Waterproof panel, process for producing a panel, and panel obtainable by said process

Abstract

The invention relates to a panel suitable for constructing a waterproof floor or wall covering, wherein the panel has a substantially planar top surface, a substantially planar bottom surface, and at least four substantially linear side edges. The invention also relates to a process for producing a panel according to the invention. The invention further relates to a panel obtainable by said process according to the invention.

1 - 40 . (canceled) 
     
     
         41 . A panel suitable for constructing a waterproof floor or wall covering, wherein the panel has a substantially planar top surface, a substantially planar bottom surface, and at least four substantially linear side edges,
 wherein the panel has a laminate structure which comprises:   a rigid core layer basically composed of a composite material comprising a mixture of mineral material and thermoplastic material,   a top layer fixed to the core layer,   
       wherein the composite material contains a ratio of weight percentages of mineral material relative to thermoplastic material which is 1 or larger, and wherein the mixture comprises one or more thermoplastic materials chosen from the group of: polyethylene, polypropylene and copolymers thereof. 
     
     
         42 . The panel according to  claim 41 , wherein the mixture further comprises one or more thermoplastic materials chosen from the group consisting of: polyvinyl acetate, polyvinyl alcohol, vinyl and vinylidene resins and copolymers thereof, acrylonitrile butadiene styrene, styrene acrylonitrile resin, polystyrenes and copolymers thereof, saturated and unsaturated polyesters, acrylics, polyamides, nylon containing polyamides, engineering plastics, acetyl, polycarbonate, polyimide, polysulfone, polyphenylene oxide and sulfide resins. 
     
     
         43 . The panel according to  claim 41 , wherein the core layer further comprises one or more conductive thermoplastic polymers. 
     
     
         44 . The panel according to  claim 41 , wherein the composite material comprises at least 60% by weight of mineral filler. 
     
     
         45 . The panel according to  claim 41 , wherein the composite material comprises at least 15% by weight of thermoplastic material. 
     
     
         46 . The panel according to  claim 41 , wherein the composite material comprises one or more additives chosen from the group consisting of: a pigment, an impact modifier, an internal lubricant, an external lubricant, a stabilizer, a wax, and/or an aid processing agent. 
     
     
         47 . The panel according to  claim 46 , wherein at least one impact modifier comprises methacrylate butadiene styrene, acrylonitrile butadiene styrene and/or a thermoplastic elastomer. 
     
     
         48 . The panel according to  claim 46 , wherein at least one stabilizer is a calcium zinc stabilizer, barium-cadmium stabilizers, barium-zinc stabilizers, organotin stabilizers or epoxidized soybean oils. 
     
     
         49 . The panel according to  claim 46 , wherein the total amount of additives present in the composite core layer is restricted to 1-15% by weight. 
     
     
         50 . The panel according to  claim 41 , wherein the core layer comprises organic fibres. 
     
     
         51 . The panel according to  claim 41 , wherein the composite material comprises at least one bio plasticizer in an amount less than 5 wt. %, which bio plasticizer is a plasticizers derived from vegetable oils or an epoxy-functional bio-derived plasticizer formed by an epoxy-functional fatty acid ester obtained from a vegetable oil selected from the group consisting of soybean oil, canola oil, corn oil, linseed oil, rapeseed oil, safflower oil, sunflower oil, tall oil, tung oil, and mixtures and derivatives thereof. 
     
     
         52 . The panel according to  claim 41 , wherein at least thermoplastic polymer is a recycled thermoplastic polymer. 
     
     
         53 . The panel according to  claim 41 , at least part of the core layer has a cellular foam structure core. 
     
     
         54 . The panel according to  claim 41 , wherein the rigid core layer comprises at least one mineral material selected from the group consisting of: magnesium oxide, calcium carbonate, chalk, clay, limestone, calcium silicate, and talc. 
     
     
         55 . The panel according to  claim 41 , wherein the density of the composite material is situated in between 1500 and 2200 kg/m 3 . 
     
     
         56 . The panel according to  claim 41 , wherein the core layer is an extruded layer formed by an extrusion process or wherein the top layer is an extruded layer formed by an extrusion process or wherein the core layer and the top layer are formed by a co-extrusion process. 
     
     
         57 . The panel according to  claim 41 , wherein the top layer is a veneer layer adhered to a top surface of the core layer. 
     
     
         58 . Panel according to  claim 57 , wherein the veneer layer is selected from the group consisting of wood veneer, cork veneer, bamboo veneer, tile veneer, stone veneer, rubber veneer, decorative plastic veneer, linoleum veneer and decorative vinyl veneer. 
     
     
         59 . The panel according to  claim 41 , wherein the core layer and the top layer are fixed to each other by virtue of a fusion bonding which has been formed under heat and pressure. 
     
     
         60 . A process for producing a panel according to  claim 41 , wherein the core layer and the top layer are fixed to each other in a fusion step wherein heat and pressure are applied to an assembly of the core layer and the top layer, and during which step a fusion bonding is established, wherein the process is a continuous process including the steps of:
 preparing a composite material by mixing of the compounds included in the composite material;   extruding a molten core layer of the composite material using an extruder;   leading the molten core layer over rollers;   providing a top layer and leading the top layer towards an upper surface of the molten core layer wherein the bottom surface of the top layer is applied onto the upper surface of the molten layer to obtain an assembled structure;   applying pressure and heat on the assembled structure such that a fusion bonding is established between the top layer and the molten core layer;   cooling of the assembled structure after formation of the fusion bonding.