IP Library Granted Patent US 12680313
Granted Patent B2
US 12680313 · App. 18/696,655 · Granted Jul 14, 2026

Decorative panel, method of producing such a panel, and a surface covering which is constructed by a multitude of such panels

Inventor: Eddy Alberic Boucké (Turnhout, BE)
Assignee: i4F Licensing NV
E04F13/0866B32B3/06B32B5/02B32B7/02B32B9/047B32B37/12B32B38/145E04F13/0894E04F15/02038E04F15/107B32B2255/20B32B2260/021B32B2260/046B32B2264/10B32B2264/303B32B2307/4026B32B2307/7376B32B2451/00B32B2607/00E04F2201/0138E04F2201/0153E04F2201/023E04F2201/042E04F2201/043
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Quick Facts
Patent No.
US 12680313
App. No.
18/696,655
Filed
Mar 28, 2024
Granted
Jul 14, 2026
Kind
B2
Art Unit
1785
USPC
428/192
Abstract

Provided is a decorative panel, in particular a wall, floor or ceiling panel, of a planar design having a top side, a bottom side and side edges. The side edges include at least one pair of opposite side edges, and preferably two pairs of opposite side edges. Each pair of opposite side edges is provided with mutually interconnecting profiles that are configured to allow for an interconnection of two adjacent panels. The panel includes a carrier layer which is made from a single layer of a ceramic, stone, and/or mineral material. The carrier layer has an upper side that is provided with a printed layer having a decorative image which includes inorganic pigments, in particular metal-based pigments. The printed layer preferably is a glaze layer.

Claims (24)

1 . A decorative panel of a planar design having a top side, a bottom side and side edges,

wherein the side edges comprise at least one pair of opposite side edges, wherein each pair of opposite side edges is provided with mutually interconnecting profiles that are configured to allow for an interconnection of two adjacent panels,

wherein the decorative panel comprises a carrier layer which is made from a single layer of a mineral material,

wherein the mineral material is a wool layer comprising vitreous fibres bonded together by a cured thermoset polymeric binder material, wherein the wool layer comprises at least one of stone wool, mineral wool, slag wool, basalt wool, and/or glass fibres;

and wherein the carrier layer has an upper side that is provided with a glaze layer having a decorative image;

wherein the decorative image is provided by printing of one or more ceramic inks on the upper side of the carrier layer, wherein the one or more ceramic inks include inorganic pigments,

wherein the inorganic pigments comprise a metal complex containing carboxylate, alkoxide, β-diketonate, cyclopentadienate, pyrazolate, imidazolate, naphthanate, thiocarboxylate, dithiocarboxylate, organophosphorus, organosulfur, phosphate, phosphite, nitrate, nitrite, halide, perchlorate, hydroxide, ammonium, borate, and/or metal oxoanion.

2 . The panel according to claim 1 , wherein the inorganic pigments comprise a metal complex containing lithium, sodium, potassium, Group II element, Group IIB element, transition metal, lanthanide, silicon, gallium, germanium, arsenic, selenium, indium, tin, antimony, lead, and/or bismuth.

3 . The panel according to claim 1 , wherein the inorganic pigments have an average particle size of 40 microns or smaller.

4 . The panel according to claim 1 , wherein the panel has an overall thickness of 2 to 20 mm.

5 . The panel according to claim 1 , wherein the panel further includes a backing layer that is directly or indirectly adhered to a bottom side of the carrier layer.

6 . The panel according to claim 1 , wherein the interconnecting profiles allow for a coupling of two panels by a vertical and/or an angling movement of the respective side edges.

7 . A method of producing a panel as defined in claim 1 , comprising the steps of:

i) producing a carrier layer made from a mineral material;

ii) providing an upper side of the carrier layer with a printed layer having a decorative image which includes inorganic pigments, which printed layer is a glaze layer,

wherein in step ii) the printed layer is-is provided by printing of one or more ceramic inks on the upper side of the carrier layer, wherein the ceramic inks are formulated as a dispersion of inorganic pigments in a liquid medium, and wherein the printed layer is fired after printing in order to obtain a glaze layer, and wherein the inorganic pigments comprise a metal complex containing carboxylate, alkoxide, β-diketonate, cyclopentadienate, pyrazolate, imidazolate, naphthanate, thiocarboxylate, dithiocarboxylate, organophosphorus, organosulfur, phosphate, phosphite, nitrate, nitrite, halide, perchlorate, hydroxide, ammonium, borate, and/or metal oxoanion.

8 . The method according to claim 7 , wherein the dispersion of inorganic pigments in a liquid medium further comprises a flux material or a frit which comprises at least one element selected from frits, zirconium silicate, zinc oxide, dolomite, calcite, kaolin, quartz, barium carbonate, wollastonite, nepheline, colemanite, calcium carbonate, cerium oxide, cobalt oxide, copper oxide, aluminium phosphate, iron carbonate, manganese oxide, sodium fluoride, chromium oxide, strontium carbonate, lithium carbonate, spodumene, talc, cristobalite, rutile, anatase, or a mixture thereof.

9 . The method according to claim 7 , wherein the dispersion of inorganic pigments in a liquid medium further comprises an anti-settling material which is selected from carbon black, clay, kaolin, aluminium silicate, carboxymethyl cellulose, bentonite, colloidal magnesium oxide and hydroxide, calcium, strontium, barium, tungsten, zinc, aluminum, silicon, tin and antimony.

10 . The method according to claim 7 , wherein the method comprises the additional step of:

providing each pair of opposite side edges of the panel with respective interconnecting profiles that are configured to interconnect with each other and thereby allow an interconnection of two adjacent panels that are obtained by the method, wherein the interconnecting profiles are formed by milling.

11 . A surface covering, in particular for a floor, ceiling or wall surface, which is constructed by a multitude of adjacent panels according claim 1 .

12 . The panel according to claim 1 , wherein the carrier layer forms a main body of said panel.

13 . The panel according to claim 1 , wherein the glaze layer has peripherical sides that run parallel to corresponding side edges of the carrier layer, wherein a constant gap width exists between each peripherical side of the glaze layer and each corresponding side edge of the carrier layer.

14 . The panel according to claim 1 , wherein the interconnecting profiles of the panel are an integral part of the carrier layer.