阅读说明：本技术 区域覆盖元件 (Area coverage element ) 是由 爱德温·林格 于 2019-09-27 设计创作，主要内容包括：本发明涉及一种区域覆盖元件(1),包括至少一个片状载体芯(2)、至少一个保护层(4)以及布置在片状载体芯(2)与至少一个保护层(4)之间的装饰层(3)。片状载体芯(2)在这种情况下由坚固的承重载体材料组成,并至少具有上侧(5)、与上侧(5)相对布置的底侧(6)以及彼此相对地布置并分别连接上侧(5)和底侧(6)的至少第一侧面(7)和第二侧面(8)。装饰层(3)由牢固地连接到载体芯(2)的印刷膜形成,印刷膜(3)至少部分地覆盖片状载体芯(2)的至少上侧(5)以及第一侧面(7)和第二侧面(8),并且保护层(4)至少覆盖连接到载体芯(2)的印刷膜的整个表面区域。(The invention relates to an area covering element (1) comprising at least one sheet-like carrier core (2), at least one protective layer (4) and a decorative layer (3) arranged between the sheet-like carrier core (2) and the at least one protective layer (4). The sheet-like carrier core (2) consists in this case of a solid load-bearing carrier material and has at least an upper side (5), a bottom side (6) arranged opposite the upper side (5) and at least a first side (7) and a second side (8) arranged opposite one another and connecting the upper side (5) and the bottom side (6) respectively. The decorative layer (3) is formed by a printed film which is firmly connected to the carrier core (2), the printed film (3) at least partially covering at least the upper side (5) and the first side (7) and the second side (8) of the sheet-like carrier core (2), and the protective layer (4) at least covering the entire surface area of the printed film which is connected to the carrier core (2).)

1. An area covering element (1) comprising at least one sheet-like carrier core (2), at least one protective layer (4) and a decorative layer (3) arranged between the sheet-like carrier core (2) and the at least one protective layer (4); the sheet-like carrier core (2) consists of a solid load-bearing carrier material and has at least an upper side (5), a bottom side (6) arranged opposite to the upper side (5) and at least a first side (7) and a second side (8) arranged opposite to each other and connecting the upper side (5) and the bottom side (6), respectively, characterized in that the decorative layer (3) is formed by a printed film firmly connected to the carrier core (2), the printed film (3) at least partially covering at least the upper side (5) and the first side (7) and the second side (8) of the sheet-like carrier core (2), and the protective layer (4) at least covering the entire surface area of the printed film connected to the carrier core (2).

2. The area covering element (1) according to claim 1, wherein said printed film at least partially covers at least said upper side (5) and said bottom side (6) and said first side (7) and said second side (8) of said sheet-like carrier core (2).

3. The area covering element (1) according to claim 2, wherein said printed film completely covers said upper side (5) and said bottom side (6) and said first side (7) and said second side (8) of said sheet-like carrier core (2).

4. The area covering element (1) according to one of claims 1 to 3, wherein the printed film further extends at least partially on a third and a fourth oppositely arranged side of the sheet-like carrier core (2).

5. The area covering element (1) according to one of the preceding claims, wherein the protective layer (4) is formed by a surface coating.

6. The area coverage element (1) according to one of claims 1 to 4, wherein the protective layer (4) is formed by a transparent useful layer, in particular a transparent protective film.

7. The area covering element (1) according to claim 6, wherein the useful layer, in particular the transparent protective film, is bonded to the printed film (3) by at least one layer (11) of adhesive substance.

8. The area covering element (1) according to one of the preceding claims, wherein the carrier material of the sheet-like carrier core (2) comprises wood, a wood material, a plastic composite, a mineral plastic composite or a mineral material.

9. The area covering element (1) according to one of the preceding claims, wherein the printed film is a film printed by digital printing.

10. The area covering element (1) according to one of the preceding claims, wherein the printed film is made of plastic, in particular a thermoplastic polymer.

11. The area covering element (1) according to one of the preceding claims, wherein the printed film is bonded onto the sheet-like carrier core (2), wherein at least one adhesive layer (9) is arranged between the printed film (3) and the sheet-like carrier core (2).

12. The area covering element (1) according to claim 11, wherein at least one adhesive layer (10) is further arranged between the sheet-like carrier core (2) and the adhesive layer (9) and/or between the adhesive layer (9) and the printed film (3).

13. The area covering element (1) according to one of the preceding claims, wherein the sheet-like carrier core (2) has a thickness of between 2mm and 25mm, in particular between 10mm and 20 mm.

14. The area covering element (1) according to one of the preceding claims, wherein the carrier core (2) is provided with at least one first coupling profile configured to co-act with a second coupling profile of an adjacent area covering element (1).

15. The area covering element (1) according to claim 14, wherein at least one first coupling profile is located at a first side and/or a second side of the carrier core.

16. The area covering element (1) according to claim 14 or 15, wherein at least one first coupling profile is located at a third and/or fourth side of the carrier core.

17. The area covering element (1) according to claim 16, wherein said first and second sides of said carrier core (2) are free of any coupling profile.

18. The area covering element (1) according to one of claims 14 to 16, wherein each side of the carrier core (2) has a coupling profile, wherein preferably complementary coupling profiles are located at opposite sides of the carrier core (2).

19. The area covering element (1) according to one of claims 14 to 18, wherein a first coupling profile and a complementary second coupling profile are located at opposite sides of the carrier core.

20. The area covering element (1) according to one of claims 14 to 19, wherein a first coupling profile and a complementary second coupling profile are located at a first side and a second side of the carrier core (2), and wherein a third coupling profile and a complementary fourth coupling profile are located at a third side and a fourth side of the carrier core (2).

21. The area covering element (1) according to one of claims 14 to 20, wherein at least one coupling profile is at least partially formed by a tongue or a pin.

22. The area covering element (1) according to one of claims 14 to 21, wherein at least one coupling contour is at least partially formed by a groove or recess.

23. The area covering element (1) according to one of claims 14 to 22, wherein at least one pair of complementary coupling profiles is configured to interlock at least two adjacent area covering elements (1) such that the area covering elements (1) are locked in a horizontal direction parallel to a plane defined by the area covering elements and in a vertical direction perpendicular to the plane defined by the area covering elements.

24. The area covering element (1) according to one of claims 14 to 23, wherein at least one side of the carrier core (2) comprises a plurality of coupling profiles, wherein at least two of the coupling profiles are identical or mutually distinct.

25. A method for producing an area covering element (1), in which method at least one decorative layer (3) formed from a printed film is applied to a sheet-like carrier core (2) made of a solid load-bearing carrier material; for this purpose, the printed film (3) is arranged on the sheet-like carrier core (2) such that at least the upper side (5) and at least a first side (7) and a second side (8) of the sheet-like carrier core (2) are at least partially covered by the printed film (3); and firmly attaching the printed film (3) to the carrier core (2), followed by applying at least one protective layer (4) such that at least the printed film (3) attached to the carrier core (2) is covered over its entire surface area by the protective layer (4).

26. A method according to claim 25, wherein said printed film (3) is adhered at least on said upper side (5) and on said first and second sides (7, 8) of said sheet-like carrier core (2); for this purpose, before the application of the printing film (3), an adhesive layer (10) is applied at least on the upper side (5) and the first and second sides (7, 8) of the sheet-like carrier core (2).

27. The method according to claim 25 or 26, wherein the sheet-like carrier core (2) is enclosed by the printed film (3); for this purpose, the printed film (3) is arranged on the sheet-like carrier core (2) such that not only the upper side (5) and the first and second lateral faces (7, 8) are completely covered by the printed film (3), but also the bottom side (6) of the sheet-like carrier core (2) is completely covered by the printed film (3).

Technical Field

The present invention relates to an area covering element for a ceiling covering, wall covering or floor covering, in particular for use outdoors.

Background

The area coverings used outdoors are usually formed as floor coverings, in particular as open-area decking or floors, or as area coverings for areas which can be walked over and possibly also partially traveled over by vehicles. In this case, the area covering consists of a plurality of area covering elements which are laid together (for example also on existing substructures, for example on system-profile substructures) to form an arrangement, in particular they are connected to form a floor covering, for example in the manner of interlocking-type paving stones and/or by means of tongue-and-groove connections or so-called snap connections.

Decking or floor coverings used outdoors to date have been constructed from floor covering elements which are typically composed of planks or panels of a plastic composite, a wood composite or a bamboo composite. These known decking boards generally have the following disadvantages: they are strongly responsive to temperature fluctuations and are therefore dimensionally unstable. In the case of decking boards where the floor covering elements are made of wood, for example produced from cork or tropical wood types, there are also disadvantages in that: they require a high level of care, undergo color loss or bleaching over time, and are prone to chipping. Thus, these floor coverings are no longer suitable for barefoot walking. The decking with floor covering elements made of solid wood material or composite wood material is also only to some extent weather resistant or not at all. It is also a disadvantage that only a limited number of possible designs are available.

In order to be able to eliminate some of the above-mentioned disadvantages of the floor coverings known hitherto for use outdoors, EP2839094B1 discloses a floor covering consisting of a plurality of prefabricated floor covering elements, each consisting of a rigid base, the upper side of which is covered with vinyl. However, also in the case of the floor covering of EP2839094B1, there is the disadvantageous problem that the choice of possible designs is still limited.

Disclosure of Invention

It is therefore an object of the present invention to further develop a floor covering element such that it can be constructed separately and is resistant and insensitive in particular to moisture, temperature variations and the effects of light.

According to the invention, this object is achieved by an area covering element having the features of claim 1. The object is also achieved by a method for manufacturing an area covering element according to claim 14. Advantageous variants of the invention form the subject matter of the dependent claims.

The invention provides an area coverage element comprising at least one sheet-like carrier core, at least one protective layer and a decorative layer arranged between the sheet-like carrier core and the at least one protective layer. In this case, the sheet-like carrier core is composed of a solid load-bearing carrier material and has at least an upper side, a bottom side arranged opposite the upper side, and at least a first side and a second side arranged opposite one another and connecting the upper side and the bottom side, respectively. The invention is characterized in that the decorative layer is formed by a printed film which is firmly connected to the carrier core. According to the invention, in this case the printed film at least partially covers at least the upper side and at least the first and second side of the sheet-like carrier core. The protective layer in turn covers at least the entire surface area of the printed film connected to the carrier core.

The area covering element of the invention is to be understood as meaning an approximately cubic, in particular approximately cuboid, area covering element, also referred to as rectangular area covering element, in particular floor covering element, for use both indoors and outdoors, which is designed for placement on an area, preferably on a floor area. Alternatively, the area covering element may be used to cover walls, ceilings and/or objects, such as furniture. In particular, in the case of the use of an area covering element as a floor covering element, this floor covering element is designed for being laid in an interlocking manner and can therefore also be understood within the scope of the invention as a paving element or a paving stone. In particular, within the scope of the invention, an area covering element is to be understood as a paving element or a paving stone for use both indoors and outdoors, for example as an area covering element for a paving slab, or for example as an area covering element for an indoor floor exposed to moisture and/or temperature influences. Alternatively, snap-in connection means, such as tongue and groove elements, can also be provided laterally on the substantially cube-shaped area covering element for laying. It is likewise conceivable to provide a laying grid on the bottom side.

The invention allows a high degree of flexibility and a range of variations in the design of area covering elements, in particular for outdoor use, since the use of a printed film as decorative layer advantageously allows a large number of very different decorations and designs to be produced in an inexpensive and simplified manner, in particular particularly advantageously independently of the carrier material of the sheet-like carrier core.

The sheet-like carrier core, also referred to as plate-like carrier core, consists of a strong, load-bearing carrier material which is usually particularly dimensionally stable, so that the carrier material itself is already largely protected against fluctuations in temperature and/or weather-related variables, bending and so-called "warping". By firmly attaching the printed film to the carrier core and due to the protective layer covering the printed film, the resistance and dimensional stability are additionally improved, so that the area covering element according to the invention is particularly advantageously insensitive both to thermal loads and to moisture and is largely light-resistant and uv-resistant. The carrier core may be rigid, semi-rigid or flexible. The stiffness of the carrier core is typically dependent on the combination of the material composition of the carrier core and the structure of the carrier core.

The fact that the printed film and the protective layer cover at least a first side and a second side opposite each other in addition to the upper side of the carrier core advantageously achieves the following effect on the one hand: in an area covering comprised of a plurality of area covering elements according to the present invention arranged in an interlocking configuration, the surface ornamentation is not visually disrupted. On the other hand, lifting, separation or peeling of the decorative layer is also effectively avoided. In this case, the decorative layer in the form of a printed film allows flexible creation possibilities, since it offers a great freedom of design. Furthermore, the printed film allows the surface of the area covering element on the floor covering surface defining the tread area to be formed in particular also as an unstructured smooth surface.

Preferably, the printed film at least partially covers at least the upper and bottom sides and the first and second sides of the sheet-like carrier core. In such a preferred embodiment, the printed film and the protective layer also extend over at least a partial area of the bottom side of the carrier core, whereby an even better retention of the mentioned layers on the carrier core is achieved and the resistance and the dimensional stability of the entire area covering element can be further increased.

The thickness of the printed film forming the decorative layer is preferably in the range of 70 to 300 μm. The printed film thickness, which in the present case is also referred to as thickness or film thickness, therefore defines the layer thickness of the decorative layer. Preferably, the thickness of the printed film and thus of the decorative layer is between 80 μm and 250 μm, particularly preferably in the range from 100 μm to 200 μm, and particularly preferably about 90 μm or about 150 μm.

According to a most particularly preferred embodiment, the printed film completely covers the upper and bottom sides and the first and second sides of the sheet-like carrier core. The carrier core is therefore surrounded by the printing film, so that the printing film and thus, together with it, also the protective layer are arranged all around the carrier core. In the present case, this is also understood to mean that the carrier core is enclosed.

For example, in this case, the printed film can be placed as a two-dimensional film element on and wrapped around a carrier core, the edges of the two-dimensional film element being arranged, for example, against one another or overlapping, and then the protective layer is applied. In this case, it is also possible to consider welding the edge of the printed film, whereby the stability can be further improved. Alternatively, the respective tubular printing film can also be pushed or pulled onto the carrier core.

For example, the printed film may also extend at least partially over the oppositely arranged third and fourth sides of the sheet-like carrier core. Thus, in such an embodiment, the carrier core is covered on all sides by the printed film and the protective layer. Most particularly advantageously, in this case, all six sides of the area covering element are completely covered by the printed film and the protective layer, so that the carrier core is completely enclosed or closed over its entire surface area.

In a preferred embodiment, the protective layer may be formed by a surface coating. Such a surface coating can be, for example, a suitable lacquer which is applied at least on the outside to the printing film connected to the carrier core, to be precise to the visible side facing away from the carrier core. For this purpose, the use of UV-curable lacquers is particularly conceivable. Such suitable lacquers may optionally also contain certain additives, such as waxes or corundum, by means of which certain properties of the surface coating, such as scratch resistance, drag, hardness, elasticity, etc., can be influenced and adapted to the respective requirements.

In an alternative embodiment, the protective layer is formed by a transparent useful layer, in particular a transparent protective film. Most particularly preferably, in this case the useful layer, in particular the transparent protective film, is bonded to the printed film by at least one layer of adhesive substance. Such a transparent protective film is preferably a transparent plastic film. A preferred layer of adhesive substance can be applied first on the outside of the printed film connected to the carrier core and optionally also on the areas of the carrier core not covered by the printed film in the form of a suitable viscous or liquid adhesive substance and, depending on the type of adhesive substance, optionally cured to finally provide and attach the protective film accordingly. Alternatively, in the case of this variant of embodiment, it is also conceivable to connect the printed film and the transparent protective film in advance and to apply these connected films together onto the carrier core. In a similar manner to the printed film, the transparent protective film may also have a thickness in the range from 70 μm to 300 μm, preferably between 80 μm and 250 μm, particularly preferably between 90 μm and 200 μm, and particularly preferably between 100 μm and 150 μm.

A variety of materials or material mixtures or composite materials are suitable as carrier materials for the sheet-like carrier core. Preferably, the carrier material of the sheet-like carrier core comprises wood or a wooden material, natural wood or heat-treated wood or particularly preferably resin-impregnated wood as carrier material. Wood fibre materials, in particular medium-density or high-density fibreboards (MDF boards or HDF boards), can also be used as carrier materials.

Also preferably, the carrier material of the sheet-like carrier core comprises a plastic or plastic composite, such as a Wood Plastic Composite (WPC), a composite of plastic and non-plastic material, or a mineral plastic composite or a mineral material. For example, the carrier core may be at least partially formed of a mineral carrier material (e.g., magnesium oxide), wherein preferably the carrier core comprises at least one mineral material pressed together by a binder (e.g., a polymeric binder) to form a panel. The plastic material is preferably a thermoplastic polymer. Suitable plastics for use herein are, in particular, plastics such as polypropylene (PP), Polyethylene (PE), Polyurethane (PU), polyvinyl chloride (PVC), polyolefins or polyesters. The pressing can be carried out cold or under the action of heat. Particles, in particular polymer fibres or natural fibres, can be used as binder material and as stabilisers, which then lead to good binding (consolidation) of the mineral particles, especially under the action of temperature and pressure, in particular if they are in the form of fibres. The fibers may be loose fibers and/or interconnected fibers, preferably woven and/or non-woven layers based on fibers. It is conceivable for the carrier core to comprise different material layers with different material compositions and/or different structures (for example different densities). The carrier core is typically solid, but may also be at least partially foamed and/or hollow.

The carrier cores produced from the above-mentioned carrier materials have proven to have a high water and heat resistance, in particular mechanical stability. Furthermore, a decorative layer formed by a printed film can be well attached to the surface of such a carrier core.

Preferably, the printed film is a film printed by digital printing. The production of the printed film, in particular the printing of suitable films, is carried out by printing an ink comprising a colouring pigment printed directly on the film. In principle, laser or inkjet printing processes are considered for digital printing, and so-called electronic ink processes can also be used. The production of printed films by means of digital printing is advantageously particularly cost-effective and also suitable for very small batches, so that a wide variety of decorative layers can be produced flexibly and inexpensively as required or according to individual specifications or customer requirements.

Alternatively, however, the printed film may also be printed by direct printing or by indirect printing or by other printing processes, such as screen printing processes, roll printing processes, gravure printing processes, etc.

The printed film is preferably made of plastic, in particular a thermoplastic polymer. Suitable plastics for use herein are, in particular, plastics such as polypropylene (PP), Polyethylene (PE), Polyurethane (PU), polyvinyl chloride (PVC), polyolefins or polyesters.

Alternatively, however, the printed film may also be made of other suitable materials, such as paper, impregnated paper, paper-based hybrid materials, or other suitable materials.

According to a particularly preferred embodiment, the printed film is bonded to the sheet-like carrier core, wherein at least one adhesive layer is arranged between the printed film and the sheet-like carrier core. In particular, by means of the adhesive layer covering the surface area or the entire surface area, a firm, stable connection can be established and a large connection resistance can be achieved. Thereby also minimizing the risk of separation or peeling of the printed film. The selection of a suitable adhesive for the adhesive layer also allows, in particular, for example, for a permanent connection of the different materials of the carrier core and of the printing film.

Furthermore, at least one adhesive layer is preferably arranged between the sheet-like support core and the adhesive layer and/or between the adhesive layer and the printed film. In this case, the adhesive layer consists of an adhesive, which in the present case may also be referred to as primer, in particular in the case of poorly bondable materials of the sheet-like support core and of the printed film, which forms a bond bridge between the respective material and the adhesive layer, thereby improving the bonding. In particular, the adhesive layer also provides particular advantages by improving the adhesion, since the high requirements of the area covering elements for outdoor use, in particular greater resistance to humidity and/or moisture and greater resistance to temperature, must be met.

It is advantageous to provide at least one primer layer on the underside of the carrier core. The primer layer typically further reinforces and/or makes the area covering element more durable. Preferably, the primer layer applied to the bottom side of the carrier core and possibly to the other sides of the carrier core is a water-impermeable (moisture-impermeable) layer. Preferably, the primer layer applied to the bottom side and/or possibly other sides of the carrier core protects the carrier core from moisture and/or termite (or other insect) infestation. It is also contemplated that the printed film is configured to protect the carrier core from moisture and/or termite (or other insect) infestation. In addition to (and on top of) and/or instead of the primer layer, the bottom side may be provided with a backing layer, for example a cork layer and/or a foamed layer and/or an elastic layer.

Depending on whether the area covering element is used as a wall covering, ceiling covering or floor covering, or depending on the arrangement of the floor covering (for example in a private dwelling or in a commercial site), or depending on whether the area covering element is self-supporting or rests on the base over its entire surface area, the carrier core may preferably have a thickness of between 2mm and 20mm or between 3mm and 30mm, preferably in the range of 5mm to 25mm, particularly preferably in the range of 7mm to 22mm, in particular in the range of 10mm to 15 mm. Most particularly preferred is a sheet-like support core having a thickness of about 8mm or about 12mm or about 18 mm.

The invention also provides a method for producing an area covering element, in which method at least one decorative layer formed from a printed film is applied to a sheet-like carrier core made of a solid load-bearing carrier material. For this purpose, the printed film is first arranged on the sheet-like carrier core in such a way that at least the upper side of the sheet-like carrier core and in each case at least the first and second side faces arranged opposite one another are at least partially covered by the printed film. The printed film is then firmly attached to the carrier core, after which at least one protective layer is applied, so that at least the printed film attached to the carrier core is covered over its entire surface area by the protective layer.

All the advantages and specific features already described above in connection with the area coverage element apply equally to this method and are not explicitly stated at this stage.

Preferably, the printed film is adhered at least on the upper side and on the first and second sides of the sheet-like support core; for this purpose, before the application of the printed film, an adhesive layer is applied at least on the upper side and on the first and second side of the sheet-like carrier core. Preferably, the printed film covers substantially the entire first and second sides of the carrier core. Preferably, the printed film extends to or towards the bottom side of the carrier core. Preferably, the printed film extends to a level below the optional interlocking means(s), also called coupling profiles, such as tongue and groove elements (seen from a top view of the area covering element). This may further protect the area coverage element, in particular in an interlocked state of a plurality of these area coverage elements. It is conceivable that at least two or all of the opposite sides of the area covering elements are provided with complementary coupling profiles, which are coupling profiles designed to co-act with each other to interlock adjacent area covering elements. However, it is also conceivable that only a single side of an area covering element (type a) is provided with a coupling contour, while a single side of another area covering element (type B) is provided with a complementary coupling contour. However, it is also conceivable that the opposite side of the area covering element (type a) is provided with a first coupling profile, while the opposite side of the other area covering element (type B) is provided with a complementary coupling profile. It is conceivable that at least one first coupling contour is located at the first side of the carrier core and/or at least one second coupling contour configured to co-act with the first coupling contour of an adjacent area covering element is located at the second side of the carrier core. This often results in a situation where the printed film overlaps the first coupling profile and/or the second coupling profile. This may be achieved by shaping the printed film according to the profile of the first coupling profile and/or the second profile. Alternatively, this may optionally be supplemented by breaking (opening) the printed film at the location of at least a part of the first coupling contour and/or at least a part of the second coupling contour. In addition to the first side and the opposite second side, the carrier core typically comprises a third side and a fourth side at the other two opposite sides. In a preferred embodiment, the printed film covers only at least a part of the upper side, at least a part of the first side and at least a part of the second side of the carrier core, and optionally the bottom side of the carrier core. This means that the third and fourth sides are not covered by the printed film. In the latter case, it may be advantageous to apply the first coupling profile to the third side and the second coupling profile to the fourth side, without any coupling profiles of the first and second sides (covered by the printed film). This results in a relatively easy to produce embodiment, while the first and second sides are well protected by the printed film, and wherein the coupling profiles at the third and fourth sides may be optimized for a reliable coupling between adjacent area covering elements. However, it is also conceivable that each side is provided with a coupling profile. More particularly, it is conceivable that the first side is provided with at least one first coupling profile, the second side is provided with at least one second coupling profile, the third side is provided with at least one third coupling profile, and the first side is provided with at least one first coupling profile. Typically, in this case, each coupling profile is complementary (meaning co-acting) with at least one other coupling profile. Each coupling profile may be different compared to the other coupling profiles. It is also conceivable that at least two coupling profiles at least two different sides of the area covering element are identical.

According to a preferred variant of the invention, the sheet-like support core is closed by a printed film; for this purpose, the printed film is arranged on the sheet-like carrier core such that not only the upper side and the first and second side faces are completely covered by the printed film, but also the bottom side of the sheet-like carrier core is completely covered by the printed film.

The invention is further illustrated by the following sixteen non-limiting terms:

1. an area covering element (1) comprising at least one sheet-like carrier core (2), at least one protective layer (4) and a decorative layer (3) arranged between the sheet-like carrier core (2) and the at least one protective layer (4); the sheet-like carrier core (2) consists of a solid load-bearing carrier material and has at least an upper side (5), a bottom side (6) arranged opposite the upper side (5) and at least a first side (7) and a second side (8) arranged opposite each other and connecting the upper side (5) and the bottom side (6), respectively, wherein the decorative layer (3) is formed by a printed film firmly connected to the carrier core (2), the printed film (3) at least partially covers at least the upper side (5) and the first side (7) and the second side (8) of the sheet-like carrier core (2), and the protective layer (4) covers at least the entire surface area of the printed film connected to the carrier core (2).

2. The area covering element (1) according to clause 1, wherein the printed film at least partially covers at least the upper side (5) and the bottom side (6) and the first side (7) and the second side (8) of the sheet-like carrier core (2).

3. The area coverage element (1) according to clause 2, wherein the printed film completely covers the upper side (5) and the bottom side (6) as well as the first side (7) and the second side (8) of the sheet-like carrier core (2).

4. The area covering element (1) according to one of clauses 1 to 3, wherein the printed film also extends at least partially on a third and a fourth oppositely arranged side of the sheet-like carrier core (2).

5. The area coverage element (1) according to one of the preceding clauses, wherein the protective layer (4) is formed by a surface coating.

6. The area coverage element (1) according to one of clauses 1 to 4, wherein the protective layer (4) is formed by a transparent useful layer, in particular a transparent protective film.

7. The area covering element (1) according to clause 6, wherein the useful layer, in particular the transparent protective film, is bonded to the printed film (3) by at least one layer of adhesive substance (11).

8. The area covering element (1) according to one of the preceding clauses, wherein the carrier material of the sheet-like carrier core (2) comprises wood, a wood material, a plastic composite, a mineral plastic composite or a mineral material.

9. The area coverage element (1) according to one of the preceding clauses, wherein the printed film is a film printed by digital printing.

10. The area covering element (1) according to one of the preceding clauses, wherein the printed film is made of plastic, in particular a thermoplastic polymer.

11. The area coverage element (1) according to one of the preceding clauses, wherein the printed film is bonded to the sheet-like carrier core (2), wherein at least one adhesive layer (9) is arranged between the printed film (3) and the sheet-like carrier core (2).

12. The area covering element (1) according to clause 11, wherein at least one adhesive layer (10) is further arranged between the sheet-like carrier core (2) and the adhesive layer (9) and/or between the adhesive layer (9) and the printed film (3).

13. The area coverage element (1) according to one of the preceding clauses, wherein the thickness of the sheet-like carrier core (2) is between 2mm and 25mm, in particular between 10mm and 20 mm.

14. A method for producing an area covering element (1), in which method at least one decorative layer (3) formed from a printed film is applied to a sheet-like carrier core (2) made of a solid load-bearing carrier material; for this purpose, the printed film (3) is arranged on the sheet-like carrier core (2) such that at least the upper side (5) and at least the first side (7) and the second side (8) of the sheet-like carrier core (2) are at least partially covered by the printed film (3); and firmly attaching the printed film (3) to the carrier core (2), and subsequently applying at least one protective layer (4) such that at least the printed film (3) attached to the carrier core (2) is covered over its entire surface area by the protective layer (4).

15. The method according to clause 14, wherein the printed film (3) is adhered at least on the upper side (5) and the first and second sides (7, 8) of the sheet-like carrier core (2); for this purpose, an adhesive layer (10) is applied at least on the upper side (5) and the first and second side faces (7, 8) of the sheet-like carrier core (2) before the application of the printing film (3).

16. The method according to clause 14 or 15, wherein the sheet-like carrier core (2) is enclosed by the printed film (3); for this purpose, the printed film (3) is arranged on the sheet-like carrier core (2) such that not only the upper side (5) and the first and second side faces (7, 8) are completely covered by the printed film (3), but also the underside (6) of the sheet-like carrier core (2) is completely covered by the printed film (3).

Drawings

The invention is described below, for example, on the basis of the schematic drawings, in which:

fig. 1 shows, in a substantially schematic representation, a side view of an embodiment of an area covering element according to the invention;

fig. 2 shows, in a substantially schematic representation, a side view of an alternative embodiment of an area covering element according to the invention;

FIG. 3 shows a detail of a preferred embodiment of an area coverage element in a schematic cross-sectional view;

FIG. 4 shows a detail of another preferred embodiment of an area covering element in a schematic sectional view;

FIG. 5 shows a detail of a further preferred embodiment of the area coverage element in a schematic cross-sectional view;

fig. 6a to 6d show different embodiments of an area covering element according to the invention with one or more coupling profiles in a schematic perspective view;

figure 7 shows a perspective view of a rectangular floor panel according to the invention;

FIG. 8 shows a cross-sectional view indicated by section A-A in FIG. 7;

fig. 9 is a sectional view indicated by a section B-B in fig. 7.

Detailed Description

Fig. 1 shows a substantially cubic or sheet-like area covering element 1 in a side view, the area covering element 1 being able to be assembled with other area covering elements 1 over a surface area in order to form a floor covering, a ceiling covering and/or a wall covering indoors or outdoors, in particular outdoors. In particular, the area coverage elements 1 may be laid in an interlocking fashion to form a decking panel.

The area covering element 1 comprises a sheet-like carrier core 2, the sheet-like carrier core 2 being formed substantially in the form of a cuboid and consisting of a strong load-bearing carrier material, such as wood or a wood-plastic composite. The sheet-like carrier core 2 has at least an upper side 5, a bottom side 6 arranged opposite the upper side 5, and four side faces which adjoin one another at right angles and which connect the upper side and the bottom side, respectively. In fig. 1, only the first side 7 and the second side 8, which are arranged opposite one another, carry a reference numeral. In the example shown, the thickness of the sheet-like carrier core 2 is approximately 20 mm.

The upper side 5 and the first and second side 7, 8 of the sheet-like carrier core 2 are covered by a decorative layer 3, the decorative layer 3 being formed by a printed film. The printed film 3 has a lower side facing the sheet-like carrier core 2 and an upper side opposite to the lower side and which may also be referred to as the visible side. The printed film 3, which in the example shown is approximately 80 μm thick, is firmly connected by its underside to the respective surface areas of the upper side 5 and the first and second side 7, 8 of the sheet-like carrier core 2.

On the upper or visible side of the printed film 3 there is also arranged a protective layer 4, which protective layer 4 is formed in the example shown by a surface coating in the form of a transparent lacquer, which lacquer can be applied in viscous or liquid form to the upper or visible side of the printed film 3 and then cured. The protective layer 4 covers the entire surface area of the printed film 3 connected to the carrier core 2. The visible side of the printed film 3 is still visible through the lacquer. The area of the upper side 5 can also be understood as the visible surface or upper surface area of the area covering element 1, which in the assembled floor covering also corresponds to the tread area.

Thus, in the case of the example of fig. 1, the sheet-like carrier core 2 is covered on three sides by the printed film 3 and thus also by the protective layer 4, so that the sheet-like carrier core 2 in the inventive concept is covered or coated on three sides by the printed film 3 and the protective layer 4.

Fig. 2 likewise shows a further exemplary embodiment of a sheet-like area covering element 1 according to the invention in a side view. The exemplary embodiment of fig. 2 differs from the exemplary embodiment of fig. 1 mainly in that the bottom side 6 of the sheet-like carrier core 2 is also completely covered by the printed film 3 and the protective layer 4, in addition to the upper side 5 and the first and second side 7, 8. The carrier core 2 is thus completely surrounded or enclosed by the printed film 3 and the protective layer 4.

Not shown in the figures, but as an alternative variant of embodiment, the protective layer 4 may additionally also be applied partially or completely on the surface area of the carrier core 2 not covered by the printed film 3.

Fig. 3 to 5 show in enlarged form in respective sectional views the details of different variants of the embodiment of the area covering element 1 according to the invention, each of the variants shown being able to be realized in the embodiment of fig. 1 and in the embodiment of fig. 2. In the case of all the variants shown in fig. 3 to 5, the printed film 3 is bonded to the carrier core 2 by its underside facing the carrier core 2. For this bonding, a full-surface-area layer of adhesive 9 is arranged in each case between the carrier core 2 and the printing film 3 for this purpose. In order to further improve the bonding of the adhesive layer 9 on the carrier material of the carrier core 2, an adhesive layer 10 is provided directly on the surface of the adhesive 9, the adhesive layer 10 likewise being applied over the entire surface area and thus being arranged between the surface of the carrier core 2 and the adhesive layer 9.

In the case of the example according to fig. 3 and 5, the adhesive layer 9 is in this case selected such that the adhesion or bonding between the adhesive layer 9 and the plastic material of the printed film 3 takes place optimally without any further precautions, so that the printed film 3 is connected directly to the adhesive layer 9 by its underside. In contrast, according to fig. 4, a further adhesive layer 10 is arranged between the adhesive layer 9 and the printed film 3 for improved adhesion.

In the case of the example of fig. 3 and 4, the protective layer 4 is formed by a surface coating, in particular a clear lacquer, which is applied directly to the visible side of the printing film 3 facing away from the carrier core 2 and is cured. In contrast, in the case of the example of fig. 5, the protective layer 4 is formed of a transparent protective film which is bonded to the visible side of the printed film 3 through the adhesive substance layer 11.

Fig. 6a to 6d show different embodiments of an area covering element according to the invention with one or more coupling profiles in a schematic perspective view. More specifically, these figures show imaginable different shapes of the area covering element according to the invention, wherein the depicted covering elements are each provided with one or more coupling profiles, allowing the area covering element to be connected to one or more other area covering elements. Here, fig. 6 shows a rectangular element 12 having a first coupling contour 13a at a first side 12a and a second coupling contour 13b at an opposite second side 12 b. The first coupling contour 13a is configured to interact with a second coupling contour 13b (of another (similar) area covering element). In this example, the first coupling profile 13a is formed by a groove extending along the first side 12a and extending in a direction parallel to the plane defined by the area covering element 12, while the second coupling profile 13b is formed by a tongue extending along the second side 12b of the area covering element 12 in a direction parallel to the plane defined by the area covering element 12. The tongue 12b may be clamped in the groove 12a to achieve a vertical locking effect and to some extent a horizontal locking effect. For example, as shown in the previous figures, the printed film may cover the combination of the first side 12a and the second side 12b and/or the combination of the remaining third side 12c and the opposite fourth side 12 d. The printed film typically covers the entire upper side 12e of the cover element 12 and may also cover at least a portion of the bottom side 12f of the cover element 12.

In fig. 6B, two different area covering elements 14, 15 (type a and type B) are shown, wherein each area covering element 14, 15 is provided with a single coupling profile 14a, 15a, wherein the coupling profiles 14a, 15a of the different covering elements 14, 15 are configured to co-act with each other.

In fig. 6c, the area coverage element 16 is shown, the area coverage element 16 being provided with alternative complementary coupling profiles 16a, 16 b. Here, the first coupling profile 16a comprises a pin or tongue 16aa and two holes 16ab, 16ac, and the second coupling profile 16b comprises a hole 16ba and two pins or tongues 16bb, 16 bc. Since the coupling profiles 16a, 16b are configured to interact with one another, different covering elements 16 can be (mechanically) connected to one another. In fig. 6d an alternative embodiment is shown, wherein in practice two different area covering elements 17, 18 (type a and type B) are shown, wherein each area covering element 17, 18 is provided with a single coupling profile 17a, 18a, wherein the coupling profiles 17a, 18a of the different covering elements 17, 18 are configured to co-act with each other. It will be apparent that, instead of the illustrated configuration, other configurations of one or more holes and/or one or more tongues (or pins) may be applied at one or more sides of the area covering element 16.

Figure 7 shows a rectangular floor panel 101 according to the invention. The panels 101 can be interconnected with similar panels for forming a covering, as will be shown in further figures. The floor panel 101 may be made of any material, but typical materials are wood, in particular HDF, MDF and LDF, mineral materials and/or plastics, in particular thermoplastics, more in particular PVC. Typically, the floor panel 101 is made of a laminate comprising a central layer (core layer) surrounded by a backing structure and a top structure (not shown). The top structure comprises a decorative layer, usually formed by a printed film, on which a protective layer is applied. The panel 101 comprises a centrally located core 102, the core 102 being provided with an upper side 103 and a lower side 104. The core 102 is integrally connected with a first pair of opposite edges, in particular a first edge 105 and a complementary second edge 106, located at the long lateral sides of the panel 101. In this exemplary embodiment, the core is also integrally connected with a second pair of opposite edges, in particular a third edge 107 and a complementary fourth edge 108, located at the short sides of the panel 101. The decorative layer at least partially covers the upper side 103 and one or more side edges 105, 106, 107, 108 of the core 102.

Fig. 8 is a sectional view indicated by a-a section in fig. 7. In this cross-sectional view, the shape of the complementary first 105 and second 106 edges is shown in detail. The first edge 105 comprises a lateral tongue 109, the lateral tongue 109 being integrally connected to the core 102. The boundary between the lateral tongue 109 and the core 102 is visualized by a vertical dashed line. The front area 109a of the lateral tongue 109 is provided with a rounded bottom surface 110. The outer end of the rounded bottom surface 110 abuts the inclined locking surface 111. The opposite end of the rounded bottom surface 110 abuts a support surface 112, the support surface 112 constituting a part of the rear region 109b of the lateral tongue 109. The second edge 106 of the panel 101 comprises an upper lip 113 and a lower lip 114, the upper lip 113 and the lower lip 114 defining a recess 115. The two lips 113, 114 are integrally connected to the core 102. The vertical dashed lines visualize the boundaries between the lips 113, 114 and the core. As shown in fig. 8, the width of the upper lip 113 is substantially less than the width of the lower lip 114. The recess 115 has a shape complementary to the shape of the lateral tongue 109. More particularly, the top surface 116 of the rear region 114a of the lower lip 114 has a (complementary) rounded shape configured to co-act with the rounded front region 109a of the lateral tongue 109, whereas the front region 114b of the lower lip 114 is provided with an upwardly protruding shoulder 117, the shoulder 117 being configured to co-act with the bearing surface 112 of the lateral tongue 109. The lower surface 118 of the upper lip 113 is inclined and corresponds to the locking surface 111 of the lateral tongue 109. By inserting the lateral tongues 109 of the panels 101 to be coupled into the recesses 115, a locking is achieved at the first edge 105 and the second edge 106 of adjacent panels 101, wherein the panels 101 are initially held in an inclined position. After insertion of the lateral tongue 109 into the recess, the panel 101 to be coupled will pivot (tilt) in a downward direction about an axis parallel to the first edge 105 until both panels 101 are located in the same (usually horizontal) plane, wherein the locking surface 111 of the lateral tongue 9 will engage with the locking surface of the upper lip 118 and at least the bottom front portion is substantially form-fittingly received in the recess 115, and wherein the bearing surface 112 is supported by the shoulder 117. The locking at the first edge 105 and the second edge 106 results in a locking of the connected panels 101 in the horizontal direction and in the vertical direction. The downwardly sloping locking principle of the first edge 105 and the second edge 106 is a relatively easy locking principle which greatly facilitates the mutual coupling of the panels at these edges 105, 106.

Fig. 9 is a sectional view indicated by a section B-B in fig. 7. In this cross-sectional view, the shape of the complementary third edge 107 and second edge 108 is shown in detail. The third edge 107 includes an upward tongue 119, an upward flank 120, and an upward groove 121 formed between the upward tongue 119 and the upward flank 120. The upward tongue 119 is connected to the core 102 by a bridge 122, the bridge 122 preferably being somewhat resilient. The side 119a of the upward tongue 119 facing the upward flank 120 is at the normal N of the upper side 103 of the core 102₁Extend in the direction of (a). Therefore, the tangent line R₁And normal N to upper side 103 of core 102₁Point towards each other (convergent orientation), wherein in the exemplary embodiment by R₁And N₁The angle of wrap is preferably between 0 and 10 degrees. Due to the converging orientation of the upward flank 120 and the side 119a of the upward tongue 119 facing the upward flank 120, the upward groove 122 is a closed groove, which the complementary counterpart can only be brought into contact with by deformation of the upward tongue 119 and/or the bridge 122. The other side 119b of the upward tongue 119 facing the upward flank 120 forms or may form an alignment edge, thereby enabling coupling with an adjacent floor panel 101 to be easily achieved. As shown, this side 119b, which serves as an alignment edge, is normal N to the upper side 103 of the core 102₁Pointing away from each other. However, the upper side 119d of the upward tongue 119 is along a normal N to the upper side 103 of the core 102₁And extends obliquely downwards in the direction of the side 119e of the upward tongue 119 facing away from the upward flank 120. This chamfer provides the option of providing a more robust and therefore more robust form to the complementary fourth edge 108. A part of a side 119e of the upward tongue 119 facing away from the upward flank 120 is oriented substantially vertically and is further provided with an outward projection 123. The lower portion 120a of the upward flank 120 is oriented at an oblique angle, while the upper portion 120b of the upward flank 120 is shown as being substantially vertical and forming a stop surface for the fourth edge 108. Between the inclined portion 120a of the upward flank and the substantially vertical portion 120b, an additional coupling element, in particular an additional projection 124, is provided. In the exemplary embodiment, lower wall portion 121a of upward groove 121 is oriented substantially horizontally. The fourth edge 108 is substantially complementary to the third edge 107. The fourth edge 108 includes a downward tongue 125, a downward flank 126, and a downward groove 127 formed between the downward tongue 125 and the downward flank 126. The downward tongue 125 is connected to the core 102 by a bridge 128, the bridge 128 preferably being somewhat resilient. The side 125a of the downward tongue 125 facing the downward flank 126 is located at the normal N of the lower side 104 of the core 102₂In the direction of (a). This means that the tangent line R to one side 125a of the downward tongue 125₂And the normal of the underside 104 of the core 102, where in the exemplary embodiment, R is₂And N₂The angle of wrap is preferably between 0 and 10 degrees. More preferably, R₁Angle of inclination and R₂Are the same. Thus, R₁And R₂Preferably parallel. Due to the converging orientation of the downward flank 126 and the side 125a of the downward tongue 125 facing the downward flank 126, the downward groove 127 is a closed groove, which the upward tongue 119 of the adjacent panel 101 can only be brought into contact with by deformation of the downward tongue 125 and/or the bridge 128, whereby the entrance of the downward groove can be widened (temporarily). The side 125b of the downward tongue 125 facing away from the downward flank 126 is oriented at an oblique angle, but has a flatter orientation than the complementary side 120a of the upward flank 120, so that in the coupled position a gap (air space) will be formed, which will normally facilitate the coupling between two floor panels 101. The inclined side 125b of the downward tongue 125 also serves as an alignment edge to further facilitate the coupling between the two floor panels 101. The other side 125c facing away from the downward flank 126 takes a substantially vertical form, but is provided with a small cavity 129, which small cavity 129 is configured to co-act with an additional projection 124 of another panel 101. The top of the side 125c facing away from the downward flank 126 forms a complementary stop surface for the stop surface 120b of the upward flank 120 (of an adjacent floor panel). The downward flank 126 is oriented substantially vertically and is provided with a recess 130, the recess 130 being adapted to receive the outward protrusion 123 of the upward tongue 119 (of an adjacent floor panel).

The above inventive concept is illustrated by several illustrative embodiments. It is contemplated that various inventive concepts may be applied without the application of the other details of the described examples. It is not necessary to describe in detail all conceivable combinations of the above-described inventive concepts, since a person skilled in the art will understand that many inventive concepts may be (re) combined to achieve a specific application.

It is obvious that the invention is not limited to the examples shown and described here, but that within the scope of the appended claims many variants are possible, which are obvious to a person skilled in the art.

The verb "to comprise" and its conjugations as used in this patent publication is understood to mean not only "comprising", but also the phrases "comprising", "consisting essentially of … …", "formed of … …" and its conjugations.

List of reference numerals

1 area covering element

2 sheet-like carrier core

3 decorative layer-printed film

4 protective layer

5 upper side

6 bottom side

7 first side of

8 second side surface

9 adhesive layer

10 adhesive layer

11 adhesive substance layer