DECORATIVE TILE, THE CORE USED IN THIS DECORATIVE TILE, AND THE METHOD OF MANUFACTURING THIS DECORATIVE TILE.

Abstract

The invention proposes a decorative cladding, specifically a decorative floor cladding, a decorative ceiling cladding, or a decorative wall cladding, comprising at least one core layer, and a decorative upper structure attached directly or indirectly to the upper surface of the aforementioned core layer. The invention also proposes a core layer suitable for the cladding as described in the invention and a method for the manufacture of such cladding.

Description

[0001] DECORATIVE PANEL AND CORE LAYER FOR USE IN SAID DECORATIVE

[0002] PANEL

[0003] The invention relates to a panel, preferably a decorative panel, in particular a decorative floor panel, decorative ceiling panel, or decorative wall panel, comprising: at least one core layer, and a decorative top structure directly or indirectly affixed to a top surface said core layer. The invention also relates to a core layer intended for use or use of a core layer in a panel according to the invention.

[0004] In the last decades many improvements have been observed in the world of decorative panels, such as floor panels and wall panels. These improvements cover various aspects of the decorative panels, such as, for example, improving the aesthetical appearance of the panels, improving mechanical coupling profiles of the panels, improving the acoustic properties of the panels, improving the scratch resistance of the panel, and improving the core composition of the panels. With respect to this latter aspect, a trend is visible that traditional core layer materials, like medium density board (MDF) and high density board (HDF) are partially replaced by other materials, like PVC based compositions. Contrary to MDF and HDF, PVC is waterproof and therefore easy to maintain and moreover exhibits relatively attractive noise reducing properties. However, the use of PVC in core compositions of decorative panels is not undisputed. As this PVC is typically softened by using hazardous plasticizers, like phthalates, health risks may be involved. Moreover, during the production of PVC toxic chemicals are used and toxic by-products and waste are generated. Furthermore, in case of a fire, PVC based panels may generate carcinogens called dioxins and furans, which is less preferred from a health safety and environmental point of view. In addition to the above, the carbon footprint of PVC, also referred to as embodied carbon, is substantial, which also puts pressure on the use of PVC in core layers of decorative panels. As awareness is increasing regarding the health safety of materials as well as regarding the environment, a response is being demanded from the industry and its customers to also use alternative raw materials for manufacturing decorative panels. More in particular, there is a need to develop a core composition of the decorative panel, which is relatively health safe and which seriously reduces the carbon footprint to spare the environment as much as possible. It is therefore a first objective of the present invention to provide a panel having a relatively low carbon footprint.

[0005] It is therefore a second objective of the present invention to provide a panel having an improved core composition.

[0006] It is therefore a third objective of the present invention to provide a panel having a more health safe and / or environmental friendly core composition.

[0007] It is therefore a fourth objective of the present invention to provide a PVC-free panel.

[0008] It is therefore a fifth objective of the present invention to provide a panel having an alternative composition of the core layer and / or a decorative top structure.

[0009] At least one of these objectives can be achieved by providing a panel, preferably a decorative panel, according to the preamble, comprising at least one core layer, and a decorative top structure directly or indirectly affixed to a top surface said core layer, wherein said at least one core layer and / or said decorative top structure comprises at least one furan resin. Furan resins, in particular furan polyesters, are thermoplastic materials which exhibit high performance properties, while the production of these furan resins allows utilization of fully renewable resources, such as plant based sugars. This eliminates the dependence on fossil fuels completely, resulting in a renewable bio-polymer. Hence, the furan resin used in the panel according to the invention may be a plant based furan polyester.

[0010] Said furan resin preferably comprises moieties corresponding to a furandicarboxylic acid (FDCA) monomer, preferably 2,5-FDCA, and / or a, preferably biobased, furan diacid, such as e.g. 5-Hydroxymethylfurfural (5-HMF) and / or one or more biobased acids, such azeleic acid, sebacic acid, glutaric acid, succinic acid, and / or dodecanadeoic acid, cyclohexane1 ,4 dicarboxylic acid, cyclohexane 1 ,2 dicarboxylic acid and cyclooctanedione. Preferably additionally, said furan resin preferably comprises moieties corresponding to a diol monomer, preferably a monoethylene glycol. The furan resin is typically obtained by polymerizing monomers providing such moieties in the polymer. To that end one can use as monomers FDCA, preferably 2,5-FDCA or a diester thereof. Thus the polymerization can be an esterification or a transesterification, both being also referred to as (poly)condensation reactions. One may preferably use dimethyl-2,5-furandicarboxylate (DMF) and / or 2, 5-dimethylfuran (2,5-DMF) and / or a derivate thereof as a monomer.

[0011] FDCA is a sugar-based compound that forms a building block (monomer) to produce a poly(alkylene 2,5-furandicarboxylate). The sugars (fructose syrup) used today to make FDCA can be produced from agricultural crops, such as wheat, com and sugar beet. When commercially available, PEF can also be produced from cellulosic sugars, which are abundant in non-edible biomass, such as agricultural and forestry residue streams.

[0012] The 2,5-FDCA moiety or monomer can for example be obtained from a 2,5- furandicarboxylate ester, which is an ester of a volatile alcohol or phenol or ethylene glycol, preferably having a boiling point of less than 150°C, more preferably having a boiling point of less than 100°C, still more preferably diester of methanol or ethanol, most preferably of methanol. 2,5-FDCA or DMF are typically considered as biosourced. The 2,5-FDCA or ester thereof may be used in combination with one or more other dicarboxylic acid, esters or lactones.

[0013] In addition to FDCA, preferably at least one diol monomer is used to produce PEF. The diol monomer can be an aromatic, aliphatic or cycloaliphatic diol. Examples of suitable diol and polyol monomers therefore include ethylene glycol, diethylene glycol, 1 ,2-propanediol, 1 ,3-propanediol, 1 ,4-butanediol, 1 ,5-pentanediol, 1 ,6- hexanediol, 1 ,4-cyclohexanedimethanol, 1 ,1 ,3,3-tetramethylcyclobutanediol, 1 ,4- benzenedimethanol, 2,2-dimethyl-1 ,3-propanediol, polyethylene glycol), poly(tetrahydofuran), 2,5-di(hydroxymethyl)tetrahydrofuran, isosorbide, glycerol, 25 pentaerythritol, sorbitol, mannitol, erythritol, threitol. Ethylene glycol, 1 ,3- propanediol, 1 ,4-butanediol, 1 ,4-cyclohexanedimethanol, 1 ,6-hexanediol, 2,2- dimethyl-1 ,3-propanediol, polyethylene glycol), poly(tetrahydofuran), glycerol, and pentaerythritol, are particularly preferred diols. These glycols used may be biobased (biosourced) glycols. Additionally or alternatively, one or more bio- succinic acid based diols may be used, and / or, preferably biobased, neopentyl glycol may be used.

[0014] In a preferred embodiment the diol is monoethylene glycol (MEG), more preferably biosourced MEG. Biosourced MEG can e.g. be obtained from ethanol which can also be prepared by fermentation from sugars, (e.g. glucose, fructose, xylose) that can be obtained from crop or agricultural by-products, forestry byproducts or solid municipal waste by hydrolysis of starch, cellulose, or hemicellulose. Alternatively, biosourced MEG can be obtained from glycerol, that itself can be obtained as waste from biodiesel.

[0015] The monomer components used for the synthesis of the furan resin, such as PEF in the PEF composition, may optionally further include, for example, terephthalic acid, 2,6-naphthalenedicarboxylic acid, propanediol, and butanediol. However, it may be preferred that the monomer components are only 2,5-FDCA and MEG.

[0016] The mole ratio of 2,5-FDCA to MEG in the monomer components is preferably 1 / 3 to 1 / 1 , and more preferably 1 / 2.5 to 1 / 1 .5. A mole ratio of 1 / 3 or more results in may result in an improved adhesion between the PEF and an adjacent layer. A mole ratio of 1 / 1 or less normally results in the PEF having a terminal carboxylic acid amount that falls within a suitable range, so that polymer degradation during or after the production process can be limited.

[0017] The intrinsic viscosity of the PEF in the PEF composition is preferably 0.50 to 1.50 dl / g, more preferably 0.70 to 1.10 dl / g. When the intrinsic viscosity is 0.50 dl / g or more, the tenacity of the resulting PEF increases, and when it is 1.50 dl / g or less, extrusion can normally easily be performed. According to the method in compliance with ASTM D4603, an intrinsic viscosity of PEF was measured using a 4:6 (weight ratio) mixture of phenol and trichloroethylene as solvent.

[0018] The weight average molecular weight (Mw) of the PEF in the PEF composition is preferably 55,000 to 200,000, more preferably 62,000 to 180,000, and even more preferably 65,000 to 150,000. When the weight average molecular weight of PEF is 55,000 or more, the tenacity of the resulting PEF increases, and when it is 200,000 or less, the melt viscosity of the furan resin decreases, so that the extrusion pressure decreases sufficiently to allow proper extrusion. This preferred molecular weight range also applies in case one or more other furan resins than PEF would be used. The weight average molecular weight is a value measured by GPC with polystyrene as a standard.

[0019] Preferably, said furan resin used in the core layer and / or the decorative top structure is at least one furan homopolymer and / or at least one 2,5- furandicarboxylate-based polymer and / or at least one furan resin selected from the group consisting of: polyethylene 2,5-furandicarboxylate) (PEF), polypropylene 2,5-furandicarboxylate) (PPF), poly(butylene 2,5-furandicarboxylate) (PBF), poly(1 ,4-cyclohexanedimethylene 2,5-furandicarboxylate) (PCHDMF), poly trimethylene furan dicarboxylate) (PTF), poly (neopentyl 2,5-furandicarboxylate) (PNF), poly(hexamethylene 2,5-furandicarboxylate) (PHMF), polypctamethylene 2,5-furandicarboxylate) (POMF), poly(decamethylene 2,5-furandicarboxylate) (PDMF), and mixtures thereof.

[0020] Each of these furan-based homopolymers has its own properties. Dependent on the desired decorative panel properties one or more of these furan-based polymers can be chosen. For example: Polyethylene 2,5-furandicarboxylate) (PEF) has relatively good moisture barrier properties, a good mechanical strength, and a moderate flexibility. Polypropylene 2,5-furandicarboxylate) (PPF) provides an increased rigidity, a relatively high thermal stability, while being a lightweight furan- based polymer with a density of approximately 1.25 g / cm3 (which is relatively low e.g. compared to PEF’s density of approximately 1.37 g.cm3.). Polyputylene 2,5- furandicarboxylate) (PBF) provides a relatively good flexibility, toughness, and impact resistance. This material may e.g. add resilience to the core layer, absorbing shocks and reducing brittleness. Poly(1 ,4-cyclohexanedimethylene 2,5- furandicarboxylate) (PCHDMF) leads to a relatively rigid (core) layer with a relatively good thermal stability. Poly(trimethylene furan dicarboxylate) (PTF) provides a balanced flexibility and strength, and exhibits a relatively good impact resistance. This material is well suitable for a core layer that requires both strength and some level of flexibility. Poly(neopentyl 2,5-furandicarboxylate) (PNF) is a relatively strong and thermally stable material, resistant to warping, which is favourable for enhancing dimensional stability and strength in the core. Poly(hexamethylene 2,5-furandicarboxylate) (PHMF) is relatively flexible (compared to various other furan-based polymers) and is moreover a durable. This material may be used to add elasticity and toughness to realize relatively flexible yet durable panels. Poly(octamethylene 2,5-furandicarboxylate) (POMF) is (also) relatively flexible and performs well in low-temperature environments, such as outdoor environments. Poly(decamethylene 2,5-furandicarboxylate) (PDMF) typically exhibits a high crystallinity and a relatively good strength, which makes this material suitable for adding rigidity and strength to decorative panels.

[0021] All of these furan resins show strong mechanical properties when compared to other traditional polymers. The furan resin used in the panel according to the invention may be at least one homopolymer and / or at least one copolymer, such as random or block copolymers, and / or mixtures or blends of one or more homopolymers, and / or of one or more copolymers, and / or of at least one homopolymer and at least one copolymer. An example of such a furan (based) copolymer is polyethylene 2,5-thiophenedicarboxylate-co-2,5-furandicarboxylate) (PEThF). PEThF exhibits relatively good barrier properties as well as an improved mechanical strength. This enhances durability and resistance to moisture. Other examples of suitable furan-based copolymers are given below. Poly(butylene succinate-co-2,5-furandicarboxylate) (PBSF) has a relatively good biodegradability, moderate flexibility, and durability, and therefore forms a relatively good evironmentally friendly option with balanced strength and flexibility. Poly(trimethylene terephthalate-co-2,5-furandicarboxylate) (PTTF) exhibits a relatively high mechanical strength and thermal stability, which may contribute to thermal stability and rigidity in floor panel cores. Poly(lactic acid-co-2,5- furandicarboxylate) (PLA-F) is biodegradable / compostable, shows moderate barrier properties, and an enhanced strength, which makes this material typically well suitable for eco-friendly decorative floor panels with moderate durability needs. Polyethylene glycol-co-2,5-furandicarboxylate) (PEGF) is relatively flexible and may be used to add flexibility to the decorative panels, possibly in a role added polymer (blended-in polymer). Polycarbonate-furandicarboxylate (PC-F) is relatively transparent, rigid, with a relatively high impact resistance. This polymer may be used in the core layer to improve its rigidity and impact resistance, enhancing durability, but may - for the same reasons - also be used in at least one layer of the decorative top structure.

[0022] In addition to 2,5-furandicarboxylate-based polymers referred to above, the decorative panel, in particular the core layer and / or decorative top structure, may comprise at least one alternative furan-based polymer, such as the furan-based polymers described as examples below. Poly(furfuryl alcohol) (PFA) exhibits a relatively high thermal stability, relatively good chemical resistance, and good mechanical strength. PFA may, for example, be used as a matrix material in a composite material used in the core layer and / or in the decorative top structure, and may therefore reinforce decorative panel. It may be preferred to at least partially cross-link PFA (and / or another cross-linkable furan-based polymer) to further improve mechanical strength and resistance to heat. Poly(furanamide) (PFAm) exhibits a relatively good tensile strength, a relatively high rigidity, and moderate flexibility, which makes this material suitable for core layers that require structural strength. Moreover, PFA is a lightweight material with a density of approximately 1.15 g / cm3. Poly(furfuryl methacrylate) (PFM) shows a relatively high thermal stability and resistance to UV degradation, with typically good adhesion properties, which makes this material suitable to create a stable, durable core layer and / or decorative top layer. Poly(furfuryl isocyanurate) (PFI) exhibits high cross-linking potential, shows a relatively strong thermal resistance, and good mechanical strength. This material is therefore typically suitable for heavy-duty flooring applications, especially in industrial settings, where it can resist mechanical stress and heat. Poly(2,5-furandimethylene carbonate) (PFC) is relatively transparent, exhibits relatively good barrier properties, and has a moderate flexibility. PFC can e.g. be used in the core layer for added barrier protection against moisture and chemicals, maintaining the floor’s integrity.

[0023] Poly(furfuryl acrylate) (PFAc) is (also) relatively well resistant to chemicals and heat, good mechanical strength, which makes this material suitable to create a protective, stable core, especially suitable for floors requiring chemical resistance. Furan-based Polyurethanes (FPU) is relatively flexible and durable and thermally stable. Moreover, FPU is one of the lightest furan-based polymers with a density of approximately 1.10-1.20 g / cm3. Poly(furfuryl carbonate) (PFC) (and / or Poly(2,5- furandimethylene carbonate)) has a relatively good recyclability and is bio-based, wherein it uses furan derivatives typically sourced from biomass. PFC is typically more flexible compared to PEF and more lightweight than PEF. PFC is typically well suitable for lightweight core layers that need thermal resistance and moderate structural integrity, and is therefore well suitable for use in floating floor systems in which the floor panels are not glued, nailed, or otherwise permanently fixed to the subfloor, but instead, the panels are connected to each other, often using a clicklock system and / or tongue-and-groove design at one or both pairs of opposite side edges. Furan-based epoxy resins exhibit a relatively high strength, a good adhesion, and chemical resistance. These resins are typically well suitable for high- durability core layers in flooring.

[0024] In case panel weight is in important factor, then preferably at least one furan-based polymer is chosen for the core layer and / or decorative layer having a relatively low density, such at least one furan-based polymer chosen from the group consisting of: Furan-based Polyurethane (FPU) (-1.10-1 .20 g / cm3), Poly(furanamide) (PFAm): (-1.15 g / cm3), Poly(decamethylene 2,5-furandicarboxylate) (PDMF): (-1.16 g / cm3), Poly(octamethylene 2,5-furandicarboxylate) (POMF): (-1.18 g / cm3), Poly(furfuryl acrylate) (PFAc): (-1.18 g / cm3), Poly(hexamethylene 2,5- furandicarboxylate) (PHMF): (-1.20 g / cm3), Polyethylene glycol-co-2,5- furandicarboxylate) (PEGF): (-1.20 g / cm3), Poly(furfuryl alcohol) (PFA): (-1.20 g / cm3), Poly(furfuryl methacrylate) (PFM): (-1.22 g / cm3), Furan-based Epoxy Resin: (-1.22-1.25 g / cm3). All of these examples have a density which is at least 10% below the typical density of rigid PVC (-1 .38 g / cm3).

[0025] Although the use of PEF has several advantages, such as providing structural integrity and dimensional stability to the decorative panel which can help reduce the risk of deformation under heavy furniture or foot traffic, contributing to the lifetime of the decorative panel, it may be preferred that the core layer and / or the decorative top structure, and even the decorative panel as such, is free of PEF, for example to reduce the brittleness of the panel and / or to reduce the rigidity of the panel. In a PEF-free core layer and / or decorative top structure and / or decorative panel as such, at least one other furan-based polymer, of which examples have been given above extensively, is used in the core layer and / or decorative top structure and / or decorative panel as such. Said at least one core layer and / or said decorative top structure may comprise a plurality of different furan resins. The different furan resins may be mixed (blended), but it is also, additionally or alternatively, imaginable that the core layer and / or the decorative top structure has a laminated structure of a plurality of layers, wherein at least two layer comprise different furan resins.

[0026] Additionally or alternatively, it is imaginable that said at least one core layer and / or said decorative top structure comprises a blend of at least one furan resin and at least one other (non-furan based) polymer, wherein said other polymer is preferably at least one polymer selected from the group consisting of: polyethylene terephthalate) (PET), polyethylene 2,6-naphthalate) (PEN), poly(L-lactic acid) (PLA) and polycarbonate (PC), PBS, PE, PP, TPU, PETG, at least one other furan- based polymers, and mixtures thereof. Polyethylene Terephthalate (PET) is known for its strength, chemical resistance, and good barrier properties. When blended with furan-based polymers, PET enhances durability and rigidity, while also improving moisture and chemical resistance. Poly(butylene succinate) (PBS) is biodegradable, flexible, and has good thermal stability, making it an eco-friendly option for blending with furan-based polymers. It also enhances the flexibility and impact resistance of the final product.

[0027] PBS adds flexibility and toughness, which can help prevent cracking in the floor panel. It’s suitable for use in both core and surface layers of flooring panels. Polyethylene (PE) is relatively flexible and moisture-resistant with a good impact resistance. It is relatively low-cost and can improve the toughness and the impact resilience of furan-based polymers. Polypropylene (PP) typically offers a relatively good resistance to moisture, chemicals, and abrasion. It is lightweight and can improve the toughness of furan-based materials without compromising durability. PP is suitable for blending into the core layer, where it can help prevent water absorption and maintain the structural integrity of the panel, especially in humid environments. Thermoplastic Polyurethane (TPU) is known for its flexibility, elasticity, and durability. It blends well with furan-based polymers, providing enhanced impact resistance, flexibility, and abrasion resistance. TPU can add a soft, resilient quality to the panel’s surface layer, making it comfortable underfoot and providing extra shock absorption, which is well suitable for residential and commercial flooring. Polycarbonate (PC) is relatively tough, impact-resistant, and offers a relatively good dimensional stability. When blended with furan-based polymers, PC adds strength and resistance to scratches and abrasions. PC is especially useful in the top layer of decorative floor panels, where it can provide a glossy, scratch-resistant surface while protecting the panel’s design, although it is also imaginable to incorporate PC in the core layer. Polylactic Acid (PLA) is a biodegradable / compostable polymer that can improve the eco-friendliness of furan- based floor panels. It also enhances rigidity and maintains thermal stability, making it useful in areas with moderate traffic. PLA may be blended in for applications where sustainability of the decorative panel is desired. It can help maintain the rigidity of the core layer while adding an eco-friendly component to the flooring material. Polyethylene Terephthalate Glycol (PETG) is a modified form of PET that combines strength and flexibility. It improves durability and impact resistance while providing clarity, making it well suitable for use in the decorative top structure, wherein PETG can e.g. serve as a transparent top layer, protecting the decorative design from scratches and UV light exposure.

[0028] Typically, the furan resin forms a polymer matrix of the core layer and / or (at least one layer of) the decorative top structure. The furan resin matrix may be enriched with one or more fillers and / or one or more functional additives. Examples of suitable fillers are limestone (calcium carbonate) and wood. Other possibly inert and / or functional fillers are for example, chalk, calcined clay, glass particles, glass fibres, carbon particles, silicon particular, a(nother) mineral and / or inorganic filler, cellulose, rice, a(nother) natural filler, a(nother) (auxiliary) polymer, such as an elastomer and / or latex. Examples of suitable mineral fillers are silica (SiO2), calcium carbonate (CaCO3), aluminium hydroxide (ATH), talc, glass fibers, kaolin clay, barium sulphate (BaSO4). The application of one or more of these (mineral) fillers for the one or more furan-based polymers used in the decorative panel typically enhance properties such as mechanical strength, thermal stability, flame retardancy, and dimensional stability. For example, silica (SiO2) aligns well with the properties of furan-based polymers and is suitable for reinforcing strength and durability, especially for applications like flooring where wear resistance is crucial. Calcium Carbonate (CaCO3) is a cost-effective filler that increases rigidity and dimensional stability. It typically helps to reduce shrinkage and improve surface smoothness and normally reduces costs without compromising mechanical properties. Aluminum Hydroxide (ATH) typically acts as a flame retardant and smoke suppressant, releasing water vapour when heated, which slows down combustion and it typically also provides added strength and stability, which makes this material suitable for fire-resistant applications, such as panels in commercial buildings, where flame retardancy is important. Talc enhances thermal and dimensional stability while adding stiffness to the furan-based polymer(s). It also reduces water absorption, which can improve the moisture resistance of furan- based polymers. Glass fibers typically significantly increase tensile strength, impact resistance, and rigidity, making them typically well suitable both for low-duty as well as for heavy-duty applications. Kaolin clay typically improves rigidity, surface finish, and dimensional stability. It is also effective at reducing shrinkage and thermal expansion, which makes this clay typically suitable for decorative panels, as it enhances surface smoothness and finish quality. Barium sulphate typically provides high-density and enhances sound insulation and wear resistance, making it well suitable for panel applications where additional weight and noise dampening are desired.

[0029] These fillers are often used to either reduce the cost price of the core layer and / or to make the core layer either more flexible or more rigid (stiff). The amount of filler in the core layer is preferably at least 50 percent by weight of the core layer, preferably in an amount of between 60 and 80 percent by weight of the core layer. Preferably, the weight amount of filler in the core layer is at least 1 .5 times the weight amount of furan resin, in particular PEF of said core layer.

[0030] The filler(s) is / are normally dispersed as powder or particles or - optionally - as separate layer(s) - in the polymer matrix. However, it is also imaginable that the furan resin does not act as matrix material, but as filler and / or reinforcement material. Here, the furan resin may be dispersed as particles, such as fibers, spheres, beads, dust, granules, etcetera, in a matrix material formed by another polymer, such as PET and / or PP, and / or may be incorporated as layer, in particular reinforcement layer. This layer may, for example, be a woven layer or a non-woven layer.

[0031] As indicated above, said at least one core layer and / or said decorative top structure preferably comprises at least one biobased (biosourced) furan resin. Said at least one core layer and / or said decorative top structure may comprise at least one recycled furan resin and / or a mixture of virgin and recycled furan resin. The furan resin used in the decorative panel is normally recyclable.

[0032] It is imaginable that the panel comprises a plurality of laminated core layers, wherein at least one core layer, preferably each core layer comprises at least one furan resin. The furan resin applied in the different core layers may differ per core layer. Hence, for example it imaginable that at least one core layer comprises PEF, while at least one other core layer comprises at least one furan resin selected from the group consisting of: PPF, PBF, PCHDMF, PTF, and PNF.

[0033] In a preferred embodiment, the panel comprises three laminated core layers in an A-B-A configuration, wherein the outer layers (A) have the same composition, and wherein the inner layer (B) has a different composition, and wherein at least one core layer, preferably each core layer, comprises at least one furan resin. It is imaginable that at least one core layer, such as the inner layer (B) is free of furan resin and is formed by another polymeric material, such as PET and / or PP, and / or by a reinforcing material, such as, preferably interconnected, glass fibers.

[0034] It may be preferred that the core layer comprises at least one lubricant configured to withstand temperatures of at least 200 degrees Celsius, preferably at least 260 to at least 270 degrees Celsius (which approximately corresponds to the melting temperature of PEF), more preferably at least 320 degrees Celsius (which approximately corresponds to the extrusion temperature). The lubricant is preferably present in an amount of less than 1 percent by weight of the core layer. Typically extrusion takes place at these higher temperature (> 270 degrees Celsius). The lubricant’s primary role is to reduce friction, minimize wear and prevent overheating of parts during extrusion. Preferably, the core layer comprises at least one lubricant formed by silicone oil, preferably in an amount of less than 1 percent by weight of the core layer. Silicone oil, contrary to e.g. ordinary wax, is an example of a lubricant which is capable to withstand extrusion temperatures of at least 270 degrees Celsius.

[0035] The core layer preferably comprises at least one toughening agent, preferably in an amount of less than 10 percent by weight of the core layer, more preferably in an amount of between 3 and 8 percent by weight of the core layer. This toughening agent may e.g. be formed by a styrene-ethylene-butylene-styrene terpolymer functionalized with maleic anhydride (SEBS-g-MA) (such as (FG1901X obtained from KRATON Corporation). This toughening agent may reduce the melt flow index (MFI) of PEF based masterbatch during extrusion, for example to a value of approximately 50 g / 10 min, which is favourable to produce the core layer.

[0036] The decorative top structure may be composed of a single layer, which is adhered, with or without adhesive, to the core layer. It is imaginable that the decorative top structure is at least partially made of at least one material chosen from the group consisting of: ceramic, stone, concrete, mineral porcelain, glass, mosaic, granite, limestone, marble, linoleum, and carpet. Preferably, at least one decorative layer of said decorative top structure may be at least partially composed of one or more of these materials. Such a decorative layer may constitute a tile or may be composed of a plurality of tiles, adhered, with or without using adhesive, onto the core layer.

[0037] The decorative top structure preferably comprises a primer layer applied onto the top surface of the core layer, and at least one further layer applied onto said primer layer. The primer may for example comprise calcium carbonate and / or a hydrogenated castor oil and wherein preferably the adhesive primer is a two- component adhesive, for example based on a (polyether) polyol and a curing agent. The primer layer facilitates adhesion of another layer, such as a basecoat layer onto the core layer.

[0038] The decorative top structure may be adhered to the core layer by using different techniques. In case the core layer and (a lower layer of) the decorative top structure are thermoplastically compatible with each other, thermoplastic fusion may be applied, wherein both layers are bonded under heat and pressure without an additional adhesive, typically by using a hot press set to a temperature just below the degradation temperature of the furan material, typically between 120- 150°C, applying even pressure. This can partially melt the surfaces, allowing them to fuse together. This creates a seamless bond without the need for an external adhesive, enhancing bond strength and durability. Additionally or alternatively, at least one adhesive may be used, such as at least one furan-based epoxy adhesive (e.g. furanyl epoxy) and / or at least one polyurethane adhesive (e.g. SikaMelt®- 9677) and / or at least one UV-curable adhesive (e.g. Dymax 3069) with furan compatibility, and / or at least one solvent-based furan adhesive and / or a reactive or non-reactive hot melt adhesive (e.g. Jowat Jowatherm-Reaktant® 607.40) and / or at least one reactive PU adhesive (e.g. Henkel LOCTITE® UR 7000) and / or at least one water-based PU adhesive (e.g. Dow MOR-FREE™ 520A / C) and / or at least one polyolefin based hot-melt adhesive and / or at least one silane-Modified polymers (SMP) based adhesives (e.g. SikaFlex®-505 UV) and / or at least one acrylic-based adhesives (e.g. Permabond TA437). For most applications, furan- based epoxy or PU adhesives provide the strongest and most durable bonds, while direct heat bonding is a great option for seamless fusion. These methods ensure a solid, resilient bond that can withstand the wear and conditions typical in flooring applications.

[0039] The decorative top structure may comprise at least one basecoat layer, directly or indirectly, applied onto the top surface of the core layer, and at least one further layer applied onto said basecoat layer. The basecoat layer is typically configured to provide a base for applying a decorative layer. At least one basecoat is preferably a white layer, which will improve the colour authenticity of a decor layer optionally digitally printed on top of said basecoat layer(s). This white basecoat layer may be an UV cured layer. This white basecoat layer may e.g. comprise unsaturated aliphatic polyurethane acrylate, and / or hydroxyethyl methacrylate, and / or titanium dioxide. The white basecoat layer may be covered by a further basecoat layer to balance to surface tension to prevent shrinkage of ink droplets optionally to be printed onto said basecoat layer. This additional basecoat layer may be an UV cured layer. This additional basecoat layer may e.g. comprise unsaturated aliphatic polyurethane acrylate, and / or hydroxyethyl methacrylate, and / or calcium carbonate, and / or silicon dioxide.

[0040] The decorative top structure typically comprises at least one decorative layer, directly or indirectly, applied onto the top surface of the core layer, and preferably at least one further layer, such as a wear layer and / or anti-scratch layer, applied onto said decorative layer. The decorative layer is preferably a digitally printed decorative layer, but may also be formed by a veneer layer (wood layer, stone layer, polymer layer, other synthetic or natural layer), or by a decorative, preferably, polymer based, film, such as a furan resin and / or PET comprising film. The wear layer(s) and the anti-scratch layer (preferably acting as top coating), are preferably UV cured layers which are at least partially transparent and / or translucent. The wear layer may at least partially be formed by at least one furan resin. Furan resin may be transparent and relatively wear resistant, which makes this material (also) suitable to act as wear layer. Additionally or alternative, at least one wear layer and / or at least one anti-scratch layer comprises at least one furan resin and / or PET, which may have a thickness ranging from 10 to 100 pm. The at least one furan resin and / or PET comprising wear layer(s) and / or anti-scratch layer(s) may be a furan resin and / or PET comprising film. This film hay have a superior transparency, heat resistance, durability, and chemical resistance.

[0041] The top surface of the decorative top structure may be provided with a relief pattern, also referred to as embossing structure, wherein said relief pattern is preferably aligned with a decorative image of the decorative layer. The relief pattern may initially be provided in one of the wear layers or another intermediate layer, and may be covered by a top coating, such that the relief of the relief pattern remains visible and / or feelable at least partially at the top surface of the decorative top structure.

[0042] It is imaginable that the decorative top structure comprises and / or is formed by a single embossed, preferably at least one furan resin and / or PET comprising, wear layer provided with a decorative print on its lower side (facing the core layer(s)). The decorative print may simply be a decorative ink layer or may be a separate decorative film. The embossing applied in or on the wear layer is preferably aligned with said decorative print. In this manner a relatively compact, simple, and hence efficient decorative panel configuration can be realized.

[0043] The panel may comprise a backing layer attached, such as glued, directly or indirectly, to a bottom surface of the core layer, wherein the backing layer is preferably at least composed of PET and / or a furan resin, such as PEF. The backing layer may be foamed or unfoamed. The backing layer may contribute to the sound dampening properties and / or comfort properties of the decorative panels. The backing layer preferably comprises PET, more preferably recycled PET, and / or at least one furan resin, such as PEF.

[0044] It is imaginable that the panel comprises at least one pair of opposing side edges complementary coupling profiles allowing intercoupling of adjacent decorative panels. This allows decorative panels according to the invention for example to realize a so-called floating (unglued) floor covering or wall covering. Each side edge of the panel may be provided with a coupling profile. Each coupling profile may comprise one or more tongues and / or one or more grooves. The coupling profiles may be formed substantially out of the core layer material (by removal of core layer material at the side edges).

[0045] The panel may be an oblong panel. The panel may be rectangular or may have an alternative polygon shape, such as e.g. a triangular shape, a hexagonal shape, and a parallelogrammatic shape. The thickness of the core layer may vary, but is often situated between 4 and 10 mm, preferably between 4.5 and 8 mm. The panel may be an indoor decorative panel. Additionally or alternatively, the panel may be an outdoor decorative panel. In this latter case, preferably thermally stable and moisture-proof, in particular weather-proof, decorative panels are used, which may result in a preference to use one or more furan-based polymers selected from the group consisting of: Poly(furfuryl alcohol) (PFA), Poly(furfuryl methacrylate) (PFM), Poly(furfuryl isocyanurate) (PFI), Polycarbonate-furandicarboxylate (PC-F), Furan- based Epoxy Resins, Polyethylene 2,5-thiophenedicarboxylate-co-2,5- furandicarboxylate) (PEThF), and mixtures thereof, in the decorative panel, in particular the core layer and / or the decorative top structure, according to the invention.

[0046] The invention also relates to a core layer for use in a decorative panel according to the invention, wherein the core layer comprises at least one furan resin.

[0047] The invention further relates to a method for producing a decorative panel, in particular a decorative panel according to the invention, comprising the steps of: a) preparing or providing at least one furan resin, b) optionally mixing said at least one furan resin with one or more additive, c) loading said at least one furan resin, optionally mixed with one or more additive, in an extruder, preferably a twin screw extruder; d) extruding said mixture by said extruder, preferably at a temperature between 270 and 320 degrees Celsius, thereby forming an extruded core layer, e) cooling, preferably actively cooling, said extruded core layer to a temperature below 100 degrees Celsius, f) applying a decorative top structure on top of said core layer thereby forming the decorative panel.

[0048] Further embodiments of the invention are presented in the non-limitative set of clauses presented below.

[0049] Clauses

[0050] 1. Decorative panel, in particular a decorative floor panel, decorative ceiling panel, or decorative wall panel, comprising:

[0051] • at least one core layer, and

[0052] • a decorative top structure directly or indirectly affixed to a top surface said core layer; wherein said at least one core layer and / or said decorative top structure comprises at least one furan resin.

[0053] 2. Decorative panel according to clause 1 , wherein said furan resin is a 2,5- furandicarboxylic acid (FDCA) based furan resin.

[0054] 3. Decorative panel according to clause 1 or 2, wherein said furan resin is a poly(alkylene 2,5-furandicarboxylate).

[0055] 4. Decorative panel according to any of the preceding clauses, wherein said furan resin is selected from the group consisting of: polyethylene 2,5-furandicarboxylate) (PEF), polypropylene 2,5-furandicarboxylate) (PPF), poly(butylene 2,5-furandicarboxylate) (PBF), poly(1 ,4-cyclohexanedimethylene 2,5-furandicarboxylate) (PCHDMF), poly trimethylene furan dicarboxylate) (PTF), and poly (neopentyl 2,5-furandicarboxylate) (PNF), poly(hexamethylene 2,5-furandicarboxylate) (PHMF), poly(octamethylene 2,5-furandicarboxylate) (POMF), and poly(decamethylene 2,5-furandicarboxylate) (PDMF); and / or, optionally wherein said at least one core layer and / or said decorative top structure, preferably the decorative panel as such, is free of polyethylene 2,5-furandicarboxylate) (PEF).

[0056] 5. Decorative panel according to any of the preceding clauses, wherein said furan resin is a furan based copolymer, such as polyethylene 2,5- thiophenedicarboxylate-co-2,5-furandicarboxylate) (PEThF), poly(hexamethylene 2,5-furandicarboxylate) (PHMF), poly(octamethylene 2,5-furandicarboxylate) (POMF), poly(decamethylene 2,5-furandicarboxylate) (PDMF), poly(ethylene terephthalate-co-2,5-furandicarboxylate) (PETF), poly(butylene succinate-co-2,5- furandicarboxylate) (PBSF), poly(trimethylene terephthalate-co-2,5- furandicarboxylate) (PTTF), Poly(lactic acid-co-2,5-furandicarboxylate) (PLA-F), Poly(ethylene glycol-co-2,5-furandicarboxylate) (PEGF), and polycarbonatefurandicarboxylate (PC-F).

[0057] 6. Decorative panel according to any of the preceding clauses, wherein said at least one core layer and / or said decorative top structure comprises a plurality of different furan resins.

[0058] 7. Decorative panel according to any of the preceding clauses, wherein said at least one core layer and / or said decorative top structure comprises a blend of at least one furan resins and at least one other polymer, wherein said other polymer is preferably selected from the group consisting of: polyethylene terephthalate) (PET), polyethylene 2,6-naphthalate) (PEN), poly(L-lactic acid) (PLA) and polycarbonate (PC), PBS, PE, PP, TPU, PETG, at least one other furan-based polymers, and mixtures thereof; and / or wherein said at least one core layer and / or said decorative top structure comprises a blend of at least one 2,5- furandicarboxylate-based furan resin and at least one other furan resin, preferably selected from the group consisting of: poly(furfuryl alcohol) (PFA), poly(furanamide) (PFAm), poly(furfuryl methacrylate) (PFM), poly(furfuryl isocyanurate) (PFI), poly(2,5-furandimethylene carbonate) (PFC), poly(furfuryl acrylate) (PFAc), furan- based polyurethanes (FPU), poly(furfuryl carbonate) (PFC), furan-based epoxy resins. 8. Decorative panel according to any of the preceding clauses, wherein said at least one core layer and / or said decorative top structure comprises at least one biobased furan resin.

[0059] 9. Decorative panel according to any of the preceding clauses, wherein said at least one core layer and / or said decorative top structure comprises at least one recycled furan resin.

[0060] 10. Decorative panel according to any of the preceding clauses, wherein the panel comprises a plurality of laminated core layers, wherein at least one core layer, preferably each core layer comprises at least one furan resin.

[0061] 11 . Decorative panel according to any of the preceding clauses, wherein the panel comprises three laminated core layers in an A-B-A configuration, wherein the outer layers (A) have the same composition, and wherein the inner layer (B) has a different composition, and wherein at least one core layer comprises at least one furan resin.

[0062] 12. Decorative panel according to any of the preceding clauses, wherein the core layer comprises at least one inorganic filler, such as limestone, and / or organic filler, such as wood particles and / or cellulose.

[0063] 13. Decorative panel according to clause 12, wherein the amount of filler in the core layer is at least 50 percent by weight of the core layer, preferably in an amount of between 60 and 80 percent by weight of the core layer.

[0064] 14. Decorative panel according to clause 12 or 13, wherein the core layer comprises at least one furan resin, and wherein the amount of filler in the core layer is at least 1 .5 times the amount of furan resin of said core layer.

[0065] 15. Decorative panel according to any of the preceding clauses, wherein the core layer comprises at least one lubricant, wherein said lubricant is preferably configured to withstand temperatures of at least 270 degrees Celsius, more preferably at least 320 degrees Celsius. 16. Decorative panel according to clause 15, wherein said lubricant is present in an amount of less than 1 percent by weight of the core layer.

[0066] 17. Decorative panel according clause 15 or 16, wherein the core layer comprises at least one lubricant formed by silicone oil, preferably in an amount of less than 1 percent by weight of the core layer.

[0067] 18. Decorative panel according to any of the preceding clauses, wherein the core layer comprises at least one toughening agent, preferably in an amount of less than 10 percent by weight of the core layer, more preferably in an amount of between 3 and 8 percent by weight of the core layer.

[0068] 19. Decorative panel according to any of the preceding clauses, wherein the decorative top structure comprises a primer layer applied onto the top surface of the core layer, and at least one further layer applied onto said primer layer.

[0069] 20. Decorative panel according to any of the preceding clauses, wherein the decorative top structure comprises at least one basecoat layer, directly or indirectly, applied onto the top surface of the core layer, and at least one further layer applied onto said basecoat layer.

[0070] 21 . Decorative panel according to any of the preceding clauses, wherein the decorative top structure comprises at least one decorative layer, directly or indirectly, applied onto the top surface of the core layer, and preferably at least one further layer, such as a wear layer and / or anti-scratch layer, applied onto said decorative layer.

[0071] 22. Decorative panel according to clause 21 , wherein the decorative layer is a digitally printed decorative layer.

[0072] 23. Decorative panel according to clause 21 , wherein the decorative layer is formed by a veneer layer or by a decorative film. 24. Decorative panel according to any of clauses 21-23, wherein a top surface of the decorative top structure is provided with a relief pattern, wherein said relief pattern is preferably aligned with a decorative image of the decorative layer.

[0073] 25. Decorative panel according to any of clauses 21-24, wherein the decorative top structure comprises at least one decorative layer, directly or indirectly, applied onto the top surface of the core layer, and at least one wear layer and / or antiscratch layer, applied onto said decorative layer, wherein said wear layer and / or anti-scratch layer comprises at least one furan resin.

[0074] 26. Decorative panel according to any of the preceding clauses, wherein the panel comprises a backing layer attached, directly or indirectly, to a bottom surface of the core layer, wherein the backing layer preferably comprises furan resin.

[0075] 27. Decorative panel according to any of the preceding clauses, wherein the panel comprises at at least one pair of opposing side edges complementary coupling profiles allowing intercoupling of adjacent decorative panels.

[0076] 28. Core layer intended for use or use of a core layer in a decorative panel according to any of the preceding clauses, wherein said core layer comprises at least one furan resin.

[0077] 29. Method for producing a decorative panel, in particular a decorative panel according to any of clauses 1-27, comprising the steps of: a) preparing or providing at least one furan resin, b) optionally mixing said at least one furan resin with one or more additive, c) loading said at least one furan resin, optionally mixed with one or more additive, in an extruder, preferably a twin screw extruder; d) extruding said mixture by said extruder, preferably at a temperature between 270 and 320 degrees Celsius, thereby forming an extruded core layer, e) cooling, preferably actively cooling, said extruded core layer to a temperature below 100 degrees Celsius, f) applying a decorative top structure on top of said core layer thereby forming the decorative panel. The invention will hereinafter be further elucidated on the basis of non-limitative exemplary embodiments shown in the following figures, wherein:

[0078] Figure 1 schematically shows a decorative panel according to the invention; Figure 2 shows the panel of figure 1 without the optional intermediate layer; Figures 3 and 4 schematically show possible configurations of complementary coupling profiles according to the invention;

[0079] Figures 5 and 6 schematically show other possible coupling profiles according to the present invention; and

[0080] Figure 7 schematically shows a decorative panel according to the invention.

[0081] Figure 1 schematically shows a panel (1) according to the invention, with a centrally located core layer (2), wherein said core layer (2) comprises an top surface (3) and a bottom surface (4), preferably on opposite sides of said core layer (2). An optional backing layer (5) is in this non-limitative embodiment attached to the bottom surface (4) of the core. Figure 1 also shows a decorative top structure (6), which is indirectly attached to the top surface (3) of the core (2). In this embodiment it is depicted that the decorative top structure (6) is attached to a primer layer (30), which is optional. Although the decorative top structure (6) is indicated as a single layer in this non-limitative embodiment, it is conceivable that the decorative top structure (6) comprises more than one layer. For example, the decorative top structure (6) may be formed by; a printed decorative layer, such as a digital print layer, veneer layer, or decorative film, an embossing structure or pattern layer, which may form a relief of the panel, and optionally a wear or protective layer.

[0082] On two opposite sides (7, 8) of the panel (1), which may alternatively be referred to as a pair of opposing edges (7, 8), complementary coupling parts (9, 10) are provided. The first coupling part (7) is in the form of a downward tongue (11) and the second coupling part (9) is in the form of an upward tongue (12). The second coupling part (9) may comprise a single upward tongue (12), at least one upward flank (13) lying at a distance from the upward tongue and a single upward groove (14) formed between the upward tongue and the upward flank, wherein at least a part of a side (15) of the upward tongue facing toward the upward flank is inclined and extends in the direction of the normal (N1) of the upper side or top surface (3) of the core, and wherein optionally at least a part of a side (16) of the upward tongue facing away from the upward flank comprises a substantially rigid first locking element (17), and on a second or fourth edge, a single downward tongue (11), at least one downward flank (18) lying at a distance from the downward tongue, and a single downward groove (19) formed between the downward tongue and the downward flank, wherein at least a part of a side (20) of the downward tongue facing toward the downward flank is inclined and extends in the direction of the normal (N2) of the lower side or bottom surface (4) of the core, and wherein the downward flank optionally comprises a, preferably substantially rigid, second locking element (21) adapted for co-action with the first locking element of a third edge of yet a further panel.

[0083] Figure 1 further shows that an upper or front side (22) of the upward tongue (12) is inclined, from a top side (22A) downwards towards the outside (16). The transition from the inside (15) of the upward tongue (12) to the top side (22A) forms an aligning edge (23). A similar construction is present on the other side, with an upper side (24) of the groove (19) being inclined. The aligning edge (25) on the downward tongue (11) is arranged on the outside (26) thereof. On both sides, the transition between the tongue (11 , 12) and the core (2) is formed by a bridge, being an upper bridge (27) on the downward tongue (11) side and a lower bridge (28) on the upward tongue (12) side. The transition (29) from the downward tongue (11) towards the inside thereof is shown rounded, to facilitate deformation.

[0084] The core layer (2) and / or the decorative top structure (6) according to figure 1 comprises a furan resin. Some non-limitative examples of the furan resin used in said core layer (2) and / or decorative top structure (6) may be: polyethylene 2,5-furandicarboxylate) (PEF), polypropylene 2,5-furandicarboxylate) (PPF), poly(butylene 2,5-furandicarboxylate) (PBF), poly(1 ,4-cyclohexanedimethylene 2,5-furandicarboxylate) (PCHDMF), poly trimethylene furan dicarboxylate) (PTF), poly (neopentyl 2,5-furandicarboxylate) (PNF), 2,5-furandicarboxylic acid (FDCA) based furan resin poly(alkylene 2,5-furandicarboxylate), and a furan based copolymer, such as polyethylene 2,5- thiophenedicarboxylate-co-2,5-furandicarboxylate) (PEThF), poly(hexamethylene 2,5-furandicarboxylate) (PHMF), poly(octamethylene 2,5-furandicarboxylate) (POMF), poly(decamethylene 2,5-furandicarboxylate) (PDMF), polyethylene terephthalate-co-2,5-furandicarboxylate) (PETF), poly(butylene succinate-co-2,5- furandicarboxylate) (PBSF), poly(trimethylene terephthalate-co-2,5- furandicarboxylate) (PTTF), Poly(lactic acid-co-2,5-furandicarboxylate) (PLA-F), Polyethylene glycol-co-2,5-furandicarboxylate) (PEGF), and polycarbonatefurandicarboxylate (PC-F).

[0085] Optionally, the furan resin is a resinthe core layer further comprises at least one other polymer, such as a regular PET polymer. The core layer (2) and the decorative top structure (6) doe not necessarily comprise the same furan resin. Also, the furan resin may be applied as a protective wear layer, affixed directly or indirectly onto the top surface of the decorative top structure (6) (not shown).

[0086] Figure 2 schematically shows a layering of the panel (1) and the decorative top structure (6) in particular. The decorative top structure (6) comprises an adhesive primer (61), a base coat (62), a transition layer (63) , a printed decor (64), a wear layer (65), a structured layer (66). The panel according to figure 2 further shows a scratch resistant layer (67), provided on top of, or part of, the decorative top structure (6). It is conceivable that different furan resins are used and / or combined in the various layers of the decorative top structure (6).

[0087] Figures 3 and 4 show possible other configurations of the complementary coupling parts and may also be usable for the invention as possible embodiments for the sideward tongue and groove combination.

[0088] Figure 3 for example shows on a first edge a sideward tongue (32) extending in a direction substantially parallel to the top surface of the panel, the bottom front region (33) of said sideward tongue being rounded at least partly, the bottom back region (24) of said tongue being configured as bearing region, wherein the bottom back region is located closer to the level of the top surface of the panel than a lowest part of the bottom front region, and on an opposite second edge (8) comprising a recess or sideward groove (35) for accommodating at least a part of the sideward tongue of a further panel, said recess being defined by an upper lip (36) and a lower lip (37), said lower lip being provided with a upwardly protruding shoulder (38) for supporting and / or facing the bearing region of the sideward tongue.

[0089] Figures 4a-4e show various variations on shapes usable for sideward tongues and grooves according to the present invention.

[0090] Figures 5 and 6 shows possible other configurations of the complementary coupling parts and may also be usable for the invention as possible embodiments for the downward and upward tongue combination. In figure 5 a similar locking system is shown compared to figures 1 and 2, with a slightly different shaping as well as with additional locking (31) on the outside of the downward tongue (11) and the upper side of the upward flank (13). In figure 6 the locking is shown as an open groove, wherein the insides (15, 20) of the tongues (11 , 12) are inclined, but not towards the cores but away from the cores. The angle of those insides (15, 20) is opposite to the one shown in figures 1 and 2.

[0091] Figure 7 schematically shows a panel (1) with a top surface (3) and a Sidebottom surface (4) on opposite sides of the core. The decorative panel (1) is rectangular with four edges. The opposite edges (7, 8) on the short sides and two opposite edges (7’, 8’) on the long sides. Along the cross section A-A indicated in figure 7 the coupling parts on the long sides would show up, represented for example by the figures 3 and 4. Along the cross section B-B the coupling parts on the short sides would be shown, represented by the other figures of the application.

[0092] It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.

[0093] The ordinal numbers used in this document, like “first”, “second”, “third” and “fourth”, are used only for identification purposes. Hence, the use of the expression “third coupling profile” does therefore not necessarily require the co-presence of a “first coupling profile”. And likewise, the use of the expressions “third locking element” and “second locking element” does therefore not necessarily require the co-presence of a “first locking element”. By "horizontal", it is meant as a direction which extends parallel to a plane defined by the tile panel, and which may intersect a core layer of the tile panel. By “vertical”, it is meant as a direction which is perpendicular to said plane defined by the tile panel. By "complementary" coupling profiles, it is meant that these coupling profiles of adjacent tile panels can cooperate with each other. However, to this end, the complementary coupling profiles do not necessarily have to have fully complementary forms (inverted designs). By “proximal side”, it is meant a side which is positioned closest to a body of the tile panel, while by “distal side”, it is meant as a side which is positioned farther from a body of the tile panel than said proximal side. The proximal side may face said tile panel body, while the distal side may face away from said tile panel body.

[0094] In the above, the expression “PEF” may selectively be replaced by at least one or more other furan resins. The expression “PET” may selectively be replaced by at least one other suitable condensation polymer, in particular polyester and / or by a copolymer of PET and / or derivate from PET, such as PETG ((polyethylene terephthalate glycol), wherein the PET copolymer, for example, comprises, as comonomer, at least one comonomer chosen from the group consisting of: diethylene glycol (DEG), cyclohexanedimethanol (CHDM), isophthalic acid (IPA), naphthalene acid (NDC), and mixtures of at least two of these comonomers. PETG is an adaptation of PET, where the ‘G’ stands for glycol, which is added at a molecular level to offer different chemical properties and is therefore considered as copolymer of PET. Compared to (virgin or recycled) PET, (virgin or recycled) PETG has greater strength and durability, as well as being more impact resistant and better suited to higher temperatures, and is therefore a suitable alternative to PET.

[0095] The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof.

Claims

Claims1. Decorative panel, in particular a decorative floor panel, decorative ceiling panel, or decorative wall panel, comprising:• at least one core layer, and• a decorative top structure directly or indirectly affixed to a top surface said core layer; wherein said at least one core layer comprises at least one furan resin and said decorative top structure preferably comprises at least one furan resin.

2. Decorative panel according to claim 1 , wherein said furan resin is a 2,5- furandicarboxylic acid (FDCA) based furan resin.

3. Decorative panel according to claim 1 or 2, wherein said furan resin is a poly(alkylene 2,5-furandicarboxylate).

4. Decorative panel according to any of the preceding claims, wherein at least one furan resin is selected from the group consisting of: polyethylene 2,5-furandicarboxylate) (PEF), polypropylene 2,5-furandicarboxylate) (PPF), poly(butylene 2,5-furandicarboxylate) (PBF), poly(1 ,4-cyclohexanedimethylene 2,5-furandicarboxylate) (PCHDMF), poly trimethylene furan dicarboxylate) (PTF), poly (neopentyl 2,5-furandicarboxylate) (PNF), poly(hexamethylene 2,5-furandicarboxylate) (PHMF), poly(octamethylene 2,5-furandicarboxylate) (POMF), and poly(decamethylene 2,5-furandicarboxylate) (PDMF).

5. Decorative panel according to any of the preceding claims, wherein said decorative top structure is free of polyethylene 2,5-furandicarboxylate) (PEF), and wherein said at least one core layer is optionally free of polyethylene 2,5- furandicarboxylate) (PEF).

6. Decorative panel according to any of the preceding claims, wherein at least one furan resin is a furan based copolymer, preferably at least one copolymerchosen from the group consisting of: polyethylene 2,5-thiophenedicarboxylate-co- 2,5-furandicarboxylate) (PEThF), poly(hexamethylene 2,5-furandicarboxylate) (PHMF), poly(octamethylene 2,5-furandicarboxylate) (POMF), poly(decamethylene 2,5-furandicarboxylate) (PDMF), polyethylene terephthalate-co-2,5- furandicarboxylate) (PETF), poly(butylene succinate-co-2,5-furandicarboxylate) (PBSF), poly(trimethylene terephthalate-co-2,5-furandicarboxylate) (PTTF), Poly(lactic acid-co-2,5-furandicarboxylate) (PLA-F), Polyethylene glycol-co-2,5- furandicarboxylate) (PEGF), and polycarbonate-furandicarboxylate (PC-F).

7. Decorative panel according to any of the preceding claims, wherein said at least one core layer and / or said decorative top structure comprises a plurality of different furan resins.

8. Decorative panel according to any of the preceding claims, wherein said at least one core layer and / or said decorative top structure comprises a blend of at least one 2,5-furandicarboxylate-based furan resin and at least one other furan resin, preferably selected from the group consisting of: poly(furfuryl alcohol) (PFA), poly(furanamide) (PFAm), poly(furfuryl methacrylate) (PFM), poly(furfuryl isocyanurate) (PFI), poly(2,5-furandimethylene carbonate) (PFC), poly(furfuryl acrylate) (PFAc), furan-based polyurethanes (FPU), poly(furfuryl carbonate) (PFC), furan-based epoxy resins.

9. Decorative panel according to any of the preceding claims, wherein said at least one core layer and / or said decorative top structure comprises a blend of at least one furan resins and at least one other polymer, wherein said other polymer is preferably selected from the group consisting of: polyethylene terephthalate) (PET), polyethylene 2,6-naphthalate) (PEN), poly(L-lactic acid) (PLA) and polycarbonate (PC), PBS, PE, PP, TPU, PETG, at least one other furan-based polymers, and mixtures thereof.

10. Decorative panel according to any of the preceding claims, wherein said at least one core layer and / or said decorative top structure comprises at least one biobased furan resin.11 . Decorative panel according to any of the preceding claims, wherein said at least one core layer and / or said decorative top structure comprises at least one recycled furan resin.

12. Decorative panel according to any of the preceding claims, wherein the panel comprises a plurality of laminated core layers, wherein at least one core layer, preferably each core layer comprises at least one furan resin.

13. Decorative panel according to any of the preceding claims, wherein the panel comprises three laminated core layers in an A-B-A configuration, wherein the outer layers (A) have the same composition, and wherein the inner layer (B) has a different composition, and wherein at least one core layer comprises at least one furan resin.

14. Decorative panel according to any of the preceding claims, wherein the core layer comprises at least one inorganic filler, preferably chosen from the group consisting of: wherein the core layer and / or decorative top structure comprises at least one filler selected from the group consisting of silica (SiO2), calcium carbonate (CaCO3), aluminium hydroxide (ATH), talc, glass fibers, kaolin clay, and barium sulphate (BaSO4), and / or organic filler, such as wood particles and / or cellulose.

15. Decorative panel according to claim 14, wherein the amount of filler in the core layer is at least 50 percent by weight of the core layer, preferably in an amount of between 60 and 80 percent by weight of the core layer.

16. Decorative panel according to claim 14 or 15, wherein the core layer comprises at least one furan resin, and wherein the amount of filler in the core layer is at least 1 .5 times the amount of furan resin of said core layer.

17. Decorative panel according to any of the preceding claims, wherein the core layer comprises at least one lubricant, wherein said lubricant is preferably configured to withstand temperatures of at least 270 degrees Celsius, more preferably at least 320 degrees Celsius.

18. Decorative panel according to claim 17, wherein said lubricant is present in an amount of less than 1 percent by weight of the core layer.

19. Decorative panel according claim 17 or 18, wherein the core layer comprises at least one lubricant formed by silicone oil, preferably in an amount of less than 1 percent by weight of the core layer.

20. Decorative panel according to any of the preceding claims, wherein the decorative top structure comprises a primer layer applied onto the top surface of the core layer, and at least one further layer applied onto said primer layer.21 . Decorative panel according to any of the preceding claims, wherein the decorative top structure comprises at least one basecoat layer, directly or indirectly, applied onto the top surface of the core layer, and at least one further layer applied onto said basecoat layer.

22. Decorative panel according to any of the preceding claims, wherein the decorative top structure comprises at least one decorative layer, directly or indirectly, applied onto the top surface of the core layer, and preferably at least one further layer, such as a wear layer and / or anti-scratch layer, applied onto said decorative layer.

23. Decorative panel according to claim 22, wherein the decorative layer is a digitally printed decorative layer.

24. Decorative panel according to claim 22, wherein the decorative layer is formed by a veneer layer or by a decorative film.

25. Decorative panel according to any of claims 22-24, wherein a top surface of the decorative top structure is provided with a relief pattern, wherein said relief pattern is preferably aligned with a decorative image of the decorative layer.

26. Decorative panel according to any of claims 22-25, wherein the decorative top structure comprises at least one decorative layer, directly or indirectly, applied onto the top surface of the core layer, and at least one wear layer and / or anti-scratch layer, applied onto said decorative layer, wherein said wear layer and / or anti-scratch layer comprises at least one furan resin.

27. Decorative panel according to any of the preceding claims, wherein the panel comprises a backing layer attached, directly or indirectly, to a bottom surface of the core layer, wherein the backing layer preferably comprises furan resin.

28. Decorative panel according to any of the preceding claims, wherein the panel comprises at at least one pair of opposing side edges complementary coupling profiles allowing intercoupling of adjacent decorative panels.

29. Core layer intended for use or use of a core layer in a decorative panel according to any of the preceding claims, wherein said core layer comprises at least one furan resin.

30. Method for producing a decorative panel, in particular a decorative panel according to any of claims 1-28, comprising the steps of: a) preparing or providing at least one furan resin, b) optionally mixing said at least one furan resin with one or more additive, c) loading said at least one furan resin, optionally mixed with one or more additive, in an extruder, preferably a twin screw extruder; d) extruding said mixture by said extruder, preferably at a temperature between 270 and 320 degrees Celsius, thereby forming an extruded core layer, e) cooling, preferably actively cooling, said extruded core layer to a temperature below 100 degrees Celsius, f) applying a decorative top structure on top of said core layer thereby forming the decorative panel.

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