Panel and method for producing a panel
The invention relates to a panel and a method for producing a panel. The panel is in particular a floor, wall or ceiling panel, and comprises at least one core layer, the core layer comprising an upper core surface and a lower core surface and at least one pair of opposite side edges; wherein the core layer comprises magnesium oxide cement; wherein the core has a density which is substantially homogenous over its entire volume, and wherein at least one decorative top layer is attached to an upper core surface of the core layer.
1. A floor, wall, or ceiling panel, comprising:
at least one core layer, the core layer comprising an upper core surface and a lower core surface and at least one pair of opposite side edges;
wherein the at least one core layer has a density in a range of 1350 kg/m 3 to 1550 kg/m 3 and comprises a cement comprising magnesium oxide and having a crystal structure expressed as a ternary system of magnesium oxide, a magnesium salt, and water;
wherein the at least one core layer further comprises at least 20 wt % natural fibers disperse in said cement;
wherein the natural fibers comprise fibers encapsulated by the cement and form an interconnected matrix with the cement crystals in the core layer;
wherein the natural fibers form a reinforcing network across the entire volume of the core layer; and
wherein the density of the core layer is substantially constant over the entire volume of the core layer, wherein the spatial variation of density is below 10% over the entire volume of the core layer.
2. The panel according to claim 1 , wherein the average length of the natural fibers is at least 2 mm.
3. The panel according to claim 2 , wherein the average length of the natural fibers is between 2 and 10 mm.
4. The panel according to claim 3 , wherein the average length of the natural fibers is between 2 and 5 mm.
5. The panel according to claim 1 , wherein at least one core layer does not contain a reinforcing layer or fiberglass.
6. The panel according to claim 1 , wherein at least part of the upper core surface and/or at least part of the lower core surface has/have a density that is less than 5% higher than the density of the at least one core layer.
7. The panel according to claim 1 , wherein the natural fibers comprise at least one chosen from the group consisting of: wood fibers, bamboo fibers, animal fibers, and/or mycelium fibers.
8. The panel according to claim 1 , wherein the cement comprises the magnesium oxide in at least 30 wt %.
9. The panel according to claim 1 , wherein the at least one core layer comprises at least 30 wt % natural fibers and up to 60 wt % natural fibers.
10. The panel according to claim 1 , wherein the magnesium salt comprises magnesium chloride and/or magnesium sulphate.
11. The panel according to claim 1 , wherein the cement comprises the magnesium chloride and/or magnesium sulphate in at least 30 wt %.
12. The panel according to claim 1 , wherein the crystal structure comprises stable crystalline phases of a 3-phase form and/or a 5-phase form.
13. The panel according to claim 1 , wherein the density of the at least one core layer is from 1400 to 1500 kg/m 3 .
14. The panel according to claim 1 , wherein the at least one pair of opposite edges is provided with complementary coupling parts.
15. The panel according to claim 1 , comprising at least one decorative layer on at least one surface of the at least one core layer.
16. The panel according to claim 15 , wherein the decorative layer comprises a thermoplastic or thermosetting resin, at least one ply of lignocellulose impregnated with a resin, a decorative print printed directly on at least one surface of the core layer, a PVC decorative film, a PP decorative film, a PET decorative film, a stone veneer, a wood veneer, a high pressure laminate (HPL), a plurality of impregnated layers, a decorative plastic or vinyl, linoleum, a decorative thermoplastic film, an acoustic layer, and/or a transparent and/or thermoplastic wear layer.
17. The panel according to claim 1 , wherein the at least one core layer comprises at least one filler chosen from the group consisting of: talc, calcium carbonate, perlite, polymer foam beads, and/or a combination thereof.
18. The panel according to claim 1 , wherein the at least one core layer has a thickness between 3 and 10 mm.
19. The panel according to claim 1 , wherein the at least one core layer comprises at least one compound chosen from the group consisting of: ferric oxide, silica fume, calcium chloride, calcium hydroxide, sodium hydroxide, aluminum sulphate and/or sodium carboxymethyl cellulose.
20. A method for producing the floor, wall, or ceiling panel according to claim 1 , comprising the steps of:
a) forming a magnesium oxide cement damp composition comprising at least the magnesium oxide, magnesium salt, natural fibers, and water;
b) subjecting the magnesium oxide cement damp composition to at least one sieving step;
c) applying at least one layer of the magnesium oxide cement damp composition upon a mold part; and
d) subjecting the magnesium oxide cement damp composition to a force having a pressure of at least 7 MPa.