Panels and decorative panel

• US 11,060,298 B2
• Filed: 03/16/2018
• Issued: 07/13/2021
• Est. Priority Date: 07/19/2017
• Status: Active Grant

• Current Assignee: Jetcoat Corporation
• Original Assignee: Jetcoat Corporation
• Inventors: Liu, Huihuang, Liu, Tungyueh, Huang, Juntai, Liu, Kuojiun
• Primary Examiner(s): Mintz, Rodney
• Application Number:
  US16/631,450
• Publication Number:
  US 20200131783A1
• Time in Patent Office: 1,215 Days
• CPC Class Codes: B32B 15/082 comprising vinyl resins; comprising acrylic resins
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 9/00 Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
• CPC Class Codes: C08K 13/02 Organic and inorganic ingredients
• CPC Class Codes: C08L 2205/025 containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 2205/035 containing four or more polymers in a blend
• CPC Class Codes: C08L 23/286 Chlorinated polyethylene
• CPC Class Codes: C08L 25/06 Polystyrene
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 53/02 of vinyl-aromatic monomers and conjugated dienes
• CPC Class Codes: C08L 91/08 Mineral waxes
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: E04F 13/0866 composed of several layers, e.g. sandwich panels or layered panels layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence
• CPC Class Codes: E04F 13/0871 having an ornamental or specially shaped visible surface E04F13/0867 takes precedence
• CPC Class Codes: E04F 13/0885 specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application
• CPC Class Codes: E04F 13/0887 Adhesive means specially adapted therefor, e.g. adhesive foils or strips
• CPC Class Codes: E04F 13/0891 with joint fillings
• CPC Class Codes: E04F 13/0894 : with tongue and groove connections
• CPC Class Codes: E04F 13/18 : of organic plastics with or without reinforcements or filling materials of plastic-bound fibres or chips E04F13/16 or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles E04F13/0864 takes precedence
• CPC Class Codes: E04F 15/02005 : Construction of joints, e.g. dividing strips E04F15/024, E04F15/04, E04F15/06, E04F15/10 and E04F15/14 take precedence; separate provisional spacers E04F21/0092
• CPC Class Codes: E04F 15/02155 : Adhesive means specially adapted therefor, e.g. adhesive foils or strips
• CPC Class Codes: E04F 15/10 : of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: E04F 2201/023 : with a continuous tongue or groove
• CPC Class Codes: E04F 2201/043 : with tongues and grooves being formed by projecting or recessed parts of the panel layers
• CPC Class Codes: F16B 5/0016 : with snap action
• CPC Class Codes: F16B 5/008 : by a rotating or sliding and rotating movement

Abstract

Disclosed is a panel comprising a substrate (1), wherein the outer surface of the substrate (1) is covered with a coating layer (8), wherein one edge of the substrate (1) is provided with a recess (3), and a groove (4) is arranged inside the substrate (1) adjacent and interconnected to the recess (4), and wherein the opposite edge of the substrate (1) is provided with a protrusion (7) that can be fitted into the recess (3), and a tongue (6) is extended from the protrusion (7) that can fitted into the groove (4). The substrate is made of 100 parts by mass of PVC resin or PVC powder, 25-45 parts of styrene elastomer, 180-280 parts of stone powder, sawdust or rock, 1-10 parts of an additive, and 1-4 parts of an elastomer coupling agent. Also disclosed is a decorative panel formed by arranging and interlocking the panels in sequence by fitting the protrusion of a panel into the recess of a neighboring panel, as well as a panel installation process.

Claims

1. A panel comprising:

a substrate (1), wherein;

an outer surface of the substrate (1) is covered with a coating layer, a patterned paper, a film or wax (8);

a first edge of the substrate is provided with a recess (3) and a groove (4) inside the substrate (1);

the groove (4) is adjacent and interconnected to the recess (3);

a second edge of the substrate (1) is provided with a protrusion (7) and a tongue (6) extending from the protrusion (7);

the second edge is opposite to the first edge;

the protrusion (7) is configured to be fitted into the recess (3);

the tongue (6) is configured to be fitted into the groove (4); and

the substrate (1) is composed of materials at mass ratios as follows;

2. The panel according to claim 1, wherein:

a locking groove (5) is provided on the protrusion (7); and

a locking protrusion (2) is provided on the recess (3) and is configured to be fitted into the locking groove (5).

3. The panel according to claim 1, wherein the substrate (1) is a wood board, a bamboo board, a metal board, a stone composite plate, a WPC board, a PVC board, a LVT board, a calcium silicate board, an aluminum composite board, a plastic film, a PVC coil, a bamboo wood composite board, a magnesium oxide board, a biological composite board, a wood composite board, a stone plate, a limestone plate, or a calcium silicone carbonate plate.

4. The panel according to claim 1, wherein the coating layer (8) is patterned or provided with three-dimensional lines, and coated on the substrate (1) at an amount of 5-500 g/m² (0.147-14.75 oz/yd²).

5. The panel according to claim 1, further comprising a structure enabling the panel to bend,

wherein the structure is at least one groove or cut where the panel is easily bent,

wherein a depth of the groove or cut is not greater than a thickness of the substrate.

6. The panel according to claim 1, wherein an upper or lower surface of the substrate (1) is provided with intersecting or parallel grooves, or other patterns.

7. The panel according to claim 6, wherein the intersecting or parallel grooves, or other patterns are 0.1-8 mm (0.0039-0.315 inch) in depth and 0.1-10 mm (0.0039-0.394 inch) in width, and coated with a coating.

8. The panel according to claim 7, wherein 1%-100% of an area with the intersecting or parallel groove or other patterns is covered with the coating.

9. The panel according to claim 1, wherein the elastomer coupling agent is prepared by a method comprising the steps of:

1) adding a polyol and allylic acid into a polymerization reactor in turn, reacting the resultant mixture under an acid catalyst for 0.1-0.5 hours at 80-120°

C., removing water and obtaining a mixture; and

2) reacting the obtained mixture with styrene or derivatives and vinyl chloride at 120-160°

C. at the presence of an initiator for 1-2 hours, raising the temperature to 200-240°

C., and allowing the reaction to proceed for another 1-3 hours to obtain the elastomer coupling agent.

10. The panel according to claim 9, wherein the polyol, allylic acid, styrene or derivatives, and vinyl chloride are at a molar ratio of 1:

2-6;

5-15;

5-15.

11. The panel according to claim 9, wherein the polyol is one or more selected from the group consisting of glycol, 1,2-propanediol, dipropylene glycol, 1,4-butanediol, 1,6-hexanediol, neopentyl glycol, triethylene glycol, diethylene glycol, trihydroxymethyl propane, pentaerythritol and glycerol.

12. A decorative panel formed by arranging and interlocking multiple panels according to claim 1, wherein the protrusion (7) of a first panel of the multiple panels is fitted into the recess (3) of a second panel of the multiple panels, and a new recess (9) is formed on a resulting joint.

13. The decorative panel according to claim 12, wherein the recess (9) on the joint is filled with a wax sealing layer or a sealing bar.

14. The decorative panel according to claim 12, further provided with coordinating trims at the edges to cover the edges.

15. The decorative panel according to claim 14, wherein the trims are made of PVC, WPC, SPC, ceramic, metal, calcium silicate, or wood.

16. A panel installation process comprising the steps of:

providing a plurality of panels according to claim 1;

covering the panels at a back with an adhesive;

arranging and seamlessly interlocking the panels in at least one of a longitudinal direction or widthwise direction;

fixing panel connections using a nail gun at a joint recess; and

covering the edges of panels with no further panel connection using trims with a trim adhesive.

17. The panel installation process according to claim 16, wherein a first panel of the plurality of panels and a second panel of the plurality of panels perpendicular to the first one are connected and fixed with the trim using the trim adhesive at a right angle corner during panel installation.

18. The panel installation process according to claim 16, wherein a respective panel of the plurality of panels is bent at a right angle corner during panel installation and then interlocked with another panel of the plurality of panels in a new installation plane.

19. The panel installation process according to claim 16, wherein a corner clip (30) is used at a right angle corner during panel installation, wherein the corner clip is composed of an arc or right angle shaped angle plate (31) and two side plates (32, 33), one of the two side plates is perpendicular to the other, the two side plates are connected respectively to two ends of the angle plate (31), two further plates (34, 35) are respectively arranged on the side plates, each in parallel to one side plate and perpendicular to the other, wherein the panels installed at the corner are respectively attached to the two side plates (32, 33) and arranged against the two further plates (34, 35).