A wall or ceiling panel includes a substrate layer and a top layer. The substrate layer, on at least one pair of opposite edges, is provided with mechanical coupling parts, and a backing layer is provided onto the surface of the substrate layer opposing the top layer, which backing layer at least partly covers the substrate layer. The backing layer at least partly extends beyond one of the edges. An assembly of a wall or ceiling panel, and a A connection member for an assembly of a wall or ceiling panel is configured to connect to the mechanical coupling parts on at least one of the edges of the substrate layer, and to at least partly extend beyond one of the edges of the substrate layer.
Legal claims defining the scope of protection, as filed with the USPTO.
.-. (canceled)
. A wall or ceiling panel, which comprises a substrate layer and a top layer, said top layer optionally comprising a decoration layer, and a wear layer provided above said decoration layer,
. The wall or ceiling panel according to, wherein said backing layer at least partly extends beyond two non-opposing edges of said substrate layer.
. The wall or ceiling panel according to, wherein said backing layer at least partly extends beyond at most two edges of said substrate layer.
. The wall or ceiling panel according to, wherein said backing layer at least partly extends beyond at most one edge of said substrate layer.
. The wall or ceiling panel according to, wherein said backing layer extends uninterruptedly along said one or more edges of said substrate layer.
. The wall or ceiling panel according to, wherein at the height of said one or more edges of the substrate layer, beyond which the backing layer extends, the backing layer extends interruptedly along approximately the entire length of said one or more edges of said substrate layer.
. The wall or ceiling panel according to, wherein said backing layer is positioned off-set with regard to the edges of said substrate layer.
. The wall or ceiling panel according to, wherein said backing layer at least partly extends beyond a first edge of said substrate layer over a first distance, and
. The wall or ceiling panel according to, wherein said backing layer has a tensile strength of between 5 and 50 MPa and/or a Young's modulus of between 0.01 and 5.00 GPa.
. The wall or ceiling panel according to, wherein said backing layer comprises a material chosen from the group of a woven textile material, a non-woven textile material, a glass fiber cloth, a polymer material, a foamed polymer material, an elastomeric material, a thin metallic or polymeric foil, or combinations thereof.
. The wall or ceiling panel according to, wherein said backing layer comprises one or more connection regions, which connection regions are configured for receiving one or more connection elements chosen from the group of nails, screws, staples, or combinations thereof.
. An assembly of a wall or ceiling panel and a connection member, wherein said wall or ceiling panel comprises a substrate layer, and a top layer, said top layer optionally comprising a decoration layer, and a wear layer provided above said decoration layer,
. The assembly according to, wherein said connection member comprises a panel-side part and a wall-side part,
. The assembly according to, wherein said wall-side part comprises at least a first material zone having a tensile strength of between 5 and 50 MPa and/or a Young's modulus of between 0.01 and 5.00 GPa.
. The assembly according to, wherein said wall-side part comprises at least a first material zone comprising a material chosen from the group of a woven textile material, a non-woven textile material, a glass fiber cloth, a polymer material, a foamed polymer material, an elastomeric material, a thin metallic or polymeric foil, or combinations thereof.
. The assembly according to, wherein said wall-side part comprises at least a second material zone which at least partly surrounds said first material zone,
. The assembly according to, wherein said wall-side part comprises one or more connection regions, which connection regions are configured for receiving one or more connection elements chosen from the group of nails, screws, staples, or combinations thereof.
. The assembly according to, wherein said wall-side part comprises at least a first material zone and said connection regions comprise a material which is more rigid than said first material zone.
. A connection member for installing wall or ceiling panels, said wall or ceiling panels being provided with at least one profiled edge, said connection member comprising:
. The connection member according to, wherein said connection region is flexibly and/or movably mounted at least by means of one of the following or a combination thereof: a portion having a material composition different from another portion of said connection member; a compressible and/or expandable material portion; a folded material portion; a bendable material portion; one or more spring portions, hinge portions, angle portions, sliding portions, or combinations thereof.
Complete technical specification and implementation details from the patent document.
The present invention concerns wall or ceiling panels, connection members, and assemblies for covering walls or ceilings, in particular assemblies comprising wall or ceiling panels and connection members cooperating therewith.
Panels for mounting on walls or ceilings are commonly installed by gluing, or by fixing by for example nailing or screwing, to a wall or ceiling, or a supporting structure in and/or on said wall or ceiling. Example of such panels are disclosed in WO 01/38668 and WO 2019/003100. As such installation methods only allow installation of panels to a wall or ceiling in a substantially fixed way, there may be some disadvantages related thereto, when used with particular panels. Many substate materials of floor or wall panels may be prone to thermal expansion and/or shrinkage. As the panels cannot move freely, such expansion and/or shrinkage may lead to gaps appearing in between panels, and/or to doming of the panels. In case of gluing, deformation of the panels may furthermore lead to loosening of the panels from the wall or ceiling, or, in case of nailing or screwing, deformation of the panels may lead to breakage and/or ripping of the panels in those spots where a screw or nail is applied.
WO 02/052113 A2 discloses a connection member which loosely slides on the bottom of the panel, thereby allowing free movement of the panel with regard to the connection member. However, by allowing such a free movement of the panel with regard to the connection member, such panel may not be adequately supported onto a wall or ceiling. The connection member has particular requirements from the point of view of strength and size, and may be costly. Further specially profiled wall panels are required to enable a good slidable connection to the connection member.
The present invention in the first place aims at providing alternative wall or ceiling panels, connection members or assemblies for covering wall or ceilings, wherein in accordance with preferred embodiments one or more problems of the state-of-the art may be solved. In particular, the present invention seeks to provide wall or ceiling panels which may be installed in such a way that they may overcome certain problems related to expansion and/or crimping, in an economic manner, while providing sufficient support onto a wall or ceiling.
Therefore, the present invention, according to its first independent aspect, is a wall or ceiling panel, wherein said panel is provided with mechanical coupling parts, on at least one pair of opposite edges, and with as a characteristic that a surface of said panel, preferably a major surface of said panel, is provided with a backing layer at least partly covering said surface and partly extending beyond one or more of said opposite edges.
Preferably, said major surface that is provided with said backing layer is opposite a major surface forming the decorative side of said wall or ceiling panels, i.e. opposite the side of the wall or ceiling panels that is visible in use. According to the most preferred embodiment, such decorative side may be formed by a top layer applied to a substrate layer of said panel. Such top layer may then comprise a decoration layer, and potentially a wear layer applied on said decoration layer. It is hence clear that, according to the most preferred embodiment, the invention is a wall or ceiling panel which comprises a substrate layer and a top layer, said top layer comprising a decoration layer, and a wear layer provided above said decoration layer, wherein said panel, preferably said substrate layer, on at least one pair of opposite edges, is provided with mechanical coupling parts, and wherein a backing layer is provided onto the major surface of the substrate layer opposing the top layer, with as a characteristic that said backing layer at least partly covers said substrate layer, and wherein said backing layer at least partly extends beyond one or more of said edges.
The mechanical coupling parts preferably allow effecting a locking between two of such wall or ceiling panels in a first direction perpendicular to the plane of the coupled wall or ceiling panels, and in a second direction parallel to the plane of the coupled wall or ceiling panels and perpendicular to the coupled edges. It is however not excluded that the mechanical coupling parts would allow for a locking in said first or in said second direction only. The mechanical coupling parts may be supplemented in use with a glue. The mechanical coupling parts may be basically shaped as a tongue at one edge and a groove at an opposite edge. The groove is e.g. delimited by an upper lip and a lower lip. The tongue and groove are essentially responsible for said locking in said direction perpendicular to the plane of the coupled wall or ceiling panels and/or in said direction parallel to the plane of the coupled wall or ceiling panels and perpendicular to the coupled edges. The tongue and groove may further comprise locking means preventing the drifting apart of the tongue and the groove, when in coupled condition. The locking means may comprise a protrusion on the upper side of the lower lip for cooperation with an excavation at the bottom of the tongue. With respect to wall or ceiling panels the lower lip is regarded as that groove lip which is positioned the closest to the wall or ceiling to be covered with the respective panels. Preferably the said panels comprise a first pair of opposite edges and a second pair of opposite edges, wherein both said pairs of opposite edges comprise mechanical coupling means as described above. The mechanical coupling means of the first pair of opposite edges can be configured such that two of such panels can be coupled to each other at these edges by means of a turning movement or a downward movement. The mechanical coupling means of the second pair of opposite edges can be configured such that two of such panels can be coupled to each other at these edges by means of a turning movement or a downward movement. For example the mechanical coupling means of both pair of opposite edges can configured to allow coupling by a turning movement. These type of coupling parts can be as described in WO 97/47834, WO 2021/070022, WO 2021/105798 or WO 2021/059062. The coupling parts described in these patent publications are incorporated by reference. For example the mechanical coupling means of the first pair of opposite edges can be configured to allow coupling by a turning movement and the mechanical coupling means of the second pair of opposite edges can be configured to allow coupling by a downward movement.
These latter panels can be installed by means of the so-called “fold down” method. These type of coupling parts can be as described in WO 2017/115202, WO 2021/111210, WO 2017/068523 or WO 2009/066153. The coupling parts described in these patent publications are incorporated by reference.
Preferably, said panels are rectangular, i.e. oblong or square, and thus also comprise a second pair of opposite edges. Preferably said second pair of opposite edges is provided with coupling parts as well, providing a locking in said first and/or in a second direction parallel to the plane of the coupled wall or ceiling panels and perpendicular to the second pair of edges.
The wall or ceiling panels of the first aspect may be particularly easy to install while still allowing expansion and shrinkage of the panels. The portion of the backing layer which extends beyond said one or more edges is suitable to connect said panel to a wall or ceiling, while this portion of the backing layer may be hidden behind an adjacent panel connected to said wall or ceiling panel. The wall or ceiling panel according to the invention may thus for example be connected to a wall or ceiling or a frame, by means of stapling, nailing or screwing through said part of the backing layer extending beyond said one or more edges. In this manner the staples, nails or screws may be hidden behind an adjacent panel. The wall or ceiling panel according to the invention could for example be connected to a wall or ceiling or a frame, by means of an adhesive, through said part of the backing layer extending beyond said one or more edges. For this, said part of the backing layer extending beyond said one or more edges, could be provided with adhesive. Said adhesive could be covered by a removable, for example peelable, protection layer—such as a strip—, which should than be removed during installation of said panel, to glue the said part of the backing layer to the wall or ceiling or frame. It is also possible to provide the adhesive during installation. By preference, the backing layer at least partly extends beyond the coupling parts as provided on at least one pair of opposite edges of the substrate layer.
Panels may thus be installed on a wall or ceiling by at least the following steps:
These steps may then potentially be repeated, wherein the step of fixing does not necessarily have to be executed immediately subsequently to the step of installing the respective panel.
It is clear that said backing layer extends along at least a portion of said one or more edges, said portion preferably forming the majority of the respective edge. The manner in which the backing layer extends along said one or more edges may be many of which here below practical examples are described, without desiring to be exhaustive. The thickness of the backing layer can be between 0.5 mm and 3 mm, for example between 1 mm and 1.5 mm.
According to a first practical example, the parts or portions of said backing layer extending beyond an edge, extend in one piece along said majority of the respective edge, i.e. along 50 percent or more of the length of the edge of the panel. Preferably, the parts or portions of said backing layer extending beyond an edge, extend in one piece along said majority of the respective edge, and preferably along at most 99 percent of the length of said edge, such that the risk of overlapping backing layers of coupled panels is low. Preferably the length of the backing layer is at least 1 mm shorter than the length of the corresponding edge it extends beyond, more preferably at least 2 mm. Preferably, the respective edge is free from other backing layer parts, i.e. other than the backing layer portion that extends in one piece along said majority of the respective edge, independently whether such other backing layer parts are performed in one piece with the backing layer portion extending along the majority of said edge.
According to a second practical example, said backing layer at least partly extends beyond at least two non-opposing edges of said panel or substrate layer, for example, in the case of rectangular panels, said backing layer may extend at least partly beyond at least one edge of said first pair and at least one edge of said second pair of opposite edges. Preferably, the respective portions or parts extending beyond said two non-opposing edges form part of the same one piece backing layer. Alternatively, it is not excluded that said respective portions would be performed as separated backing layer portions.
In the second practical example, the part or portion of the backing layer which extends beyond said two non-opposing edges of the substrate layer may be suitable to connect said panel to a wall or ceiling, and may be beneficial as it is easier to control the position of the panel. By having extending parts of the backing layer beyond two non-opposing edges of the substrate layer, a more secure installation of the panel may be obtained, independently of the type of mechanical coupling parts applied at said edges, if any.
It is clear that the second practical example may be combined with the first practical example. Herein the backing layer extends in one piece along the majority of at least one or at least both of said non-opposing edges. Preferably one or both of said non-opposing edges are free from other backing layer parts or portions i.e. other than the backing layer portion that extends in one piece along said majority of the respective edge, independently whether such other backing layer parts are performed in one piece with the backing layer portion extending along the majority of said edge.
According to a first special possibility of said first practical example, said backing layer at least partly extends beyond one edge only. For example, if the panels are rectangular panels with a first pair of opposite long edges and a second pair of opposite short edges, the said backing layer at least partly extends beyond a said long edge only. Further preferably, if said long edges comprise mechanical coupling parts shaped as a said tongue and a said groove, the backing layer preferably extends beyond the long edge comprising the groove. Further preferably, the backing layer extend in one piece along said majority of the respective long edge, i.e. along 50 percent or more of the length of the edge of the panel, more preferably along 80 percent or more of the length of the long edge. According to a second special possibility of at least said second practical example, said backing layer at least partly extends beyond two non-opposing edges only. In summary, these special possibilities, relate to a backing layer extending at least party beyond at most two edges and/or to a panel having extending backing layer portions at most at two edges only. It is clear that the remaining edges are thus free from other backing layer parts or portions. These special possibilities may avoid that, in an installed condition, the part of the backing layer which extends beyond the edges of the substrate layer coincides with the extending part of the backing layer of an adjacent panel.
According to a third special possibility, said backing layer at least partly extends beyond at least both edges of a pair of opposite edges. Preferably, in such case, the backing layer portions extending beyond respective opposing edges are preferably positioned in a staggered relationship, namely wherein the portion of the edge directly opposite to a portion of an edge having an extending backing layer portion, is free from an extending backing layer portion itself. In this way, these directly opposite edge portions can be installed adjacently without the extending backing layer portions obstructing the good installation. According to another possibility, the backing layer portions extending beyond respective opposing edges are positioned at least partly opposite to each other, namely wherein a portion of the edge directly opposite to a portion of an edge having an extending backing layer portion, also comprises an extending backing layer portion itself. In such case the respective portions preferably also comprise an edge portion free from extending backing layer part, such that an adjacent installation remains possible with the adjacent panels being in an offset relationship such that an edge portion having an extending backing layer portion may be installed adjacent to an edge portion being free from an extending backing layer portion.
From the above it is clear that, preferably, the wall or ceiling panel comprises only one, one piece, backing layer. According to some embodiments, said backing layer extends uninterruptedly along said edges of said substrate layer. For example, said backing layer may extend along just one edge, thereby forming a border aligned with said edge. Further, for example, said backing layer may extend along two non-opposing edges, forming a continuous border aligned with said two non-opposing edges. Said backing layer may thus extend along said edges of said substrate layer to form a border aligned with said edges. Alternatively, said backing layer may also extend interruptedly along said edges of said substrate layer. In some embodiments, said backing layer may thus extend in two, three or more parts beyond or along said edges of said substrate layer. For example, said backing layer may extend in two parts along a long edge of the wall or ceiling panel. In some embodiments, said backing layer may extend in two, three or more parts, said parts separately extending beyond or along one, two or more of said edges. For example, said backing layer may extend in one part along a long edge of the wall or ceiling panel, and in two parts along a short edge of the wall or ceiling panel.
It is clear that at least the embodiments wherein said backing layer extends interruptedly, i.e. with two or more parts, along and beyond a respective edge, may be put in practice with a single one piece backing layer or with a plurality of separated backing layer portions.
According to a further practical example, said backing layer has a size equaling or about equaling the size of said panel, wherein said backing layer is preferably positioned off-set with regard to one or more of the edges of said panel or substrate layer. In such case an embodiment can be obtained with backing layer portions extending beyond one edge or beyond two non-opposing edges in a convenient manner.
Preferably, said backing layer at least partly extends beyond a first edge of said panel or substrate layer over a first distance, wherein at an opposing second edge of said panel or substrate layer, said backing layer is absent over a second distance, wherein said second distance is at least the same or larger than said first distance. As such, the part of said major surface which is free from said backing layer of a first panel may thus accommodate the part of the backing layer which extends beyond said first edge of a second panel, preferably in a complementary way. In some embodiments, an opposing edge of said substrate layer or panel is free from said backing layer over about said first distance. In some embodiments, an opposing edge of said substrate layer or panel is free from said backing layer over a distance substantially larger than said first distance, for example two or three times said first distance.
According to some embodiments, said backing layer may at least partly extend beyond said one or more edges over a distance which is at least about 1% of the width and/or length of said wall or ceiling panel. By preference, said backing layer may at least partly extend beyond said one or more edges over a distance which is at least about 2%, at least about 3%, at least about 4%, at least about 5%, at least about 10%, or at least about 15% of the width and/or length of said wall or ceiling panel. Preferably the distance over which the respective backing layer part or portion extends is at least 1 centimeter. Preferably the distance over which the respective backing layer extends, lies between 10 and 20 mm, for example between 12 and 18 mm, for example between 14 and 16 mm.
According to a further or another embodiment, said backing layer is more flexible than said panel, or, as the case may be, said substrate layer. As a result of such flexibility, slight movement of the panel with regard to the wall or ceiling on which it is installed is allowed. In particular, although the panel and/or its substrate material may be subject to expansion and/or shrinkage, the more flexible backing layer thus allows some deformation which at least partly compensates for the expansion and/or shrinkage of the substrate layer or the panel, and may thereby ensure good installation to the wall or ceiling, also during expansion and/or crimping. For example, said movement may take place over at least 0.1 mm, preferably over at least 0.2 mm, more preferably over at least 0.3 mm, 0.4 mm, 0.5 mm, or even over at least 1 mm. More in particular, said movement may take place in the directions contained in the plane of the wall or ceiling covering, i.e. in a horizontal and/or vertical direction in the case of a wall covering.
According to some embodiments, said backing layer is at least 1% more flexible than said substrate layer. By preference, said backing layer is at least 2% more flexible than said substrate layer, is at least 3%, 4%, 5%, or 10% more flexible than said substrate layer. In some embodiments, said backing layer is at least 15% more flexible, 20% more flexible, or even 25% more flexible than said substrate layer. Preferably said flexibility is expressed by means of the Young's modulus of the respective material.
According to some embodiments, said backing layer has a tensile strength of between 5 and 50 MPa. As such, the backing layer may provide sufficient support without breaking for installing the wall or ceiling panel, or a multitude of such panels, onto a wall or ceiling. By preference, said backing layer has a tensile strength of between 10 and 25 MPa, more by preference of between 10 and 20 MPa.
Alternatively or additionally, said backing layer has a Young's modulus of between 0.01 and 5.00 GPa. The backing layer may thus be deformed to a certain extent such that expansion and/or crimping of the substrate layer is at least partly compensated for.
In the context of the present disclosure, tensile strength and Young's modulus may for example be measured according to ISO 527-1:2019 for plastics, or according to ISO 37:2017 for vulcanized and thermoplastic rubbers. Depending on the material, other ISO standards may apply and are readily available which allow accurate measurement of the tensile strength.
According to some preferred embodiments, said backing layer has a tensile strength of between 5 and 50 MPa, and has a Young's modulus of between 0.01 and 5.00 GPa.
According to some embodiments, said backing layer comprises a material chosen from the group of a woven textile material, a non-woven textile material, a glass fiber cloth, a polymer material, a foamed polymer material, an elastomeric material, a thin metallic or polymeric foil, or combinations thereof.
Preferably, said backing layer is based on polyvinylchloride or polyethylene terephthalate (PET) or polyethylene, preferably expanded and/or crosslinked polyethylene, for example so-called IXPE (irradiated cross-linked polyethylene). According to an alternative, said backing layer is based on bounded cork granules, polyvinyl chloride or polyurethane. The backing layer can comprise non-woven PET fibers.
Preferably, said backing layer comprises fibrous material, as is the case, for example with woven and non-woven textile material. The fibrous material may reinforce the backing layer and prevent inadvertent ripping at the locations of stapling, nailing or screwing.
According to a further or another embodiment, said backing layer comprises one or more connection regions, which connection regions are configured for receiving one or more connection elements chosen from the group of nails, screws, staples, or combinations thereof. It is clear that said connection region is by preference formed by the portions of the backing layer that extend beyond said one or more edges. Thus a said portion of the backing layer that extend beyond said one or more edges can be a said connection region.
Preferably, said backing layer is connected, for example provided at said major surface, by means of a glue connection, for example a polyurethane dispersion glue, a polyvinyl alcohol glue, a tetrahydrofuran glue, a hotmelt glue. According to a special embodiment, the glue available between the backing layer and said major surface may be deformable under shear stress. In such case, the deformation of the glue may be used to cope with expansion and shrinkage of the panels, without the backing layer necessarily being flexible, or more flexible than the panel material.
Preferably, said backing layer comprises a print indicating the connection region and/or the preferred area for applying fixings and/or the preferred distance between fixings, such as staples or nails. For example the connection region can comprise a band-shaped print which indicates the preferred area of the connection region in which the connection elements should be applied. If the connection elements are staples, this band-shaped print can be indicated as the stapling zone. For example this band-shaped print is at a distance from the respective edge and also at a distance of the border of the backing layer which is furthest from the said edge. For example, the connection region can be rectangular shaped, wherein said band-shaped print is located centrally in said connection region and runs substantially parallel to the respective edge. For example, the dimensions of said band-shaped print, seen according to a direction perpendicular to the length direction of said edge, can be between 5 and 15 mm, preferably between 8 and 12 mm, for example 10 mm. The distance of said band-shaped print to the edge, seen according to said direction perpendicular to the length direction of said edge, can be between 2 and 8 mm, preferably between 4 and 6 mm, for example 5 mm. The distance of said band-shaped print to the border, seen according to said direction perpendicular to the length direction of said edge, can be between 2 and 8 mm, preferably between 4 and 6 mm, for example 5 mm.
It is noted that the backing layer or backing layer portions may be provided separately, i.e. as an accessory, such that a user or installer themselves may attach the backing layer or backing layer portions on-site, i.e. during installation, onto for example said major surface or said substrate layer. According to some embodiments, said backing layer may be provided on a roll, such that a user or installer may cut the backing layer to the desired size. Herein, the backing layer may upon choice of the installer be cut to a size corresponding to the full length of the wall or ceiling panel, or to any other size shorter or longer than the full length of the respective panel. In particular, when the wall or ceiling panel has a substantial length, attaching the backing layer to the wall or ceiling panel may comprise the risk of attaching the backing in a skewed orientation. Hence, a user or installer may also choose to cut the backing layer to a size which is smaller than the full length of the wall or ceiling panel, as to apply a plurality of smaller backing layer portions instead of a single backing layer portion. It may be more easy to install the smaller backing layer portions in an off-set position. According to some embodiments, the backing layer may also be provided in the form of pre-cut backing layer portions. If the backing layer or backing layer portions are provided separately, then it preferably comprise a print to ensure correct installation/connecting of said backing layer or backing layer portions. This print can further indicate the connection region and/or the preferred area of the connection region and/or the preferred distance between fixings, such as staples or nails.
According to a further or another embodiment, the separately provided backing layer may be attached by means of an adhesive. According to some embodiments, the separately provided backing layer may comprise a self-adhesive portion, preferably covered with a peel-off strip. By preference, the portion of the backing layer which extends beyond or along one of the edges of the wall or ceiling panel, or along a majority of one of said edges, is free of adhesive. This portion may be provided with a print indicating the connection region and/or the preferred distance between fixings, such as staples or nails.
In general, preferably, the backing layer at least extends beyond an edge comprising a mechanical coupling part basically shaped as a groove. In that case, the most convenient installation may be obtained.
With the same aim as in the first independent aspect, the present invention, in accordance with its second independent aspect, is an assembly of a wall or ceiling panel and a connection member, wherein said wall or ceiling panel at least one edge comprises a profiled edge region, with as a characteristic that said connection member is configured to connect to said profiled edge region, and is configured to at least partly extend beyond said one edge. Said profiled edge region preferably comprises a mechanical coupling part, in which case, preferably also the opposite edge comprises a profiled edge region with a mechanical coupling part, wherein the mechanical coupling parts of the respective opposite edges allow two such panels to become coupled at the respective edge, wherein in a coupled condition the panels become locked to one another in a first direction perpendicular to the plane of coupled panels, and/or in a second direction in the plane of the coupled panels and perpendicular to the respective edges.
According to the most preferred embodiment, said panels comprise a major surface forming a decorative side. The decorative side may be formed by a top layer applied to a substrate layer of said panel. Such top layer may then comprise a decoration layer, and potentially a wear layer applied on said decoration layer. It is hence clear that, according to the most preferred embodiment, the invention, in accordance with its second independent aspect, is an assembly of a wall or ceiling panel and a connection member, wherein said wall or ceiling panel comprises a substrate layer, and a top layer, said top layer comprising a decoration layer, and a wear layer provided above said decoration layer, wherein said substrate layer, on at least one pair of opposite edges, is provided with mechanical coupling parts, and with as a characteristic that said connection member is configured to connect to said mechanical coupling parts on at least one of the edges of said substrate layer, and is configured to at least partly extend beyond one of the edges of said substrate layer.
As stated before, the mechanical coupling parts preferably allow effecting a locking between two of such wall or ceiling panels in a first direction perpendicular to the plane of the coupled wall or ceiling panels, and in a second direction parallel to the plane of the coupled wall or ceiling panels and perpendicular to the coupled edges. It is however not excluded that the mechanical coupling parts would allow for a locking in said first or in said second direction only. The mechanical coupling parts may be supplemented in use with a glue. The mechanical coupling parts may be basically shaped as a tongue at one edge and a groove at an opposite edge. The groove is e.g. delimited by an upper lip and a lower lip. The tongue and groove are essentially responsible for said locking in said direction perpendicular to the plane of the coupled wall or ceiling panels and/or in said direction parallel to the plane of the coupled wall or ceiling panels and perpendicular to the coupled edges. The tongue and groove may further comprise locking means preventing the drifting apart of the tongue and the groove, when in coupled condition. The locking means may comprise a protrusion on the upper side of the lower lip for cooperation with an excavation at the bottom of the tongue. With respect to wall or ceiling panels the lower lip is regarded as that groove lip which is positioned the closest to the wall or ceiling to be covered with the respective panels. Preferably the said panels comprise a first pair of opposite edges and a second pair of opposite edges, wherein both said pairs of opposite edges comprise mechanical coupling means as described above. The mechanical coupling means of the first pair of opposite edges can be configured such that two of such panels can be coupled to each other at these edges by means of a turning movement or a downward movement. The mechanical coupling means of the second pair of opposite edges can be configured such that two of such panels can be coupled to each other at these edges by means of a turning movement or a downward movement. For example the mechanical coupling means of both pair of opposite edges can configured to allow coupling by a turning movement. These type of coupling parts can be as described in WO 97/47834, WO 2021/070022, WO 2021/105798 or WO 2021/059062. The coupling parts described in these patent publications are incorporated by reference. For example the mechanical coupling means of the first pair of opposite edges can be configured to allow coupling by a turning movement and the mechanical coupling means of the second pair of opposite edges can be configured to allow coupling by a downward movement. These latter panels can be installed by means of the so-called “fold down” method. These type of coupling parts can be as described in WO 2017/115202, WO 2021/111210, WO 2017/068523 or WO 2009/066153. The coupling parts described in these patent publications are incorporated by reference.
Preferably, the panels of the assembly of the second aspect, are rectangular, i.e. oblong or square, and thus also comprise a second pair of opposite edges. Preferably said second pair of opposite edges is provided with coupling parts as well, providing a locking in said first and/or in a second direction parallel to the plane of the coupled wall or ceiling panels and perpendicular to the second pair of edges.
In light of the present invention, the wording “connection member” is to be interpreted as a separate element which is used in combination with a wall or ceiling panel in order to allow installing the wall or ceiling panel onto a wall or ceiling. As described herein, this separate element is configured to connect to the profiled edge and/or to one or more of the mechanical coupling parts of the panel. The connection member on its own is considered to be an independent aspect of the invention as well, which may be used in combination with any wall or ceiling panels, thereby allowing an installation that is more flexible and may cope with dimensional variations due to changing ambient climate conditions.
According to some embodiments, said connection member has substantially smaller dimensions than the length and/or width of the wall or ceiling panel. As such, said connection member can be connected to said mechanical coupling parts in multiple locations along the length and/or width of the wall or ceiling panel and/or multiple connection members can be positioned along the length and/or width of a wall or ceiling panel. It may be possible that the connection member is able to slide, possibly in a limited fashion, along the mechanical coupling parts of the panel. Such embodiment enables the panel to slightly move with regard to the wall or ceiling after installation, which may help in coping with or compensating expansion and/or shrinkage of the panel, or a covering composed from such panels. For example, such movement may take place over at least 0.1 mm, preferably over at least 0.2 mm, more preferably over at least 0.3 mm, 0.4 mm, 0.5 mm, or even over at least 1 mm. More in particular, said movement may take place in the directions contained in the plane of the wall or ceiling covering, i.e. in a horizontal and/or vertical direction in the case of wall covering.
By preference, said connection member comprises a panel-side part and a wall-side part, wherein said panel-side part is configured to at least partly engage with said profiled edge and/or mechanical coupling parts on at least one of the edges of said substrate layer or panel, and the wall-side part is the remaining portion of the connecting member. The wall-side part is preferably configured for receiving one or more connecting elements, such as screws, nails or staples, to connect the connection member to a wall or a ceiling or a frame, such as a wood frame or metallic frame. The panel-side part could also be indicated as the panel part and the wall-side part could also be indicated as the wall part. In a specific embodiment, the wall-side part is preferably completely positioned beyond the respective edge with which the panel-side part engages. In another specific embodiment the wall-side part can only partially be positioned beyond the respective edge with which the panel-side part engages. In a specific embodiment the panel-shaped part can be positioned beyond the respective edge with which the panel-side part engages. The panel-side part and the wall-side part can comprise the same material or can comprise the same type of material. For example both the panel-side part and the wall-side part can comprise plastics or both the panel-side part and the wall-side part can comprise metals. However it is also possible the panel-side part is made from a different material than the wall-side part. For example the panel-side part can be made from metals; for example an alloy, and the wall-side part can be made from plastics. The benefit here is that the panel-side part can be made sufficiently thin and this while still having the required strength. For example the panel-side part can have thickness dimensions of at most 0.5 mm, for example at most 0.3 mm, at most 0.25 mm, at most 0.2 mm. The portion of the panel-side part which is provided to engage with the panel can be made sufficiently thin, such that thin panels, e.g. panels of less than 6 mm or less than 5 mm, can be installed with this connection member. The wall-side part can be made from plastics such that the wall-side part can be easily provided with the required flexibility. Such connection members comprising a metallic panel-side part and a plastic wall-side part can be shaped by multi-material injection molding, overmolding or insert molding. For example, the metallic panel-side part can form a frame into which the plastic wall-side part engages.
According to some embodiments, the connection member may comprise means for interacting with said profiled edge and/or mechanical coupling means, for example a connector, more specifically a hook shaped connector. The said plate-shaped part can comprise said connector. The connector can be made from a metal or alloy, and can be thinner than 0.5 mm. Said means for interacting may be a perpendicular element which is positioned as to divide the connection member into the panel-side part and the wall-side part. Such means for interacting may be shaped as such to, preferably effectively, interact with at least a part of the mechanical coupling parts at an edge of the substrate layer or of the wall or ceiling panel. A skilled person will readily understand that any upstanding element which extends transversally with regard to the plane of the connection member, may function as a “perpendicular element” or a “means for interacting with a profiled edge” as disclosed herein. It is clear that the profiled edge and/or the mechanical coupling parts, in a coupled condition, preferably provide sufficient clearance for the means for interacting or the perpendicular element to become engaged with the respective edge.
According to a preferred embodiment, the means for interacting or the perpendicular element may be hook-shaped. Thereby an effective interaction with at least a part of the mechanical coupling parts can be obtained. For example a hook may limit the movement of the respective panel in said first direction, namely perpendicularly to the plane of the wall or ceiling covering. This can for example be obtained when a part of a mechanical coupling part, for example at least said protrusion on the upper side of said lower lip of said groove, becomes caught in the hook-shaped portion of the means for interacting. In such case the hook-shaped means for interacting or perpendicular element may comprise a first portion shaped to protrude transversally from the connection member to become seated between the mechanical coupling parts at the location of the distal end of the lower lip of the groove, wherein said means for interacting then further comprise a second portion protruding transversally with respect to said first portion, wherein said second portion becomes seated in between said protrusion on the upper side of said lower lip and the bottom of the tongue. It is clear that at least said first and said second portion together form said hook.
The interaction or engagement of the means for interacting or the perpendicular element may be such that the respective panel cannot move in said first direction, i.e. that there is no play in said first direction or there is even a tensioned fit between the connection member and said profiled edge. According to an alternative embodiment, some play may be available in said first direction, preferably a play of 0.5 mm or less, or 0.2 mm or less.
The means for interacting or the perpendicular element and the coupling parts may be shaped as such that, in a coupled state of two adjacent wall or ceiling panels, the means for interacting or the perpendicular element is locked tightly in between the coupling parts of two adjacent panels. In light of the present invention, the wording “locked tightly” means that the respective means or element fits in between the coupling parts without play, or even fit with a tension. In the case of mechanical coupling part basically shaped as a tongue and a groove, this means that, both, the edge comprising the tongue and the edge comprising the groove are contacting said means or element, for example at the location of the distal end of the lower lip of the groove and the portion of the tongue opposite thereto. This is however not necessarily the case, and embodiments having play are feasible as well. For example, a play of at most 1 mm, preferably at most 0.5 mm, more preferably at most 0.4 mm, 0.3 mm, 0.2 mm or most preferably at most 0.1 mm, between the means or element and one of the distal end of the groove or the opposing face of the edge with the tongue.
Unknown
December 18, 2025
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