Decorative panel, and covering material composed of such decorative panels

Abstract

The present invention relates to connectable decorative panels, in particular floor, wall or ceiling panels with tongue and groove, and also to coverings, in particular floor, wall or ceiling coverings, made up of a plurality of interconnected decorative panels according to the invention.

Description

Technical Field

[0001] The present invention relates to a decorative panel, in particular a floor panel, a wall panel or a ceiling panel. The present invention also relates to a covering material composed of a plurality of interconnected decorative panels according to the present invention, in particular a floor covering material, a wall covering material or a ceiling covering material.

Background Art

[0002] Over the past decade, significant progress has been made in the market for floor coverings for flooring. It is known to install floor panels on the underlying floor in various ways. For example, it is known that the floor panels are attached to the underlying floor by adhesion or by nailing them on top. This technique has the disadvantage that it is rather complex and subsequent replacement can only be carried out by disassembling the floor panels. According to an alternative installation method, the floor panels are roughly installed on the underlay, whereby the floor panels are mutually adapted to each other by tongue and groove joints. The floor thus obtained, also called a floating floor, has the advantages that it is easy to install and that the finished floor surface can move, which is often convenient for receiving potential expansion and contraction phenomena. The options and requirements for flooring have also evolved similarly. In contrast, flooring used to be formed of products made of wood or wood such as MDF or HDF, and was conventionally also called laminate. Recently, the market has also evolved with respect to plastic-based panels such as PVC panels and mineral-based panels such as magnesium oxide panels. Each of these alternatives has its respective advantages and disadvantages. Regardless of the raw material, one of the disadvantages of known panels is that it is often difficult to join and fix the panels together such that a waterproof connection is formed between the panels. Permitting moisture to penetrate the joints between the panels can not only affect the panels if the panels are at least partially formed of moisture-sensitive materials such as MDF or HDF, but can also facilitate the growth of microorganisms between the panels, which is undesirable from a hygiene and health perspective. Summary of the Invention Problems to be Solved by the Invention

[0003] The first object of the present invention is to provide an improved connection between panels, specifically a waterproof connection between panels.

[0004] The second object of the present invention is to provide a panel with an improved angling down coupling mechanism, specifically, to realize a substantially waterproof connection part between panels.

Means for Solving the Problems

[0005] To achieve this object, the present invention provides a first pair of at least opposing edges, in which several such panels can be joined to each other, such that their joints, in the joined state of two such panels, provide locking in a first direction (R1) perpendicular to the plane of the panel and a second direction (R2) perpendicular to each respective edge and parallel to the plane of the panel. The first joint comprises a lateral tongue, which comprises a front region and a rear region. The upper surface of the front region is preferably at least partially inclined downwardly in a direction away from the rear region. And the bottom surface and / or side surface of the rear region of the lateral tongue define a first contact portion, and the lateral tongue comprises a passive bottom surface located adjacent to the first contact portion. The second joint comprises a recess (or groove) for receiving at least a portion of the lateral tongue of another panel. The recess is defined by an upper lip and a lower lip. The lower lip extends beyond the upper lip, and the lower lip defines a second contact portion configured to cooperate, specifically actively cooperate, with the first contact portion of another panel in the joined state of the panels such that the panels are pushed laterally at least towards each other by a force, specifically a tensile force (T1). The upper surface of the lower lip is at least partially curved, specifically smoothly curved. And the at least partially curved upper surface of the lower lip and the passive bottom surface of the lateral tongue are positioned relative to each other such that an intermediate space exists adjacent to each other with the first and second contact portions actively cooperating in the joined state of the two panels. And the lower surface of the upper lip is preferably at least partially inclined and configured to abut at least a portion of the upper surface of the front region of the lateral tongue of another panel, providing a decorative panel with a preamble.

[0006] During installation, the panel to be installed is typically held in an inclined position against the already installed panel, with the side tongues of the panel to be installed partially inserted into the recesses of the already installed panel. The panel to be installed is then tilted downward as the side tongues are clamped into the recesses. This clamping effect closes the seam formed between the panels, which prevents water from entering the seam. The method of joining by angling down the panels to be installed is also called angling-down joining. Due to the height of the shoulder, the joint may slide substantially within the plane of the panels and snap into the joint of the first panel into the joint of the second panel. This joining method is also called a lateral snap action. Preferably, at least a portion of the upper surface of the shoulder, and more preferably, substantially the entire upper surface of the shoulder, is oriented horizontally. Preferably, the underside of the first joining portion, which faces the shoulder when the adjacent panels are joined, and which is typically located adjacent to the lateral tongue, is at least partially, and preferably entirely, horizontally oriented. Preferably, the shoulder and the facing underside mutually surround a space when the adjacent panels are joined, which typically facilitates joining.

[0007] The panels according to the invention achieve (tension) between the panels in a relatively efficient way by a combination of co-acting contacts and adjacent intermediate spaces, which allow the contacts to press the panels towards each other and make the joint between the panels as close to solid and watertight as possible. If there were no intermediate spaces adjacent to the contacts in the joined state of the panels, it would be practically impossible to join the joint, or less tension would be achieved between the (top surfaces of) the panels, which would result in a less (watertight) joint.

[0008] Preferably, the bottom surface and / or the side surface of the front region is / are rounded and / or at least partially convex. This typically facilitates the insertion of the outer end of the lateral tongue portion, also typically referred to as the nasal tip, into the recess of the lateral tongue portion when acting as a sliding surface during joining. The bottom surface and / or the side surface of the front region of the lateral tongue portion can be formed at least partially by the same surface. Preferably, the rounded shape of the nasal tip of the lateral tongue portion is a smoothly rounded shape, which means there are no sharp edges or other discontinuities.

[0009] As described above, in the joined state of the two panels, the passive bottom surface faces the upper surface of the lower lip portion at a certain distance, which enables the contact portion to achieve a desired pre-tension between the panels. Here, it is typically preferred that the passive bottom surface is defined by the cut-out portion on the lower surface of the lateral tongue portion, which more preferably results in a substantially flat passive bottom surface. Preferably, the at least partially rounded upper surface (section) of the lower lip portion is configured as a sliding surface for the sliding co-movement with the preferably rounded bottom surface and / or the side surface of the front region of the lateral tongue portion during the joining of the two panels. Preferably, at least a part of the upper surface of the lower lip portion is smoothly curved, which means there are no sharp edges or other discontinuities. This will facilitate the joining process. Preferably, at least a part of the upper surface of the lower lip portion is smoothly curved according to a substantially constant radius. An additional advantage of this embodiment is that the joining part is relatively easy to manufacture and practical compared to more complex joining parts.

[0010] Preferably, substantially the entire upper surface of the lower lip portion is smoothly curved according to a substantially constant radius. This will typically facilitate the sliding of the side tongue portion into the recess during the joining of adjacent panels. Further, such a constant radius can be achieved by using a single milling tool, which is preferable from an economic and efficiency perspective.

[0011] Preferably, the side surface of the front region of the side tongue portion and the opposing portion of the upper surface of the lower lip portion are formed substantially complementarily and, preferably, are substantially complementarily curved. This allows the side tongue portion to be designed as robust as possible while minimizing the amount of material cut away for designing the recess, which prevents unnecessary weakening of the second joint. Preferably, the side surface of the front region of the side tongue portion and the opposing portion of the upper surface of the lower lip portion are at least partially spaced apart and surround a (front) space with respect to each other. Preferably, the front space is smaller than the bottom space defined by the passive bottom surface of the side tongue portion and the opposing portion of the upper surface of the lower lip portion. Preferably, the maximum distance a between the side surface of the front region of the side tongue portion and the opposing portion of the upper surface of the lower lip portion is smaller than the maximum distance b between the passive bottom surface of the side tongue portion and the opposing portion of the upper surface of the lower lip portion.

[0012] Preferably, as described above, the lower surface of the upper lip portion slopes downwardly toward the core of the panel, and the upper surface of the front region of the side tongue portion also slopes downwardly in a direction away from the core of the panel. Here, the inclination angles may be the same. Each inclination angle is preferably located between 20 degrees and 30 degrees, and includes those angles, with respect to the plane defined by the panel. This inclination can considerably facilitate the joining process so that the panel is substantially in-plane. Further, this inclined orientation may contribute to increasing the tension between the panels if there is a possibility of a pre-tension existing between the lower surface of the upper lip portion and the upper surface of the front region of the side tongue portion in the joined state, and this pre-tension can be transmitted to the contact portion and / or to a substantially vertical contact surface defined at the joint between the two panels.

[0013] The decorative panel according to the present invention is mainly intended for indoor use, but can also be used outdoors if necessary. The decorative panel according to the present invention typically has a limited thickness (20 millimeters or less) and is preferably configured to be installed as a floating (floor) covering material used in homes, offices, stores, etc., without using an adhesive, and in particular. Thereby, specifically, applications in so-called laminate floors are intended, and typically, a waterproof (water-resistant) decorative superstructure is applied on the core layer of the panel. In many cases, those core layers are formed of wood, wood-based materials, particle board and / or fiber board such as medium density fiberboard (MDF) or high density fiberboard (HDF). However, alternative materials such as thermoplastic materials, specifically polyvinyl chloride (PVC) and / or polyurethane (PU), and / or minerals such as calcium carbonate and / or magnesium hydroxide and / or calcium hydroxide (hydrate) may also be used to at least partially constitute the core layer. Optionally, in order to facilitate bonding and optionally to make the joint more water-repellent, which would be advantageous for achieving a waterproof connection between the joints, a glide agent such as paraffin, oil, wax, etc. may be provided at the contact part of the decorative floor panel.

[0014] Another preferred embodiment of the panel according to the present invention is presented below.

[0015] As described above, preferably, the passive bottom surface is at least partially flat or flattened, which is easy to achieve during manufacturing and ensures the existence of the intermediate space. Preferably, it is conceivable that the flat passive bottom surface is at least partially inclined in the direction towards the front region with respect to the plane of the panel. Here, the inclined upper surface of the side tongue and the inclined passive bottom surface preferably approach in the direction away from the rear region of the side tongue. The angle of inclination enclosed between the inclined upper surface of the side tongue and the inclined passive bottom surface is preferably 15 degrees or less, more preferably 10 degrees or less, and may be, for example, 5 degrees. This results in a somewhat inclined nose tip of the side tongue while keeping the rear region of the side tongue relatively robust, which will result in a sturdy tongue that can be inserted into the recess relatively easily. For the sake of completeness, it should be noted that the passive bottom surface does not necessarily have to be a flat surface, and when the intermediate space is formed in the joined state of the two panels, it may be, for example, a concave surface and / or a convex surface and / or a special-shaped surface.

[0016] Preferably, the upper surface of the lower lip defines the deepest point of the recess, and in the joined state of the two panels, the deepest point is arranged at a distance from and opposite to the passive bottom surface. This means that when the nose tip of the side tongue is slid along the upper surface of the lower lip towards its final locking position during joining, the nose tip first moves (slides) downward and substantially upward, which makes it easier to properly position the nose tip of the side tongue and makes it easier for the lower surface of the upper lip and the upper surface of the front region of the side tongue to come into contact with each other.

[0017] Preferably, the upper surface of the lower lip defines the deepest point of the recess, the shoulder of the lower lip defines the highest point of the lower lip, the deepest point and the highest point define the depth of the lower lip (LLD), and the first and second contact portions are disposed entirely above half of the depth of the lower lip (i.e., 50%). Generally, it is preferred to dispose the contact portions as high as possible so as to enable the contact portions to efficiently transmit the clamping force between the contact portions to the substantially vertical contact surfaces of the two panels that define the joint formed between the panels.

[0018] In a preferred embodiment, the upper surface of the lower lip defines the deepest point of the recess, the shoulder of the lower lip defines the highest point of the lower lip, the deepest point and the highest point define the depth of the lower lip (LLD), and the minimum thickness of the lateral tongue (STD) measured between the at least partially inclined upper surface of the lateral tongue and the passive bottom surface exceeds the depth of the lower lip. This means that the thickness of the lateral tongue is relatively thick compared to the depth of the lower lip, and also means that a part of the lateral tongue is located above the shoulder (level) of the lower lip. Typically, this results in greater robustness and thus a less fragile joint of the panel according to the present invention.

[0019] Preferably, the first contact portion is inclined upward in a direction away from the front region of the side tongue portion, and the inclined first contact portion and the plane of the panel preferably enclose an angle of at least 45 degrees, and the second contact portion is inclined upward in a direction away from the upper lip portion, and the inclined second contact portion and the plane of the panel preferably enclose an angle of at least 45 degrees. These inclination angles typically have a sufficiently large horizontal component (parallel to the plane of the panel) to achieve sufficient tension to achieve a (water)tight connection between the panels. The first contact portion and the second contact portion extend in (slightly) different directions, but generally, it is preferred that the first contact portion and the second contact portion extend in substantially parallel directions. This parallel inclination will generally facilitate sliding the second contact portion on the first contact portion during installation of the panel.

[0020] Preferably, the bottom and / or side surfaces of the front regions of the lateral tongues are configured to cooperate with the lower lip and together define a bottom front contact surface when the two panels are joined. This bottom front contact surface typically provides additional stability and locking of the joint in the joined state. Preferably, the entire bottom front contact surface is disposed below the level of the first and second contact portions. This results in the lateral tongues having an inclined orientation (inclined heartline) in both the joined and unjoined states, which is effective for clamping the lateral tongues between the lower and upper lips. Furthermore, this positioning of the bottom front contact surface may increase the clamping force between the contact portions and, consequently, the clamping force between the substantially vertical contact surfaces at or near the top surfaces of adjacent panels. Preferably, the contact surfaces defined by the bottom front contact surface on one side and the first and second contact portions on the other side mutually enclose an angle of 70 to 110 degrees, preferably 80 to 100 degrees, and more preferably substantially 90 degrees (± 2 to 3 degrees). A larger angle will typically affect the clamping effect of the lateral tongues, while a smaller angle will typically affect the coupling of the coupling portions.

[0021] Typically, in the joined state, the (upper) joint formed by (or between) the two panels defines a vertical plane (VP). This vertical plane is perpendicular to the plane of the panel. Preferably, the vertical plane subdivides the lower lip into an inner lower lip and a lower outer lower lip. Preferably, at least a part and more preferably the entire surface of the bottom front contact surface (described above), as well as the first and second contact portions, are arranged on the same side of the vertical plane. This results in a relatively large distance and / or inclined directionality between the second contact portion defined by the contact between the lower surface of the upper lip on one side and the upper surface of the front region of the side tongue of another panel on the other side, and the bottom contact surface on the other side, which facilitates the joining and locking of adjacent panels. Typically, the upper lip is entirely arranged on the same side of the vertical plane. The upper surface of the front region of the side tongue preferably intersects the vertical plane (VP). Here, the largest part of the upper surface is arranged (and more preferably, in contact) under the lower surface of the upper lip. The entire upper surface (upper part) of the lower lip extending between the vertical plane (VP) and the second contact portion is preferably formed by a smooth curved surface configured to act as a sliding surface for facilitating joining.

[0022] Preferably, in the joined state, the joint formed by the two panels defines a vertical plane (VP), the vertical plane subdividing the lower lip into an inner lower lip and a lower outer lower lip, and in the joined state, the entire bottom surface and the entire side surface of the inner lower lip (when their surfaces are different surfaces) are arranged at a distance from the second joint, specifically from the lateral tongue. Preferably, on the upper surface of the lower lip, there are provided staggered and / or cut-out portions (and / or stepped portions) which are at least partially arranged under the upper lip and are configured to receive the end portion of the lateral tongue of another panel. These staggered and / or cut-out portions can create a desired space between the tip of the lateral tongue and the upper surface of the lower lip, which can not only facilitate joining but also allow the lateral tongue to expand slightly during normal use, for example, by moisture absorption and / or during heating. Preferably, the upper lip and the staggered and / or cut-out portions of the lower lip are configured to clamp the end portion (i.e., the tip) of the lateral tongue. This can further enhance the locking effect between the joints. Preferably, the staggered and / or cut-out portions and / or the stepped portions are entirely located under the upper lip, which is usually the position where the tip of the lateral tongue is arranged in the joined state.

[0023] Preferably, the upper surface of the lower lip portion includes a curved rear upper surface and a curved front upper surface, the rear upper surface and the front upper surface being staggered, and preferably, the front upper surface is deeper than the rear upper surface. The curvatures of the rear upper surface and the front upper surface may vary relative to each other, but are preferably substantially the same as each other. Due to the staggered directions, the virtual centers of the curvatures of the front upper surface and the rear upper surface do not coincide and are spaced apart from each other. The rear upper surface and the front upper surface are preferably deeper than the rear upper surface, which is typically achieved by cutting (machining) additional material during manufacture, resulting in a slightly larger space for accommodating the outer end (tip) of the lateral tongue portion. As described above, the transition between the front upper surface and the rear upper surface is preferably realized by a step (step portion).

[0024] Preferably, the panel defines an upper surface and a bottom surface that together define the thickness (PT) of the panel. The thickness (ST) (or height) of the shoulder measured from the bottom surface of the panel to the highest point of the shoulder exceeds 30%, preferably 50% of the thickness (PT) of the panel. As described above, by providing a relatively thick (or high) shoulder, the contact portion can be disposed at a higher level, which is conducive to efficiently transmitting the tightening force from the contact portion to the upper joint formed between the panels, and thus this will result in a relatively tight connection between the panels at the upper joint.

[0025] In the joined state of the panel, the upper surface of the shoulder is preferably disposed at a distance from the opposing lower surface of the first joint. This prevents the upper surface of the shoulder and the opposing lower surface on the opposite side of the first joint from co - acting with each other, which could affect the desired tension between the panels. Thus, this means that the contact portion is surrounded by two spaces, namely, the intermediate space mentioned above and the space above the shoulder. Preferably, the upper surface of the shoulder is substantially parallel to the plane of the panel. Preferably, the opposing lower surface on the opposite side of the second joint is also substantially parallel to the plane of the panel. In this way, both components can be realized in a relatively robust manner without forming weak zones at the shoulder and / or the opposing lower surface of the second joint.

[0026] The lower lip is preferably disposed entirely below (i.e., at a lower level compared to) the upper lip. This facilitates the insertion of the lateral tongue into the recess.

[0027] Preferably, the upper surface of the front region of the lateral tongue and the side surface of the front region of the lateral tongue are connected by a transition convex surface, and the lower surface of the upper lip and the side surface of the upper lip are connected by a transition convex surface. One or more of those convex surfaces can act as sliding surfaces during the joining of the joints, specifically, during a lateral snap - action.

[0028] In the decorative panel according to the present invention, the first coupling part and the second coupling part may also be provided at least on a second pair of opposing edges. This means that all panel edges are configured to be joined according to an angling-down movement. The structure of the different first coupling parts at different panel edges may be the same or different, i.e., the same applies to the different second coupling parts. For example, in the case of a rectangular (square-shaped) panel, it is assumed that at the short edges, the thickness of the shoulder is smaller or larger than the thickness of the shoulder at the long edges, and the same applies to the other components of the coupling part. Such a panel is also called an angle-angle panel, which functions properly but may not be easy to install.Therefore, generally, in at least a further, specifically, a second pair consisting of opposing edges, some of such panels can be coupled to each other by a lowering movement or a vertical movement, whereby their coupling portions, in the coupled state of such two panels, provide locking in a first direction (R1) perpendicular to the plane of the panel and in a second direction (R2) perpendicular to each respective edge and parallel to the plane of the panel. The third coupling portion includes an upward tongue, at least one upper flange located at a distance from the upward tongue, and an upward groove formed between the upward tongue and the upper flange. The upward groove is adapted to receive at least a part of the downward tongue of the fourth coupling portion of another panel. The side of the upward tongue facing the upper flange is the inner side of the upward tongue, and the side of the upward tongue facing away from the upper flange is the outer side of the upward tongue. The fourth coupling portion includes a downward tongue, at least one lower flange located at a distance from the downward tongue, and a downward groove formed between the downward tongue and the lower flange. The downward groove is adapted to receive at least a part of the upward tongue of the third coupling portion of another panel. The side of the downward tongue facing the lower flange is the inner side of the downward tongue, and the side of the downward tongue facing away from the lower flange is the outer side of the downward tongue. Preferably, the inner side and the inner side of the upward tongue are configured to cooperate with the inner side of the downward tongue of another panel in the coupled state of the panels such that the panels are pushed at least laterally towards each other by a tensile force (T2). The tensile force (T2) contributes to achieving a firm and preferably waterproof connection between the third coupling portion and the fourth coupling portion.

[0029] Preferably, at least a part of the inner side of the upward tongue portion is inclined toward the upper flange, and at least a part of the inner side of the downward tongue portion is inclined toward the lower flange. This "closed groove" coupling mechanism will enable the two panels to be fixed in the first direction (R1). In an alternative embodiment, at least a part of the inner side of the upward tongue portion is inclined away from the upper flange, and at least a part of the inner side of the downward tongue portion is inclined away from the lower flange. This "open groove" coupling mechanism typically enables the third and fourth joints to be more easily connected.

[0030] Preferably, a first locking element is provided on the outside of the upward tongue portion, and a second locking element configured to cooperate with the first locking element of another panel is provided on the lower flange. This will enable the two panels to be fixed in the first direction (R1). The first locking element preferably comprises an outer bulge, and the second locking element preferably comprises a recess. The outside of the outer bulge comprises an upper part and an adjacent lower part. The lower part comprises an inclined locking surface, and the upper part preferably comprises a curved guiding surface. The recess comprises an upper part and an adjacent lower part. The lower part comprises an inclined locking surface. In the joined state of the adjacent panels, the inclined locking surface of the lower part of the outer bulge and the inclined locking surface of the lower part of the recess are in contact to achieve the locking effect between the panels, and / or in the joined state of the adjacent panels, the upper part of the first locking element and the second locking element are preferably at least partially spaced apart. Preferably, the length of the inclined locking surface of the lower part of the outer bulge is greater than that of the inclined locking surface of the lower part of the recess, preferably at least 1.5 times greater. Preferably, the upper part extends over a larger vertical section compared to the lower part, and preferably the height of the upper part is at least three times the height of the lower part.

[0031] The first locking element on the outer side of the upward tongue portion, during joining, is a protrusion of the panel and typically the outermost part of the panel on one side. And in order to push one panel into the other, since a force needs to be overcome during joining, it will hit the lower flange of another panel. By providing a (curved) guiding surface on the upper part, another or other panels can be guided downward, as a result, the joining may be carried out gradually, and large material deformation and / or peak stress can be suppressed. In this way, the lower part can be inclined and constitutes the part of the bulge that returns from the outermost part of the bulge towards the upward tongue portion. Also, this inclined surface has a guiding function for guiding the panels towards their final stage. The inclination of the locking surface further enables potential upward forces or movements of the panels to generate vertical or horizontal force components. The horizontal component can be utilized to hold the panels together, push the panels towards each other, and improve the connectivity and waterproofness of the connection between the panels. The second locking element can be a recess comprising an upper part and an adjacent lower part. The lower part is provided with an inclined locking surface for co-operating with the first locking element. The inclined surface further has the advantage of a rounded surface that is relatively easy to manufacture or cut, and it is relatively easy for a relatively large contact surface between the two panels to develop a locking force on the joined panels.

[0032] The upper part may extend over a greater vertical interval compared to the lower part in order to gradually guide the panel to a predetermined position. The upper part typically does not produce a vertical locking effect, and as a result, the horizontal part of the upper part typically has little relevance compared to the lower part that produces a vertical locking effect. The portions of the first and second locking elements that are in contact in the coupled state of the panel are typically formed by the inclined locking surfaces of the locking elements, i.e., by the lower part. In the coupled state of the panel, the upper parts of the first and second locking elements may be at least partially spaced apart. This spacing allows the upward tongue to move upward without being obstructed by the lower flange, and this upward movement is similarly transmitted to shift to a closing horizontal movement, improving the connection or locking of the panel and allowing the panels to be pushed together.

[0033] The outer side of the upward tongue may comprise an upper outer part and a lower outer part, the first locking element being disposed between the upper outer part and the lower outer part, and the lower outer part being disposed closer to the inner side of the upward tongue compared to the upper outer part. The upper outer part may preferably be substantially vertical and define an outer vertical surface, and the first locking element projects at least partially, preferably up to 2 mm, from the outer vertical surface. For example, the upper outer part above the first locking element defines a vertical surface, and the lower outer part below the first locking element defines another vertical surface, and these vertical surfaces are parallel but offset with the vertical surface of the lower outer part being disposed closer to the upper flange. This difference creates a relatively large distance between the panels at the intersection between the inclined locking surface of the upward tongue and the lower outer part, which allows for a greater upward angling or rotational movement of the upward tongue, i.e., allows for a potentially greater closing or tensile force exerted by the locking element to improve the connectivity and waterproofness of the panel.

[0034] The lower outer part may be substantially vertical, and the inclined locking surface or the lower part and the lower outer part enclose an angle of 100 degrees to 175 degrees, specifically, an angle of 100 degrees to 150 degrees, more specifically, an angle of 110 degrees to 135 degrees. Such angles have been proven to provide the best combination of locking and guiding characteristics. The angle enclosed by the upper contact surface and the inclined contact surface and the angle enclosed by the lower outer part and the inclined locking surface or the lower part can have a difference within 20 degrees and are preferably the same. This enables relatively easy manufacturing in that the same or similar tools can be used to cut both elements from the panel.

[0035] The outermost part of the first locking element can be arranged at a lower horizontal level compared to the upward groove. In this way, during the downward movement of the panel during connection, the widest or outermost part of the first locking element hits relatively slowly, which facilitates the connection of the two panels.

[0036] Adjacent to, and typically directly adjacent to or directly below, the upper contact surface, there may be an inclined contact surface. At the inclined contact surface, the panel is in contact so as to create a connection or seal between the panels. The inclination preferably is such that when looking at the downward tongue, the inclined surface extends outward, and when looking at the upper flange, the inclined surface extends inward. The inclination angle is such that the downward tongue has such a protrusion and the upper flange has a recessed part, and these parts are in contact in the connected state, thus providing a vertical locking effect. Also, the inclination forms a slight labyrinth, which improves the waterproofness of the connection.

[0037] Adjacent to, and typically directly adjacent to or immediately below, the inclined contact surface, the downward tongue may have an outer surface. This outer surface may be, for example, the outermost surface of the downward tongue or the surface of the outer tongue furthest from the lower flange. Similarly, adjacent to, and typically directly adjacent to or immediately below, the inclined contact surface, the upper flange has an inner surface. There is a space between the inner surface and the outer surface. This space is intended to prevent any force exerted on or by the panel from causing the panel to be pushed together elsewhere other than the upper contact surface and / or the inclined contact surface. If the inner surface and the outer surface come into contact, they can prevent the upper contact surface from coming into contact, which would be detrimental to the waterproofness of the connection. Thus, at the top, at the upper contact surface and the inclined contact surface, the purpose is to create a connection between the panels, whereas below these contact surfaces, the purpose is to avoid such a connection.

[0038] The upper contact surface may be at least partially vertical and defines an inner vertical surface. The inclined contact surface of the downward tongue preferably extends horizontally beyond the inner vertical surface by at most 1 mm, and the inclined contact surface of the upper flange is inward compared to the inner vertical surface. Such a configuration causes the downward tongue to project locally from the inner vertical surface and the upper flange to be locally recessed. In the coupled state, the inclined contact surfaces grip each other's back sides and can produce a vertical locking effect. By limiting the horizontal extent of the protrusion, the downward tongue can still be combined with downward or vertical movement while providing the vertical locking effect. Thus, a portion of the downward tongue may extend beyond the inner vertical surface, and this portion may be elongated relative to a larger vertical portion compared to the horizontal portion, preferably with the vertical portion being at least three times the horizontal portion. This allows for a relatively small horizontal portion that still enables the panel to be connected to downward or vertical movement.

[0039] Thus, a portion of the downward tongue can extend beyond the inner vertical surface, and the portion can be substantially trapezoidal or wedge-shaped. Such a shape provides a robust portion capable of withstanding forces to form a tight connection between the panels, while allowing the portion to be pushed into the space formed within the upper flange when the panel is subjected to some locking, coupling, or other force within the plane of the panel. This also similarly improves the waterproofness of the connection between the panels.

[0040] The inclined contact surface can be arranged outside and / or adjacent to the inner vertical surface, and preferably, it is arranged completely outside the inner vertical surface or entirely on one side of the inner vertical surface. This enables a relatively simple structure that provides a tight connection between the two panels. Preferably, the upper contact surface defining the vertical surface transitions directly into the inclined contact surface. In such a configuration, the connection of the contact surfaces continues from the upper contact surface to the inclined contact surface, with an increasing number of continuous surfaces, and thus, the connection between the panels and the waterproofness of the connection are improved. In the coupled state, the bottom of the downward tongue can contact the upper side of the upward groove at the groove contact surface, and there is a gap between the first and second coupling portions, extending from the inclined contact surface to the groove contact surface. Such a gap can be utilized, for example, to collect dust or shavings from the panels that are potentially generated during the coupling of the two panels. Further, such a gap aims to prevent any force exerted on or by the panels from causing the panels to be pushed together elsewhere other than the upper contact surface and / or the inclined contact surface. The groove contact surface is preferably mostly horizontal and enables the force exerted downwardly, typically by stepping on the panel, on the panel and specifically on the connection between the two panels, to be transmitted to the subfloor or surface under the panel.

[0041] The upper surface of the upward tongue portion and the upper surface of the downward groove may be spaced apart from each other in the coupled state such that there is a gap between the two surfaces. Here too, such a gap serves to prevent any force exerted on or by the panel from causing the panel to be pushed together elsewhere other than the upper contact surface and / or the inclined contact surface. The upward movement of the upward tongue portion can, for example, more specifically, in a so-called closed groove locking connection, give rise to a horizontal force that closes or tightens the connection between two panels. To allow for such upward movement, the gap is provided between the upward tongue portion and the downward groove. The upper surface of the downward groove can be formed, for example, by the bottom surface of a bridge portion that connects the downward tongue portion to another part of the panel.

[0042] The upper contact surface and the inclined contact surface of the upper flange may enclose a first angle with each other, and the upper contact surface and the inclined contact surface of the downward tongue portion may enclose a second angle with each other, and the difference between the first angle and the second angle is within 20 degrees. For example, the inclined contact surface of the upper flange may enclose a first angle of 120 degrees with each other, and the upper contact surface and the inclined contact surface of the downward tongue portion may enclose a second angle of 125 degrees with each other. Since the difference between the two angles is 20 degrees or less, it is 5 degrees within 20 degrees. By creating a difference between the angles, a configuration can be provided that enables a biting-in operation to increase the locking force at the connection and improve the waterproofing. Pushing or biting the locking elements into each other can result in an enhancement of the locking force or connection in the panel.

[0043] Preferably, the upper flange and the outer side of the downward tongue define a substantially vertical upper contact surface of the panel, and adjacent to the upper contact surface, both the downward tongue and the upper flange have an inclined contact surface. The inclined contact surface of the downward tongue of the panel is configured to engage with the inclined contact surface of the upper flange of an adjacent panel in the coupled state of the panel. Each substantially vertical upper contact surface and each adjacent inclined surface surround each other at an angle (α) of 100 degrees to 175 degrees. Preferably, a third locking element such as a bulge or a recess is provided on the outer side of the downward tongue, and a fourth locking element such as a recess or a bulge is provided on the upper flange and configured for co-action with the third locking element of another panel so as to fix the two panels in the first direction (R1). More preferably, the third locking element is at least partially defined by the upper contact surface of the downward tongue, and the fourth locking element is at least partially defined by the upper contact surface of the upper flange.

[0044] Preferably, at least a part of the joint forms an integral part of the core layer of the panel. In other words, the sides of the core can be shaped such that their special-shaped edges at least partially constitute the joint. Preferably, the panel comprises at least one core layer and at least one decorative upper structure or decorative upper part directly or indirectly attached to the core layer, and the upper structure or upper part defines the upper surface of the panel. Typically, this upper structure or upper part is waterproof, thus protecting the core, which may or may not be composed of a moisture-sensitive material composition, from water (and other liquids). Preferably, the upper part comprises a printed decorative layer and at least one durability layer covering the printed decorative layer. This allows the one or more core layers to be at least partially composed of a moisture-sensitive material such as wood, medium-density fiberboard (MDF), or high-density fiberboard (HDF) due to the improved water resistance of the joint including the first joint and the second joint.

[0045] The panel may comprise, for example, a layered structure comprising a central core (or core layer) and at least one decorative upper part directly or indirectly attached to or integrated with the core layer, the upper part defining the upper surface of the panel. The upper part preferably comprises at least one decorative layer directly or indirectly attached to the upper surface of the core layer. The decorative layer can be a printed layer such as a printed PVC layer, a printed PU layer or a printed paper layer, and / or may be coated by at least one protective (upper) layer covering the decorative layer. The protective layer also forms part of the decorative upper part. The presence of the printed layer and / or the protective layer will be able to prevent the tile from being damaged by scratching and / or by environmental factors such as UV / moisture and / or wear. The printed layer may be formed by a film on which decorative printing is applied, the film being attached onto the base layer and / or intermediate layer such as an undercoat layer disposed between the base layer and the decorative layer. Also, the printed layer may be formed by at least one ink layer applied directly onto the upper surface of the core layer or onto an undercoat layer applied to the base layer. The panel may comprise at least one durability layer directly or indirectly attached to the upper surface of the decorative layer. The durability layer also forms part of the decorative upper part. Each panel may comprise at least one lacquer layer directly or indirectly attached to the upper surface of the decorative layer, preferably to the upper surface of the durability layer.

[0046] The lower surface (back side) of the core (layer) can also form the lower surface (back) of the panel itself. However, it is conceivable and potentially preferable that the panel comprises a backing layer attached directly or indirectly to the lower surface of the core. Typically, the backing layer acts as a balance layer to stabilize the shape, specifically the flatness, of the panel itself. Further, the backing layer typically contributes to the sound attenuation properties of the panel itself. Since the backing layer is typically a closed layer, applying the backing layer to the lower surface of the core will cover at least partially, and preferably entirely, the core grooves. Here, the length of each core groove is preferably smaller than the length of the backing layer. The backing layer may be provided with a cut, and at least a part of the cut overlaps at least one core groove. The at least one backing layer is preferably at least partially formed of a flexible material, preferably an elastomer. The thickness of the backing layer typically varies from about 0.1 to 2.5 mm. Non-limiting examples of materials that can at least partially constitute the backing layer are polyethylene, cork, polyurethane, polyvinyl chloride and ethylene vinyl acetate. Optionally, the backing layer contains one or more additives such as fillers (such as chalk), dyes, resins and / or one or more plasticizers. In certain embodiments, the backing layer is at least partially formed of a composition of resin-bonded powdered (or shaved) cork particles. Instead of cork, other wood-related products, such as wood, may be used. The thickness of the polyethylene backing layer is, for example, typically 2 mm or less. The backing layer may be solid or foamed. The foamed backing layer can further improve the sound attenuation properties. The solid backing layer can improve the desired balance effect and stability of the panel.

[0047] In a preferred embodiment, at least one core layer comprises at least one main polymer and at least one plasticizer composition, preferably comprising polyvinyl butyral (PVB), more preferably in a content of 35 to 65% by weight of the plasticizer composition. This plasticizer composition has the advantage over standard plasticizers used in floor panels of being relatively safe and less toxic. Thus, there is proposed a plasticizer composition that is well suited to be incorporated into the decorative panel, specifically into the core (and / or another layer) of the decorative panel. At the same time, the panel is essentially elastically deformable by containing the plasticizer composition in the material layer. Furthermore, in the claimed panel, it has been found that the components contained in the plasticizer composition do not tend to migrate in the main polymer matrix. Thus, by incorporating a plasticizer composition as claimed, harmful leaching of plasticizer components out of the matrix is avoided. Furthermore, the plasticizer composition used in the panel according to the invention is preferably a phthalate-free and thus superior to standard plasticizers and different polymer-based plasticizer composition. Therefore, the polymer-based plasticizer composition used in the panel according to the invention can also be regarded as a softening agent composition, or more simply as a softening agent. The presence of this plasticizer composition (or softening agent) provides the desired flexibility (elasticity) to the material layer of the panel and thus to the panel itself, which does not make the panel so brittle and thus not so fragile. Furthermore, this also facilitates the proper installation of the panel on a floor that is, for example, (slightly) uneven, and further improves the acoustic properties (both acoustic transmission and acoustic reflection) of the panel itself. The panel according to the invention can also provide sufficient flexibility for handling the panel, which can facilitate the storage and / or transportation of the panel before installation. Thus, it is conceivable that the panel is formed by a strip (or sheet) provided as a roll that is unrolled from the roll. The length of such a strip is typically 1 to 30 meters.The panel may be, for example, long and may have a width of 10 to 100 cm and a length of 50 to 250 cm. The polymer blend compound used in at least one material layer of the core is mainly intended as a substantially non-mobile plasticizer for flexible polymer-based panels and / or for impact modification of other polymers, and both the elasticity and the acoustic properties (sound attenuation properties) are improved. When PVB is used, for example, in a PVB-based core as the sole plasticizer additive, there is typically insufficient compatibility between PVB and PVC, which leads to a limited plasticizing effect and brittleness of the mixture. Here, a less favorable microstructure (having a trace amount of PVB embedded in a PVC-based matrix) may also cause undesirable drawbacks such as reduced tear strength, the risk of partial degradation over time, and the risk of non-uniform freeze fracture. According to the present invention, by including PVB in a solid-state non-mobile plasticizer, by mixing PVB with one or more alloy copolymers, the above-mentioned drawbacks of using PVB as a plasticizer, especially in PVC, are avoided. Furthermore, PVB can be maximized and the properties of the final polymer matrix can be enhanced. Here, the improved elongation at break, changes in flexural modulus and tensile modulus, improved strength, and maintained surface tension are typically considered to be the most important improved properties. This enables the realization of a new design for designing the panel, especially since this type of polymer-based plasticizer composition is scalable, and the microstructure of the mixture is reproducible and homogeneous.

[0048] The panel according to the present invention can also be formed at least in part by magnesium oxide. More specifically, the panel according to the present invention may comprise at least one core layer having an upper side and a lower side, and a decorative upper structure (upper part) directly or indirectly attached to the upper side of the core layer. The at least one core layer comprises at least one composite layer made of at least one magnesium oxide (magnesia) and / or magnesium hydroxide-based composition, specifically magnesia cement. Particles, specifically cellulose and / or silicone-based particles, may be dispersed in the magnesia cement. Optionally, one or more reinforcing layers, for example a glass fiber layer, may be embedded in the composite layer. The core composition may also include magnesium chloride which gives rise to magnesium oxychloride (MOC) cement and / or magnesium sulphate which gives rise to magnesium oxysulphate (MOS) cement. The application of magnesium oxide and / or magnesium hydroxide-based compositions, specifically magnesia cements containing MOS and MOC, has been found to significantly improve the flammability (non-flammability) of the decorative panel itself. Furthermore, the panel, which is relatively fire-resistant, also has significantly improved dimensional stability when subjected to temperature variations during normal use. Magnesia-based cement is a cement based on magnesia (magnesium oxide), and the cement is the reaction product of a chemical reaction in which magnesium oxide acts as one of the reactants. Magnesia may still be present in the magnesia cement and / or undergoes a chemical reaction in which another chemical bond is formed, as described below. The additional advantages of magnesia cement compared to other cement types are presented below. The first additional advantage is that magnesia cement can be produced in a relatively energy-efficient, i.e. cost-effective, manner. Furthermore, magnesia cement has relatively high compressive and tensile strengths.Another advantage of magnesia cement is that this cement typically has a natural affinity for cellulose materials such as inexpensive plant fiber wood flour (wood chips) and / or wood pieces, i.e., this not only improves the bonding of the magnesia cement, but also leads to weight reduction and further sound insulation (attenuation). Magnesium oxide when combined with cellulose and optionally clay produces a magnesia cement that absorbs water vapor, i.e., this cement does not deteriorate (rot) as it efficiently discharges moisture. Furthermore, magnesia cement is a relatively good thermal and electrical insulating material, which makes the panel particularly suitable for use as flooring in radar bases and hospital operating rooms. An additional advantage of magnesia cement is that it has a relatively low pH compared to other cement types, which enables the important durability of any glass fibers as particles dispersed in the cement matrix and / or as a reinforcing layer (as fiber glass), and furthermore enables the use of other types of fibers in a durable manner. Additionally, an advantage of the decorative panel is that it is suitable for use both indoors and outdoors. As already mentioned, the magnesia cement is based on magnesium oxide and / or magnesium hydroxide. The magnesia cement itself may not contain magnesium oxide, depending on another reactant used to manufacture the magnesia cement. Here, for example, it is conceivable that magnesia as a reactant is converted to magnesium hydroxide during the manufacturing process of the magnesia cement. Therefore, the magnesia cement itself may contain magnesium hydroxide. Typically, the magnesia cement may contain water, specifically, water of hydration. Water is usually used as a binder to produce a strong and coherent cement matrix. The magnesia-based composition, specifically, the magnesia cement, may contain magnesium chloride (MgCl2). Typically, when magnesia (MgO) is mixed with magnesium chloride in an aqueous solution, a magnesia cement containing magnesium oxychloride (MOC) will be formed.The bonding phase consists of Mg(OH)2, 5Mg(OH)2.MgCl2.8H2O (5-form), 3Mg(OH)2.MgCl2.8H2O (3-form), and Mg2(OH)ClCO3·3H2O. Since this phase has excellent mechanical properties, the 5-form is a preferred phase. In relation to other cement types such as Portland cement, MOC has excellent properties. MOC does not require wet curing and has high fire resistance, low thermal conductivity, and good abrasion resistance. MOC cement can be used with different aggregates (additives) and fibers with good adhesion. Also, it can undergo different types of surface treatments. MOC generates high compressive strength (e.g., 8,000 - 10,000 psi) within 48 hours. The compressive strength gain occurs early during curing, i.e., the 48-hour strength is at least 80% of the ultimate strength. The compressive strength of MOC preferably ranges from 40 to 100 N / mm2. The flexural tensile strength is preferably 10 - 17 N / mm2. The surface hardness of MOC is preferably 50 - 250 N / mm2. The longitudinal elastic modulus is preferably 1 - 3×104 N / mm2. The flexural strength of MOC is relatively low but can be significantly improved by the addition of fibers, specifically cellulose-based fibers. MOC is compatible with a wide range of synthetic resin fibers, mineral fibers (such as basalt fibers), and organic fibers such as bagasse, wood fibers, and hemp. The MOC used in the panel according to the present invention can be reinforced by one or more of these fiber types. MOC is non-shrinking, has abrasion resistance and acceptable wear resistance, and has impact resistance, indentation resistance, and scratch resistance. MOC is resistant to thermal and freeze-thaw cycles and does not require air entrainment to improve durability. Also, MOC has excellent thermal conductivity, low electrical conductivity, and excellent bonding properties to various substrates and additives, and has acceptable fire-resistant properties. MOC is less preferred when the panel is exposed to relatively extreme weather conditions (temperature and humidity) that affect not only the set properties but also the phase development of magnesium oxychloride.Over a certain period, atmospheric carbon dioxide reacts with magnesium oxychloride to form a surface layer consisting of Mg2(OH)ClCO3.3H2O. This layer acts to retard the leaching process. Eventually, additional leaching results in the formation of hydromagnesite, 4MgO.3CO3.4H2O, which is insoluble and enables the cement to maintain its structural integrity. The magnesium-based composition, specifically the magnesia cement, is based on magnesium sulfate, specifically magnesium sulfate heptahydrate (MgSO4·7H2O). The latter salt is also known as Epsom salt. In aqueous solution, MgO reacts with MgSO4, which results in a basic magnesium sulfate cement (MOS) having very good binding properties. In MOS, 5Mg(OH)2.MgSO4.8H2O is the most commonly found chemical phase. MOS is not as strong as MOC, but MOS begins to decompose at a temperature more than twice that of MOC and thus is well-suited for refractory applications for longer fire protection. Furthermore, the products of their decomposition at high temperatures are less harmful (sulfur dioxide) than the products of acid chlorides (hydrochloric acid), and in addition, less corrosive. Furthermore, the meteorological conditions (humidity, temperature and wind) during application are not as critical for MOS as for MOC. The mechanical strength of the MOS cement mainly depends on the type and relative content of the crystalline phases in the cement. Four basic magnesium salts that can contribute to the mechanical strength of the MOS cement, namely, 5Mg(OH)2·MgSO4·3H2O (513 phase), 3Mg(OH)2·MgSO4·8H2O (318 phase), Mg(OH)2·2MgSO4·3H2O (123 phase) and Mg(OH)2·MgSO4·5H2O (115 phase), are found to exist in the ternary system MgO-MgSO4-H2O at different temperatures from 30 to 120 degrees Celsius. Usually, the 513 phase and 318 phase can only be obtained by curing the cement under saturated vapor conditions when the molar ratio of MgO to MgSO4 is fixed at (about) 5:1.The 318 phase significantly contributes to the mechanical strength and is stable at room temperature. Therefore, it has been found to be preferably present in the applied MOS. This also applies to the 513 phase. The 513 phase typically has a (micro)structure consisting of a needle-like structure. This can be confirmed by scanning electron microscope (SEM) analysis. The needles of basic magnesium sulfate 5Mg(OH)2·MgSO4·3H2O can be formed substantially uniformly and will typically have a length of 10 - 15 μm and a diameter of 0.4 - 1.0 μm. When referring to a needle-like structure, it may also mean a flake-like structure and / or a whisker-like structure. In practice, it does not seem feasible to obtain a MOS containing more than 50% of the 513 or 318 phase, but it can be applied by adjusting the crystal phase composition to improve the mechanical strength of the MOS. Preferably, the magnesia cement contains at least 10%, preferably at least 20%, and more preferably at least 30% of the 5Mg(OH)2·MgSO4·3H2O (513 phase). This preferred embodiment will provide a magnesia cement having sufficient mechanical strength for use in the core layer of the floor panel. The crystal phase of the MOS can be adjusted by using an organic acid, preferably citric acid, and / or by modifying the MOS with phosphoric acid and / or phosphate. During this modification, a new MOS phase can be obtained, which can be represented by 5Mg(OH)2·MgSO4·5H2O (515 phase) and Mg(OH)2·MgSO4·7H2O (517 phase). The 515 phase can be obtained by modifying the MOS by using citric acid. The 517 phase can be obtained by modifying the MOS by using phosphoric acid and / or phosphate (H3PO4, KH2PO4, K3PO4, and K2HPO4). These 515 and 517 phases can be measured by chemical element analysis, and SEM analysis proves that the microstructures of the 515 and 517 phases are both water-insoluble needle-like crystals.Specifically, the compressive strength and water resistance of MOS can be improved by adding citric acid. Therefore, when MOS is applied to the panel according to the present invention, it is preferably included in 5Mg(OH)2·MgSO4·5H2O (515 phase) and / or Mg(OH)2·MgSO4·7H2O (517 phase). As described above, adding phosphoric acid and phosphates can extend the curing time and improve the compressive strength and water resistance of MOS cement by changing the hydration process and phase composition of MgO. Here, phosphoric acid or phosphate ionizes in solution to form H2PO4-, HPO42- and / or PO43-, and these anions adsorb to [Mg(OH)(H2Ox)]+ to suppress the formation of Mg(OH)2 and form a new sulfite. Furthermore, it promotes the formation of the magnesium phase, resulting in a compact structure, high mechanical strength and good water resistance of MOS cement. The improvement caused by adding phosphoric acid or phosphate to MOS cement follows the order of H3PO4 = KH2PO+ >> K2HPO4 >> K3PO4. MOS has better volume stability, less shrinkage, good bonding properties and low corrosion resistance than MOC under significantly wide weather conditions, and thus may be more suitable than MOS. The density of MOS is typically in the range of 350 - 650 kg / m3. The flexural tensile strength is preferably 1 - 7 N / mm2.

[0049] The magnesium cement composition preferably includes one or more silicone-based additives. Without limitation, various silicone-based additives can be used, including silicone oil, neutral-curing silicone, silanol, silanol fluid, silicone (micro)spheres, and mixtures and derivatives thereof. Silicone oil includes liquid polymerized siloxanes having organic side chains, including, without limitation, polymethylsiloxane and its derivatives. Neutral-curing silicone includes silicones that release alcohol or other volatile organic compounds (VOCs) when they cure. Other silicone-based additives and / or siloxanes (e.g., siloxane polymers) can also be used, including, without limitation, siloxanes terminated with hydroxyl (hydroxy) groups and / or other reactive groups, acrylic siloxanes, urethane siloxanes, epoxy siloxanes, and mixtures and derivatives thereof. As detailed below, one or more crosslinking agents (e.g., silicone-based crosslinking agents) can also be used. The viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) can be about 100 cSt (at 25°C), which is referred to as low viscosity. In alternative embodiments, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 20 cSt (25°C) to about 2000 cSt (25°C). In other embodiments, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 100 cSt (25°C) to about 1250 cSt (25°C). In other embodiments, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 250 cSt (25°C) to about 1000 cSt (25°C).In still other embodiments, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 400 cSt (25 °C) to about 800 cSt (25 °C). And in certain embodiments, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 800 cSt (25 °C) to about 1250 cSt (25 °C). One or more silicone-based additives having higher viscosities and / or lower viscosities can also be used. For example, in another embodiment, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 20 cSt (25 °C) to about 200,000 cSt (25 °C), from about 1,000 cSt (25 °C) to about 100,000 cSt (25 °C), or from about 80,000 cSt (25 °C) to about 150,000 cSt (25 °C). In other embodiments, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 1,000 cSt (25 °C) to about 20,000 cSt (25 °C), from about 1,000 cSt (25 °C) to about 10,000 cSt (25 °C), from about 1,000 cSt (25 °C) to about 2,000 cSt (25 °C), or from about 10,000 cSt (25 °C) to about 20,000 cSt (25 °C). In still other embodiments, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 1,000 cSt (25 °C) to about 80,000 cSt (25 °C), from about 50,000 cSt (25 °C) to about 100,000 cSt (25 °C), or from about 80,000 cSt (25 °C) to about 200,000 cSt (25 °C). Also, in yet another embodiment, the viscosity of the one or more silicone-based additives (e.g., silicone oil, neutral-curing silicone, silanol fluid, siloxane polymer, etc.) is from about 20 cSt (25 °C) to about 100 cSt (25 °C). Other viscosities can also be used as needed.In a preferred embodiment, the magnesium cement composition, specifically, the magnesium oxychloride cement composition, contains a single type of silicone-based additive. In other embodiments, a mixture of two or more silicone-based additives is used. For example, in some embodiments, the magnesium oxychloride cement composition can include a mixture of one or more silicone oils and neutral-curing silicone. In certain embodiments, the ratio of silicone oil to neutral-curing silicone can be from about 1:5 to about 5:1 by weight. In other such embodiments, the ratio of silicone oil to neutral-curing silicone can be from about 1:4 to about 4:1 by weight. In other such embodiments, the ratio of silicone oil to neutral-curing silicone can be from about 1:3 to about 3:1 by weight. In still other such embodiments, the ratio of silicone oil to neutral-curing silicone can be from about 1:2 to about 2:1 by weight. In another such embodiment, the ratio of silicone oil to neutral-curing silicone can be about 1:1 by weight. It is contemplated that one or more cross-linking agents are used in the magnesia cement. In some embodiments, the cross-linking agent is a silicone-based cross-linking agent. Exemplary cross-linking agents include, but are not limited to, methyltrimethoxysilane, methyltriethoxysilane, methyltris(methylethylketoxime)silane, and mixtures and derivatives thereof. Other cross-linking agents (including other silicone-based cross-linking agents) can also be used. In some embodiments, the magnesium oxychloride cement composition includes one or more silicone-based additives (e.g., one or more silanols and / or silanol fluids) and one or more cross-linking agents. The ratio of one or more silicone-based additives (e.g., silanols and / or silanol fluids) to the cross-linking agent can be from about 1:20 to about 20:1 by weight, from about 1:10 to about 10:1 by weight, or from about 1:1 to about 10:1 by weight.

[0050] The magnesium (oxychloride) cement composition containing one or more silicone-based additives may exhibit a reduced sensitivity to water as compared to a standard magnesium (oxychloride) cement composition. Further, in some embodiments, the magnesium (oxychloride) cement composition containing one or more silicone-based additives may exhibit a slight sensitivity to water, or may exhibit no sensitivity to water at all. Further, the magnesium (oxychloride) cement composition containing one or more silicone-based additives can exhibit hydrophobicity and water resistance.

[0051] In addition, the magnesium (oxychloride) cement composition containing one or more silicone-based additives can exhibit improved curing characteristics. For example, the magnesium (oxychloride) cement composition cures to form various reaction products including 3Mg(OH)2.MgCl2.8H2O (phase 3) and 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structures. In some situations, a higher proportion of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure is preferred. In such situations, the addition of one or more silicone-based additives to the magnesium oxychloride cement composition can stabilize the curing process, which can increase the yield rate of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure. For example, in some embodiments, the magnesium oxychloride composition containing one or more silicone-based additives can cure to form 80% or more of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure. In other embodiments, the magnesium oxychloride composition containing one or more silicone-based additives can cure to form 85% or more of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure. In still other embodiments, the magnesium oxychloride composition containing one or more silicone-based additives can cure to form 90% or more of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure. In yet other embodiments, the magnesium oxychloride composition containing one or more silicone-based additives can cure to form 95% or more of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure. In still other embodiments, the magnesium oxychloride composition containing one or more silicone-based additives can cure to form 98% or more of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure. In yet other embodiments, the magnesium oxychloride composition containing one or more silicone-based additives can cure to form approximately 100% of the 5Mg(OH)2.MgCl2.8H2O (phase 5) crystal structure.

[0052] Furthermore, the magnesium (oxychloride) cement composition containing one or more silicone-based additives can also exhibit improved strength and bonding properties. Optionally, the magnesium (oxychloride) cement composition containing one or more silicone-based additives can also be used to produce relatively thin magnesium (oxychloride) cement or concrete structures. For example, the magnesium (oxychloride) cement composition containing one or more silicone-based additives can also be used to produce cement or concrete structures or layers having a thickness of 8 mm or less, preferably 6 mm or less. To achieve the bonding between the joints, it is beneficial to mix magnesium oxide and / or magnesium hydroxide and / or magnesium chloride and / or magnesium sulfate with one or more silicone-based additives. As a result, temporary deformation of the joints may be desirable and / or necessary because this leads to a certain improvement in flexibility and / or elasticity. For example, in some embodiments, the cement structures and concrete structures formed using the oxychloride magnesium cement composition can be bent or flexed without cracking or breaking. The magnesium (oxychloride) cement composition containing one or more silicone-based additives can further contain one or more additional additives. The additional additives can be used to enhance specific properties of the composition. For example, in some embodiments, the additional additives can be used to form the structure formed using the disclosed oxychloride magnesium cement composition to look like rock (e.g., granite, marble, sandstone). In certain embodiments, the additional additives can contain one or more pigments or colorants. In other embodiments, the additional additives can contain fibers including, but not limited to, paper fibers, wood fibers, polymer fibers, organic fibers, and fiberglass. Also, the oxychloride magnesium cement composition can form a UV-stable structure such that the color and / or appearance are not significantly faded over time due to exposure to ultraviolet light.Also, although not limiting, plasticizers (e.g., polycarboxylic acid plasticizers, polycarboxylic acid ether-based plasticizers, etc.), surfactants, water, and other additives including mixtures and combinations thereof can also be included in the composition. As described above, the magnesium oxychloride cement composition can, when applied, include magnesium oxide (MgO), water-soluble magnesium chloride (MgCl2(aq)), and one or more silicone-based additives. Also, instead of water-soluble magnesium chloride (MgCl2), magnesium chloride (MgCl2) powder can also be used. For example, magnesium chloride (MgCl2) powder can be used in combination with some water that would be equivalent or otherwise similar to the addition of water-soluble magnesium chloride (MgCl2(aq)). In some embodiments, when applied, the ratio of magnesium oxide (MgO) to water-soluble magnesium chloride (MgCl2(aq)) in the magnesium oxychloride cement composition can vary. In some of such embodiments, the ratio of magnesium oxide (MgO) to water-soluble magnesium chloride (MgCl2(aq)) is about 0.3:1 to about 1.2:1 by weight. In other embodiments, the ratio of magnesium oxide (MgO) to water-soluble magnesium chloride (MgCl2(aq)) is about 0.4:1 to about 1.2:1 by weight. In still further other embodiments, the ratio of magnesium oxide (MgO) to water-soluble magnesium chloride (MgCl2(aq)) is about 0.5:1 to about 1.2:1 by weight. Water-soluble magnesium chloride (MgCl2(aq)) can be described (or otherwise caused to occur) as a magnesium chloride brine solution. Also, the water-soluble magnesium chloride (MgCl2(aq)) (or magnesium chloride brine) can include, although not limited to, relatively small amounts of other compounds or substances including magnesium sulfate, magnesium phosphate, hydrochloric acid, phosphoric acid, etc. In a preferred embodiment, the amount of the one or more (liquid) silicone-based additives in the magnesium oxychloride cement composition can be defined as the ratio of the silicone-based additive to magnesium oxide (MgO).For example, in some embodiments, the weight ratio of the silicone-based additive to magnesium oxide (MgO) is from 0.06 to 0.6.

[0053] Preferably, it is also conceivable and advantageous to mix at least one oil such as linseed oil or silicone oil into the core layer. This makes the magnesium-based core layer and / or the thermoplastic-based core layer more flexible and reduces the risk of breakage. Instead of or in addition to the oil, it is conceivable to mix one or more water-soluble polymers or polycondensed (synthetic) resins such as polycarboxylic acid into the core layer. This ensures that the panel does not shrink during drying, curing, and setting, which prevents the formation of cracks, and furthermore, gives the core layer greater hydrophobicity after drying, curing, and setting, which has the advantage of preventing the ingress of water (moisture) during subsequent storage and use.

[0054] It is conceivable that the core layer is made of polycaprolactone (PCL). This biodegradable polymer is particularly suitable because it has been found to be formed so as to dissolve by the exothermic reaction of the reaction mixture. The polymer has a melting point of about 60°C. The PCL may be of low density or high density. The latter is particularly suitable for producing a stronger core layer. Instead of, or in addition to, other polymers, preferably other poly(lactic-co-glycolic acid) (PLGA), poly(lactic-acid) (PLA), poly(glycolic acid) (PGA), polyhydroxyalkanoates (PHA), polyethylene glycol (PEG), polypropylene glycol (PPG), polyesteramide (PEA), polylactic acid-caprolactone copolymer, polylactic acid-trimethylene carbonate copolymer, polysebacic acid-ricinoleic acid copolymer, and polymers selected from the group consisting of combinations thereof may also be used.

[0055] Alternatively, the panel, specifically the core layer, can be at least partially formed of PVC, PET, PP, PS or (thermoplastic) polyurethane (PUR). PS may be in the form of expanded PS (EPS) in order to further reduce the density of the panel, which leads to cost savings and facilitates handling of the panel. Preferably, at least a fraction of the polymer used may be formed of recycled thermoplastics such as recycled PVC or recycled PUR. Recycled PUR may be formed based on recyclable polymers, for example, based on recyclable PET. PET can be chemically recycled by utilizing the glycolysis or depolymerization of PET into monomers or oligomers and then ultimately into polyurethane polyols. Also, in order to improve the flexibility and / or impact resistance to at least some extent, it is also conceivable that rubber and / or elastomer members (particles) are dispersed within at least one composite layer. A mixture of unused and recycled thermoplastic materials is envisioned to be used to constitute at least a part of the core. Preferably, in this mixture, the unused thermoplastic material and the recycled thermoplastic material are basically the same. For example, such a mixture can be PVC-based or PUR-based overall. The core (layer) may be solid, or may be foamed, or in either case, the core is composed of a plurality of members / layers.

[0056] It may be advantageous if the core layer consists of porous granules, specifically, porous ceramic granules. Preferably, the granules have a plurality of micropores with an average diameter of 1 to 10 microns, preferably 4 to 5 microns. That is, the individual granules preferably have micropores. Preferably, the micropores are interconnected. These micropores are preferably not limited to the surface of the granules and are seen substantially throughout the cross-section of the granules. Preferably, the size of the granules is 200 to 900 microns, preferably 250 to 850 microns, particularly 250 to 500 microns or 500 to 850 microns. Preferably, at least two different sizes of granules, most preferably two different sizes of granules, are used. Preferably, small granules and / or large granules are used. The small granules may have a size range of 250 to 500 microns. Preferably, the large granules have a diameter of 500 to 850 microns. Each of the granules may consist of substantially the same size or two or more predetermined sizes. Alternatively, within each range, two or more different size ranges can be used with particles of various different sizes. Preferably, two different sizes or size ranges are used. Preferably, each of the granules consists of a plurality of fine particles, and substantially each fine particle is partially bonded to one or more adjacent fine particles so as to define a lattice that defines the micropores. Each fine particle preferably has an average size of 1 to 10 microns when the average is 4 to 5 microns. Preferably, the average size of the micropores is 2 to 8 microns, most preferably 4 to 6 microns. The micropores may have an irregular shape. Thus, the size of the micropores, and in fact, the medium-sized pores mentioned below, are determined by dividing the sum of the widest diameter of the pores and the narrowest diameter of the pores by 2. Preferably, the ceramic material is uniformly dispersed throughout the cross-section of the core layer without substantially forming a mass of ceramic material. Preferably, the fine particles have an average size of at least 2 or 4 microns, and / or 10 microns or less or 6 microns or less, most preferably 5 to 6 microns.This particle size range has been found to enable the controlled formation of the micropores.

[0057] The granules may also comprise a plurality of substantially spherical mesopores having an average diameter of 10 to 100 microns. They substantially increase the total porosity of the material without compromising the mechanical strength of the ceramic material. The mesopores are preferably interconnected via a plurality of micropores. That is, the mesopores may be in fluid communication with each other via the micropores. The average porosity of the ceramic material itself is preferably at least 50%, more preferably 60% or more, and most preferably 70 to 75% average porosity. The ceramic material used to produce the granules can be any known (non-toxic) ceramic, such as calcium phosphate or glass-ceramic. The ceramic may be a silicate, but is preferably calcium phosphate, particularly α- or β-tricalcium phosphate or hydroxyapatite, or a mixture thereof. Most preferably, the mixture is hydroxyapatite and β-tricalcium phosphate, particularly β-tricalcium phosphate in an amount of 50% or more by weight, most preferably 85% β-tricalcium phosphate and 15% hydroxyapatite. Most preferably, the material is 100% hydroxyapatite. Preferably, the cement composition or dry premix comprises 15 to 30% by weight of the granules based on the total dry weight of the composition or premix.

[0058] The porous particles lead to a lower average density of the core layer and thus may lead to a reduction in weight, which is advantageous from an economic and handling perspective. Further, the presence of the porous particles within the core layer typically leads to at least a somewhat increased porosity of the upper and lower surfaces of the core layer which is beneficial for attaching additional layers, such as an underlayer, an (initially liquid) adhesive layer, or another decorative or functional layer, to the upper and / or lower surfaces of the core layer. In many cases, these layers are initially applied in liquid form and the pores allow the liquid material to be sucked (penetrated) into the pores, which increases the contact surface area between the layers and thus improves the bonding strength between said layers.

[0059] Most decorative panels according to the present invention will have a square or rectangular shape, although it is also envisioned that the panels according to the present invention may have another shape, such as hexagonal, octagonal, rhomboid, or parallelogram shape (when viewed from above). Preferably, the thickness of the panel is in the range of 3.0 mm to 20.0 mm, preferably in the range of 4.0 mm to 12.0 mm. The panel according to the present invention can be rigid, semi-rigid or flexible. Typically, the panel will have at least some elasticity in order to enable the bonding of the joints and to achieve (and maintain) the desired tensile strength.

[0060] The present invention also relates to a decorative cladding for floors, ceilings or walls, composed of a number of interconnected decorative panels according to the present invention.

[0061] Further embodiments of the present invention are described in the following non-limiting set of clauses.

[0062] Clause 1. A decorative panel, in particular a floor panel, a wall panel or a ceiling panel, comprising, in a first pair of at least opposing edges, a first coupling part and a second coupling part that enable several such panels to be joined to each other, such that their joints provide locking in a first direction (R1) perpendicular to the plane of the panel and in a second direction (R2) perpendicular to each of said edges and parallel to the plane of the panel in the joined state of two such panels. The first coupling part comprises a lateral tongue, the lateral tongue comprising a front region and a rear region, the bottom and / or side surfaces of the front region being at least partially rounded. The upper surface of the front region slopes at least partially downward in a direction away from the rear region, and the bottom and / or side surfaces of the rear region of the lateral tongue define a first contact part, and the lateral tongue comprises a passive bottom surface located adjacent to the first contact part, the passive bottom surface being defined by a cut-out part on the lower surface of the lateral tongue. The second coupling part comprises a recess for receiving at least a part of the lateral tongue of another panel, the recess being defined by an upper lip and a lower lip, the lower lip extending beyond the upper lip, and the lower lip is provided with an upwardly protruding shoulder defining a second contact part configured to co-act actively with the first contact part of another panel in the joined state of the panels such that the panels are pushed at least laterally towards each other by a tensile force (T1), the upper surface of the lower lip being at least partially smoothly curved and configured as a sliding surface for the bottom surface and / or the side surface of the front region of the lateral tongue of another panel during joining, and The at least partially curved upper surface of the lower lip portion and the passive bottom surface of the side tongue portion are positioned relative to each other such that in the joined state of the two panels, an intermediate space exists adjacent to actively co - act the first and second contact portions, and the lower surface of the upper lip portion is at least partially inclined and configured to abut at least a part of the upper surface of the front region of the side tongue portion of another panel, a decorative panel.

[0063] 2. The panel according to clause 1, wherein the passive bottom surface of the side tongue portion is substantially flat.

[0064] 3. The panel according to clause 1 or clause 2, wherein the passive bottom surface is at least partially inclined downward in the direction towards the front region.

[0065] 4. The panel according to clause 3, wherein the inclined upper surface of the side tongue portion and the inclined passive bottom surface approach in the direction away from the rear region of the side tongue portion.

[0066] 5. The panel according to any one of the above clauses, wherein the upper surface of the lower lip portion defines the deepest point of the recess, and in the joined state of the two panels, the deepest point is disposed at a distance from the passive bottom surface.

[0067] 6. The panel according to any one of the above clauses, wherein the upper surface of the lower lip portion defines the deepest point of the recess, the shoulder of the lower lip portion defines the highest point of the lower lip portion, the deepest point and the highest point define the depth of the lower lip (LLD), and the first and second contact portions are disposed entirely above half of the depth of the lower lip portion.

[0068] 7. The upper surface of the lower lip portion defines the deepest point of the recess, the shoulder of the lower lip portion defines the highest point of the lower lip portion, the deepest point and the highest point define the depth of the lower lip portion (LLD), and the minimum thickness of the lateral tongue portion (STD) measured between the at least partially inclined upper surface of the lateral tongue portion and the passive bottom surface exceeds the depth of the lower lip portion, the panel according to any one of the above clauses.

[0069] 8. The first contact portion is inclined upward in a direction away from the front region of the lateral tongue portion, and the inclined first contact portion and the plane of the panel preferably enclose an angle of at least 45 degrees, and the second contact portion is inclined upward in a direction away from the upper lip portion, and the inclined second contact portion and the plane of the panel preferably enclose an angle of at least 45 degrees, the panel according to any one of the above clauses.

[0070] 9. The first contact portion and the second contact portion extend in a substantially parallel direction, the panel according to any one of the above clauses.

[0071] 10. The bottom surface and / or side surface of the front region of the lateral tongue portion are configured to co-operate with the lower lip portion and to define a bottom front contact surface together in the joined state of two panels, the panel according to any one of the above clauses.

[0072] 11. The entire bottom front contact surface is disposed below the level of the first and second contact portions, the panel according to clause 10.

[0073] 12. The contact surface defined by the bottom front contact surface on one side and the first and second contact portions on the other side encloses an angle between 70 degrees and 110 degrees, preferably between 80 degrees and 100 degrees, with each other, the panel according to clause 10 or clause 11.

[0074] 13. The joint formed by two panels in a joined state defines a vertical plane (VP), and the vertical plane subdivides the lower lip into an inner lower lip and a lower part of an outer lower lip, the panel according to any one of the above clauses.

[0075] 14. At least a part of the front bottom contact surface, preferably the entire front bottom contact surface, and the first and second contact portions are located on the same side of the vertical plane, the panel according to any one of clauses 10 to 12 and clause 13.

[0076] 15. The upper surface of the front region of the lateral tongue intersects the vertical plane (VP), the panel according to clause 13 or clause 14.

[0077] 16. The entire upper surface of the lower lip extending between the vertical plane (VP) and the second contact portion is a smooth curved surface, the panel according to any one of clauses 13 to 15.

[0078] 17. The upper surface of the lower lip is provided with alternately cut portions that are at least partially disposed under the upper lip and configured to accommodate the end portion of the lateral tongue of another panel, the panel according to any one of the above clauses.

[0079] 18. The upper lip and the alternately cut portions of the lower lip are configured to clamp the end portion of the lateral tongue, the panel according to clause 17.

[0080] 19. The alternately cut portions are entirely disposed under the upper lip, the panel according to any one of clauses 17 to 18.

[0081] 20. The panel defines an upper surface and a bottom surface that define the thickness (PT) of the panel, and the thickness (ST) of the shoulder measured from the bottom surface of the panel to the highest point of the shoulder exceeds 30%, preferably more than 50% of the thickness (PT) of the panel. The panel according to any one of the above clauses.

[0082] 21. In the joined state of the panel, the upper surface of the shoulder is disposed at a distance from the opposing lower surface of the first joint. The panel according to any one of the above clauses.

[0083] 22. The upper surface of the shoulder is substantially parallel to the plane of the panel. The panel according to any one of the above clauses.

[0084] 23. The seam formed by two panels in the joined state or between two panels defines a vertical plane (VP). The vertical plane subdivides the lower lip into an inner lower lip and a lower part of the outer lower lip. And in the joined state, the entire bottom surface and the entire side surface of the inner lower lip are disposed at a distance from the second joint. The panel according to any one of the above clauses.

[0085] 24. The lower lip is entirely disposed below the upper lip. The panel according to any one of the above clauses.

[0086] 25. The upper surface of the front region of the lateral tongue and the side surface of the front region of the lateral tongue are connected by a transition convex surface. The panel according to any one of the above clauses.

[0087] 26. The lower surface of the upper lip and the side surface of the upper lip are connected by a transition convex surface. The panel according to any one of the above clauses.

[0088] 27. The first joint and the second joint are also provided in a second pair consisting of at least opposing edges. The panel according to any one of the above clauses.

[0089] 28. The panel can be joined to several other such panels, specifically a second pair, consisting of at least opposite edges, by a downward or vertical movement, such that the joints between two such panels in their joined state provide locking in a first direction (R1) perpendicular to the plane of the panel and in a second direction (R2) perpendicular to each respective edge and parallel to the plane of the panel. The panel is provided with a third joint and a fourth joint which enable this. The third joint comprises an upward tongue, at least one upper flange located at a distance from the upward tongue, and an upward groove formed between the upward tongue and the upper flange. The upward groove is adapted to receive at least a part of a downward tongue of the fourth joint of another panel. The side of the upward tongue facing the upper flange is the inner side of the upward tongue, and the side of the upward tongue facing away from the upper flange and opposite is the outer side of the upward tongue. The fourth joint comprises a downward tongue, at least one lower flange located at a distance from the downward tongue, and a downward groove formed between the downward tongue and the lower flange. The downward groove is adapted to receive at least a part of the upward tongue of the third joint of another panel. The side of the downward tongue facing the lower flange is the inner side of the downward tongue, and the side of the downward tongue facing away from the lower flange and opposite is the outer side of the downward tongue. The panel according to any one of the preceding clauses.

[0090] 29. The inner side and the inside of the upward tongue are configured to co - operate with the inner side of the downward tongue of another panel in the joined state of the panels such that the panels are pushed at least laterally towards each other by a tensile force (T2). The panel according to clause 28.

[0091] 30. At least a part of the inside of the upward tongue portion is inclined toward the upper flange, and at least a part of the inside of the downward tongue portion is inclined toward the lower flange, so that two panels can be fixed in the first direction (R1). The panel according to clause 28 or clause 29.

[0092] 31. A first locking element is provided on the outside of the upward tongue portion, and a second locking element configured to cooperate with the first locking element of another panel is provided on the lower flange, so that two panels can be fixed in the first direction (R1). The panel according to any one of clauses 28 to 30.

[0093] 32. The first locking element includes an outer bulging portion, and the second locking element includes a recess. The outside of the outer bulging portion includes an upper portion and an adjacent lower portion. The lower portion includes an inclined locking surface, and the upper portion preferably includes a curved guiding surface. The recess includes an upper portion and an adjacent lower portion. The lower portion includes an inclined locking surface. In the coupled state of adjacent panels, the inclined locking surface of the lower portion of the outer bulging portion and the inclined locking surface of the lower portion of the recess are in contact to realize the locking effect between the panels, and / or in the coupled state of adjacent panels, the upper portion of the first locking element and the second locking element are preferably at least partially separated. The panel according to clause 31.

[0094] 33. The length of the inclined locking surface of the lower portion of the outer bulging portion is greater than that of the inclined locking surface of the lower portion of the recess, preferably at least 1.5 times greater. The panel according to clause 32.

[0095] 34. The upper portion extends over a larger vertical section compared to the lower portion, preferably the height of the upper portion is at least three times the height of the lower portion. The panel according to clause 32 or clause 33.

[0096] 35. The upper flange and the outer side of the downward tongue define a substantially vertical upper contact surface of the panel, and the adjacent upper contact surfaces of both the downward tongue and the upper flange have inclined contact surfaces. The inclined contact surface of the downward tongue of the panel is configured to engage with the inclined contact surface of the upper flange of an adjacent panel in the joined state of the panels. Each substantially vertical upper contact surface and each adjacent inclined surface surround each other at an angle (α) of 100 degrees to 175 degrees. The panel according to any one of clauses 28 to 34.

[0097] 36. A third locking element is provided on the outer side of the downward tongue, and a fourth locking element configured to cooperate with the third locking element of another panel is provided on the upper flange, enabling two panels to be fixed in the first direction (R1). The panel according to any one of clauses 28 to 35.

[0098] 37. The third locking element is at least partially defined by the upper contact surface of the downward tongue, and the fourth locking element is at least partially defined by the upper contact surface of the upper flange. The panel according to clauses 35 and 36.

[0099] 38. At least a part of each of the joints forms an essential part of the core layer of the panel. The panel according to any of the above clauses.

[0100] 39. The panel comprises at least one core layer and at least one decorative upper part directly or indirectly attached to the core layer, the upper part defining the upper surface of the panel. The panel according to any of the above clauses.

[0101] 40. The upper part consists of a printed decorative layer, and at least one durability layer covers the printed decorative layer. The panel according to clause 39.

[0102] 41. The panel according to clause 39 or clause 40, wherein at least one core layer is made of a moisture-sensitive material such as wood.

[0103] 42. The panel according to any one of clauses 39 to 41, wherein at least one core layer is at least partially composed of medium-density fiberboard (MDF) or high-density fiberboard (HDF).

[0104] 43. The panel according to any one of the above clauses, wherein the panel is rectangular or hexagonal.

[0105] 44. The panel according to any one of the above clauses, wherein the panel has a vertical thickness in the range of 3.0 mm to 20.0 mm, preferably in the range of 4.0 mm to 12.0 mm.

[0106] 45. The panel according to any one of the above clauses, wherein substantially the entire upper surface of the lower lip is smoothly curved according to a substantially constant radius.

[0107] 46. The upper surface of the lower lip includes a curved rear upper surface and a curved front upper surface, the rear upper surface and the front upper surface are staggered, and preferably, the front upper surface is deeper than the rear upper surface. The panel according to any one of the above clauses.

[0108] 47. The side surface of the front region of the side tongue and the opposing portion of the upper surface of the lower lip are substantially complementarily formed, and preferably, are substantially complementarily curved. The panel according to any one of the above clauses.

[0109] 48. The maximum distance a between the side surface of the front region of the side tongue and the opposing portion of the upper surface of the lower lip is smaller than the maximum distance b between the passive bottom surface of the side tongue and the opposing portion of the upper surface of the lower lip. The panel according to any one of the above clauses.

[0110] 49. A decorative covering material for floors, ceilings or walls, composed of a number of interconnected decorative panels as described in any one of the above clauses.

Brief Description of the Drawings

[0111] The present invention will be described based on the following non-limiting and exemplary embodiments shown in the drawings. [Figure 1] A rectangular floor panel according to the present invention is shown. [Figure 2] Cross-sectional views along line A-A of FIG. 1 of each side edge are shown. [Figure 3] The method of joining the side edges shown in FIG. 2 is shown. [Figure 4] A cross-sectional view of the joined state of the side edges of FIG. 2 is shown. [Figure 5] Longitudinal cross-sectional views along line B-B of FIG. 1 of each side edge are shown. [Figure 6] The method of joining the side edges shown in FIG. 5 is shown. [Figure 7] Further details of the longitudinal cross-sectional views of each side edge in the joined state are shown. [Figure 8] An alternative embodiment of the side edge of FIG. 2 that enables another method of joining is shown. [Figure 9] Another alternative embodiment of the side edge of FIG. 2 is shown.

Modes for Carrying Out the Invention

[0112] FIG. 1 shows a decorative panel 1, and a decorative upper layer 12 is provided on the upper side 2. The panel is rectangular, having a length extending longitudinally along line B-B and a width extending transversely along line A-A. Thus, the plane of the panel is defined by the combination of line A-A and line B-B. On the opposing side edges 3 and 4, a first coupling part in the form of a profile 5 and a second coupling part in the form of a profile 6 are provided respectively. On the opposing side edges 9 and 10, a third coupling part in the form of a profile 7 and a fourth coupling part in the form of a profile 8 are provided respectively.

[0113] Figure 2 shows the first joint portion 5 of the side edge portion 3 in a cross section. The first joint portion 5 includes a side tongue portion 20 having a front region 21 and a rear region 22, and the bottom surface 23 and / or the side surface 23 of the front region 21 is at least partially rounded. The upper surface 24 of the front region 21 is at least partially inclined downward in a direction away from the rear region 22. And the bottom surface 26 and / or the side surface 26 of the rear region 22 of the side tongue portion 20 defines a first contact portion 26, and the side tongue portion 20 includes a passive bottom surface 27 located adjacent to the first contact portion 26. The passive bottom surface 27 is defined by an incision in the lower side of the side tongue portion 20. In the present specification, the passive bottom surface 27 extends over an intermediate region 28 between the rear region 22 and the front region 21 and is substantially flat. The passive bottom surface 27 is inclined downward in a direction toward the front region 21 such that the inclined upper surface 24 of the side tongue portion and the inclined passive bottom surface 27 approach in a direction away from the rear region of the side tongue portion. Further, the second joint portion 6 includes a recess 30 for accommodating at least a part of the side tongue portion 20 of another panel. The recess 30 is defined by an upper lip portion 31 and a lower lip portion 32. The lower lip portion 32 extends beyond the upper lip portion 3 and is provided with an upwardly protruding shoulder portion 33 that defines a second contact portion 34 configured to actively cooperate with the first contact portion 26 of another panel in a joined state of such panels, as will be described in connection with FIG. 4. The upper surface 35 of the lower lip portion 32 is at least partially smoothly curved and is configured as a sliding surface for the at least partially rounded bottom surface 23 and / or the side surface 23 of the front region 21 of the side tongue portion 20 of another panel during the joining of the first joint portion and the second joint portion. The upper surface 35 of the lower lip portion is provided with staggered incisions 35s that are at least partially located under the upper lip portion 31 and are configured to accommodate the end portions of the side tongue portion 20 of another panel.

[0114] Figure 3 shows a method of joining two panels 1 and 1', each provided with first and second joints 5 and 6 as shown in Figure 2. The two panels are joined to each other by an angling operation with respect to the arrow MA. As is apparent from Figure 3, the curvature of the upper surface 35 of the lower lip portion 32 functions as a sliding surface for the at least partially rounded bottom surface 23 and / or the side surface 23 of the tongue portion 20.

[0115] Figure 4 shows the joints 5 and 6 of the two panels 1 and 1' once the joining shown in Figure 3 has been completed by the angling operation. Each contact portion 26 and 34 in the illustrated joined state generates a tensile force (T1) that directs the side edges 3 and 4 towards each other. Further, in the illustrated joined state, the at least partially curved upper surface 35 of the lower lip portion 32 and the passive bottom surface 27 of the lateral tongue portion 20 are positioned relative to each other such that an intermediate space S exists adjacent to and co-acts actively with the first and second contact portions 26 and 34. The passive bottom surface 27 is depicted as a substantially flat surface, but alternatively may have a concave or convex surface as long as the amount of the intermediate space S is maintained between the tongue portion and the recess in the joined state. The lower surface 36 of the upper lip portion 31 is at least partially inclined and configured to abut at least a part of the upper surface 24 of the front region of the lateral tongue portion 20. The upper surface 35 of the lower lip portion defines the deepest point 38 of the recess, and the shoulder 33 of the lower lip portion defines the highest point 39 of the lower lip portion, and the deepest point and the highest point define the lower lip depth (LLD). On the upper surfaces of the panels 1 and 1' that are pushed together by the tensile force from the contact portions 26 and 34, there is a seam 40 that defines a vertical plane VP that subdivides the lower lip portion 32 into an inner lower lip portion 32i and an outer lower lip portion 32o. The upper surface of the shoulder 33 is located at a distance from the first joint 5 such that an intermediate space also exists in this portion in the present specification.

[0116] Figure 5 shows a longitudinal cross-section of panel 1 shown in Figure 1 along line B-B. At each of the side edges 9, 10, there are provided a third coupling part in the form of profile 7 and a fourth coupling profile in the form of profile 8, respectively. The third coupling part 7 includes an upward tongue 71, an upper flange 72 located at a distance from the upward tongue, and an upward groove 73 formed between the upward tongue 71 and the upper flange 72. The upward groove is adapted to receive at least a part of the downward tongue 81 of the fourth coupling part 8 of another panel. The side of the upward tongue 71 facing the upper flange 72 is the inner side 77 of the upward tongue, and the side of the upward tongue 71 facing away from the upper flange 72 is the outer side 76 of the upward tongue. A first locking element 75 is provided on the outer side of the upward tongue 71 facing away from the upper flange 72. The fourth coupling part 8 includes a downward tongue 81, a lower flange 82 located at a distance from the downward tongue, and a downward groove 83 formed between the downward tongue 81 and the lower flange 82. The downward groove 83 is adapted to receive at least a part of the upward tongue 71 of the third coupling part 7 of another panel. The side of the downward tongue 81 facing the lower flange 82 is the inner side 87 of the downward tongue, and the side of the downward tongue 81 facing away from the lower flange 82 is the outer side 86 of the downward tongue 81. A second locking element 85 adapted to cooperate with the first locking element 75 of another panel is provided on the lower flange 82.

[0117] Figure 6 shows how the third coupling profile 7 and the fourth coupling profile 8 of Figure 5 can be coupled when connecting panel 1 and panel 1' to each other. Thereby, panel 1' is moved vertically downward along the arrow, and profiles 7 and 8 engage with each other by receiving the upward tongue 71 into the downward groove 83 and the downward tongue 81 into the upward groove 73.

[0118] Figure 7 shows in more detail the side edges 7 and 8 in the coupled state after the coupling by the vertical movement as shown in Figure 6. Note that the side edges 7 and 8 of the embodiment of Figure 7 are directly visible from the drawing and include minor adaptations with respect to the embodiment shown in Figures 5 and 6, which will be further described below. As long as Figures 5 - 7 commonly have the same shape configuration, they are denoted by the same reference numerals. The inner side 77 of the upward tongue 71 is in contact with the inner side 87 of the downward tongue 81 of another panel, and as a result, those panels generate a tensile force (T2) that pushes the side edges 7 and 8 towards each other. The portion of the inner side 77 of the upward tongue is inclined towards the upper flange 72, and the portion of the inner side 87 of the downward tongue 81 is inclined towards the lower flange 82, and as a result, the two coupled panels are connected in a direction perpendicular to the plane of the panel (i.e., the vertical direction). Further, the first and second locking elements 75 and 85 are connected to each other and further contribute to the vertical connection of the coupled panels. The first locking element is the bulge 75, and the second locking element is the recess 85. The bulge 75 has an upper portion 90 and an adjacent lower portion 88, the lower portion 88 having an inclined locking surface, and the upper portion 90 preferably having a curved guiding surface. The recess 85 has an upper portion 94 and an adjacent lower portion 92, the lower portion 92 having an inclined locking surface. The upper portions 90 and 94 are at a distance from each other, respectively, thereby allowing an intermediate space. On the upper side of the coupled side edges 7 and 8, the upper contact surfaces 95 and 96 are both pushed in by the interaction of the inner sides 77 and 87. Further, the upper contact surfaces 95 and 96 are each provided with a bulge 98 and a recess 97 that are connected to each other in the coupled state. On the bulge 98 and the recess 97, inclined contact surfaces 99a and 99b that engage with each other are provided, respectively.

[0119] FIG. 8 shows an alternative embodiment of the side edges 3 and 4 according to FIG. 2, wherein the upper surface 24 of the front region 21 of the side tongue and the side surface 23 of the front region 21 of the side tongue are connected by a transition convex surface 100, and the lower surface 36 of the upper lip 31 and the side surface 102 of the upper lip 31 are connected by a transition convex surface 104. All other configurations of the side edges 3 and 4 are the same as those in FIG. 2. The illustrated embodiment enables a coupling operation by shifting the panels toward each other in a planar direction as indicated by the arrow "snap".

[0120] FIG. 9 shows an alternative embodiment of the side edges 3 and 4 according to FIG. 2, wherein the upper surface 35 of the lower lip 32 has alternating cut-out portions 35s that are complementary in size to the end portion 23 of the tongue 20 so as to clamp and accommodate the end portion 23. All other configurations of the side edges 3 and 4 are the same as those in FIG. 2.

[0121] The inventive concepts described above are illustrated by several exemplary embodiments. Each inventive concept is assumed to be applicable without applying other details of the described embodiments at that time. It is not necessary to elaborate on all possible combinations of the above-described inventive concepts for those skilled in the art to understand that they can combine many inventive concepts to reach a specific application.

[0122] It is obvious that the present invention is not limited to the practical embodiments illustrated and described in this specification, and many modifications will be possible within the scope of the appended claims, which will be apparent to those skilled in the art.

[0123] It should be understood that the verb "comprise" and its conjugations used in this patent publication do not only mean "comprise", but also mean the expressions "include", "substantially consist of", "formed by" and their conjugations.

Claims

Claim 1 A decorative panel, in a first pair consisting of at least opposite edges, several such panels can be joined to each other, whereby their joints, in the joined state of two such panels, provide locking in a first direction (R1) perpendicular to the plane of the panel and in a second direction (R2) perpendicular to each of said edges and parallel to the plane of the panel, a decorative panel comprising a first joint and a second joint, the first joint comprising a lateral tongue, the lateral tongue comprising a front region and a rear region, the bottom and / or side surfaces of the front region being at least partially rounded, the upper surface of the front region being at least partially inclined downward in a direction away from the rear region, and the bottom and / or side surfaces of the rear region of the lateral tongue defining a first contact portion, and the lateral tongue comprising a passive bottom surface located adjacent to the first contact portion, the passive bottom surface being defined by a cut-out portion on the lower surface of the lateral tongue, the second joint comprising a recess for receiving at least a part of the lateral tongue of another panel, the recess being defined by an upper lip and a lower lip, the lower lip extending beyond the upper lip, and on the lower lip there is provided a shoulder projecting upward which defines a second contact portion configured to co-act actively with the first contact portion of another panel in the joined state of the panels such that the panels are pushed at least laterally towards each other by a tensile force (T1), the upper surface of the lower lip being at least partially smoothly curved and configured as a sliding surface for the bottom surface which is at least partially rounded and / or for the side surface of the front region of the lateral tongue of another panel during joining, and The at least partially curved upper surface of the lower lip portion and the passive bottom surface of the lateral tongue portion are positioned relative to each other such that in the joined state of the two panels, an intermediate space exists adjacent to actively co - move the first and second contact portions, and the lower surface of the upper lip portion is at least partially inclined and configured to abut at least a part of the upper surface of the front region of the lateral tongue portion of another panel. The bottom surface and / or side surface of the front region of the lateral tongue portion are configured to co - move with the lower lip portion and to define a bottom front contact surface together in the joined state of the two panels. In the joined state, the seam formed by the two panels defines a vertical plane (VP), the vertical plane subdivides the lower lip portion into an inner lower lip portion and a lower outer lip portion, and the entire bottom front contact surface, the first contact portion, and the second contact portion are located on the same side of the vertical plane. Decorative panel.

2. The decorative panel according to claim 1, wherein the passive bottom surface of the lateral tongue portion is substantially flat.

3. The decorative panel according to claim 1 or claim 2, wherein the passive bottom surface is at least partially inclined downward in a direction towards the front region.

4. The decorative panel according to claim 3, wherein the inclined upper surface of the lateral tongue portion and the inclined passive bottom surface approach in a direction away from the rear region of the lateral tongue portion.

5. The decorative panel according to any one of claims 1 to 4, wherein the upper surface of the lower lip portion defines the deepest point of the recess, and in the joined state of the two panels, the deepest point is disposed at a distance from the passive bottom surface.

6. The decorative panel according to any one of claims 1 to 5, wherein the upper surface of the lower lip portion defines the deepest point of the recess, the shoulder of the lower lip portion defines the highest point of the lower lip portion, the deepest point and the highest point define the depth (LLD) of the lower lip portion, and the first contact portion and the second contact portion are disposed entirely above half of the depth of the lower lip portion.

7. The upper surface of the lower lip portion defines the deepest point of the recess, the shoulder portion of the lower lip portion defines the highest point of the lower lip portion, the deepest point and the highest point define the depth of the lower lip portion (LLD), and the minimum thickness of the lateral tongue portion (STD) measured between the at least partially inclined upper surface of the lateral tongue portion and the passive bottom surface exceeds the depth of the lower lip portion. The decorative panel according to any one of claims 1 to 6.

8. The first contact portion is inclined upward in a direction away from the front region of the lateral tongue portion, and the second contact portion is inclined upward in a direction away from the upper lip portion. The decorative panel according to any one of claims 1 to 7.

9. The upper surface of the lower lip portion includes a curved rear upper surface and a curved front upper surface, and the rear upper surface and the front upper surface are staggered. The decorative panel according to any one of claims 1 to 8.

10. The entire bottom front contact surface is disposed below the levels of the first contact portion and the second contact portion. The decorative panel according to any one of claims 1 to 9.

11. The bottom front contact surface on one side and the contact surface defined by the first contact portion and the second contact portion on the other side surround each other at an angle between 70 degrees and 110 degrees. The decorative panel according to any one of claims 1 to 10.

12. The side surface of the front region of the lateral tongue portion and the opposing portion of the upper surface of the lower lip portion are substantially complementary. The decorative panel according to any one of claims 1 to 11.

13. The entire upper surface of the lower lip portion extending between the vertical plane (VP) and the second contact portion is a smooth curved surface. The decorative panel according to any one of claims 1 to 12.

14. On the upper surface of the lower lip portion, there are provided staggered cut portions that are at least partially disposed under the upper lip portion and configured to accommodate the end portions of the lateral tongue portions of another panel. The decorative panel according to any one of claims 1 to 13.

15. The panel defines an upper surface and a bottom surface that define the thickness (PT) of the panel, and the thickness (ST) of the shoulder measured from the bottom surface of the panel to the highest point of the shoulder exceeds 30% of the thickness (PT) of the panel. The decorative panel according to any one of claims 1 to 14.

16. The joint formed by two panels in a combined state, or the joint between two panels, defines a vertical plane (VP). The vertical plane subdivides the lower lip into an inner lower lip and a lower part of an outer lower lip. And in the combined state, the entire bottom surface and the entire side surface of the inner lower lip are arranged at a distance from the second joint. The decorative panel according to any one of claims 1 to 15.

17. The panel can be joined to several such panels by a lowering movement or a vertical movement to another, specifically a second pair, consisting of at least opposite edges, so that their joints in the joined state of two such panels are in a first direction (R1) perpendicular to the plane of the panel, and in a second direction (R2) perpendicular to each edge and parallel to the plane of the panel, and having a third joint and a fourth joint that enable locking. The third joint includes an upward tongue, at least one upper flange located at a distance from the upward tongue, and an upward groove formed between the upward tongue and the upper flange. The upward groove is adapted to receive at least a part of the downward tongue of the fourth joint of another panel. The side surface of the upward tongue facing the upper flange is the inner side of the upward tongue, and the side surface of the upward tongue facing away from the upper flange is the outer side of the upward tongue. The fourth coupling part includes a downward tongue part, at least one downward flange located at a distance from the downward tongue part, and a downward groove formed between the downward tongue part and the downward flange. The downward groove is adapted to receive at least a part of the upward tongue part of the third coupling part of another panel. The side surface of the downward tongue part facing the downward flange is the inner side of the downward tongue part, and the side surface of the downward tongue part facing away from the downward flange and opposite is the outer side of the downward tongue part. The decorative panel according to any one of claims 1 to 16.

18. The panel includes at least one core layer and at least one decorative upper part directly or indirectly attached to the core layer. The decorative upper part defines the upper surface of the panel, and The decorative upper part includes a printed decorative layer, and at least one durability layer covers the printed decorative layer. The decorative panel according to any one of claims 1 to 17.

19. The maximum distance a between the side surface of the front region of the lateral tongue part and the opposing part of the upper surface of the lower lip part is smaller than the maximum distance b between the passive bottom surface of the lateral tongue part and the opposing part of the upper surface of the lower lip part. The decorative panel according to any one of claims 1 to 18.

20. A decorative covering material for a floor, ceiling or wall, composed of a number of interconnected decorative panels according to any one of claims 1 to 19.

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