts. In the illustrated embodiment, the first floor panel 1a includes a first connecting member 30, and the second floor panel 1b includes a second connecting member 40. The first connecting member 30 and the second connecting member 40 are connected by a downward angular movement. In particular, the upper side of the second upper contact area CZU2 defines the rotation point R during the connection of the floor panels 1a and 1b. The rotation angle α can be formed by the intersection of the decorative surface layers 6, particularly at the top side of the decorative surface layer 6a. The maximum rotation angle α can depend at least in part on the thickness Td of the decorative surface layer 6 of the floor panels 1a and 1b to be connected. The (maximum) rotation angle α can be defined by cos ^(-1)((Td of the first floor panel 1b) / (Td of the second adjacent floor panel 1a))=α.

[0307] The top surface 56 of the third connecting member 30 has a length D1. The side surface 55 of the upper lip 43 of the fourth connecting member 40 has a length D2. Optionally, the (maximum) rotation angle α may depend at least in part on the relative proportions of the lengths D1 and D2. The (maximum) rotation angle α may optionally be defined by α = cos(-1)((D2) / D1).

[0308] Furthermore, the (maximum) rotation angle α can depend at least in part on the distance Dg, which lies between the lower sides 2b of the substrate 2 of the first flooring slab 1a, or between the lower sides of the backing layers directly or indirectly attached to the lower side of the substrate 2, particularly at the first connecting member 30, between the lower side and the horizontal plane HP defined by the floor or ground to which the adjacent flooring slabs 1a, 1b are to be connected. The lower side 2b of the substrate 2 of the first connecting profile 30, or the lower side of the backing layers directly or indirectly attached to the lower side of the substrate 2, can define a lower plane LP. The intersection of the horizontal plane HP and the lower plane LP can form the (maximum) rotation angle α. The horizontal plane HP can define a horizontal plane length LHP, which is defined by the distance between the intersection of the lower plane LP and the horizontal plane HP and the endpoint of the rear portion 31c of the lateral tenon 31 of the third connecting member 30. The rotation angle α can be defined by α = tan(-1)((D_G) / L_HP).

[0309] During the subsequent steps of connecting the first connecting member 30 and the second connecting member 40, the distance Dg can decrease, thus reducing the (maximum) rotation angle α. In the subsequent steps of connecting the floorboards 1a and 1b, as shown from the upper to the lower diagram, the rotation angle α decreases, eventually becoming essentially zero. For example, when the first connecting member 30 and the second connecting member 40 are connected, the lower plane LP can overlap with the horizontal plane HP. When the connected floorboards 1a and 1b are disconnected, particularly when the first connecting member 30 and the second connecting member 40 are disconnected, the distance Dg can increase, thus increasing the (maximum) rotation angle α.

[0310] In the illustrated embodiment, the side edges Td of the decorative surface layer are substantially vertical. However, in another embodiment, the side edges of the decorative surface layer 6 can be upwardly inclined Td' and Td''. Opposite sides can be parallel or form an angle with each other. The upwardly inclined side edges Td' and Td'' of the decorative surface layer can form angles δ' and δ'' with the top surface or upper side of the substrate 2a, respectively. The angles δ' and δ'' of two adjacent floorboards 1a and 1b do not need to be equal. The size and relationship of the angles δ' and δ'' of adjacent floorboards 1a and 1b can affect the size of angle α.

[0311] The first connecting member 30 can be divided into three height-distinguishable sub-parts D1, D11, and D12, wherein the sum of the three sub-parts D1, D11, and D12 is equal to the thickness of the substrate Ts. The height of the first sub-part D1 corresponds to the length D1 of the top side surface 56. The second sub-part D11 is defined by the distance between the lowest point of the middle portion 31b of the lateral tenon and the lower side of the second upper contact area CZU2. The third sub-part D12 is defined by the distance between the lowest point of the middle portion 31b of the lateral tenon 31 and the lower side 2b of the substrate 2 of the flooring 1a. Preferably, the second sub-part D11 is larger than the first sub-part D1 and / or the third sub-part D12. Optionally, the first sub-part D1 is smaller than the second sub-part D11 and / or the third sub-part D12. Preferably, the first sub-part D1 is smaller than both the second sub-part D11 and the third sub-part D12.

[0312] The fourth connecting component 40 can be divided into three height-distinguishable sub-parts D2, D21, and D22, wherein the sum of the three sub-parts D1, D11, and D12 is equal to the thickness of the substrate Ts. The height of the first sub-part D2 corresponds to the length D2 of the side surface 55 of the upper lip 43. The second sub-part D21 is defined by the distance between the lowest point of the middle segment 44b of the lower lip 44 and the lower side of the second upper contact area CZU2. The third sub-part D12 is defined by the distance between the lowest point of the middle segment 44b of the lower lip 44 and the lower side 2b of the substrate 2 of the flooring slab 1b. Preferably, the second sub-part D21 is larger than the first sub-part D2 and / or the third sub-part D22. Optionally, the first sub-part D2 is smaller than the second sub-part D21 and / or the third sub-part D22. Preferably, the first sub-part D2 is smaller than both the second sub-part D21 and the third sub-part D22.

[0313] In the connected state of the floorboards 1a and 1b shown, the decorative surface layer 6 at least partially covers the top surface or upper side 2a of the substrate 2. Optionally, at least a portion of the side edge of the substrate 2 of at least one connecting member 40 or 30 is not covered by the decorative surface layer 6. In the illustrated embodiment, a portion of the side edge of the substrate 2 of the first connecting member 30 is not covered by the decorative surface layer 6. In the connected state of adjacent floorboards 1a and 1b, the adjacent decorative surface layers 6 shown are spaced apart by a distance Dp to form one or more joint lines.

[0314] Figure 5 The cross-section schematically illustrates the following based on Figure 2The side edges 3 and 4 of the flooring slab 1 are treated with a waterproof barrier agent 10. The substrate 2 is preferably made of MDF and / or HDF and / or wood. The (average) density ρ of the MDF and / or HDF and / or wood of the substrate 2 can vary along the thickness Ts direction of the substrate 2. Therefore, the (average) density ρ of the MDF and / or HDF and / or wood of the substrate 2 can define a density distribution curve along the thickness Ts direction of the substrate 2. Optionally, the (average) density ρ of the MDF and / or HDF and / or wood of the substrate 2 near the upper side 2a of the substrate 2 or near the decorative surface layer 6 can be higher than the average density ρ near the central region of the substrate 2. The (average) density ρ of the MDF and / or HDF and / or wood of the substrate 2 near the upper side 2a of the substrate 2 or near the decorative surface layer 6 can be part of a higher density region. The (average) density ρ of the MDF and / or HDF and / or wood materials of substrate 2 near the center region of substrate 2 may be part of a lower density region. The (average) density ρ of the MDF and / or HDF and / or wood materials of substrate 2 near the lower side 2b of substrate 2 or near the backing layer 5 may be higher than the average density ρ near the center region of substrate 2. The (average) density ρ of the MDF and / or HDF and / or wood materials of substrate 2 near the lower side 2b of substrate 2 or near the backing layer 5 may be part of a higher density region. It is conceivable that the (average) density ρ of the MDF and / or HDF and / or wood materials of substrate 2 may differ among the three height-distinguished sub-parts D1, D11, D12 of the third connecting member 30, wherein the sum of the three sub-parts D1, D11, D12 is equal to the thickness of substrate Ts. Optionally, the (average) density ρ of the MDF and / or HDF and / or wood material of the substrate 2 may differ among the three height-distinguished sub-parts D2, D21, and D22 of the fourth connecting member 40, wherein the sum of the three sub-parts D2, D21, and D22 is equal to the thickness of the substrate Ts. It is conceivable that the average density ρ of the MDF and / or HDF and / or wood material of the substrate 2 is higher in sub-parts D1 and D2 than in sub-parts D11 and D21, and / or the average density ρ is higher in sub-parts D1 and D2 than in sub-parts D12 and D22. Preferably, the average density ρ of the MDF and / or HDF and / or wood material of the substrate 2 in sub-parts D11 and D21 is lower than the average density ρ at sub-parts D1, D12; D2, D22, respectively. The central portion or sub-portion D11 and / or sub-portion D21 of substrate 2 may have more holes than the top or sub-portions D1 and / or D2 and / or bottom or sub-portions D12 and / or sub-portions D22 of substrate 2.

[0315] The illustrated distribution of the different sub-parts D1, D11, D12 of the first connecting member 30 and / or the sub-parts D2, D21, D22 of the second connecting member 40 can be moved along the thickness Ts direction of the substrate 2 of the flooring slab 1. It is conceivable that the different sub-parts D1, D11, D12 and / or D2, D21, D22 respectively at least partially or completely overlap.

[0316] The shown side edges 3 and 4 of the substrate 2 are treated with a waterproof barrier agent 10. It is conceivable that one of the side edges 3 and 4 of the flooring slab 1 is treated with the waterproof barrier agent 10. The waterproof barrier agent 10 can be at least partially impregnated into the substrate 2, wherein the MDF and / or HDF and / or wood material of the substrate can be configured such that the waterproof barrier agent 10 is dispersed throughout at least a portion of the substrate 2, particularly throughout at least a portion of at least one side edge of the substrate 2. In the illustrated embodiment, the first side edge 3 is treated with the waterproof barrier agent 10, and the second side edge 4 is treated with two different waterproof barrier agents 10a and 10b. The two different waterproof barrier agents 10a and 10b form a laminated coating on the second side edge 4. In another embodiment, at least one side edge 3 or 4 can be treated with more than two different waterproof barrier agents, optionally forming a laminated coating on the respective side edge. The waterproof barrier agent 10 can have a penetration depth 12 into the substrate 2, which is defined by the distance between the side edge of the substrate 2 and the edge 11 of the waterproof barrier agent. For example, the penetration depth 12 of the first side edge 3 can be defined by the distance between the top side surface 56 and the edge 11 of the waterproof barrier agent. Similarly, the penetration depth 12 of the second side edge 4 can be defined by the distance between the side surface 55 of the upper lip 44 and the edge 11 of the waterproof barrier agent. The penetration depth 12 of the waterproof barrier agent 10 can vary along the thickness direction of the substrate Ts. The penetration depth 12 of the waterproof barrier agent 10 can depend on the (average) concentration ρ of the MDF material and / or HDF material and / or wood material of the substrate 2. The penetration depth 12 of the waterproof barrier agent 10 can be higher at locations where the MDF material and / or HDF material and / or wood material of the substrate 2 has a lower (average) density ρ. Therefore, the penetration depth 12 near the upper side 2a of the substrate 2 or near the decorative surface layer 6 can be lower than the penetration depth near the central region of the substrate 2. The concentration of the waterproof barrier agent 10 in the top of the side edge can be lower than the concentration in the lower part located below the top. Optionally, the concentration follows a parabolic distribution along the substrate thickness Ts direction. In the illustrated embodiment, the waterproof barrier agent 10 is at least disposed in the top of the side edges 3, 4, or at least partially disposed in the first sub-parts D1 and D2 of the respective side edges 3, 4. It is contemplated that at least a portion of the center of the side edges 3, 4, or at least a portion of the second sub-parts D11, D21, are also treated with the waterproof barrier agent 10. In the illustrated embodiment, the bottom of the side edges 3, 4, or the third sub-parts D12, D22, do not contain the waterproof barrier agent 10. However, it is contemplated that the bottom or third sub-parts are at least partially treated with at least one waterproof barrier agent 10.

[0317] Figure 6 Schematic illustration along Figure 1The longitudinal section of the flooring 1 shown is taken from line BB. The flooring 1, particularly the substrate 2 of the flooring 1, includes MDF and / or HDF materials and / or wood materials. The third side edge 7 includes a third connecting member 70, and the fourth side edge 8 includes a fourth connecting member 80. The third connecting member 70 shown includes an upward tenon 71, an upward wing 72 spaced apart from the upward tenon 71, and an upward groove 73 formed between the upward tenon 71 and the upward wing 72, wherein the upward groove 73 can be adapted to receive at least a portion of the downward tenon 81 of the fourth connecting member 80 of another flooring 1. The side of the upward tenon 71 facing the upward wing 72 is the inner side 77 of the upward tenon 71, and the side of the upward tenon 71 facing away from the upward wing 72 is the outer side 76 of the upward tenon 71. A first locking element 75 may be provided on the outer side of the upward tenon 71 facing away from the upward wing 72. The fourth connecting member 80 shown includes a downward tenon 81, a downward wing 82 spaced apart from the downward tenon, and a downward groove 83 formed between the downward tenon 81 and the downward wing 82, wherein the downward groove 83 is adapted to receive at least a portion of the upward tenon 71 of the third connecting member 70 of the other floorboard. The side of the downward tenon 81 facing the downward wing 82 is the inner side 87 of the downward tenon, and the side of the downward tenon 81 away from the downward wing 82 is the outer side 86 of the downward tenon 81. A second locking element 85 is adapted to cooperate with a first locking element 75 of the other floorboard and is disposed at the downward wing 82. The third connecting member 70 and the fourth connecting member 80 can be connected to each other when connecting the first floorboard and the second floorboard. Thus, the first floorboard can move vertically downward, wherein the connecting members 70 and 80 engage with each other by receiving the upward tenon 71 in the downward groove 83 and receiving the downward tenon 81 in the upward groove 73.

[0318] Figure 7 The longitudinal section schematically illustrates the data based on... Figure 6 The side edges 7 and 8 of the floor panels 1a and 1b are in a connected state. The side edges 7 and 8 can be connected by vertical movement. Preferably, the connecting parts 70 and 80 are engaged with each other by receiving the upward tenon 71 of the first floor panel 1a into the downward groove 83 of the second floor panel 1b, and by receiving the downward tenon 81 of the second floor panel 1b into the upward groove 73 of the first floor panel 1a. It should be noted that... Figure 7 The side edges 7 and 8 of the embodiment are relative to Figure 6 The illustrated embodiments include some minor modifications, which can be directly observed from the accompanying drawings and are further described below. As long as Figure 6 and Figure 7They share the same common features, which are indicated by the same reference numerals. In the illustrated embodiment, the inner side 77 of the upward tenon 71 contacts the inner side 87 of the downward tenon 81 of the other floorboard 1b, preferably causing the floorboards 1a and 1b to generate a tension force T2, which forces the side edges 7 and 8 to move toward each other. The tension force T2 can be a horizontal force. A portion of the inner side 77 of the upward tenon 71 is inclined toward the upward wing 72, and a portion of the inner side 87 of the downward tenon 81 is inclined toward the downward wing 82, preferably causing the two joined floorboards 1a and 1b to lock together in a direction perpendicular to the panel plane (i.e., in the vertical direction). Furthermore, the first locking element 75 and the second locking element 85 interlock with each other, further contributing to the vertical interlocking of the joined floorboards 1a and 1b. The first locking element is a protrusion 75, and the second locking element is a recess 85. The protrusion 75 has an upper portion 90 and an adjacent lower portion 88, wherein the lower portion 88 includes an inclined locking surface, and the upper portion 90 includes a preferably curved guide surface. The recess 85 includes an upper portion 94 and an adjacent lower portion 92, wherein the lower portion 92 includes an inclined locking surface. The respective upper portions 90 and 94 are spaced apart from each other, thereby allowing an intermediate space 99. At the upper side of the joined side edges 7 and 8, the upper contact surfaces 95 and 96 are forced together due to the interaction of the inner sides 77 and 87. Optionally, the tension force T2 or horizontal force at the upper contact surfaces 95 and 96 is substantially equal to the tension force T2 or horizontal force at the inner sides 77 and 87. Furthermore, the respective upper contact surfaces 95 and 96 are provided with a protrusion 98 and a recess 97, which interlock with each other in the joined state. Above the protrusion 98 and the recess 97 are corresponding inclined contact surfaces 99a and 99b, which engage with each other. An inclined surface 13 may be provided on the upper side 2a or top surface of the substrate 2 above the upper contact surfaces 95 and 96. Optionally, the top surface of the inclined surface 13 is at least partially treated or impregnated with a waterproof barrier agent 10.

[0319] At least one of the side edges 7 and 8 of the connected floorboards 1a and 1b may be treated with a waterproof barrier agent 10. In the illustrated embodiment, both side edges 7 and 8 are treated with the waterproof barrier agent 10. The waterproof barrier agent 10 is preferably disposed in the top of the floorboards 1a and 1b. In the illustrated embodiment, at least a portion of the upper contact surfaces 95 and 96 of the side edges 7 and 8 of the substrate 2 of the respective floorboards 1a and 1b are treated with and / or impregnated with the waterproof barrier agent 10.

[0320] Figure 8 A second embodiment is schematically shown in longitudinal section, with the side edges 7 and 8 of floor panels 1a and 1b in a connected state. It should be noted that... Figure 8 The side edges 7 and 8 of the embodiment are relative to Figure 6 and Figure 7The illustrated embodiments include some minor modifications, which can be directly observed from the accompanying drawings and are further described below. As long as Figure 6 , Figure 7 and Figure 8 They share the same common features, which are indicated by the same reference numerals. The flooring panels 1a, 1b shown, particularly the substrate 2 of flooring panels 1a, 1b, may be made of MDF and / or HDF and / or wood materials. Flooring panels 1a, 1b also include a decorative surface layer 6 disposed on top of or on the top surface 2a of the substrate 2. The decorative surface layer 6 has a thickness Td, which is preferably at least the thickness of the substrate Ts. The decorative surface layer 6 at least partially covers the top surface or upper side 2a of the substrate 2. Optionally, at least a portion of the side edge of the substrate 2 of at least one connecting member 70, 80 is not covered by the decorative surface layer 6. In the illustrated embodiment, a portion of the side edge of the substrate 2 of the fourth connecting member 40 is not covered by the decorative surface layer 6. In the connected state of adjacent flooring panels 1a, 1b, the illustrated adjacent decorative surface layers 6 are spaced apart by a distance Dp to form one or more caulking lines. The illustrated connecting members 70, 80 mutually enclose a conical space 163. The conical space 63 shown is enclosed by the top side surface 78 of the third connecting member 70 and the top side surface 85 of the fourth connecting member 80. In the illustrated embodiment, the conical space 63 narrows in the upward direction or towards the upper side 2a of the substrate 2. In the illustrated embodiment, the upward tenon 71 is configured to apply a horizontal force FH or a tension force F1 to the inner side 87 of the downward tenon 81. This can cause the upper side 2a of the substrate, particularly the side surface 78 of the third connecting member 70 and the top side surface 85 of the fourth connecting member 80, to actively close, and / or this can cause the side surface 78 of the third connecting member 70 to apply a horizontal force FH or a tension force T1 to the top side surface 85 of the fourth connecting member 80.

[0321] Figure 9 Schematic illustration along Figure 1The third embodiment is a longitudinal section of the corresponding side edges 7 and 8 taken from line BB, wherein side edges 7 and 8 respectively include a third connecting member 70 and a fourth connecting member 80. The floorboards 1a and 1b are preferably made at least partially of MDF and / or HDF and / or wood. The third connecting member 70 and the fourth connecting member 80 of the first floorboard 1a and the second floorboard 1b can be connected by a vertical movement V or a downward movement. The connecting members 70 and 80 are engaged with each other by receiving an upward tongue 71 of the first floorboard 1a in a downward groove 83 of the other floorboard, and by receiving a downward tongue 81 of the other floorboard in an upward groove 73 of the first floorboard 1a. The third connecting member 70 also includes an insert 79 configured to provide locking of the connected floorboards 1a and 1b in a direction perpendicular to the plane of the floorboards, preferably in a substantially vertical direction. However, it is conceivable that the fourth connecting member 80 includes the insert 79. Side edges 7 and 8 may include chamfers 13 or bevels 13 on the upper side 2a or top surface of the substrate 2, preferably on the top surface 91 of the fourth connecting member 80 or the fourth side edge 8 and / or on the top surface 74 of the third connecting member 70 or the third side edge 7. The side edges 7 and 8 are treated with a waterproof barrier agent 10. Preferably, at least the upper portion of the side edges 7 and 8 is treated with the waterproof barrier agent 10. The waterproof barrier agent 10 may have a penetration depth into the substrate 2, which may be defined by the distance between the side edges 91 and 74 of the substrate 2 and the edge 11 of the waterproof barrier agent. Preferably, the edge 11 of the waterproof barrier agent follows a parabolic distribution along the thickness direction of the substrate.

[0322] Figure 10A method for manufacturing a flooring panel 1 according to the present invention is schematically illustrated. In step A, a substrate 2 is provided. The substrate 2 may comprise MDF material and / or HDF material and / or wood material. The substrate includes an upper side 2a or top surface and a lower side 2b or bottom surface. In step E, a decorative surface layer 6 may be prepared. In this embodiment, the decorative surface layer 6 comprises a decorative printed layer. The decorative printed layer is prepared by printing a decorative pattern onto a carrier layer 101. The carrier layer 101 may be a paper layer or a polymer layer. The decorative pattern is printed onto the carrier layer or carrier film 101 by a (digital) printer 101. Subsequently, the printed ink layer may be cured and / or dried (not shown). However, it is conceivable that the decorative surface layer 6 comprises multiple sub-layers, including the decorative printed layer. At least one translucent or transparent protective layer covering the decorative printed layer may be applied to the decorative printed layer. In step B, the decorative surface layer 6 is attached directly or indirectly to the top or upper side 2a of the substrate 2. The decorative surface layer 6 can be adhered to the substrate 2, preferably by at least one adhesive, such as epoxy resin and / or hot melt adhesive. The decorative surface layer 6 can be adhered to the substrate 2 by applying heat and pressure P to both the decorative surface layer 6 and the substrate 2. Optionally, in step B, the decorative surface layer 6 is attached to the top side of the substrate 2 using heated calendering rollers (not shown). In step C, the first substrate edge 102 and the second substrate edge 103 are shaped to form a first connecting member and a second connecting member to allow adjacent floorboards to lock into each other when joined. The specifications of the connecting members can be found in […]. Figure 2-9The shaping of side edges 102, 103 can be performed, for example, by (laser) cutting the substrate 2. In step D, at least one side edge 102, 103 is treated with at least one waterproof barrier agent 10. In the illustrated embodiment, both side edges 102, 103 are treated with at least one barrier agent 10. It is conceivable (not shown) that at least one side edge 102, 103 is treated with two or more waterproof barrier agents, which can form a laminated coating. Preferably, at least the top side of the side edges 102, 103 is treated with the waterproof barrier agent 10. The waterproof barrier agent 10 can be applied to the respective side edges 102, 103 of the substrate 2, for example, by spraying or dipping. In the illustrated embodiment, the waterproof barrier agent 10 is applied to at least one side edge 102, 103 using a sprayer 104. Optionally, a primer layer can be applied to the side edges 102, 103 before applying one or more waterproof barrier agents 10. Instead of treating at least one side edge 102, 103 with the waterproof barrier agent 10, or in conjunction with it, at least one side edge of the substrate may be subjected to a heat-burning or ironing step to at least partially burn said edge (not shown), thereby making the substrate 2 more water-resistant or waterproof. Optionally (not shown), the top of at least one side edge 102, 103 is provided with a bevel. This bevel may, for example, be pressed into the substrate 2, preferably also pressed into the decorative surface layer 6. Subsequently, the waterproof barrier agent 10 may be applied to the bevel, or it may be exposed to a heat-burning or ironing step to burn the bevel, thereby making the beveled portion more water-resistant or waterproof.

[0323] Figure 11 Another embodiment of a method for manufacturing flooring material 1 according to the present invention is illustrated schematically. Figure 11 The illustrated embodiments and Figure 10 The methods shown have some similarities. Figure 11 It also shows relative to Figure 10 Some optional additional steps are shown in the method. These optional additional steps will be explained in more detail below. Figure 11The method is shown to include step F: pressing at least one bevel 13 in at least a portion of the top surface or upper side 2a of the substrate 2, preferably at at least one side edge 102, 103 of the substrate 2. In the illustrated embodiment, step F is performed simultaneously with step B, i.e., covering the upper side of the substrate 2 with the decorative surface layer 6. However, it is conceivable that step F is performed before or after step B. Step F may be performed after, before, or simultaneously with step C. The bevel 13 shown has a generally curved form; however, the bevel 13 may be generally straight. The shape of the bevel 13 may depend on the shape of the pressing element 106 and the magnitude of the pressure applied to the substrate 2. Optionally, the pressing element 106 is heated to thermally press at least one bevel 13 into at least the substrate 2. This is advantageous because it simultaneously provides a heat treatment to partially close holes or other openings in the substrate surface of the bevel 13. Thus, the substrate surface of the slope 13 can be closed, thereby reducing the water permeability of the substrate surface of the slope 13 and optionally creating a (more) water-resistant or waterproof surface. It is conceivable that the slope 13 may be at least partially covered by the decorative surface layer 6, or the slope 13 may not be covered by the decorative surface layer 6.

[0324] Figure 11 Another optional method step G is also shown: applying at least one side edge 102, 103 with at least one coating 10b. Preferably, the bevel 13 is also coated with at least one coating 10b. The coating 10b can be applied, for example, in a liquid state, by applying (protective) coating 10b to the desired portion of the substrate 2, for example, by smearing 105 or lubricating. The (protective) coating 10b can be applied in a liquid state and subsequently cured, preferably UV cured. It is contemplated that the waterproof barrier 10a is configured as a primer layer to promote and / or improve the adhesion of the (protective) coating 13 applied on top thereon. Alternatively or additionally, the coating is not applied in a liquid state but in a solid state, for example, by transfer. In the illustrated embodiment, step G is performed after the side edges 102, 103 and preferably the bevel 13 have been treated with the waterproof barrier 10a. However, it is also contemplated that the coating 10b be applied before the side edges 102, 103 have been treated with the waterproof barrier 10a. In the illustrated embodiment, due to the order of application of coating 10b and waterproof barrier 10a, and / or due to the chemical composition of the respective chemicals and the degree of absorption by the wood material and / or MDF material and / or HDF material of the substrate 2, the penetration depth of coating 10b is less than the penetration depth of waterproof barrier 10a. However, it is conceivable that the penetration depths of coating 10b and waterproof barrier 10a are substantially equal, or that the penetration depth of coating 10b is greater than that of waterproof barrier 10a. In the illustrated embodiment, a layered coating can be observed. However, waterproof barrier 10a and coating 10b may be mixed or mixed to a certain extent.

[0325] Figure 12 An embodiment of the composition of a substrate 200 for a flooring panel according to the present invention is illustrated schematically. In the illustrated embodiment, the substrate 200 comprises a plurality of substrate layers 201. The substrate layers 201 preferably comprise HDF material and / or MDF material and / or wood material. In the illustrated embodiment, the substrate 200 comprises three substrate layers 201. Preferably, an intermediate layer 202 is provided between at least two adjacent substrate layers 201. The illustrated embodiment includes an intermediate layer 201 between each adjacent substrate layer. Preferably, the intermediate layer 202 is a reinforcing layer. The reinforcing layer 202 can be adhesively adhered to the substrate layers 201. The illustrated reinforcing layer 202 is a mesh or has a mesh structure to allow adhesive to penetrate through the open structure of the reinforcing layer 202. The reinforcing layer is configured to strengthen the substrate and prevent the substrate from deforming in the upward and / or downward directions when absorbing moisture.

[0326] Figure 13a and Figure 13b schematically shown Figure 13a The wood fiber composition of the MDF or HDF material blank and Figure 13b A magnified detailed view of a compressed slab of MDF or HDF material. The MDF or HDF material slab can be formed by well-known manufacturing processes, comprising wood fibers 113 situated in a matrix of glue and / or wax and / or resin and / or air. The MDF or HDF material slab can be pressed by a pressure element (e.g., a pressure roller) and subsequently cut or sawn into individual elongated panels or sheets. After pressing the slab, a substrate for the flooring material according to the invention can be obtained. It can be observed that the compressed slab or substrate ( Figure 13b ) relative to slab ( Figure 13a The slab is compressed. Therefore, the slab is larger than the substrate in the height or vertical (z-direction). Optionally, after applying greater pressure to a portion of the (compressed) slab or substrate, a slope including a further compressed portion can be formed. This slope can be smaller than the slab in the height or vertical (z-direction). Figure 13a ) and substrate ( Figure 13bThe board and substrate comprise wood fibers 113, between which air and / or wax and / or resin may be present. In the illustrated embodiment, most of the wood fibers 113 are oriented (aligned). This can be achieved, for example, by applying an electric field during substrate manufacturing and / or by physical manipulation during substrate manufacturing. It can be observed that the wood fibers 113 are primarily horizontal, in-plane oriented (x, y plane), or oriented along the longitudinal direction of the board or substrate. Optionally, at least a portion of the wood fibers 113 is aligned along the x and / or y directions. A portion of the wood fibers 113 may extend along the vertical (z) direction or the transverse direction of the board or substrate. When exposed to water or moisture, the wood fibers 113 may expand in the transverse or z direction, rather than in the longitudinal or x, y directions. Preferably, the connecting members of the long sides of the substantially elongated substrate (and elongated floorboards) extend in a direction perpendicular to the orientation of most of the wood fibers 113. In the illustrated figures, the connecting members of the long sides of the elongated substrate are preferably disposed in the y, z plane. The connecting members on the short sides of the basically elongated substrate (and elongated floorboards) preferably extend in a direction parallel to the orientation of most of the wood fibers 113. Therefore, in the figures shown, the connecting members on the short sides of the elongated substrate are preferably disposed in the x, z plane.

[0327] Figure 14An enlarged cross-sectional view of the upper portion of the connected floorboards 1a and 1b is schematically shown. In the illustrated embodiment, the top surface 56 of the first connecting member is at least partially treated with at least one waterproof barrier agent 10. The side surface 55 of the upper lip of the second connecting member is at least partially treated with at least one waterproof barrier agent 10. It is contemplated that the (top)side surfaces 56 and 55 have slightly different shapes. For example, the (top)side surfaces 56 and 55 may be inclined upwards. Optionally, the substrate is provided with a bevel or chamfer above the (top)side surfaces 55 and 56. In the illustrated embodiment, the penetration profile of the waterproof barrier agent 10 is at least partially parabolic. It is contemplated that the portion of the substrate below the (top)side surfaces 55 and 56 is free of the waterproof barrier agent 10. It is contemplated that the substrate 2 comprises a substrate layer, wherein a lower substrate layer 201b is located below the top substrate layer 201a. In the illustrated embodiment, the lower substrate layer 201b is substantially free of the waterproof barrier agent 10 and / or untreated with a waterproof barrier agent. Preferably, a reinforcing layer 202 or intermediate layer is provided between the substrate layers 201a and 201b. If water or another fluid or liquid seeps through the joint or joint J formed between adjacent, preferably interconnected, floorboards 1a and 1b and comes into contact with the substrate layer 201b, the corresponding side edges 155 and 156 can expand. In this case, the side edges 155 and 156 can expand. When at least one reinforcing layer is positioned between the substrate layers 201a and 201b, particularly above the lower substrate layer 201b, the expansion of the wood fibers and subsequently the substrate 2 will occur primarily along the expansion direction Ds, which is either in-plane or in the board plane direction. In the illustrated embodiment, the expansion direction Ds of the lower substrate layer 201b (which is parallel to the board plane direction and the in-plane direction) occurs in a substantially horizontal direction. Preferably, a space 163 exists below the joint J, allowing at least a portion of the substrate 2, particularly at least a portion of the lower substrate layer 201b, to extend or expand along the expansion direction Ds or along the in-plane or board plane direction. Over time, water or fluids or liquids can evaporate, causing the corresponding side edges 155, 156 to shrink back to their original configuration. This in-plane expansion results in a reduction in the distance between the side edges 155, 156. The result is further closure, and optionally even further sealing of adjacent floor panels 1a, 1b. This can lead to the formation of an additional waterproof barrier between the floor panels. Therefore, by applying at least one reinforcing layer, the direction of expansion of the underlying substrate layer can be controlled to a certain extent, and generally sufficiently.

[0328] Figure 15A floor cover 110 comprising a plurality of interconnected floor panels 1 is schematically shown. The floor panels 1 shown include a first pair of opposing edges 3, 4 and a second pair of opposing edges 7, 8. The floor panels 1 are interconnected to form the floor cover 110. A first side edge 3 may be connected to a second side edge 4 of another floor panel 1, and a third side edge 7 may be connected to a fourth side edge 8 of another floor panel 1. The first side edge 3 and the second side edge 4 may be defined by side edges provided on the long side of the elongated floor panel 1. Preferably, the first side edge 3 and the second side edge 4 are connected by a downward angular movement A or a rotational movement. The third side edge 7 and the second side edge 8 may be defined by side edges provided on the short side of the elongated floor panel 1. The third side edge 7 and the fourth side edge 8 are preferably connected or interconnected by a descending movement or a horizontal displacement movement. The floor panels 1 are locked both in a vertical direction perpendicular to the plane defined by the interconnected floor panels and in a horizontal direction parallel to the plane.

[0329] The verb “including” and its variations used in this patent disclosure should be understood not only to mean “including”, but also to mean the phrases “containing”, “consistently composed of”, “formed by” and their variations.

[0330] The ordinal numbers used in this document, such as "first," "second," "third," and "fourth," are for identification purposes only. Therefore, the use of the term "third connecting component" does not necessarily require the simultaneous presence of a "first connecting component." Similarly, the use of the terms "third locking element" and "second locking element" does not necessarily require the simultaneous presence of a "first locking element." "Horizontal" refers to a direction extending parallel to the plane defined by the flooring panel, and this direction may intersect with the substrate of the flooring panel. "Vertical" refers to a direction perpendicular to the plane defined by the flooring panel. "Complementary" connecting components refer to connecting components of adjacent flooring panels that can mate with each other. However, for this purpose, complementary connecting components do not necessarily have to have completely complementary shapes (reverse design). "Proximal" refers to the side positioned closest to the body of the flooring panel, while "distal" refers to the side positioned further away from the body of the flooring panel than the proximal side. The proximal side may face the body of the flooring panel, while the distal side may...

[0331] The verb “including” and its variations used in this patent disclosure should be understood not only to mean “including”, but also to mean the phrases “containing”, “consistently composed of”, “formed by” and their variations.

Claims

1. A flooring material, comprising: A substrate having side edges and a decorative surface layer applied to the substrate, wherein at least one side edge and its opposite side edge together form a first pair of opposing side edges of the substrate; wherein the first pair of opposing side edges respectively include a mechanical first connecting member and a second connecting member, the mechanical first connecting member and the second connecting member allowing the floorboard to be connected to a similar floorboard at the corresponding side edge by a downward angular movement, such that, in the connected state, the floorboard and the other floorboard are locked both in a vertical direction perpendicular to the board plane defined by the interconnected floorboards and in a horizontal direction parallel to the board plane, wherein the first connecting member includes a lateral tongue, wherein the The lateral tenon includes a front section, a rear section, and a middle section located between the front and rear sections. The bottom and / or side surfaces of the front section of the lateral tenon are at least partially curved. The bottom surface of the front section defines a front downward tenon contact portion. The top surface of the front section of the lateral tenon is at least partially inclined downward in a direction away from the middle and rear sections. The top surface of the front section defines a front upward tenon contact portion. The bottom surface of the middle section of the lateral tenon defines a middle lower contact portion located between adjacent non-functional portions of the middle section of the lateral tenon. The bottom and / or side surfaces of the rear segment of the tongue are at least partially inclined upwards in a direction away from the middle and front segments, wherein the inclined portions of the bottom and / or side surfaces of the rear segment define a rear downward tenon contact portion, wherein the rear segment is configured to receive an upwardly projecting locking element of a second connecting member of another floorboard, wherein the second connecting member includes a recess for receiving at least a portion of a lateral tenon of the other floorboard, the recess being defined by an upper lip and a lower lip, wherein the lower lip extends beyond the upper lip, wherein the lower lip includes a front segment, a rear segment, and a middle segment located between the front and rear segments, wherein the upper lip is located at the... Above and connected to the front segment of the lower lip, wherein the lower lip is provided with an upwardly projecting locking element located in the rear segment of the lower lip, wherein the bottom surface and / or side surface of the front segment of the lower lip is at least partially curved, wherein the bottom surface of the front segment of the lower lip defines a front-to-upper lip contact portion, wherein the bottom surface of the upper lip is at least partially inclined downward in a direction away from the middle and rear segments of the lower lip, wherein the bottom surface of the front segment defines a front-to-downper lip contact portion, wherein the top surface of the middle segment of the lower lip defines a middle-to-upper lip contact portion, the middle-to-upper lip contact portion being located between adjacent non-functional portions of the middle segment of the lower lip, wherein...The top and / or side surfaces of the rear section of the lower lip are at least partially inclined upwards in a direction away from the middle and front sections of the lower lip, wherein the inclined portions of the top and / or side surfaces of the rear section define a rear-to-upper lip contact portion, and wherein the top and / or side surfaces of the rear section of the lower lip partially define the upwardly projecting locking element, wherein, in the connected state of adjacent floorboards, the lateral tongue and the lower lip define at least three spaced-apart lower contact areas, wherein: the front lower contact area is defined by the synergistic action between the front downward tongue contact portion of one floorboard and the front upward lip contact portion of the other floorboard; the middle lower contact area is defined by the interaction between the middle downward tongue contact portion of one floorboard and the middle upward lip contact portion of the other floorboard. The synergistic effect defines the lower rear contact area, which is defined by the synergistic effect between the lower rear tenon contact portion of the flooring board and the upper rear lip contact portion of the other flooring board. In the connected state of adjacent flooring boards, the lateral tenon and the upper lip define at least two spaced-apart upper contact areas, wherein: the first upper contact area is defined by the synergistic effect between the upper front tenon contact portion of the flooring board and the lower front lip contact portion of the other flooring board; the second upper contact area is defined by the synergistic effect between the top side surface of the first connecting member of the flooring board and the side surface of the upper lip of the other flooring board, the side surface of the upper lip being located above the lower front lip contact portion; wherein the decorative surface layer is substantially rigid; wherein the thickness of the decorative surface layer is at least 4 mm; and wherein the height of the side surface of the upper lip and / or the height of the upper lip at its distal end is less than 1 mm and / or less than 20% of the thickness of the substrate segment.

2. The flooring material according to claim 1, wherein, The decorative surface layer is made at least in part of a material selected from the group consisting of: ceramics, stone, concrete, mineral ceramics, glass, mosaic, granite, limestone, marble, linoleum, and carpet.

3. The flooring material according to claim 1 or 2, wherein, The thickness of the decorative surface layer is at least the thickness of the substrate.

4. The flooring material according to any one of the preceding claims, wherein, The decorative surface layer partially covers the top surface of the substrate, wherein at least one uncovered portion of the top surface of the substrate is configured to form a caulking line.

5. The flooring material according to claim 4, wherein, The width of at least one uncovered portion of the top surface of the substrate is equal to or less than 1 mm.

6. The flooring material according to any one of the preceding claims, wherein, When adjacent floorboards are joined together, adjacent decorative surface layers are spaced apart by a distance, preferably less than 1.1 mm, to form one or more joint lines.

7. The flooring material according to any one of the preceding claims, wherein, The lower rear contact area is larger than the sum of the lower front contact area and the lower middle contact area.

8. The flooring material according to any one of the preceding claims, wherein, The height of the middle lower contact area is located between the lower height of the front lower contact area and the higher height of the rear lower contact area.

9. The flooring material according to any one of the preceding claims, wherein, Both the upper lip contact portion and the lower tenon contact portion are planar and together define the lower contact area of ​​the planar surface.

10. The flooring material according to claim 9, wherein, Both the upper lip contact portion and the lower tenon contact portion are planar and extend horizontally, and together define the lower contact area of ​​the horizontal plane.

11. The flooring material according to any one of the preceding claims, wherein, The lower middle contact area is larger than the front contact area, preferably at least 1.5 times larger.

12. The flooring material according to any one of the preceding claims, wherein, The lower middle contact area is smaller than the rear contact area, preferably at most 1 / 2.

13. The flooring material according to any one of the preceding claims, wherein, The lower front contact area is smaller than the rear contact area, preferably at most 1 / 3.

14. The flooring material according to any one of the preceding claims, wherein, The height of the lower front contact area is less than the height of the lower rear contact area, preferably at most 1 / 10.

15. The flooring material according to any one of the preceding claims, wherein, The width of each non-functional portion of the middle segment of the lower lip is greater than the width of the middle portion that contacts the upper lip, preferably at least twice as wide.

16. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle segment of the lower lip is a bent non-functional portion and / or includes at least one concave portion, the non-functional portion being located between the front upper lip contact portion and the middle upper lip contact portion; and / or wherein the non-functional portion of the middle segment of the lower lip is a bent non-functional portion and / or includes at least one concave portion, the non-functional portion of the middle segment of the lower lip being located between the middle upper lip contact portion and the rear upper lip contact portion; and / or wherein the lateral tenon... The non-functional portion of the middle section is a bent non-functional portion and / or includes at least one concave portion, and the non-functional portion of the middle section of the lateral tenon is located between the front downward tenon contact portion and the middle downward tenon contact portion; and / or wherein the non-functional portion of the middle section of the lateral tenon is a bent non-functional portion and / or includes at least one concave portion, and the non-functional portion of the middle section of the lateral tenon is located between the middle downward tenon contact portion and the rear downward tenon contact portion.

17. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lower lip is provided with an upper surface that slopes downward in the direction of the front upper lip contact portion. The sloped upper surface is connected to the middle upper lip contact portion. The non-functional portion of the middle section of the lower lip is located between the front upper lip contact portion and the middle upper lip contact portion.

18. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lower lip is provided with a horizontal upper surface, which is spaced apart from both the front upper lip contact portion and the middle upper lip contact portion. The non-functional portion of the middle section of the lower lip is located between the front upper lip contact portion and the middle upper lip contact portion.

19. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle segment of the lower lip defines the lowest point or lowest region of the lower lip, and the non-functional portion of the middle segment of the lower lip is located between the front upper lip contact portion and the middle upper lip contact portion.

20. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle segment of the lower lip is a bent non-functional portion and / or includes at least one concave portion, the non-functional portion of the middle segment of the lower lip being located between the middle upper lip contact portion and the rear upper lip contact portion.

21. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle segment of the lower lip is provided with an upper surface that is inclined upward in a direction away from the middle upper lip contact portion. The inclined upper surface is connected to the rear upper lip contact portion. The non-functional portion of the middle segment of the lower lip is located between the middle upper lip contact portion and the rear upper lip contact portion.

22. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lower lip is provided with a horizontal upper surface portion, which is connected to and preferably integrally formed with the middle upward lip contact portion. The non-functional portion of the middle section of the lower lip is located between the middle upward lip contact portion and the rear upward lip contact portion.

23. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle segment of the lower lip is positioned at a higher height level than the non-functional portion of the middle segment of the lower lip, the non-functional portion of the middle segment of the lower lip is located between the middle upward lip contact portion and the rear upward lip contact portion, and the non-functional portion of the middle segment of the lower lip is located between the middle upward lip contact portion and the front upward lip contact portion.

24. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lower lip is configured to form a front middle gap with the non-functional portion of the middle section of the lateral tenon. The non-functional portion of the middle section of the lower lip is located between the front upper lip contact portion and the middle upper lip contact portion. The non-functional portion of the middle section of the lateral tenon is located between the front lower tenon contact portion and the middle lower tenon contact portion.

25. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lower lip is configured to form a middle rear gap with the non-functional portion of the middle section of the lateral tenon. The non-functional portion of the middle section of the lower lip is located between the middle upper lip contact portion and the rear upper lip contact portion. The non-functional portion of the middle section of the lateral tenon is located between the middle lower tenon contact portion and the rear lower tenon contact portion.

26. The flooring material according to claims 24 and 25, wherein, The cross-section of the front middle gap is larger than the cross-section of the middle rear gap, by at least twice.

27. The flooring material according to any one of the preceding claims, wherein, The side surface of the lower lip connected to the upper lip includes at least one non-functional portion, such that in the connected state of adjacent floorboards, at least one lower front gap is formed between the lateral tongue and the non-functional portion of the lower lip; and / or wherein the side surface of the upper lip includes at least one non-functional portion, such that in the connected state of adjacent floorboards, at least one upper front gap is formed between the lateral tongue and the non-functional portion of the upper lip.

28. The flooring material according to claim 27, wherein, The second upper contact area defines a vertical plane (VP), wherein the front lower contact area is intersected by the vertical plane, and wherein the upper front gap is located on both sides of the vertical plane.

29. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lateral tenon, located between the front downward tenon contact portion and the middle downward tenon contact portion, is a bent non-functional portion and / or includes at least one concave portion.

30. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lateral tenon, located between the front downward tenon contact portion and the middle downward tenon contact portion, includes a horizontal lower surface portion connected to the middle downward tenon contact portion, and preferably integrally formed with the middle downward tenon contact portion.

31. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lateral tenon, located between the front downward tenon contact portion and the middle downward tenon contact portion, includes a lower surface portion that slopes downward in a direction away from the middle downward tenon contact portion. The sloped lower surface portion is located between the middle downward tenon contact portion and the front downward tenon contact portion, and is preferably spaced apart from both of them by a distance.

32. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lateral tenon, located between the middle downward tenon contact portion and the rear downward tenon contact portion, includes a lower surface portion that slopes upward in a direction away from the middle downward tenon contact portion.

33. The flooring material according to any one of the preceding claims, wherein, The non-functional portion of the middle section of the lateral tenon, located between the middle downward tenon contact portion and the rear downward tenon contact portion, is a bent non-functional portion and / or includes at least one concave portion.

34. The flooring material according to any one of the preceding claims, wherein, The second upper contact area defines a vertical plane (VP), wherein the front lower contact area is intersected by the vertical plane.

35. The flooring material according to claim 34, wherein, The vertical plane (VP) divides the concave portion into an inner region enclosed by the upper lip and the lower lip, and an opposite outer region, wherein the portion of the front lower contact area located in the outer region is larger than the portion of the front lower contact area located in the inner region, preferably at least twice as large.

36. The flooring material according to any one of the preceding claims, wherein, The width of the lower lip exceeds the thickness of the substrate.

37. The flooring material according to claims 35 and 36, wherein, The width of a portion of the lower lip located in the outer region exceeds the thickness of the substrate.

38. The flooring material according to any one of the preceding claims, wherein, The side surface of the lower lip connected to the upper lip includes at least one non-functional portion, such that, in the connected state of adjacent floorboards, at least one lower front gap is formed between the lateral tongue and the non-functional portion of the lower lip.

39. The flooring material according to any one of the preceding claims, wherein, The side surface of the upper lip, preferably connected to the lower lip, includes at least one non-functional portion, such that, in the connected state of adjacent floorboards, at least one upper front gap is formed between the lateral tongue and the non-functional portion of the upper lip.

40. The flooring material according to claim 39, wherein, The upper front gap is positioned between the first upper contact area and the second upper contact area.

41. The flooring material according to any one of the preceding claims, wherein, The top side surface of the first connecting member of the flooring material and the side surface of the upper lip located above the front lower lip contact portion are configured to form a tapered space that narrows upward, the tapered space preferably being located above the upper front gap, and the tapered space positioning the second upper contact area on the upper surface of the substrate.

42. The flooring material according to any one of the preceding claims, wherein, The floorboard is configured such that the upwardly protruding locking element, particularly the rear upper lip contact portion, applies a horizontal force to the lateral tongue of another floorboard in the connected state of adjacent floorboards, thereby causing the second upper contact area to actively close and / or causing the top side surface of the first connecting member to apply a horizontal force to the side surface of the upper lip.

43. The flooring material according to any one of the preceding claims, wherein, At the lower rear contact area, both the lower rear tenon contact portion and the upper rear lip contact portion are inclined and preferably extend in parallel, wherein the angle of inclination between the plate plane and each of the lower rear tenon contact portion and the upper rear lip contact portion is between 45 degrees and 60 degrees, and includes 45 degrees and 60 degrees.

44. The flooring material according to any one of the preceding claims, wherein, The rear section of the lateral tongue is provided with a receiving space for accommodating an upwardly protruding locking element of another floorboard, wherein the width of the receiving space exceeds the width of the upwardly protruding locking element, such that in the connected state of the interconnected floorboards, there is a lower end gap between the distal end of the upwardly protruding element and the lower surface of the first connecting member.

45. The flooring material according to claim 44, wherein, The lower surface of the first connecting member is connected to the rear section of the lateral tenon via a preferably continuous, curved transition, wherein the curved transition preferably has a radius between 0.5 and 1 cm.

46. ​​The flooring material according to any one of the preceding claims, wherein, At the second upper contact area, at least one edge of the substrate, and preferably the flooring material itself, is recessed and / or chamfered to form a bevel or filler line.

47. The flooring material according to any one of the preceding claims, wherein, The lower front contact area is a curved contact area.

48. The flooring material according to any one of the preceding claims, wherein, The lower front contact area is defined by the synergistic effect between the downward tongue contact portion of the curved front of the flooring sheet and the upward lip contact portion of the flat front of the other flooring sheet.

49. The flooring material according to any one of the preceding claims, wherein, The side surface of the upper lip includes a generally vertical top segment and a bottom segment located below the top segment, preferably at least partially inclined, wherein at least a portion of the top segment is configured to cooperate with the top side surface of the first connecting member to define the second upper contact area, wherein the bottom segment of the side surface is positioned inward relative to the top segment of the side surface.

50. The flooring material according to claim 49, wherein, The height of the side surface is at least 1 mm, wherein the height of the bottom segment is preferably greater than the height of the top segment.

51. The flooring material according to claim 50, wherein, The height of the side surface is less than 1 mm, wherein the height of the bottom segment is preferably less than the height of the top segment.

52. The flooring material according to any one of the preceding claims, wherein, The distance between the top surface of the substrate and the lower front contact area is less than 4 mm.

53. The flooring material according to any one of the preceding claims, wherein the ratio between (i) the distance between the top surface of the substrate and the lower front contact area and (ii) the height of the decorative surface layer is between 0.3 and 1.

54. The flooring material according to any one of the preceding claims, wherein, The upper side of the second upper contact area is defined at the point of rotation during the connection of the floor panels, wherein the maximum rotation angle during the connection is determined by the thickness of the decorative surface layer and is between 3 and 10 degrees.

55. The flooring material according to any one of the preceding claims, wherein, The maximum width of the lateral tenon exceeds the thickness of the substrate.

56. The flooring material according to any one of the preceding claims, wherein, The substrate includes a second pair of opposite side edges, wherein the second pair of opposite side edges also include a first connecting component and a second connecting component, respectively.

57. The flooring material according to any one of the preceding claims, wherein, The substrate includes a second pair of opposing side edges, wherein the second pair of opposing side edges further includes a third connecting member and a fourth connecting member, the third connecting member and the fourth connecting member allowing the flooring board to be connected to a similar flooring board at the respective side edge by a descending movement or a horizontal displacement movement, such that, in the connected state, the flooring board and the other flooring board are locked both in a vertical direction perpendicular to the board plane defined by the interconnected flooring boards and in a horizontal direction parallel to the board plane.

58. The flooring material according to any one of the preceding claims, wherein, One of the third and fourth connecting components is the same as the second connecting component.

59. The flooring material according to any one of the preceding claims, wherein, At least one pair of connecting components are configured to work together in the connected state of adjacent floor panels without applying an active force to bring the floor panels closer to each other.

60. The flooring material according to any one of the preceding claims, wherein, The mechanical connecting components are entirely made of the substrate.

61. The flooring material according to any one of the preceding claims, wherein, The upper edges of the first pair and / or the second pair of opposite side edges form a lowered edge surface.

62. The flooring material according to any one of the preceding claims, wherein, The substrate includes MDF and / or HDF materials and / or wood materials.

63. The flooring material according to claim 62, wherein, The MDF or HDF material has an average density greater than 600 kg per cubic meter and includes at least a higher density region near the decorative surface layer, wherein the higher density region has a density of 900 kg per cubic meter or higher.

64. The flooring material according to claim 62 or 63, wherein, The MDF or HDF material comprises wood fibers bonded together with urea-formaldehyde resin or melamine-urea-formaldehyde resin.

65. The flooring material according to claim 62 or 63, wherein, The MDF or HDF material comprises wood fibers bonded together with a substantially formaldehyde-free adhesive.

66. The flooring material according to any one of the preceding claims, wherein, At least one side edge of the substrate is treated with at least one waterproof barrier agent, wherein the waterproof barrier agent is preferably impermeable to water and / or moisture-proof.

67. The flooring material according to any one of the preceding claims, wherein, At least one edge, particularly the side edge, of the substrate is treated with at least one antimicrobial agent, preferably with at least one waterproof barrier agent with antimicrobial properties.

68. The flooring material according to any one of the preceding claims, wherein, The flooring material has a rectangular or parallelogram shape, and preferably is oblong.

69. The flooring material according to any one of the preceding claims, wherein, At least one side edge of the substrate is provided with at least one first reactant and at least one second reactant, wherein the first reactant and the second reactant are configured to react with each other when in contact, thereby forming a waterproof barrier on and / or inside the at least one said edge.

70. A floor covering comprising a plurality of floor panels, preferably interconnected, according to any one of the preceding claims.

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