A decorative panel, and a decorative covering material composed of panels interconnected in such a manner, which is suitable for constructing a floor, ceiling, or wall covering material by interconnecting a plurality of said panels

Abstract

The present invention relates to a decorative panel suitable for constructing a floor, ceiling, or wall covering by interconnecting a plurality of said panels, the decorative panel having a substantially planar top surface, a substantially planar bottom surface, and at least four substantially straight side edges, at least one pair of which is provided with interconnecting coupling means for interconnecting the panel with other panels, the decorative panel having a laminate structure including a core layer having an upper side and a lower side, and a decorative top layer connected to the upper side of the core layer, the core layer including a layer of cementitious mineral material, the cementitious mineral material layer including cement and a dispersant. The present invention also relates to decorative coverings, particularly decorative floor coverings, decorative ceiling coverings, or decorative wall coverings, comprising a plurality of interconnected decorative panels.

Description

Technical Field

[0001] The present invention relates to a decorative panel suitable for constructing a floor, ceiling, or wall covering material by connecting a plurality of the panels to each other, and a decorative covering material constructed by the panels connected to each other in this way.

[0002] The present invention particularly relates to the following decorative panel. That is, having a substantially planar upper surface, having a substantially planar bottom surface, having at least four substantially straight side edge ends, and at least a pair of these side edge ends are provided with mutual connection means for the panel to be mutually connected with other panels, having a laminated structure, the laminated structure including a core layer having an upper portion and a lower portion, and a decorative upper layer connected to the upper portion of the core layer, and the core layer includes a layer of a cementitious mineral material.

Background Art

[0003] The main advantage of the cementitious mineral material as the core layer is that it provides attractive stability of the panel when exposed to temperature fluctuations during normal use, compared to a core layer made of a thermoplastic material. Another advantage compared to thermoplastic materials is the fire resistance of the mineral material. Moreover, in view of actual use, the mineral material can have attractive properties in terms of heat insulation, sound absorption, and compressive strength.

Summary of the Invention

Problems to be Solved by the Invention

[0004] The disadvantage of the cementitious mineral material is that it consumes a considerable amount of time and energy in the manufacturing process. The mineral material consists of a slurry containing a mixture of cement and water, but this slurry is poured into a mold to form a uniform layer, and then solidified (cured) at a high temperature to form a hydrated complex of cement, and the excess moisture is removed by heat.

[0005] In this context, significant cost savings can be achieved by minimizing the excess water used in the process. However, reducing the amount of water impairs the fluidity of the slurry, which should be avoided in view of the requirement that the layer can be spread uniformly over the entire mold.

Means for Solving the Problem

[0006] To mitigate the above problem, the present invention proposes the following. That is, A decorative panel, which is suitable for constructing a floor, ceiling, or wall covering material by connecting a plurality of said panels to each other, having a substantially planar upper surface, having a substantially planar bottom surface, having at least four substantially straight side edge ends, and at least a pair of said side edge ends being provided with interconnecting means for interconnecting the panel with other panels, having a laminated structure, said laminated structure including a core layer having an upper portion and a lower portion, and a decorative upper layer connected to the upper portion of the core layer, The core layer includes a cementitious mineral material layer, and the cementitious mineral material layer includes cement and a dispersant, a decorative panel.

[0007] During the production of the layer of cementitious mineral material, a dispersant is added to the slurry of water and cement to reduce the amount of water in the slurry. Such a dispersant promotes the homogeneous dispersion of solids in the suspension and can impart sufficient fluidity to the slurry even with a low water content. Thereby, a slurry having sufficient fluidity can be produced while reducing the use of water in the slurry by 40%. In the related art, said dispersant is also called a superplasticizer or a "plasticizer".

[0008] Therefore, the dispersant or fluidizing agent used in the context of the present text regarding the mineral slurry is a compound to be distinguished from other well-known types of plasticizers. The other well-known types of plasticizers are those used in (thermo) plastics to reduce the attractive force between individual polymer chains and make the plastic more flexible and durable.

[0009] Nevertheless, when using a dispersant in the context of the present text regarding the mineral slurry, the entire physical and chemical reaction of the subsequent hardening process of the cementitious mineral material changes due to the low water content. For example, the hardening time of the material may be prolonged, and the adhesion to the decorative upper layer of the core layer may be hindered. In particular, when the material has a foamed structure containing air bubbles, it should be considered that the size of the air bubbles may change, and thus the compressive strength of the entire material may be impaired.

[0010] Therefore, in the panel according to the present invention, the dispersant preferably includes polycarboxylate ethers (PCEs), and preferably includes lignosulfonate (LS) as a second dispersant.

[0011] When using such a dispersant, especially when mixed with the second dispersant, it has been found that a layer suitable for producing a decorative panel having the properties required for the intended use can be obtained without impairing the strength of the core layer of the cementitious mineral material. Moreover, when the mineral material has a foamed structure, it has been found that the size of the air bubbles can be controlled to an appropriate degree.

[0012] When applying both of the dispersant compounds, the content of lignosulfonate is particularly effective when it is in the range of 1.0% to 30% by weight, preferably 5.0% to 30% by weight of the total weight of polycarboxylate ether and lignosulfonate.

[0013] More preferably, in the decorative panel according to the present invention, the weight content ratio of the dispersant to the cement weight is at most 1%, and may be at most 0.5%.

[0014] When the content rate is relatively low in this way, it has already been demonstrated that it is sufficiently effective in reducing the water content when producing the cementitious mineral material from the slurry.

[0015] In particular, in the panel according to the present invention, the cement is preferably a calcium-based cement, a calcium silicate-based cement, and / or a magnesium-based cement.

[0016] Moreover, in the panel according to the present invention, the cementitious mineral material particularly preferably contains a particulate material dispersed in the cementitious mineral material.

[0017] In such a material, the cement acts as a binder for the particulate material.

[0018] In the panel according to the present invention, an attractive example of the cementitious mineral material is a material composed of concrete, magnesia, foamed concrete, and / or gypsum.

[0019] In the panel according to the present invention, the core layer preferably contains the cementitious mineral material in an amount of at least 50% by weight, preferably 50 - 90% by weight.

[0020] According to a preferred feature of the panel of the present invention, a reinforcing layer is included in the core layer.

[0021] In a preferred embodiment of the panel according to the present invention, a waterproof layer is located between the core layer and the upper layer, and preferably, it is in the form of a waterproof adhesive that attaches the upper layer to the core layer.

[0022] Regarding the preferred cementitious mineral materials included in the scope of the present invention, the present invention will be described in more detail in the following sections for each individual preferred material, namely, foam concrete, magnesia, and gypsum.

[0023] Foam concrete In the panel according to the present invention, the following are preferred. That is, The cementitious mineral material includes, or consists of, foam concrete (aerated concrete), and the foam concrete consists of a base material of a concrete material in which air pockets as bubbles are present. - The bubbles in the foam concrete occupy 60 to 85% by volume of the total volume of the foam concrete, or - The density of the foam concrete is in the range of 400 to 800 kg / m 3 of.

[0024] Typically, foam concrete is produced by autoclaving a concrete material under high temperature and high pressure. In a preceding step, the concrete material is generally produced by mixing a slurry of cement and water with a dispersant, pouring it into a mold, and curing the resulting mixture at a high temperature.

[0025] The core layer containing foam concrete can give the panel attractive properties such as a relatively light weight, appropriate insulation, and good sound absorption. Moreover, the panel has sufficient strength for the intended use.

[0026] In order to further improve these advantageous properties, it is preferable that the major part of the bubbles in the foam concrete is of the closed-cell type, and the major part is preferably at least 80% of the bubbles, and most preferably at least 90%.

[0027] Moreover, from the viewpoint of improving these advantages, it is preferable that the major part of the bubbles in the foam concrete is small enough in size to absorb water by capillary action.

[0028] In a particularly preferred embodiment of the panel in which the core layer is based on foamed concrete, the cement is tobermorite, i.e., Ca5Si6O 16 (OH)2·4H2O and / or Ca5Si6(O,OH) 18 ·5H2O, and other calcium silicate hydrate minerals.

[0029] In a further preferred embodiment of the panel according to the present invention, the particulate material is dispersed in the foamed concrete, and the particulate material includes sand, pulverized fuel ash, fly ash, lime, and / or aluminum oxide powder.

[0030] Additionally or alternatively, the particulate material may include cellulose-based particles, preferably lignocellulosic particles such as wood particles.

[0031] In particular, at least a part of the cellulose-based particles is preferably a fiber.

[0032] Additional or alternative particulate materials that can be included in the cementitious mineral material include so-called cementitious materials such as blast furnace slag fine powder, silica fume, natural pozzolan, metakaolin, and calcined shale or calcined clay.

[0033] The cellulose-based particles as wood particles may be wood powder, wood chips, wood wool, and / or wood chips. Instead of wood, other natural fiber sources such as flax may be used.

[0034] In a preferred embodiment, the core layer includes at least one reinforcing layer such as a textile fiber layer, a cellulose layer (especially a paper layer), a carbon fiber layer, and / or a glass fiber layer. The reinforcing layer may be a woven layer or a non-woven layer. In a more preferred embodiment, the core layer includes at least two cementitious mineral layers, and at least one reinforcing layer is located between the two cementitious layers. In this case, the core typically includes three (or more) core layers. At least one reinforcing layer may be incorporated into one or more cementitious mineral layers, and / or the cementitious mineral layer may be subdivided into two (substantive) cementitious mineral (sub)layers. The cementitious mineral material can be considered to penetrate partially or entirely into the holes formed in the reinforcing layer.

[0035] Magnesia In the panel according to the present invention, the following are preferred. That is, The cementitious mineral material contains magnesia or consists of magnesia, and the magnesia includes magnesia cement based on at least one of the following compounds. Magnesium oxide and / or magnesium hydroxide (preferably both in hydrated form) Magnesium chloride Magnesium oxychloride 5Mg(OH)2-MgCl2-8H2O Mg2(OH)ClCO3·3H2O Magnesite, especially hydro-magnesite (Mg5(CO3)4(OH)2·4H2O) Ammonium dihydrogen phosphate (NH4H2PO4) Struvite (NH4MgPO4·6H2O) and / or dittmarite (NH4MgPO4·H2O) MgHPO4 Potassium dihydrogen phosphate (KH2PO4) Potassium magnesium phosphate hexahydrate (MgKPO4·6H2O) At least one borate Magnesium sulfate, particularly the sulfate mineral epsomite heptahydrate (MgSO4·7H2O) 5Mg(OH)2 - MgSO4 - 3H2O (513 phase) and / or 3Mg(OH)2 - MgSO4 - 8H2O (318 phase) 5Mg(OH)2 - MgSO4 - 5H2O (515 phase) and / or Mg(OH)2 - MgSO4 - 7H2O (517 phase)

[0036] Magnesia of the above type can endow the panel with attractive properties such as relatively light weight, appropriate insulation, and good sound absorption. Moreover, the panel has sufficient strength for the intended use.

[0037] Typically, magnesia is produced by mixing a slurry of magnesia cement and water with a dispersant, pouring it into a mold, and curing the resulting mixture at a high temperature.

[0038] Preferably, in the panel according to the present invention, the magnesia further contains particulate matter dispersed in the magnesia, and the particulate matter preferably contains cellulose-based particles.

[0039] In particular, the cellulose-based particles contain lignocellulose such as wood materials, and preferably at least a part of the cellulose-based particles is preferably fiber.

[0040] In addition, the magnesia may further contain at least one filler selected from the group consisting of steel, glass, polypropylene, wood, acrylic, alumina, claw, carbon, cellulose, coconut, kevlar, nylon, perlon, polyethylene, PVA, rock wool, sisal, and ficuse.

[0041] In the panel according to the present invention, the magnesia layer preferably has at least a partially foamed structure containing pores.

[0042] The foamed structure of the magnesia layer further contributes to the relatively light weight, proper insulation, and good sound absorption of the panel.

[0043] The foamed structure may include continuous open pores (bubbles) and / or independent pores (bubbles), and preferably, most of the pores are independent pores.

[0044] Gypsum In the panel according to the present invention, the cementitious mineral material includes or consists of gypsum, and the gypsum preferably includes hydrated plaster of the structural formula CaSO4-2H2O.

[0045] In the gypsum mineral structure, gypsum in a partially anhydrous form, that is, CaSO4-xH2O (x ranges from 0 to 0.6), acts as a cement. This anhydrous form of gypsum is also called plaster.

[0046] Typically, gypsum is produced by mixing a homogeneous slurry of plaster, water, and a dispersant, pouring the mixture into a mold, and curing the resulting mixture at a high temperature.

[0047] Furthermore, in the panel according to the present invention, the gypsum preferably has a foamed structure containing pores.

[0048] The foamed structure can be formed by adding a foaming agent such as alkyl sulfate and / or alkyl ether sulfate to the initial slurry.

[0049] In this way, foamed gypsum with a relatively low density of 650-850 g / cm 3 is obtained.

[0050] In the panel according to the present invention, the total content rate of the dispersant in the gypsum is preferably 0.05-0.5% by weight.

[0051] It has been found that being within this range is most effective for obtaining the advantages as described above.

[0052] General features Some preferred general features of the panel according to the present invention are as follows. - The upper layer includes at least one decorative layer and at least one transparent wear layer covering the decorative layer. - The panel includes a support layer attached to the lower side of the core layer. - The panel has a thickness of 3 to 10 mm. - The panel has a rectangular outer shape including four side edges. - The pair of side edges of the panel are opposite side edges.

[0053] Preferably, in the panel according to the present invention, the upper layer includes at least one decorative layer and at least one transparent wear layer covering the decorative layer. A suitable wear layer in this context has a melting temperature exceeding 100°C and is preferably made of polyurethane.

[0054] The decorative layer will be visible and is used to give the panel an attractive appearance. For this purpose, the decorative layer may have a design pattern. To give a few examples of possible designs, for example, a wood grain-like design, a mineral grain design similar to the grain of natural stones such as marble or granite, or a color pattern, a color mix, or a single color.

[0055] The decorative upper layer is preferably a printed decorative upper layer. That is, the printed decorative image on the upper layer is realized by painting and / or (inkjet type) printing, especially digital printing. The decorative image may be printed directly on the core layer. However, it is typically more preferred that the printed decorative layer includes a base layer or a base film, especially a thermoplastic base layer or a thermoplastic film on which the decorative image is printed. Before or following the printing process, the base layer is attached to the core layer directly or indirectly, for example, by fusion or adhesion.

[0056] Preferably, the decorative upper layer covers only at least a part of the upper side of the core layer. Preferably, the decorative upper layer is substantially not provided on the side walls and the rear surface of the core layer.

[0057] In particular, in the panel, it is preferable that the mutual connection means is in the following form.

[0058] In the panel according to the present invention, the mutual connection means includes first and second connection outer shapes at the first and second side edges which are the pair of side edges respectively. The first connection outer shape includes - an upward tongue, - at least one upward flange provided away from the upward tongue, - an upward groove formed between the upward tongue and the upward flange, and adapted to receive at least a part of the downward tongue of the second connection outer shape of another identical panel, - preferably, at least one first locking element, preferably provided on the distal side of the upward tongue facing away from the upward flange. The second connection outer shape includes - a first downward tongue, - at least one first downward flange provided away from the downward tongue, - A first downward groove formed between the downward tongue and the downward flange, the downward groove being adapted to receive at least a portion of the upward tongue of the first connecting outer shape of another identical panel, - Preferably, at least one second locking element, adapted for co-action with the first locking element of said other identical panel, preferably provided on the downward flange,

[0059] Preferably, the first locking element includes a bulge and / or a recess, and the second locking element includes a bulge and / or a recess. The bulge is generally adapted to be at least partially received in the recess of an adjacent connected panel, thereby achieving a locked connection, preferably a vertically locked connection. It is also conceivable to form the first locking element and the second locking element not by a combination of a bulge and a recess, but by other combinations such as surfaces with co-acting outer shapes and / or high-friction contact surfaces. In the latter embodiment, at least one of the first locking element and the second locking element may be formed by an optional separate contact surface made of a plastic material (flat or other shape) configured to generate friction between it and the other locking element of the other panel in the engaged (connected) state.

[0060] The following configurations are also within the scope of the present invention. The first connecting outer shape and the second connecting outer shape are configured such that a pre-tension acts in the connected state, and this tension biases the connected panels towards each other at their respective edge ends. Preferably, this is achieved by overlapping the contours of the first connecting outer shape and the second connecting outer shape, in particular by overlapping the contours of the downward tongue and the upward groove and / or by overlapping the contours of the upward tongue and the downward groove. The first connecting outer shape and the second connecting outer shape are configured to be able to connect two of the panels to each other by folding movement and / or vertical movement. In the connected state, at least a part of the downward tongue of the second connecting part is inserted into the upward groove of the first connecting part, and the downward tongue is clamped by the first connecting part and / or the upward tongue is clamped by the second connecting part.

[0061] Preferably, The side part of the upward tongue facing the upward flange is the inner part of the upward tongue, and the side part of the upward tongue facing the side opposite to the upward flange is the outer part of the upward tongue. The side part of the downward tongue facing the downward flange is the inner part of the downward tongue, and the side part of the downward tongue facing the side opposite to the downward flange is the outer part of the downward tongue. At least a part of the inner part of the upward tongue is inclined toward or away from the upward flange. At least a part of the inner part of the downward tongue is inclined toward or away from the downward flange. In this way, the "closed groove" connection or the "open groove" connection can be realized between the panels according to the inclination directions of the inner parts of the upward tongue and the downward tongue.

[0062] Furthermore, in the panel according to the present invention, the panel includes at least one third connecting outer shape and at least one fourth connecting outer shape respectively located on each of the third panel side and the fourth panel side. The third connecting outer shape is - a side tongue extending in a direction substantially parallel to the upper side of the decorative panel, - at least one second downward flange provided away from the side tongue, - a second downward groove formed between the side tongue and the second downward flange. The fourth connecting outer shape is - A third groove configured to accommodate at least a part of the lateral tongue of the third connecting profile of the second identical panel, defined by an upper lip portion and a lower lip portion, the lower lip portion being provided with an upward locking element, including the third groove, The third connecting profile and the fourth connecting profile are configured such that the third and fourth connecting profiles of two identical panels can be connected to each other by rotational movement, in which rotational movement, at least a part of the lateral tongue of the first panel is inserted into the third groove of the other identical panel, and at least a part of the upward locking element of the other panel is inserted into the second downward groove of the first panel.

[0063] Preferably, at least a part of each connecting profile is integrally formed with the core layer. It is conceivable to form each connecting profile as a whole by profiling the edge of the core layer.

[0064] The present invention also relates to a decorative covering material, particularly a decorative floor covering material, a decorative ceiling covering material, or a decorative wall covering material, including a plurality of decorative panels according to the present invention connected to each other. The covering material may be preferably installed at vertical corners such as the inner corners between intersecting walls or furniture, and the outer corners such as the entrance passage.

[0065] Preferred embodiments of the present invention are shown in the following set of non-limiting clauses. Clause

[0066] 1. A decorative panel, which is a decorative panel suitable for constructing a floor, ceiling, or wall covering material by connecting a plurality of said panels to each other, Having a substantially planar upper surface, Having a substantially planar bottom surface, Having at least four substantially straight side edge ends, and at least a pair of said side edge ends being provided with mutual connection means for connecting the panel to other panels, It has a laminated structure, and the laminated structure includes at least one core layer having an upper part and a lower part, and a decorative upper layer directly or indirectly connected to the upper part of the core layer, in particular, a printed decorative upper layer. The core layer includes a cementitious mineral material layer, and the cementitious mineral material layer includes cement and a dispersant, which is a decorative panel.

[0067] 2. The decorative panel according to item 1, wherein the dispersant includes polycarboxylate ethers (PCEs), and preferably includes lignosulfonate (LS) as a second dispersant, which is a decorative panel.

[0068] 3. The decorative panel according to item 2, wherein the content of lignosulfonate is in the range of 1.0% by weight to 30% by weight of the total weight of polycarboxylate ether and lignosulfonate, preferably in the range of 5.0% by weight to 30% by weight of the total weight, which is a decorative panel.

[0069] 4. The decorative panel according to one of the preceding items, wherein the weight content ratio of the dispersant to the weight of the cementitious mineral material is at most 1%, and may be at most 0.5%, which is a decorative panel.

[0070] 5. The panel according to one of the preceding items, wherein the cement is a calcium-based cement, a calcium silicate-based cement, and / or a magnesium-based cement, which is a panel.

[0071] 6. The panel according to one of the preceding items, wherein the cementitious mineral material includes a particulate material dispersed in the cementitious mineral material, which is a panel.

[0072] 7. The panel according to one of the preceding items, wherein the cementitious mineral material consists of concrete, magnesia, foamed concrete, and / or gypsum, which is a panel.

[0073] 8. A panel according to one of the preceding claims, wherein the core layer contains at least 50% by weight, preferably 50 - 90% by weight, of a cementitious mineral material.

[0074] 9. A panel according to one of the preceding claims, wherein a reinforcing layer is included in the core layer.

[0075] 10. A panel according to one of the preceding claims, wherein a waterproof layer is located between the core layer and the upper layer, and preferably is in the form of a waterproof adhesive that attaches the upper layer to the core layer.

[0076] 11. A panel according to one of the preceding claims, wherein the cementitious mineral material includes or consists of foamed concrete, and the foamed concrete consists of a base material of a concrete material in which air pockets as bubbles are present, - the bubbles in the foamed concrete occupy 60 - 85% by volume of the total volume of the foamed concrete, or - the density of the foamed concrete is in the range of 400 - 800 kg / mm 3 of the panel.

[0077] 12. The panel according to claim 11, wherein the major part of the bubbles is of the closed-cell type, and the major part is preferably at least 80% of the bubbles, most preferably at least 90% of the bubbles.

[0078] 13. A panel according to one of the preceding claims 11 or 12, wherein the major part of the bubbles in the foamed concrete is small enough in size to absorb water by capillary action.

[0079] 14. A panel according to one of the preceding claims 11 to 13, wherein The cement is tobermorite, i.e., Ca5Si6O 16 (OH)2·4H2O and / or Ca5Si6(O,OH) 18 ·5H2O and other calcium silicate hydrate minerals, panel.

[0080] 15. The panel according to one of the preceding items 11 to 13, The particulate material is dispersed in the foamed concrete, and the particulate material includes sand, pulverized fuel ash, fly ash, lime, and / or aluminum oxide powder, panel.

[0081] 16. The panel according to one of the preceding items 1 to 10, The cementitious mineral material contains or consists of magnesia, and the magnesia includes magnesia cement based on at least one of the following compounds, panel. - Magnesium oxide and / or magnesium hydroxide (preferably, both in hydrated forms) - Magnesium chloride - Magnesium oxychloride - 5Mg(OH)2-MgCl2-8H2O - Mg2(OH)ClCO3·3H2O - Magnesite, especially, hydromagnesite (Mg5(CO3)4(OH)2·4H2O) - Ammonium dihydrogen phosphate (NH4H2PO4) - Struvite (NH4MgPO4·6H2O) and / or dittmarite (NH4MgPO4·H2O) - MgHPO4 - Potassium dihydrogen phosphate (KH2PO4) - Potassium magnesium phosphate hexahydrate (MgKPO4·6H2O) - At least one borate - Magnesium sulfate, especially, sulfate mineral epsomite heptahydrate (MgSO4-7H2O) - 5Mg(OH)2-MgSO4-3H2O (513 phase) and / or 3Mg(OH)2-MgSO4-8H2O (318 phase) -5Mg(OH)2-MgSO4-5H2O (515 phase) and / or Mg(OH)2-MgSO4-7H2O (517 phase)

[0082] 17. The panel according to claim 16, wherein the magnesia further contains particulate matter dispersed in the magnesia, and the particulate matter preferably contains cellulose-based particles.

[0083] 18. The panel according to claim 16 or 17, wherein the cellulose-based particles contain lignocellulose such as wood materials, and preferably at least a part of the cellulose-based particles is fiber.

[0084] 19. The panel according to any one of the preceding claims 16 to 18, wherein the magnesia layer has at least a partially foamed structure containing pores.

[0085] 20. The panel according to any one of the preceding claims 1 to 10, wherein the cementitious mineral material contains gypsum or consists of gypsum, and the gypsum contains hydrated plaster of the structural formula CaSO4·2H2O.

[0086] 21. The panel according to claim 20, wherein the gypsum has a foamed structure containing pores.

[0087] 22. The panel according to claim 20, wherein the total content rate of the dispersant in the gypsum is 0.05 to 0.5% by weight.

[0088] 23. The panel according to any one of the above claims, wherein the mutual connection and coupling means includes first and second coupling outer shapes at the first and second side edges which are the pair of side edges respectively, the first coupling outer shape is - an upward tongue portion, - At least one upward-facing flange provided away from the upward-facing tongue, - An upward-facing groove formed between the upward-facing tongue and the upward-facing flange, and adapted to receive at least a part of the downward-facing tongue of the second connecting profile of another identical panel, - At least one first locking element, preferably provided on the distal side of the upward-facing tongue facing away from the upward-facing flange, The second connecting profile comprises - A first downward-facing tongue, - At least one first downward-facing flange provided away from the downward-facing tongue, - A first downward-facing groove formed between the downward-facing tongue and the downward-facing flange, and adapted to receive at least a part of the upward-facing tongue of the first connecting profile of another identical panel, - At least one second locking element, adapted for co-action with the first locking element of said other identical panel, preferably provided on the downward-facing flange,

[0089] 24. A panel according to any of the preceding claims, The panel includes at least one third connecting profile and at least one fourth connecting profile located on the third panel side and the fourth panel side respectively, The third connecting profile comprises - A lateral tongue extending in a direction substantially parallel to the upper side of the panel, - At least one second downward-facing flange provided away from the lateral tongue, - A second downward-facing groove formed between the lateral tongue and the second downward-facing flange, The fourth connecting profile comprises - A third groove configured to receive at least a part of the lateral tongue of the third connecting profile of a second identical panel, defined by an upper lip portion and a lower lip portion, and having an upward locking element provided on the lower lip portion, The third connecting outer shape and the fourth connecting outer shape are configured such that the third and fourth connecting outer shapes of two identical panels can be connected to each other by rotational movement. In this rotational movement, at least a part of the lateral tongue of the first panel is inserted into the third groove of the other identical panel, and at least a part of the upward locking element of the other panel is inserted into the second downward groove of the first panel.

[0090] 25. The panel according to one of the preceding claims, wherein the core layer includes at least one reinforcing layer such as a textile layer, a cellulose layer, a carbon fiber layer, and / or a glass fiber layer.

[0091] 26. The panel according to claim 25, wherein the core layer includes at least two layers of cementitious mineral materials, the cementitious mineral materials include cement and a dispersant, and at least one reinforcing layer is located between the two layers of cementitious mineral materials.

[0092] 27. The panel according to one of the preceding claims, wherein at least a part of each connecting outer shape is integrally formed with the core layer.

[0093] 28. The panel according to one of the preceding claims, wherein the printed decorative upper layer covers only at least a part of only the upper side of the core layer.

[0094] 29. The panel according to one of the preceding claims, The side of the upward tongue facing the upward flange is the inner side of the upward tongue, and the side of the upward tongue facing the side opposite to the upward flange is the outer side of the upward tongue. The side of the downward tongue facing the downward flange is the inner side of the downward tongue, and the side of the downward tongue facing the side opposite to the downward flange is the outer side of the downward tongue. At least a part of the inner side of the upward tongue portion is inclined toward the upward flange or away from the upward flange. A panel in which at least a part of the inner side of the downward tongue portion is inclined toward the downward flange or away from the downward flange.

[0095] 30. The panel according to one of the preceding items, wherein the printed decorative layer includes a base layer or a base film on which a decorative image is printed.

[0096] 31. A decorative covering material, particularly a decorative floor covering material, a decorative ceiling covering material, or a decorative wall covering material, A decorative covering material including a plurality of decorative panels according to any one of items 1 to 30 connected to each other.

Brief Description of the Drawings

[0097] The present invention will be further described with reference to the following attached drawings.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0098] Figure 1 shows the decorative panel 1. An upper decorative layer 12 is provided on the upper side portion 2 of the decorative panel 1. The panel is rectangular, has a length in the longitudinal direction along line B-B, and a width in the transverse direction along line A-A.

[0099] On the side edge ends 9 and 10, a first connecting outer shape 7 and a second connecting outer shape 8 are respectively provided. On the side edge ends 3 and 4, a third connecting outer shape 5 and a fourth connecting outer shape 6 are respectively provided.

[0100] Figure 2 shows a cross-section of the panel 1 shown in Figure 1 in the transverse direction along line A-A. The panel 1 has a core layer 10. The core layer 10 consists of a layer of foamed concrete and contains small closed-cell bubbles 11. An upper decorative layer 12 is preferably attached to the upper side portion of the foamed concrete layer 10 via a thin waterproof adhesive layer. A support layer is attached to the lower side portion of the foamed concrete layer 10. On the side edge ends 3 and 4, a third connecting outer shape 5 and a fourth connecting outer shape 6 are respectively provided.

[0101] As a modification of the panel 1, the core layer 10 may be a foamed magnesia layer or a foamed gypsum layer.

[0102] Figure 3 shows in detail the third and fourth connecting outer shapes 5 and 6 depicted in Figure 2 when two panels 1 and 1' are connected to each other.

[0103] The third connecting outer shape 5 of the panel 1' includes a lateral tongue portion 51 extending in a direction substantially parallel to the upper side portion of the panel, a first downward flange 53 provided away from the lateral tongue portion 51, and a second downward groove 54 formed between the lateral tongue portion 51 and the first downward flange 53.

[0104] The fourth connecting outer shape 6 of the panel 1 includes a third groove 61 configured to accommodate at least a part of the lateral tongue portion 51 of the third connecting outer shape 5 of the second identical panel 1'. The third groove 61 is defined by an upper lip portion 62 and a lower lip portion 63, and an upward locking element 64 is provided on the lower lip portion.

[0105] In the state shown in FIG. 3, the third connecting outer shape 5 and the fourth connecting outer shape 6 are configured such that their respective panels 1, 1' can be connected to each other by a rotational movement as indicated by the arrow T. In this rotational movement, the lateral tongue portion 51 of the panel 1' is inserted into the third groove 61 of another identical panel 1, and the upward locking element 64 of the panel 1 is inserted into the second downward groove 54 of the panel 1'.

[0106] FIG. 4 shows another design of the connecting outer shapes 5 and 6, similar to FIG. 3, with rounded tongue portion 51 and third groove 61. The rotational movement for connection can also be called a hinge movement in this embodiment as an alternative to FIG. 3. All other functional features and their reference numerals are the same as those already defined in FIG. 3.

[0107] FIG. 5 shows a longitudinal cross-section of the panel 1 shown in FIG. 1 along the line B-B. The panel 1 has a core layer 10. The core layer 10 consists of a layer of cellular concrete and contains small closed-cell air bubbles. An upper decorative layer 12 is attached to the upper portion of the cellular concrete layer 10.

[0108] The first connecting outer shape 7 and the second connecting outer shape 8 are respectively provided at the side edge ends 9 and 10.

[0109] The first connecting outer shape 7 includes an upward tongue portion 71, an upward flange 72 provided away from the upward tongue portion 71, and an upward groove 73 formed between the upward tongue portion 71 and the upward flange 72. The upward groove 73 is adapted to receive at least a part of the downward tongue portion 81 of the second connecting outer shape 8 of another identical panel. Preferably, at least one first locking element 75 is provided on the distal side portion of the upward tongue portion 71 facing away from the upward flange 72.

[0110] The second connecting profile 8 includes a first downward tongue portion 81, a first downward flange 82 provided apart from the downward tongue portion 81, and a first downward groove 83 formed between the downward tongue portion 81 and the downward flange 82. The downward groove 83 is adapted to receive at least a part of the upward tongue portion 71 of the first connecting profile 7 of another identical panel, and a second locking element 85 adapted for co-action with the first locking element 75 of another identical panel is provided on the downward flange 82.

[0111] FIG. 6 shows how the profiles 7 and 8 of the panels can interact when connecting the first connecting profile 7 of panel 1 and the second connecting profile 8 of panel 1'. Here, by moving panel 1' vertically downward to receive the upward tongue portion 71 in the downward groove 83 and the downward tongue portion 81 in the upward groove 73, the profiles 7 and 8 engage with each other.

Claims

1. A decorative floor panel suitable for constructing a floor covering material by connecting a plurality of said panels to each other, the decorative floor panel having a substantially planar upper surface, a substantially planar bottom surface, at least four substantially straight side edge ends, and at least a pair of said side edge ends being provided with mutual connection means for connecting the panel to other panels, a laminated structure, said laminated structure including at least one core layer having an upper portion and a lower portion, and a printed decorative upper layer directly or indirectly connected to the upper portion of said core layer, a first panel side edge end including a first connecting outer shape, a second panel side edge end including a second connecting outer shape, said second connecting outer shape being designed to connect with the first connecting outer shape of a second identical panel in both horizontal and vertical directions, said first connecting outer shape including - an upward tongue, - at least one upward flange provided away from the upward tongue, - an upward groove formed between the upward tongue and the upward flange, said upward groove being adapted to receive at least a part of the downward tongue of the second connecting outer shape of another identical panel, said second connecting outer shape including - a first downward tongue, - at least one first downward flange provided away from the downward tongue, - a first downward groove formed between the downward tongue and the downward flange, said first downward groove being adapted to receive at least a part of the upward tongue of the first connecting outer shape of another identical panel, a third panel side edge end including a third connecting outer shape, a fourth panel side edge end including a fourth connecting outer shape, said fourth connecting outer shape being designed to connect with the third connecting outer shape of another identical panel in both horizontal and vertical directions, said third connecting outer shape including - a lateral tongue extending in a direction substantially parallel to the upper portion of said decorative floor panel, - at least one second downward flange provided away from the lateral tongue, - a second downward groove formed between the lateral tongue and said second downward flange, said fourth connecting outer shape including - a third groove configured to receive at least a part of the lateral tongue of the third connecting outer shape of a second identical panel, said third groove being defined by an upper lip portion and a lower lip portion, and an upward locking element being provided on said lower lip portion. The third connecting outer shape and the fourth connecting outer shape are configured such that the third connecting outer shape and the fourth connecting outer shape of two identical panels can be connected to each other by rotational movement. In this rotational movement, at least a part of the tongue portion on the side of the first panel is inserted into the third groove of the other identical panel, and at least a part of the upward locking element of the other panel is inserted into the second downward groove of the first panel. The core layer includes at least one cementitious mineral material layer, and the cementitious mineral material layer includes cement and a dispersant. The cementitious mineral material includes or consists of foamed concrete, and the foamed concrete consists of a base material of a concrete material in which air pockets as bubbles are present. The main part of the bubbles in the foamed concrete is small enough in size to absorb water by capillary action. A decorative floor panel with a panel thickness of 3 to 10 mm. **Claim 2** The decorative floor panel according to claim 1, wherein the dispersant includes polycarboxylate ethers (PCEs). **Claim 3** The decorative floor panel according to claim 2, wherein the content rate of lignosulfonate is in the range of 1.0% by weight to 30% by weight of the total weight of polycarboxylate ether and lignosulfonate. **Claim 4** The decorative floor panel according to any one of claims 1 to 3, wherein the weight content rate of the dispersant with respect to the weight of the cementitious mineral material is at most 1%. **Claim 5** The decorative floor panel according to any one of claims 1 to 4, wherein the cement is a calcium-based cement, a calcium silicate-based cement, and / or a magnesium-based cement. **Claim 6** The decorative floor panel according to any one of claims 1 to 5, wherein the cementitious mineral material includes a particulate material dispersed in the cementitious mineral material. **Claim 7** The decorative floor panel according to any one of claims 1 to 6, wherein the cementitious mineral material consists of concrete, magnesia, foamed concrete, and / or gypsum. **Claim 8** The decorative floor panel according to any one of claims 1 to 7, wherein the core layer contains at least 50% by weight of the cementitious mineral material. **Claim 9** The decorative floor panel according to any one of claims 1 to 8, wherein a reinforcing layer is included in the core layer. **Claim 10** The decorative floor panel according to any one of claims 1 to 9, wherein the waterproof layer is located between the core layer and the upper layer.

11. - The air bubbles in the foamed concrete occupy 60 to 85% by volume of the total volume of the foamed concrete, or - The density of the foamed concrete is in the range of 400 to 800 kg / m ３ of the decorative floor panel according to any one of claims 1 to 10.

12. The decorative floor panel according to any one of claims 1 to 11, wherein the air bubbles are mainly of the closed-cell type, and the main part is at least 80% of the air bubbles.

13. The decorative floor panel according to any one of claims 1 to 12, wherein the cement is a calcium silicate hydrate mineral.

14. The decorative floor panel according to any one of claims 1 to 12, wherein particulate materials are dispersed in the foamed concrete, and the particulate materials include sand, pulverized fuel ash, fly ash, lime, and / or aluminum oxide powder.

15. The decorative floor panel according to any one of claims 1 to 10, wherein the cementitious mineral material contains or consists of magnesia, and the magnesia includes magnesia cement based on at least one of the following compounds. - Magnesium oxide and / or magnesium hydroxide - Magnesium chloride - Magnesium oxychloride -5Mg(OH) ２ -MgCl ２ -8H ２ O -Mg ２ (OH)ClCO ３ ·3H ２ O - Magnesite - Ammonium dihydrogen phosphate (NH ４ H ２ PO ４ ) - Struvite (NH ４ MgPO ４ ·6H ２ O) and / or Dittmarite (NH ４ MgPO ４ ·H ２ O) -MgHPO ４ - Potassium phosphate (KH ２ PO ４ ) - Potassium magnesium phosphate hexahydrate (MgKPO ４ ·6H ２ O) - At least one borate - Magnesium sulfate -5Mg(OH) ２ -MgSO ４ -3H ２ O (513 phase) and / or 3Mg(OH) ２ -MgSO ４ -8H ２ O (318 phase) - 5Mg(OH) ２ - MgSO ４ - 5H ２ O (515 phase) and / or Mg(OH) ２ - MgSO ４ - 7H ２ O (517 phase)

16. The decorative floor panel according to claim 15, wherein the magnesia further contains particulate matter dispersed in the magnesia.

17. The decorative floor panel according to claim 15 or 16, wherein the cellulose-based particles contain lignocellulose.

18. The decorative floor panel according to any one of claims 15 to 17, wherein the magnesia layer has at least a partially foamed structure containing pores.

19. The cementitious mineral material contains gypsum or consists of gypsum, and the gypsum contains hydrated plaster having the structural formula CaSO ４ -2H ２ O, and the decorative floor panel according to any one of claims 1 to 10.

20. The decorative floor panel according to claim 19, wherein the gypsum has a foamed structure containing pores.

21. The decorative floor panel according to claim 19, wherein the total content rate of the dispersant in the gypsum is 0.05 to 0.5% by weight.

22. The decorative floor panel according to any one of claims 1 to 21, wherein the core layer includes at least one reinforcing layer.

23. The decorative floor panel according to claim 22, wherein the core layer includes at least two layers of cementitious mineral material, the cementitious mineral material includes cement and a dispersant, and at least one reinforcing layer is located between the two layers of cementitious mineral material.

24. The decorative floor panel according to any one of claims 1 to 23, wherein at least a part of each connecting outer shape is integrally formed with the core layer.

25. The decorative floor panel according to any one of claims 1 to 24, wherein the printed decorative upper layer covers at least a part of only the upper side of the core layer.

26. The side of the upward tongue facing the upward flange is the inner side of the upward tongue, and the side of the upward tongue facing the side opposite to the upward flange is the outer side of the upward tongue. The side of the downward tongue facing the downward flange is the inner side of the downward tongue, and the side of the downward tongue facing the side opposite to the downward flange is the outer side of the downward tongue. At least a part of the inner side of the upward tongue is inclined toward or away from the upward flange. The decorative floor panel according to any one of claims 1 to 25, wherein at least a part of the inner side of the downward tongue is inclined toward or away from the downward flange.

27. The decorative floor panel according to any one of claims 1 to 26, wherein the printed decorative layer includes a base layer or a base film on which a decorative image is printed.

28. A decorative floor covering material, comprising a plurality of decorative floor panels according to any one of claims 1 to 27 connected to each other.

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