Panel, Covering, and Method for Manufacturing Such a Panel

Abstract

A panel and a method of manufacturing a panel, such as a floor panel, a wall panel or a ceiling panel, in particular a decorative floor panel including at least a first edge having a first coupling part configured to be coupled to a second coupling part of another panel. At least one expandable material located adjacent at least a part of an upper portion of the first edge. A covering, in particular a floor covering, comprising multiple interconnected panels is also provided.

Claims

1. A panel comprising: a. at least one first edge and at least one opposite second edge, wherein said first edge comprises a first upper edge portion, wherein said second edge comprises a second upper edge portion; b. at least one first coupling part arranged on said first edge, and at least one second coupling part arranged on said opposite second edge, wherein the first coupling part of said panel and the second coupling part of another panel are arranged to be coupled to provide a locking of two coupled panels, such that a least a part of the first upper edge portion faces at least a part of the second upper edge portion to form a top seam in between the panels; c. wherein at least one upper edge portion is provided with a channel-shaped recessed portion extending along the length of one said upper edge portion, wherein the recessed portion is configured to adjoin an upper edge portion of an adjacent panel, in coupled condition of two panels, d. wherein at least a part of at least one upper edge portion, located directly below said channel-shaped recessed portion, is provided with at least one expandable material layer, the at least one expandable material layer comprising at least one material configured to expand or swell upon contact with moisture, wherein an exposed portion of said expandable material layer is in direct contact with an atmosphere surrounding the expandable material layer.

2. The panel according to claim 1, wherein the at least one expandable material layer is positioned such that during expanding or swelling of said expandable material layer upon contact with moisture, the top seam is tightened in a waterproof manner.

3. The panel according to claim 1, wherein the panel comprises a core, wherein the expandable material layer is affixed, either directly or indirectly, onto said core.

4. The panel according to claim 1, wherein, in coupled condition of two adjacent panels, the at least one expandable material layer provided at the at least one upper edge portion of a panel is at least partially covered by an opposing upper edge portion of an adjacent panel.

5. The panel according to claim 1, wherein, in coupled condition of two adjacent panels, the at least one expandable material layer provided at the at least one upper edge portion of a panel is at least partially left uncovered by an opposing upper edge portion of an adjacent panel.

6. The panel according to claim 1, wherein the thickness of the expandable layer increases in a direction away from a part of the upper edge portion configured to co-act with the upper edge portion of an adjacent panel.

7. The panel according to claim 1, wherein, the first one upper edge portion is provided with at least one first expandable material layer and wherein the second upper edge portion is provided with at least one second expandable material layer.

8. The panel according to claim 1, wherein the at least one upper edge portion is provided with a plurality of expandable material layers, wherein each expandable material layer comprises at least one material configured to expand or swell upon contact with moisture.

9. The panel according to claim 1, wherein each upper edge portion is provided with at least one expandable material layers, wherein, in coupled condition of adjacent panels, the expandable material layers of opposing upper edge portions are configured to co-act with each other.

10. The panel according to claim 1, wherein the at least one expandable material layer is formed by a material strip.

11. The panel according to claim 1, wherein the at least one expandable material layer follows the shape of a curved and/or angled portion of a coupling part.

12. The panel according to claim 1, wherein the thickness of at least one expandable material layer decreases in a direction away from an outer end of the panel edge.

13. The panel according to claim 1, wherein the thickness of the expandable material layer is between 10 and 1000 micron.

14. The panel according to claim 1, wherein the at least one expandable material layer provided is partially covered by at least one protective layer.

15. The panel according to claim 1, wherein at least a part of each upper edge portion, located below said channel-shaped recessed portion, is configured to act as contact surface, which upper contact surfaces are arranged to be in contact in coupled condition of the panels.

16. The panel according to claim 15, wherein the contact surfaces extend vertically at least partly.

17. The panel according to claim 1, wherein the channel-shaped recess defines a bevel or grout line connecting an upper side of the panel and a side wall of the panel.

18. The panel according to claim 1, wherein the expandable material is at least partially enclosed by a core of the panel and a decorative layer of the panel.

19. The panel according to claim 1, wherein the material layer comprises at least one hydrogel-forming water-swellable polymer.

20. The panel according to claim 1, wherein the expandable material layer, in swollen or expanded state, forms a water-impermeable barrier, a waterproof barrier and/or a water-resistant barrier.

21. The panel according to claim 1, wherein the first coupling part and the second coupling part of another panel are arranged to be coupled by means of a downward motion; wherein the first coupling part comprises an upward tongue, at least one upward flank lying at a distance from the upward tongue and an upward groove formed in between the upward tongue and the upward flank, wherein the upward groove is adapted to receive at least a part of a downward tongue of a second coupling part of another panel, wherein the side of the upward tongue facing towards the upward flank is the inside of the upward tongue and the side of the upward tongue facing away from the upward flank is the outside of the upward tongue; wherein the second coupling part comprises a downward tongue, at least one downward flank lying at a distance from the downward tongue, and a downward groove formed in between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a part of an upward tongue of a first coupling part of another panel, wherein the side of the downward tongue facing towards the downward flank is the inside of the downward tongue and the side of the downward tongue facing away from the downward flank is the outside of the downward tongue.

22. The panel according to claim 1, wherein the panel comprises at least one third edge and at least one opposite fourth edge, wherein said third edge comprises a third upper edge portion, wherein said fourth edge comprises a fourth upper edge portion; a. at least one third coupling part arranged on said third edge, and at least one fourth coupling part arranged on said opposite fourth edge, wherein the third coupling part of said panel and the fourth coupling part of another panel are arranged to be coupled to provide a locking of two coupled panels, such that a least a part of the third upper edge portion faces at least a part of the fourth upper edge portion to form a top seam in between the panels; b. wherein the third edge portion and/or the fourth edge portion is provided with at least one expandable material layer which comprises at least one material configured to expand or swell upon contact with moisture.

23. The panel according to claim 1, wherein the panel comprises a layered structure, comprising a core layer and at least one decorative top section, directly or indirectly affixed to said core layer, wherein the top section defines a top surface of the panel, and wherein the top section comprises at least one decorative layer affixed, either directly or indirectly, to an upper surface of the core layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0164] The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures, wherein:

[0165] FIGS. 1a-1c show three schematic representations of two coupled panels, without material layers;

[0166] FIGS. 2a-2f show six schematic representation of two coupled panels with material layers according to the present invention;

[0167] FIGS. 3a-3c schematically show various details of locking systems for panels according to the present invention; and

[0168] FIG. 4 schematically shows a cross section of two coupled panels according to the invention.

DESCRIPTION OF THE INVENTION

[0169] FIGS. 1a-1c schematically show two panels (1), each panel (1) comprising a first coupling part (2) and at least one second coupling part (3) arranged on opposite sides of the panel (1), wherein the first coupling part (2) of said panel and the second coupling part (3) of another panel (1) are arranged to be coupled to provide a locking of two coupled panels (1). Each panel (1) comprises a core (4) provided with an upper side (5) and a lower side (6), wherein at the upper side (5) of the core (4) a recessed portion (7) is provided, wherein in coupled condition the recessed portions (7) of two panels (1) form a recess (8), such as a grout or a bevel. Beneath the recess (8), the panels (1) are in contact at upper contact portions (10).

[0170] In FIG. 1a, the recess (8) is formed as a bevel, as the recessed portions (7) are both chamfered or angled portions. In FIG. 1b, the recess (8) is formed as a grout, as the recessed portions (7) are both square or rectangular in cross section, and together form a rectangular recess (8). In FIG. 1c, the right panel (1) is provided with a recessed portion (7) similar to the one shown in FIG. 1b, whereas the recessed portion (7) of the left panel coincides with the recess produced to form the first coupling part (2).

[0171] FIGS. 2a-2f show six schematic representation of two coupled panels with material layers (9). FIGS. 2a and 2d show panels like FIG. 1a, FIGS. 2b and 2e show panels like FIG. 1b and FIGS. 2c and 2f show panels like FIG. 1c, but these are interchangeable to some extent. Compared to the FIG. 1 embodiments, the coupled panels (1) are provided with a material layer (9).

[0172] In FIG. 2a, the material layer (9) is provided in a Y-shape, wherein a portion of the material layer (9) is provided on the chamfered or angled surfaces of the bevel, and another portion is provided between the upper contact surfaces (10) of the panels (1). It is imaginable that one of the portions is omitted, and that thus the material layer (9) is provided on the bevel only, or between the upper contact surfaces (10) only.

[0173] In FIG. 2b, the material layer (9) is provided in a T-shape, wherein a portion of the material layer (9) is provided on the bottom of the grout, and another portion is provided between the upper contact surfaces (10) of the panels (1). It is imaginable that one of the portions is omitted, and that thus the material layer (9) is provided on the grout only, or between the upper contact surfaces (10) only.

[0174] In FIG. 2c, the material layer (9) is provided with a portion of the material layer (9) on the bottom of the grout, and another portion is provided between the upper contact surfaces (10) of the panels (1). It is imaginable that one of the portions is omitted, and that thus the material layer (9) is provided on the grout only, or between the upper contact surfaces (10) only.

[0175] In FIG. 2d, the material layer (9) is provided between the upper contact surfaces (10) of the panels (1).

[0176] In FIG. 2e, the material layer (9) in a U-shape wherein a portion of the material layer (9) is provided on the bottom of the grout, and other portions are provided at the walls of the grout, from the bottom of the grout upward.

[0177] In FIG. 2f, the material layer (9) is provided at the bottom of the grout only. FIG. 2f also schematically shows the presence of a protective coating (11) on top of the material layer (9).

[0178] FIGS. 3a-3c schematically show a number of details for locking systems for panels according to the present invention. The figures show panels with first coupling part (2) and a second coupling part (3) arranged on opposite sides of the panel. wherein the first coupling part (2) comprises an upward tongue (12), an upward flank (13) lying at a distance from the upward tongue and an upward groove (14) formed in between the upward tongue (12) and the upward flank (13). The upward groove is adapted to receive at least a part of a downward tongue of a second coupling part of another panel, wherein the side of the upward tongue facing towards the upward flank is the inside of the upward tongue and the side of the upward tongue facing away from the upward flank is the outside of the upward tongue. The second coupling part (3) comprises a downward tongue (15a downward flank (16) lying at a distance from the downward tongue, and a downward groove (17) formed in between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a part of an upward tongue of a first coupling part of another panel. The side of the downward tongue facing towards the downward flank is the inside of the downward tongue and the side of the downward tongue facing away from the downward flank is the outside of the downward tongue.

[0179] The outside of the downward tongue and the upward flank both comprise an upper contact surface (10) near or at or adjoining or towards a top or upper side of the panel, which upper contact surfaces (10) are arranged to be in contact in coupled condition of the panels and extend vertically. The outside of the upward tongue (12) comprises a first locking element in the form of an outward bulge (18) and the downward flank (16) is provided with a second locking element, in the form of a recess (19), wherein at least a part of the first and at least a part of second locking element are arranged to be in contact, in coupled condition of the panels and form a locking element surface (20).

[0180] The outside of the outward bulge (18) comprises an upper portion (21) and an adjoining lower portion (22), wherein the lower portion comprises an inclined locking surface and the upper portion comprises a curved guiding surface; wherein the recess (19) comprises an upper portion (23) and an adjoining lower portion (24), wherein the lower portion comprises an inclined locking surface; wherein the parts of the first and second locking element that are in contact, in coupled condition of the panels, are the inclined locking surfaces of the locking elements and/or wherein, in coupled condition of the panels, the upper portions of the first and second locking elements are spaced apart at least partially.

[0181] FIG. 4 shows a cross section of (a part of) two panels (30) according to the invention, in coupled condition. More in particular, this cross section shows a third edge (31) and a fourth edge (32) of the panel according to the invention. These edges (31, 32) may be combined with any of the first and second edges as shown in FIGS. 1a-3c. Alternatively, these edges (31, 32) may also be applied at remaining edges of the panel (30), wherein a panel (30) in this case would typically have two third edges and two fourth edges. The third edge (31) comprises a third upper edge portion (31a), wherein said fourth edge (32) comprises a fourth upper edge portion (32a). At least one third coupling part (33) arranged on said third edge (31), and at least one fourth coupling part (34) arranged on said opposite fourth edge (32), wherein the third coupling part (33) of the panel (30) and the fourth coupling part (34) of another panel (30) are arranged to be coupled to provide a locking of two coupled panels, such that a least a part of the third upper edge portion (31a) faces, in particular co-acts or is configured to co-act with, at least a part of the fourth upper edge portion (32a) to form a top seam (35) in between the panels; wherein the third upper edge portion (31a) and/or the fourth upper edge portion (32a) is provided with at least one expandable material layer (36) which comprises at least one material configured to expand or swell upon contact with moisture. The third coupling part (33) and the fourth coupling part (34) of another panel (30) are arranged to be coupled by means of an angling down motion, also referred to as turning or rotary movement. As shown in this figure, the third coupling part (30) comprises: a sideward tongue (37) extending in a direction substantially parallel to the upper side of the core, at least one second downward flank (37a) lying at a distance from the sideward tongue, and a second downward groove (37b) formed between the sideward tongue (37) and the second downward flank (37a), and wherein the fourth coupling part (34) comprises: a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile (33) of an adjacent panel (30), said third groove being defined by an upper lip (38) and a lower lip (39), wherein said lower lip (39) is provided with an upward locking element (40), wherein the third coupling part (33) and the fourth coupling part (34) are configured such that two of such panels (30) can be coupled to each other by means of a turning movement, wherein, as shown in FIG. 4, in the coupled condition at least a part of the sideward tongue (37) of a first panel (30) is inserted into the third groove of an adjacent, second panel, and wherein at least a part of the upward locking element (40) of said second panel is inserted into the second downward groove (37b) of said first panel (40). The panels (30) shown typically have a thickness situated in between and including 8 and 12 mm. A lower side of the upward sideward tongue (37) may comprise a flat portion, which is in particular advantageous in case thinner panels, typically having a thickness of 5 mm or less, are applied.

[0182] The above-described inventive concepts are illustrated by several illustrative embodiments. 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.

[0183] 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.