Panel and method of producing a panel

Abstract

The invention relates to a panel, in particular a floor panel, wall panel, ceiling panel or building panel, comprising at least one core layer comprising at least one composite material; and at least one surface layer; wherein the at least one composite material comprises textile waste, at least one mineral material and / or at least one polymeric binder. The invention also relates to the production of such panel.

Description

[0001] Panel and method of producing a panel

[0002] The invention relates to a panel, in particular a floor panel, wall panel, ceiling panel or building panel. The invention also relates to the production of such panel.

[0003] In modern times, the construction industry encounters numerous challenges primarily stemming from the rise in urban population and depletion of natural resources essential for construction / building material production. Moreover, heightened awareness regarding climate change necessitates companies to reconsider their approaches in creating sustainable construction materials. A key strategy being considered by numerous companies in the present times is recycling as it does not only solve the problem with dwindling natural resources used to facilitate production but also helps in reducing carbon footprint and mitigating greenhouse gas emissions. In view thereof, efforts have been made over time to develop technologies that cater to the production of useful and low-cost products from waste. While recycling is environmentally beneficial, it is not always economically feasible. This is why efforts are being made to improve recycling technologies and develop policies that encourage recycling, such as extended producer responsibility (EPR) programs and deposit-refund systems.

[0004] When it comes to the production of bulk products, like decorative panels, there is a serious interest in using for example organic waste and recycled plastics within such products. However, several challenges are encountered in this process. While the integration of sustainable materials to the production of decorative panels offers many environmental benefits, it is crucial to ensure that products made from these materials, including decorative panels, meet the necessary standards to ensure safety and performance. One of the primary challenges being faced is achieving strong interfacial bonding when integrating organic waste into different polymer matrices being used in the production of panels such as floor panels, wall panels or ceiling panels. The organic waste and the polymer matrices may have different physical and chemical properties, which can lead to weak interfacial bonding. The organic waste may not adhere to the other materials used in floor panel production, which can lead to uneven distribution of the organic waste within the floor panels. Consequently, the quality and performance of the resulting panels are not guaranteed as the structural integrity and durability of the resulting floor panels may not be as desired.

[0005] Another significant challenge pertains to the presence of impurities within recycled plastics. These impurities, which may include contaminants or residues from previous uses, pose several obstacles. Firstly, they can have adverse effects on both the performance and appearance of, for example, the floor panels produced from recycled plastics. For instance, impurities might weaken the structural integrity of the panels or cause inconsistencies in their surface texture and colour. Secondly, the presence of impurities can complicate the manufacturing process itself. Contaminants may require additional processing steps to remove or mitigate their impact, leading to increased production time and costs. Furthermore, addressing impurities effectively necessitates careful quality control measures to ensure that the resulting floor panels meet the desired standards for performance, aesthetics, and durability.

[0006] It is therefore an object of the invention to provide a panel and production method thereof which addresses the challenges encountered when incorporating waste materials and / or recycled materials in the final products.

[0007] The invention provides thereto a panel, in particular a floor panel, wall panel, ceiling panel or building panel, comprising at least one core layer comprising at least one composite material, and preferably at least one surface layer attached to the at least one core layer, wherein at least one composite material comprises at least one waste material, at least one refuse material and / or at least one recycled material. The at least one core layer preferably comprises at least 10 wt%, preferably at least 30 wt%, and more preferably at least 50 wt% of at least one waste material, such as textile waste. The composition of the at least one composite material preferably comprises at least 5 wt%, and preferably at least 10 wt% of at least one fibrous and / or particulate material and / or at least 10 wt% and preferably at least 25 wt% of at least one mineral material and / or at least 30 wt% and preferably at least 40 wt% of at least one polymer material, in particular based on a total weight of the composite material. Preferably, the at least one composite material comprises textile waste, in particular at least 10 wt% of textile waste in particular based on a total weight of the composite material. The at least one composite material preferably comprises at least 25 wt% of at least one mineral material and / or at least 40 wt% of at least one polymer material in particular based on a total weight of the composite material.

[0008] The at least one composite material preferably comprises at least 10 wt% of fibrous material.

[0009] The panel according to the present invention has several benefits. The use of a core layer comprising at least one composite material which comprises at least one waste material, at least one refuse material and / or at least one recycled material results in that the carbon intensity of the panel as produced is significantly lower than the carbon intensity of panel produced using virgin materials.

[0010] In a preferred embodiment, the at least one composite material comprises at least 25 wt% of at least one mineral material and / or at least 40 wt% of at least one polymer material and / or at least 10 wt% of at least one fibrous material in particular based on a total weight of the composite material. The use of at least one mineral materials as filler material further reduces the need for the use of (virgin) plastics. This is not only beneficial from an economical point of view, but also from an environmental point of view. Mineral fillers exhibit a lower environmental impact compared to polymers. Further, the panel's mineral composition within the specified range gives the core layer a sufficient amount of flexibility and rigidity such that the panel’s structural and dimensional integrity are not negatively affected. Polymers are often derived from non-renewable fossil fuels, which are rather impactful for the environment in a negative sense, and wherefore it can be desired to minimize the polymer content, if possible. Mineral materials are typically obtained from natural sources and are relatively easy to process wherefore their carbon emissions per unit produced is relatively low when compared to alternative materials. Further, the use of mineral material in the core layer can positively contribute to the durability, thermal stability and / or strength of the panel. However, it is also possible that a lower mineral content is present in the composite material. In another possible embodiment, the composite material may comprise in up to 60 wt% of at least one mineral material, in particular based on a total weight of the composite material. At least one waste material may be textile waste. In a possible embodiment, the at least one composite material comprises textile waste. The at least one composite material preferably comprises at least 10 wt% of textile waste, in particular based on a total weight of the composite material. Within the context of the present invention, textile waste comprises for example at least one textile based material. It is also possible that the textile waste comprises fabric waste or is formed by fabric waste. Alternatively, and / or additionally textile waste may comprise wool waste. Preferably, at least part of the textile waste is post consumer clothing waste and / or industrial textile and / or clothing waste. It is conceivable that at least one composite material comprises up to 30 wt% of textile waste, in particular up to 40 wt% of textile waste, more in particular up to 50 wt% or 60 wt% of textile waste, in particular based on a total weight of the composite material. The amount of textile waste which can be applied depends at least partially on the composition of the textile waste. It is possible that at least one composite material comprises up to 75 wt% or even 90 wt% or alternatively 100 wt% of textile waste, in particular based on a total weight of the composite material.

[0011] Non-limiting example of waste materials which can be applied within the context of the present invention are municipal waste, carpet waste, textile waste and / or postconsumer waste. Where it is mentioned that textile waste is applied, also municipal waste, carpet waste and / or post-consumer waste can be meant. Alternatively, agricultural waste such as cork dust, rice husk and the like could be used as waste material.

[0012] At least one surface layer can for example comprise a visual and / or tactile pattern or texture.

[0013] It is also conceivable that part of the polymer content of the composite material is formed by the polymer content of the textile waste. Hence, it is conceivable that the composite material comprises in the range of 35-45 wt% of mineral material and in the range of 55-65 wt% of textile waste. The textile waste can comprise a polymer content which acts as polymer binder within the composite material. It is also conceivable that at least one further polymer material is included in the composite material. This can be at least one virgin and / or recycled polymer. The virgin and / or recycled polymer can be applied as polymer material and / or polymeric binder. At least one polymer material may comprise at least one particulate material and / or at least one polymeric binder. It is also possible that at least one polymer material comprises at least one thermoplastic polymer and / or at least one thermosetting polymer. At least one polymeric binder could also be referred to as an encapsulating material. It is possible that at least one particulate material has a higher melting temperature than at least one polymeric binder. At least one particulate material can for example be a particulate polymer. Therefore the particulate material will typically not melt during the extrusion step, whereas the polymeric binder will melt. At least part of the particulate material will therefore be present as such in the final product. It is for example possible that at least part of the particulate material has a melting point above 220 degrees Celsius. Nonlimiting examples of such materials are polyester, polyethylene terephthalate (PET), nylon and / or polystyrene. At least one polymeric binder preferably has a melting point below about 220 degrees Celsius. Non-limiting examples of polymeric binders which can be applied within the present invention are polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), Ethylene-Vinyl Acetate (EVA), nylon and / or acrylic. At least one fibrous material preferably has a melting temperature above about 220 degrees Celsius. At least part of the fibrous material and / or particulate material will therefore typically be present as such in the final product. At least one fibrous material may for example comprise polyester, polyethylene terephthalate, nylon, polystyrene, cotton and / or cellulose.

[0014] The composite material may comprise at least 10 wt%, in particular at least 15 wt% and more in particular 20 wt% of at least one fibrous material in particular based on a total weight of the composite material. It is also possible that at least one composite material comprises at least 20wt%, preferably at least 40wt%, of at least one fibrous material. The fibrous material may comprise natural fibres and / or synthetic fibres. It is possible that at least one fibrous material comprises 20-40 wt% of at least partially synthetic fibres and / or at least partially natural fibres, 20-40 wt% of polyester, and / or 10-30 wt% of at least one polyolefin, in particular based on a total weight of the composite layer. At least part of the synthetic fibres may comprise polyamide.

[0015] The at least one composite material, and in particular the composition thereof, may comprise in the range of 10-30 wt%, preferably 15-25 wt% of at least one polyolefin, in particular based on a total weight of the composite material. At least one polyolefin may for example comprise polypropylene and / or polyethylene.

[0016] Within the context of the present invention the panel may be a decorative panel. The panel can for example be a floor panel, a wall panel, a ceiling panel and / or a building panel.

[0017] The panel according to the invention benefits of a good sustainability. The panel in particular has a carbon intensity of less than 5kg CO2eq or CO2-equivalent. The panel has more in particular a carbon intensity of less than 5 kg CO2eq / m2 based on a comprehensive Life Cycle Assessment (LCA) using a time horizon of 20 years (GWP20 - IPCC AR5). This is relatively low value compared to equivalent products which are based on merely virgin materials. The use of at least one waste, refuse and / recycled material reduces reliance on non-renewable resources and helps manage waste by diverting it from landfills. Specifically, the carbon intensity of the panel according to the invention after production is less than 5kg CO2eq / m2. The / m2emission benefit in the composite material forming a core layer of a panel by using waste material, such as textile waste, as a component of the composite material is more than -1 kg CO2eq / m2. In practice, the emission of the production process of a panel according to the present invention is about 0.5kg CO2eq / m2. These values are based on a comprehensive Life Cycle Assessment (LCA) using a time horizon of 20 years (GWP20 - IPCC AR5).

[0018] The composition of the textile waste strongly depends on the origin of the textile waste. In case the textile waste originates from post-consumer clothing. It is for example possible that the textile waste comprises polyester, polypropylene, cotton and / or metals. It is also possible that the textile waste comprises cellulose, at least one polyester and / or at least one polyolefin. Preferably, at least part of the textile waste, if applied, has a composition comprising at least 50 wt% of polyester and / or at least 10 wt% of cotton. It is also conceivable that at least part of the textile waste comprises in the range of 40-90 wt% of polyester, preferably in the range of 50-75 wt% of polyester, in particular based on the total weight of the textile waste material. At least part of the textile waste could for example comprise in the range of 10-30 wt% of cotton, in particular in the range of 15-25 wt% of cotton, more in particular about 20 wt% of cotton, in particular based on the total weight of the textile waste material. Preferably, the textile waste comprises at least 1 wt% polypropylene and / or at least 1 wt% metal. Metal could for example arise from buttons, studs and / or zippers present in the textile waste. The at least one composite material may for example also comprise in the range of 0.1-10 wt%, preferably 1 -5 wt% of at least one metal and / or at least one ceramic or metal, for example but not limited to ferric oxide. The metal and / or ceramic material may originate from buttons, zippers and / or the like.

[0019] It is possible that at least one composite material comprises in the range of 10 wt% to 50 wt% of at least one mineral material and in the range of 50 wt% to 90 wt% of textile waste, based on a total weight of the composite material. Considering the core layer as such, the composition of the core layer will strongly depend on the type of textile waste and / or mineral filler applied. It is for example possible that the composite material and / or the core layer comprises in the range of 20-40 wt% of cellulose, in the range of 20-40 wt% of polyester, in the range of 10-30 wt%, preferably 15-25 wt% of at least one polyolefin, in the range of 10-40 wt% of at least one mineral material, optionally in the range of 0.1 -5 wt% of processing agents and / or optionally in the range of 0.1 -10 wt%, preferably 1-5 wt% of at least one metal. The wt% are in particular based on a total weight of the composite material. The mineral material can for example comprise calcium carbonate, magnesium carbonate, calcium magnesium carbonate, talc, chalk, calcium sulfate alumina trihydrate (ATH), magnesium dihydroxide (MDH), a metal oxide and / or combinations thereof. Possible processing agents which could be applied are at least one antioxidant, paraffin, titanium dioxide, plasticizers, elastomers, plastomers and / or combinations thereof. This may improve the fire resistance and smoke density test results required for use in commercial applications, such as EN 13501 or ASTM E84.The at least one metal material can for example be ferric oxide. It is possible that at least one metal originates from buttons, studs and / or zippers.

[0020] The fibrous material typically comprises fibres. Possibly, at least part of the fibres has an average length of at least 2 mm. It is also conceivable that at least part of the fibres has an average length in the range of 0.1 to 3 mm, preferably in the range of 0.5 to 2 mm, more preferably in the range of 0.75 to 1 .5 mm. It is possible that the composite material comprises textile fibres. It is possible that the fibres are visible with the naked eye within the core layer. Possibly, at least part of the textile waste comprises textile fibres, wherein at least part of the textile fibres has an average length of at least 2 mm. It is also conceivable that at least part of the textile fibres have an average length in the range of 0.1 to 3 mm, preferably in the range of 0.5 to 2 mm, more preferably in the range of 0.75 to 1 .5 mm. It is possible that at least part of the textile waste has a fibrous structure and / or a porous structure. The thickness of the fibres may vary depending on the types of textile applied. At least part of the textile waste may comprise at least one particulate material. Therefore the core layer and / or the composite material may comprise at least one particulate material. At least part of at least one particulate material preferably comprising particles having an average particle size of at least 0.1 mm. It also possible that at least part of the particulate material has a particle size in the range of 0.1 to 0.5 mm. It is also possible that at least part of the textile waste comprises particles having an average particle size of at least 0.1 mm. At least part of the textile waste may comprise particles having an average particle size in the range of 0.2 to 2 mm, preferably in the range of 0.5 to 1 .5 mm. At least part of the particles may be metal particles and / or polymer particles. At least part of the polymer particles may be thermosetting polymers.

[0021] It is conceivable that at least part of the textile waste is encapsulated by at least one polymer material, for example a polymeric binder. At least part of the polymer material may act as a polymeric binder. It is for example possible that at least part of the textile fibres and / or at least part of the particles is encapsulated by at least one polymeric binder. It is also possible that at least part of the fibrous material is encapsulated by at least one polymer material. This will improve dispersion of the fibres and / or particles within the composite material and prevent agglomeration thereof. This is beneficial for the strength and uniformity of the material. The polymer binder can also provide a protective function for the fibres and / or particles. At least part of the textile waste and / or fibrous material may be dispersed within at least part of the core layer. It is also possible that such embodiments prevent phase separation of the components of the composite material.

[0022] Preferably, the at least one composite material comprises at least 15 wt% of at least one polymer material, for example at least one polymeric binder. It is also conceivable that the composite material comprises in the range of 20 to 40 wt% of at least one polymer material or polymeric binder. At least one composite material preferably comprises polyethylene, preferably high density polyethylene. At least one polymer material may comprise polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), ABS (acrylonitrile butadiene styrene), PU (polyurethane), polyamides (PA), acrylonitrile- styrene-butyl acrylate (ASA) and / or ethylene vinyl alcohol copolymers (EVOH). At least one composite material preferably comprises at least one polymer matrix. It is conceivable that at least one polymer matrix is formed by any of the abovementioned polymers. At least one polymer and / or polymeric binder may be a virgin polymer and / or at least polymer may be a recycled polymer. It is also possible that at least one polymer is a biopolymer. If at least one biopolymer is applied, these are preferably derived from nontoxic, bio-renewable feedstocks. It is also conceivable that the at least one biopolymer is a bio-based organic polymer comprising polylactide-based materials.

[0023] At least one mineral material may comprise magnesium oxide, magnesium carbonate, magnesium oxysulphate, magnesium oxychloride cement (MOC), magnesium chloride (MgCI2), magnesium sulphate (MgSO4), Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite mineral, stone, chalk, clay, calcium silicate and / or talc. These material were found to be suitable filler materials to apply in combination with textile waste.

[0024] The composite material may optionally comprise natural fibres, reinforcing additives and / or biomass waste. At least one core layer, and in particular at least one composite material, may further comprise at least one natural material chosen from the group of: cellulose, hemicellulose, lignin, bast fibre, animal fibre, cork and / or combinations thereof. These materials could further enhance the material characteristics of the panels. These material(s) could also further contribute to the environmentally friendly character of the panels. At least one additive could also contribute to the strength of the interfacial bonding of (textile) waste to the at least one binder material.

[0025] It is possible that at least one waste material is applied comprising cellulose and hemicellulose and / or lignin substances which comprise woody biomass, softwood and hardwood species, plant biomass, agricultural residues, wheat straw and / or combinations thereof. Fibre bast components, if applied, may be derived from plant’s stem such as hemp, flax, kenaf, jute, or combinations thereof. Animal fibre may comprise wool, silk, alpaca, mohair, cashmere, and the like. The composite material may further comprise suberin substances. Said suberin substances may comprise cork, barks from plants such as eucalyptus grandis and mimosa scabrella, potato skin, and / or combination thereof.

[0026] At least one core layer is preferably an extruded core layer. A benefit of a core layer being formed via an extrusion process is that the panels can be produced in a relatively cheap way. Further, an extruded core layer is found to be advantageous in regard to the rigidity obtained, as well as being capable of forming a fusion bonding with the top layer, if applied. Here, the extrusion process and the fusion process can be performed simultaneously during production of the panel.

[0027] It is also possible that at least one core layer is a co-extruded core layer, comprising a structural core component and at least one further core component, said structural component comprising at least one composite material comprises at least 10 wt%, and preferably at least 50 wt% of at least one waste material, in particular textile waste and wherein the composition of the at least one composite material comprises at least 10 wt% of at least one fibrous material, at least 25 wt% of at least one mineral material and at least 40 wt% of at least one polymer material. At least one further core component could be a plain core component. At least one further core component can be at least one surface layer. It is also possible that at least one core layer and at least one surface layer are co-extruded. Applying a co-extrusion process, preferably a single manifold co-extrusion process, is beneficial as it will enable equalization of irregularities and / or inconsistencies of the core layer which may occur due to the waste material, and in particular the fibrous and / or particulate content thereof. Alternatively, at least one surface layer can be attached to the at least one core layer via hot pressing and / or lamination.

[0028] Alternatively, at least one core layer can be a moulded core layer. In another possible embodiment, it is conceivable that the core layer is formed via hot- pressing. It is also conceivable that the core layer is formed via a curing process.

[0029] It is possible that further additives are applied within the core layer and / or composite material. It is possible that at least one core layer, and in particular at least one composite material, comprises at least one chain extender and / or at least one coupling agent. This may further enhance the material characteristics of the panel, and prevent that the textile waste, if applied, has a negative impact on the strength and / or hardness of the panel. The addition of coupling agent may augment the adhesion of the waste material to the binder material. At least one coupling agent may be applied in the form of maleic anhydride-grafted polymers, for example polyethylene-graft-maleic anhydride (PE-g-MA). The presence of a coupling agent is deemed to enhance the adhesion between the (textile) waste and the polymer matrix. The composite material may further comprise chitosan which can enhance stiffness, strength and reduce surface hydrophilicity, also exhibits antibacterial properties. Possibly, the at least one core layer comprises at least 0.1 wt% of at least one chain extender and / or 0.1 wt% of at least one coupling agent, in particular based on the total weight of the at least one composite material. At least one coupling agent, if applied, may comprises at least one organofunctional compound.

[0030] An upper surface of the at least one core layer preferably has a Shore D hardness of at most 70 and / or at least part of an upper surface of the at least one surface has a Shore D hardness of at most 75. It is for example possible that an upper surface of the at least one core layer has a Shore D hardness in the range of 40 to 70, preferably in the range of 50 to 65. An upper surface of the at least one surface layer may have a Shore D hardness in the range of 50 to 75, preferably in the range of 55 to 65. The panel’s high hardness ensures it will pass scratch resistance testing for laminate flooring, which is beneficial if applied for this purpose. Hence, this embodiment enables enhanced durability and resistance to wear and tear.

[0031] The panel may have a tensile strength of at least 2.5 Mpa and / or a tensile modulus of at least 600 Mpa. The panel could also have a flexural modulus of at least 650 Mpa and / or a flexural strength of at least 5 Mpa. The density of the at least one core layer is preferably at least 1200kg / m3, preferably at least 1400kg / m3. The panel according to the invention preferably has a relatively high stiffness and significant load-bearing capacity, making it resistant to bending and deformation under stress. The panel according to the invention is durable and has a good impact-resistant making it suitable for structural and load-bearing applications. In an alternative embodiment, it is conceivable that at least part of the core layer is foamed.

[0032] The panel preferably comprises at least one pair of opposing side edges, said pair of opposing side edges comprising complementary coupling parts configured for mutual coupling of adjacent panels. Hence, the core layer of the panel according to the present invention may comprise at least one pair of opposing (side) edges, said pair of opposing (side) edges comprising complementary coupling parts configured for mutual coupling of adjacent panels. The coupling parts may form part of the core layer. The coupling parts of the panel may for example be interlocking coupling parts, which are preferably configured for providing both horizontal and vertical locking. Interlocking coupling parts are coupling parts that require elastic deformation, a click or a movement in multiple directions to couple or decouple the parts with or from each other. Any suitable interlocking coupling parts as known in the art could be applied. A non-limiting example is an embodiment wherein a first edge of said first pair of opposing side edges comprises a first coupling part, and wherein a second edge of said first pair of opposing side edges comprises a complementary second coupling part, said coupling parts allowing a plurality of panels to be mutually coupled; wherein the first coupling part comprises a sideward tongue extending in a direction substantially parallel to a plane defined by the panel, and wherein the second coupling part comprises a groove configured for accommodating at least a part of the sideward tongue of another panel, said groove being defined by an upper lip and a lower lip. It is conceivable the complementary coupling parts require a downward scissoring motion when engaging, or are locked together by means of a horizontal movement. It is further conceivable that the interconnecting coupling parts comprise a tongue and a groove wherein the tongue is provided on one side edge of one pair of opposing side edges, and the groove is provided on the other side edge, or an adjacent side relative to that of the tongue, of the same pair of opposing side edges. Such a design of a coupling mechanism is well-known in the art and has proven highly suitable for panels for floor coverings such as a floating floor.

[0033] The panel according to the invention may further comprise at least one surface layer and / or top layer, preferably a decorative top layer. The at least one surface layer can for example be a decorative top layer. Such decorative top layer may for example be a high pressure laminate (HPL), a plurality of impregnated layers containing lignocellulose, a wood veneer, a thermoplastic layer containing at least a decorative layer and optionally a protective top layer, a stone veneer or the like, and / or a combination of said decorative layers. The decorative top layer may possibly also comprise at least one ply of cellulose-based layer and a cured resin, wherein the cellulose-based layer is preferably paper or kraft paper. Said ply of cellulose-based material may also be a veneer layer adhered to a top surface of the core layer. The veneer layer is preferably selected from the group consisting of wood veneer, cork veneer, bamboo veneer, and the like. Other decorative top layers that can be considered according to the invention include ceramic tiles or porcelain, a real stone veneer, a rubber veneer, a decorative plastic or vinyl, linoleum, and decorative thermoplastic film or foil which may be laminated with a wear layer and optionally a coating. Examples of thermoplastics may be PP, PET, PVC and the like. It is also possible to provide on the top facing surface of the upper core layer an optional primer and print the desired visual effect in a direct printing process. The decorative layer can receive a further finishing with a thermosetting varnish or lacquer such as polyurethane (PUR) or a melamine based resin. It is also conceivable that the panel comprises a top layer consisting of a ceramic tile. Such ceramic tile may for example be attached to the top surface of the core layer by means of an adhesive, such as but not limited to polyurethane. It is also conceivable that the top layer is made of a ceramic and / or stone material.

[0034] It is also possible that the panel comprises multiple surface layers. It is for example possible that at least one core layer is enclosed between at least two surface layers. It is also possible that the at least one core layer is substantially encapsulated by at least one surface layer. It is possible that at least one surface layer substantially encloses the coupling parts of the panel, if applied. The at least one surface layer may form a shell around the at least one core layer. It is possible that the at least one surface layer is at least partially transparent. It is preferable that the at least one surface layer comprises at least one polymeric material which is also present in the at least one core layer. This has the advantage of facilitating recycling at the end of the product life cycle. It is preferable that the at least one surface layer comprises a polymeric binder with a melt flow index (MFI) of at least 5 g / 10min. This allows the at least one surface layer to encapsulate surface irregularities of the core layer, particularly a core layer comprising a composite comprising particulate components and / or at least one fibrous and / or particulate material. In one particularly advantageous embodiment, the at least one surface layer comprises at least one polymeric binder chosen from the group of HDPE, PP, EVA, nylon, acrylic, PE, PVC, or any combination thereof, and at least one mineral filler chosen from the group of talc, limestone, calcium carbonate, ATH, MDH, or any combination thereof.

[0035] In an alternative embodiment, the invention relates to a panel, in particular a floor panel, wall panel, ceiling panel or building panel, comprising at least one core layer, and at least one surface layer attached to the at least one core layer, wherein at least one core layer is made of at least one waste material, at least one refuse material and / or at least one recycled material. The waste material can for example be or comprise textile waste. Any of the examples and embodiments given in the present application apply to this embodiment.

[0036] The invention also relates to a method of producing a panel, in particular a floor panel, wall panel, ceiling panel or building panel, said method comprising the steps of providing at least one mineral material and providing at least one waste material, in particular textile waste, extruding the at least one mineral material and at least one waste material, in particular the textile waste, into at least one core layer comprising a composite material and applying at least one surface layer onto at least one surface of at least one core layer. The at least one composite material preferably comprises at least 10 wt% of textile waste, preferably at least 30 wt%, more preferably at least 50 wt%, and the composition of the at least one composite material preferably comprises at least 10 wt% of at least one fibrous material and / or at least 25 wt% of at least one mineral material and / or at least 40 wt% of at least one polymer material, in particular based on a total weight of the composite material. The invention also relates to a method of producing a panel, in particular a floor panel, wall panel, ceiling panel or building panel, comprising the steps of providing pellets comprising waste, in particular textile waste and at least one polymer material or polymeric binder, extruding the pellets into at least one core layer; and preferably applying at least one decorative top layer onto an upper surface of at least one core layer. The method(s) according to the invention may result in the provision of a panel according to the present invention. The embodiments described for the method(s) may apply to the panel(s) and vice versa. The ratio of the at least one (textile) waste material to the at least one polymer material and / or mineral material ensures that the end product meets industry standards. The method enables that the product produced meets the industry standards in relation to structural integrity, durability and fire resistance.

[0037] It is preferred that at least part of at least one waste material is provided in the form of pellets. The textile waste can for example be provided in pellets. It s for example possible that at least part of the pellets comprises textile waste. In this way, the pellets could be easily processed into a core layer, for example via extrusion. It is conceivable that pellets of textile waste and optionally polymer pellets and / or at least one (mineral) filler are formed into a core layer. The filler can be at least one mineral material. The polymer material in the core layer can originate from the pellets comprising textile waste and / or from the provision of at least one polymer material to the extruder. The melt flow index of the at least one polymer material or polymer binder is preferably at least 5g / 10min. This will positively contribute to the processability of the composite material. The melt flow index of at least one polymer allows the polymer to flow more readily around the refuse material, such as textile waste, in particular the fibres and / or particulates thereof, ensuring better dispersion and uniform distribution.

[0038] The carbon intensity of the panel after production is in particular less than 5kg CO2eq / m2. This is relatively low value compared to equivalent products which are based on merely virgin materials. The use of at least one waste, refuse and / recycled material reduces reliance on non-renewable resources and helps manage waste by diverting it from landfills. Specifically, the carbon intensity of the panel according to the invention after production is less than 5kg CO2eq / m2. It is conceivable that a carbon intensity of less than 1 kg CO2eq / m2, preferably even a negative carbon intensity is achieved by offsetting the carbon emissions produced during production with carbon negative materials such as refuse material. The emission benefit in the composite material forming a core layer of a panel by using waste material, such as textile waste, as a component of the composite material is less than -1 kg CO2eq / m2. In practice, the emission of the production process of a panel according to the present invention is about 0.5kg CO2eq / m2. These values are based on a comprehensive Life Cycle Assessment (LCA) using a time horizon of 20 years (GWP20 - IPCC AR5). At least part of the textile waste applied may have a composition comprising at least 50 wt% polyester and at least 10 wt% cotton. It is for example possible that the textile waste comprises at least 1 wt% polypropylene and / or at least 1 wt% metal. At least part of the pellets may comprise textile fibres. Preferably, at least part of the textile fibres has an average length of at least 2 mm. It is also conceivable that at least part of the textile fibres have an average length in the range of 0.1 to 3 mm, preferably in the range of 0.5 to 2 mm, more preferably in the range of 0.75 to 1 .5 mm. It is possible that at least part of the textile waste has a fibrous structure and / or a porous structure. The thickness of the fibres may vary depending on the types of textile applied. It is also possible that at least one (textile) waste material comprises at least one porous organic substance or at least one fibrous organic substance. The least one polymer material may comprise at least one polymeric binder and / or at least one particulate material, in particular at least one particulate polymer.

[0039] The waste material applied may comprise fibres. This will result in the composite core layer comprising at least one fibrous material. The fibrous material typically comprises fibres. Possibly, at least part of the fibres has an average length of at least 2 mm. It is also conceivable that at least part of the fibres has an average length in the range of 0.1 to 3 mm, preferably in the range of 0.5 to 2 mm, more preferably in the range of 0.75 to 1 .5 mm. At least part of the fibrous material may be polymeric fibrous material. At least part of the fibrous material may be natural and / or cellulosic material. At least part of at least one particulate material may be polymeric particulate material and / or at least part of at least one particulate material may be metallic particulate material. At least part of at least one particulate material may for example comprise copper.

[0040] Preferably, the method comprises the step of providing at least one mineral material, and wherein the mineral material and the pellets are extruded into at least one core layer. At least one mineral material may comprise magnesium oxide, magnesium carbonate, magnesium oxysulphate, magnesium oxychloride cement (MOC), magnesium chloride (MgCI2), magnesium sulphate (MgSO4), Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite mineral, stone, chalk, clay, calcium silicate and / or talc. At least one polymeric binder or polymer material may comprise polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), ABS (acrylonitrile butadiene styrene), PU (polyurethane), polyamides (PA), acrylonitrile- styrene-butyl acrylate (ASA) and / or ethylene vinyl alcohol copolymers (EVOH). Further additional ingredients are possible such as but not limited to a chain extender, a binder and / or a coupling agent. Hence, the method may include that at least one chain extender and / or at least one coupling agent are added. The extrusion can be a co-extrusion step.

[0041] In a beneficial embodiment, the method comprises the steps of providing textile waste, washing and / or drying at least part of the textile waste, shredding at least part of the textile waste, mixing at least part of the shredded textile waste with at least one polymer (material) and pelletizing the mixture of shredded textile waste and the at least one polymer (material). In this way, a useable initial extrudable material can be provided which could be applied to form a panel according to the present invention. It is possible that the textile waste is initially sorted and / or separated and then at least partially heated. At least part of the textile waste could for example be separated based on composition and / or density. The textile waste, and / or the formed pellets could for example be subjected to a temperature up to 220 degrees Celsius. This upper temperate limit may prevent that premature degradation or thermo-oxidative degradation occurs.

[0042] One possible embodiment composition of a core layer according to the present invention is:

[0043] Another non-limiting possible embodiment of a core layer or core composition according to the present invention is:

[0044] 20-40% of cellulose (preferably coming from cotton fibers or the like);

[0045] 20-40% of polyester (from polyester clothing);

[0046] 10-30%, preferably 15-25% of at least one polyolefin (polypropylene, polyethylene);

[0047] 10-40% of mineral content (calcium carbonate, magnesium carbonate, calcium magnesium carbonate, talc, chalc, calcium sulfate and the like);

[0048] 0.1-5% of processing agents (antioxidant, paraffin, titanium dioxide, plasticizers, elastomers, plastomers etc); and / or optionally 0.1 -10%, preferably 1-5% of at least one ceramic or metal (ferric oxide, preferably coming from buttons, zippers and the like).

[0049] The invention will be further elucidated based on the following non-limitative clauses.

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

[0051] - at least one core layer comprising at least one composite material; and

[0052] - at least one surface layer attached to the at least one core layer; wherein the at least one composite material comprises at least 50 wt% of textile waste; and / or wherein the composition of the at least one composite material comprises at least 10 wt% of at least one fibrous material, at least 25 wt% of at least one mineral material and / or at least 40 wt% of at least one polymer material, based on a total weight of the composite material. 2. Panel according to clause 1 , wherein the carbon intensity of the panel after production is less than 5kg CO2eq / m2 based on a comprehensive Life Cycle Assessment (LCA) using a time horizon of 20 years (GWP20 - IPCC AR5).

[0053] 3. Panel according to any of the previous clauses, wherein the textile waste has a composition comprising at least 50 wt% of polyester and at least 10 wt% of cotton.

[0054] 4. Panel according to any of the previous clauses, wherein the at least one composite material comprises in the range of 10-30 wt%, preferably 15-25 wt% of at least one polyolefin, based on a total weight of the composite material.

[0055] 5. Panel according to any of the previous clauses, wherein the at least one composite material comprises in the range of 0.1 -10 wt%, preferably 1-5 wt% of at least one metal.

[0056] 6. Panel according to any of the previous clauses, wherein at least one composite material comprises in the range of 25 wt% to 50 wt% of at least one mineral material and in the range of 50 wt% to 90 wt% of at least one mineral material, based on a total weight of the composite material.

[0057] 7. Panel according to any of the previous clauses, wherein at least part of fibrous material comprises fibres having an average length of at least 2 mm.

[0058] 8. Panel according to any of the previous clauses, wherein at least part of the composite material comprises at least one particulate material, said particulate material comprising particles having an average particle size of at least 0.1 mm.

[0059] 9. Panel according to any of the previous clauses, wherein at least part of the textile waste, in particular the fibrous material and / or particulate material, is encapsulated by at least one polymer material.

[0060] 10. Panel according to any of the previous clauses, wherein at least one polymer material comprises at least one polymeric binder. 11 . Panel according to any of the previous clauses, wherein the at least one surface layer comprises polyethylene, in particular high density polyethylene.

[0061] 12. Panel according to any of the previous clauses, wherein the at least one polymeric material comprises polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), ABS (acrylonitrile butadiene styrene), PU (polyurethane), polyamides (PA), acrylonitrile- styrene-butyl acrylate (ASA) and / or ethylene vinyl alcohol copolymers (EVOH).

[0062] 13. Panel according to any of the previous clauses, wherein the at least one mineral material comprises magnesium oxide, magnesium carbonate, magnesium oxysulphate, magnesium oxychloride cement (MOC), magnesium chloride (MgCI2), magnesium sulphate (MgSO4), Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite mineral, stone, chalk, clay, calcium silicate and / or talc.

[0063] 14. Panel according to any of the previous clauses, wherein the at least one core layer, and in particular the at least one composite material, comprises at least one natural material chosen from the group of: cellulose, hemicellulose, lignin, bast fibre, animal fibre, cork and / or combinations thereof.

[0064] 15. Panel according to any of the previous clauses, wherein the at least one core layer is an extruded core layer.

[0065] 16. Panel according to any of the previous clauses, wherein the at least one core layer and the at least one surface layer are co-extruded.

[0066] 17. Panel according to any of the previous clauses, wherein the at least one core layer, and in particular the at least one composite material, comprises at least one chain extender and / or at least one coupling agent.

[0067] 18. Panel according to any of the previous clauses, wherein an upper surface of the at least one core layer has a Shore D hardness of at most 70 and / or wherein at least part of an upper surface of the at least one surface layer has a Shore D hardness of at most 75. 19. Panel according to any of the previous clauses, wherein the panel has a tensile strength of at least 2.5 Mpa.

[0068] 20. Panel according to any of the previous clauses, wherein the panel has a tensile modulus of at least 600 Mpa.

[0069] 21 . Panel according to any of the previous clauses, wherein the panel has a flexural modulus of at least 650 Mpa.

[0070] 22. Panel according to any of the previous clauses, wherein the panel has a flexural strength of at least 5 Mpa.

[0071] 23. Panel according to any of the previous clauses, wherein the density of the at least one core layer is at least 1200 kg / m3, preferably at least 1400 kg / m3.

[0072] 24. Panel according to any of the previous clauses, wherein at least part of the at least one core layer is foamed.

[0073] 25. Panel according to any of the previous clauses, comprising at least one pair of opposing side edges, said pair of opposing side edges comprising complementary coupling parts configured for mutual coupling of adjacent panels.

[0074] 26. Method of producing a panel, in particular a floor panel, wall panel, ceiling panel or building panel, comprising the steps of:

[0075] - providing at least one mineral material and providing textile waste;

[0076] - extruding the at least one mineral material and textile waste into at least one core layer comprising a composite material; and

[0077] - applying at least one surface layer onto at least one surface of the at least one core layer; wherein the at least one composite material comprises at least 50 wt% of textile waste, and wherein the composition of the at least one composite material comprises at least 10 wt% of at least one fibrous material, at least 25 wt% of at least one mineral material and at least 40 wt% of at least one polymer material, based on a total weight of the composite material. 27. Method according to clause 26, wherein at least part of the textile waste is provided in the form of pellets.

[0078] 28. Method according to any of clauses 26-27, wherein at least part of the pellets comprises textile fibres and / or at least one particulate material, wherein at least part of the textile fibres has an average length of at least 2 mm and / or at least part of the particulate material has an average particle size of at least 0.1 mm.

[0079] 29. Method according to any of clauses 26-28, comprising the step of providing at least one polymer material and extruding the at least one polymer material, the at least one mineral material and the textile waste into at least one core layer comprising a composite material.

[0080] 30. Method according to any of clauses 26-29, wherein the melt flow index of the at least part of at least one polymer material is at least 5g / 10min.

[0081] 31 . Method according to any of clauses 26-30, wherein the carbon intensity of the panel after production is less than 5kg CO2eq / m2 based on a comprehensive Life Cycle Assessment (LCA) using a time horizon of 20 years (GWP20 - IPCC AR5).

[0082] 32. Method according to any of clauses 26-31 , wherein the textile waste has a composition comprising at least 50 wt% polyester and at least 10 wt% cotton.

[0083] 33. Method according to any of clauses 26-32, wherein at least one polymer material comprises at least one polymeric binder and / or at least one particulate material, in particular at least one particulate polymer.

[0084] 34. Method according to any of clauses 26-33, wherein at least one mineral material comprises magnesium oxide, magnesium carbonate, magnesium oxysulphate, magnesium oxychloride cement (MOC), magnesium chloride (MgCI2), magnesium sulphate (MgSO4), Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite mineral, stone, chalk, clay, calcium silicate and / or talc. 35. Method according to any of clauses 26-34, wherein at least one polymer material comprises polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), ABS (acrylonitrile butadiene styrene), PU (polyurethane), polyamides (PA), acrylonitrile-styrene-butyl acrylate (ASA) and / or ethylene vinyl alcohol copolymers (EVOH).

[0085] 36. Method according to any of clauses 26-35, wherein at least one chain extender and / or at least one coupling agent is added.

[0086] 37. Method according to any of clauses 26-36, wherein the extrusion is a coextrusion step of at least one core layer and at least one surface layer.

[0087] 38. Method according to any of clauses 26-37, wherein the at least one surface layer comprises polyethylene, in particular high density polyethylene.

[0088] 39. Method according to any of clauses 26-38, comprising the steps of:

[0089] - providing textile waste;

[0090] - washing and / or drying at least part of the textile waste;

[0091] - shredding at least part of the textile waste;

[0092] - mixing at least part of the shredded textile waste with at least one polymer material; and

[0093] - pelletizing the mixture of shredded textile waste and the at least one polymer material.

[0094] It will be apparent that the invention is not limited to the working examples 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. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above-described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application. 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 . Panel, in particular a floor panel, wall panel, ceiling panel or building panel, comprising:- at least one core layer comprising at least one composite material; and- at least one surface layer attached to the at least one core layer; wherein the at least one composite material comprises at least 50 wt% of textile waste; and wherein the composition of the at least one composite material comprises at least 10 wt% of at least one fibrous material, at least 25 wt% of at least one mineral material and at least 40 wt% of at least one polymer material, based on a total weight of the composite material.

2. Panel according to claim 1 , wherein the carbon intensity of the panel after production is less than 5kg CO2eq / m2 based on a comprehensive Life Cycle Assessment (LCA) using a time horizon of 20 years (GWP20 - IPCC AR5).

3. Panel according to any of the previous claims, wherein the textile waste has a composition comprising at least 50 wt% of polyester and at least 10 wt% of cotton.

4. Panel according to any of the previous claims, wherein the at least one composite material comprises in the range of 10-30 wt%, preferably 15-25 wt% of at least one polyolefin, based on a total weight of the composite material.

5. Panel according to any of the previous claims, wherein the at least one composite material comprises in the range of 0.1 -10 wt%, preferably 1-5 wt% of at least one metal.

6. Panel according to any of the previous claims, wherein at least one composite material comprises in the range of 25 wt% to 50 wt% of at least one mineral material and in the range of 50 wt% to 90 wt% of at least one mineral material, based on a total weight of the composite material.

7. Panel according to any of the previous claims, wherein at least part of fibrous material comprises fibres having an average length of at least 2 mm.

8. Panel according to any of the previous claims, wherein at least part of the composite material comprises at least one particulate material, said particulate material comprising particles having an average particle size of at least 0.1 mm.

9. Panel according to any of the previous claims, wherein at least part of the textile waste, in particular the fibrous material and / or particulate material, is encapsulated by at least one polymer material.

10. Panel according to any of the previous claims, wherein at least one polymer material comprises at least one polymeric binder.11 . Panel according to any of the previous claims, wherein the at least one surface layer comprises polyethylene, in particular high density polyethylene.

12. Panel according to any of the previous claims, wherein the at least one polymeric material comprises polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), ABS (acrylonitrile butadiene styrene), PU (polyurethane), polyamides (PA), acrylonitrile- styrene-butyl acrylate (ASA) and / or ethylene vinyl alcohol copolymers (EVOH).

13. Panel according to any of the previous claims, wherein the at least one mineral material comprises magnesium oxide, magnesium carbonate, magnesium oxysulphate, magnesium oxychloride cement (MOC), magnesium chloride (MgCI2), magnesium sulphate (MgSO4), Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite mineral, stone, chalk, clay, calcium silicate and / or talc.

14. Panel according to any of the previous claims, wherein the at least one core layer, and in particular the at least one composite material, comprises at least one natural material chosen from the group of: cellulose, hemicellulose, lignin, bast fibre, animal fibre, cork and / or combinations thereof.

15. Panel according to any of the previous claims, wherein the at least one core layer is an extruded core layer.

16. Panel according to any of the previous claims, wherein the at least one core layer and the at least one surface layer are co-extruded.

17. Panel according to any of the previous claims, wherein the at least one core layer, and in particular the at least one composite material, comprises at least one chain extender and / or at least one coupling agent.

18. Panel according to any of the previous claims, wherein an upper surface of the at least one core layer has a Shore D hardness of at most 70 and / or wherein at least part of an upper surface of the at least one surface layer has a Shore D hardness of at most 75.

19. Panel according to any of the previous claims, wherein the panel has a tensile strength of at least 2.5 Mpa.

20. Panel according to any of the previous claims, wherein the panel has a tensile modulus of at least 600 Mpa.21 . Panel according to any of the previous claims, wherein the panel has a flexural modulus of at least 650 Mpa.

22. Panel according to any of the previous claims, wherein the panel has a flexural strength of at least 5 Mpa.

23. Panel according to any of the previous claims, wherein the density of the at least one core layer is at least 1200 kg / m3, preferably at least 1400 kg / m3.

24. Panel according to any of the previous claims, wherein at least part of the at least one core layer is foamed.

25. Panel according to any of the previous claims, comprising at least one pair of opposing side edges, said pair of opposing side edges comprising complementary coupling parts configured for mutual coupling of adjacent panels.

26. Method of producing a panel, in particular a floor panel, wall panel, ceiling panel or building panel, comprising the steps of:- providing at least one mineral material and providing textile waste;- extruding the at least one mineral material and textile waste into at least one core layer comprising a composite material; and- applying at least one surface layer onto at least one surface of the at least one core layer; wherein the at least one composite material comprises at least 50 wt% of textile waste, and wherein the composition of the at least one composite material comprises at least 10 wt% of at least one fibrous material, at least 25 wt% of at least one mineral material and at least 40 wt% of at least one polymer material, based on a total weight of the composite material.

27. Method according to claim 26, wherein at least part of the textile waste is provided in the form of pellets.

28. Method according to any of claims 26-27, wherein at least part of the pellets comprises textile fibres and / or at least one particulate material, wherein at least part of the textile fibres has an average length of at least 2 mm and / or at least part of the particulate material has an average particle size of at least 0.1 mm.

29. Method according to any of claims 26-28, comprising the step of providing at least one polymer material and extruding the at least one polymer material, the at least one mineral material and the textile waste into at least one core layer comprising a composite material.

30. Method according to any of claims 26-29, wherein the melt flow index of the at least part of at least one polymer material is at least 5g / 10min.31 . Method according to any of claims 26-30, wherein the carbon intensity of the panel after production is less than 5kg CO2eq / m2 based on a comprehensive Life Cycle Assessment (LCA) using a time horizon of 20 years (GWP20 - IPCC AR5).

32. Method according to any of claims 26-31 , wherein the textile waste has a composition comprising at least 50 wt% polyester and at least 10 wt% cotton.

33. Method according to any of claims 26-32, wherein at least one polymer material comprises at least one polymeric binder and / or at least one particulate material, in particular at least one particulate polymer.

34. Method according to any of claims 26-33, wherein at least one mineral material comprises magnesium oxide, magnesium carbonate, magnesium oxysulphate, magnesium oxychloride cement (MOC), magnesium chloride (MgCI2), magnesium sulphate (MgSO4), Sorel cement, fiber cement, MOS cement, limestone, calcium carbonate, calcite mineral, stone, chalk, clay, calcium silicate and / or talc.

35. Method according to any of claims 26-34, wherein at least one polymer material comprises polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polystyrene (PS), ABS (acrylonitrile butadiene styrene), PU (polyurethane), polyamides (PA), acrylonitrile-styrene-butyl acrylate (ASA) and / or ethylene vinyl alcohol copolymers (EVOH).

36. Method according to any of claims 26-35, wherein at least one chain extender and / or at least one coupling agent is added.

37. Method according to any of claims 26-36, wherein the extrusion is a coextrusion step of at least one core layer and at least one surface layer.

38. Method according to any of claims 26-37, wherein the at least one surface layer comprises polyethylene, in particular high density polyethylene.

39. Method according to any of claims 26-38, comprising the steps of:- providing textile waste;- washing and / or drying at least part of the textile waste;- shredding at least part of the textile waste;- mixing at least part of the shredded textile waste with at least one polymer material; and- pelletizing the mixture of shredded textile waste and the at least one polymer material.

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