NL2035203B1

NL2035203B1 - Tile panel, surface covering and method of manufacturing such a panel

Info

Publication number: NL2035203B1
Application number: NL2035203A
Authority: NL
Inventors: Alberic Bouké Eddy
Original assignee: I4F Licensing Nv
Priority date: 2023-06-28
Filing date: 2023-06-28
Publication date: 2025-01-09
Also published as: WO2025003160A1

Abstract

The present invention relates to a decorative tile panel for covering a floor, ceiling, or wall. Furthermore, the invention relates to a surface covering for a floor, ceiling or wall surface which is constructed by a multitude of neighbouring tile panels according to the invention, wherein the plurality of tile panels are preferably interconnected.

Description

Tile panel, surface covering and method of manufacturing such a panel

The present invention relates to a decorative tile panel, such as a wall panel, a floor panel, or a ceiling panel. The invention also relates to a decorative laminated film for realizing a tile panel according to the invention. Furthermore, the invention relates to a surface covering for a floor, ceiling or wall surface which is constructed by a multitude of neighbouring tile panels according to the invention. The invention additionally relates to a method of manufacturing a tile panel according to the invention. it has been common for centuries, to apply a surface covering of neighbouring tiles in a traditional way by applying a cement layer onto the surface, and subsequently position and fix the tiles onto the cement layer in a surface covering pattern. In this traditional method, grout is furthermore applied between adjacent side edges of neighbouring tile panels to fill up an interspatial gap between adjacent side edges, which filled gaps are commonly referred to as ‘grout lines’. These grout lines are visible as slightly recessed joint lines of grout which are present between adjacent top surfaces of neighbouring tiles.

As an alternative to the traditional way of applying a tile covering, it has been proposed in the art to develop a tile panel which has a top surface made from a synthetic material having similar properties as a traditional tile material such as ceramic material. When such tile panels are positioned adjacent to each other and adhered onto a surface, a covering of neighbouring tiles can be achieved in a different, and practical way in which no cement or grout is necessary. Typically, the adjacent side edges of these neighbouring tile panels are laid in abutting contact with each other, and may include interconnecting coupling profiles. In this way, one can dispense with the application of grout in the form of grout lines.

However, in order to mimic an overall appearance of a traditional tile covering, it has recently been proposed to provide the side edges of a tile panel with an imitation grout line by milling a rectangular groove in the top surface of the tile panel which recess extends along a side edge of the tile panel, which exposes a core layer of the tile panel, wherein the colour of the core layer determines the visual appearance of the imitation grout line. However, exposing the core layer at the location of the imitation grout line locally weakens the tile panel and makes the core layer vulnerable to damage, fouling, and moisture, which could degrade the core layer, and hence the tile panel as such. Moreover, this solution restricts the freedom of composition of the core layer, as the core layer should be able to resist to some extent negative effects due to exposure. it is a first objective of the present invention to reduce or eliminate the drawbacks known from the prior art, by developing a new tile panel having improved properties, in particular in view of the imitation grout line. it is a second objective of the present invention to provide a more durable and/or reliable tile panel with at least one imitation grout line or other channel-shaped recess. lt is a third objective of the present invention to provide a tile panel with at least one imitation grout line or other channel-shaped recess, which increases the freedom of design of the composition of a core layer of the tile panel. it is a fourth objective of the present invention to provide an improved tile panel with at least one imitation grout line or other channel-shaped recess, which can be manufactured in a relatively efficient manner.

At least one of these objectives can be achieved by a tile panel according to the preamble, comprising: e at least one core layer, and e at least one decorative top structure, directly or indirectly affixed to said core layer, wherein the decorative top structure defines a top surface of the tile panel, wherein said decorative top structure comprises: o a bottom section comprising at least one back layer, and o atop section comprising a decorative layer and preferably at least one, at least partially transparent or translucent wear layer covering said decorative layer at least partially, and e a plurality of side edges at least partially defined by said core layer and/or by said decorative top structure,

wherein the decorative top structure is provided with at least one channel-shaped recess, preferably at least one imitation grout line and/or at least one bevel, connecting different side edges, preferably opposing side edges, and/or located at a side edge of the tile panel, wherein said at least one channel-shaped recess is at least partially formed by a cut-away portion of the top section of the decorative top structure and optionally a part of the bottom section of the decorative top structure, and wherein an exposed top surface of the channel-shaped recess is at least partially defined by the bottom section, in particular at least one back layer, of the decorative top structure.

At least a part of the exposed top surface of the channel-shaped recess is left uncovered by the top section of the decorative top structure as a result of which the bottom section of the decorative section becomes visible and/or defines said exposed top surface. Exposure of the potentially vulnerable core layer to define the exposed top surface of the channel-shaped recess is no longer needed, as at least one back layer of the bottom section of the decorative top structure covers said core layer at the location of the channel-shaped recess(es) (and typically also beyond). As the core layer is less vulnerable due to the coverage by the (at least one) back layer, more freedom of design is realized to choose a desired core layer composition.

Due to the cut-away portion of at least the top section of the decorative top structure, the exposed top surface of the channel-shaped recess is recessed with respect to a (highest) top surface of the panel as defined by the (remaining part of the) top section of the decorative top structure. This top surface of the tile panel may either be flat or textured (e.g. embossed, preferably embossed in register with a decorative layer making part of said top section). This top surface of the tile panel, as defined by the top section of the decorative top structure, is typically connected to said at least one channel-shaped recess, wherein said top surface of the tile panel, and the surface of the channel-shaped recess together form the total top surface of the tile panel. Even in case the top surface of the top section is provided with a texture, such as an embossing with indentations, the maximum depth of the channel-shaped recess is typically but not necessarily larger than the maximum depth of said indentations.

During production of the tile panel and/or of the decorative top structure, the channel-shaped recess is formed by material removal of the top section and optionally (a part of) the bottom section of the decorative top structure, which is also referred to as a cut-away portion of the decorative top structure. This material removal may be realized for example by at least one of these techniques: milling, cutting, etching, carving, sanding, lasering, and/or by locally incinerating (burning) the decorative top section. However, it is imaginable that the channel-shaped recess is created by design during the production process without having to remove material, for example by using digital (3D) printing, by pressing the channel-shaped recess into the decorative top structure, and/or by applying a top section of the decorative top structure which is slightly more narrow in at least one direction (length and/or width) than the bottom section of the decorative tile panel.

As indicated above, said at least one channel-shaped recess may be partially formed by a cut-away portion of the bottom section of the decorative top structure.

This secures that the top section of the decorative top section is locally entirely removed, thereby exposing at least one back layer of the bottom section of the decorative top structure. The exposed back layer(s) preferably comprise(s) at least one pigment corresponding with the intended colouring of the channel-shaped recess and/or the intended colouring of the exposed portion of the bottom section.

In case the channel-shaped recess is an imitation grout line, preferably a grey pigment is issued to imitate mortar and/or a darker pigment is used compared to the top section of the decorative top structure in order to create a visual depth effect. Optionally, the exposed surface, in particular exposed top surface, of the channel-shaped recess, and/or an exposed surface of at least one back layer comprises a textured surface to closely resemble the look and feel of an actual grout line.

Preferably, the bottom section of the decorative top structure has a nominal thickness Tn, wherein the thickness Ts of the bottom section (right) below the channel-shaped recess is smaller than the nominal thickness Tn. More preferably, the thickness T. of the bottom section below the channel-shaped recess complies with the following formula: T, > Te 2 0.6T,. This secures a sufficiently thick remaining portion of the bottom section at the location of the channel-shaped recess to protect the underlying core layer.

Preferably, the bottom section has a sufficient thickness, and hence material mass, to allow cutting away a part of the bottom section without exposing the core layer.

Preferably, the thickness of the bottom section is situated between 0.2 and 1 mm, 5 preferably between and including 0.3 and 1 mm, more preferably between and including 0.3 and 0.5 mm. Preferably, the thickness of the back layer is at least four times the thickness of the wear layer.

Preferably, the channel-shaped is partially defined by a side wall, typically either one or two side walls, wherein a part of said side wall is defined by the bottom section of the decorative top structure. A transition between said side wall{s) and the exposed top surface of the channel-shaped recess is preferably continuous, more preferably smoothly continuous. The exposed side wall(s) and the exposed top surface may be integrated and/or undistinguishable.

Each side wall of the channel-shaped recess may define an upper edge. This upper edge is preferably substantially linear and/or preferably runs in parallel with at least one side edge of the tile panel. The width of the channel-shaped recess is generally situated between 1 and 5 mm. In case the channel-shaped recess is configured to act as imitation grout line, the desired width often depends on whether the imitation grout line is configured to connected to either (i) a vertical wall part or (ii) another imitation grout line of an adjacent tile panel. In this first embodiment (i), the width of the imitation grout line is preferably between 2 and 4.5 mm, while in this second embodiment (ii), the width of the imitation grout line is preferably between 1 and 2.25 mm. Preferably, the width of said channel-shaped recess is at least three times the maximum depth of said channel-shaped recess with respect to the top surface of the tile panel. This provided the channel-shaped recess a sufficiently robust appearance, while the depth of the channel-shaped recess can be kept limited. This latter is preferred, since less material has to be removed during production, and less fouling can be collected in the channel-shaped recess during normal use of the tile panel. To this end, the maximum depth of the channel- shaped recess is preferably 0.3 — 1.5 mm, preferably 0.3 - 0.8 mm, more preferably 0.3 -0.3 mm.

Preferably, one side edge is provided with a channel-shaped recess, while an opposing side edge is not provided with an imitation grout line. This results in the preferred situation that the seam of the channel-shaped recess and an adjacent tile panel coincides with a vertical plane defined by the side edge of the (second) tile panel, free of a channel-shaped recess, which is less visible to the human eye and therefore attractive from an aesthetic point of view. In this manner, the imitation grout line appears as an uninterrupted body to the human eye. This channel- shaped recess-free side edge may be provided with a chamfered edge connecting to the top surface of the tile panel. Also a top edge of the channel-shaped recess may be provided with such a chamfered edge connecting to the top surface of the tile panel. These chamfered edges typically compensates a possible (slight) height difference between the panels and ensures a smoother transition between the top surface and the channel-shaped recess.

It is imaginable that an exposed surface of the channel-shaped recess is at least partially covered by at least one coating. This coating may be a transparent and/or translucent coating. Additionally or alternatively, this coating may be formed by a wear layer. By way of example, this coating may comprise polyvinyl! chloride (PVC).

Alternatively, a cured ethoxyline resin (ER) or a polyurethane (PU) material may be used. In case a non-transparent opaque coating would be used, the coating preferably comprises at least one pigment corresponding with the intended colouring of the channels-shaped recess. In case the channel-shaped recess is an imitation grout line, preferably a grey pigment is issued to imitate mortar and/or a darker pigment is used compared to the top section of the decorative top structure in order to create a visual depth effect. Optionally, the coating comprises a textured surface to closely resemble the look and feel of an actual grout line.

Preferably, the gloss level of the top section of the decorative top structure is higher than the gloss level of the bottom section of the decorative top structure and/or — if applied — of a coating applied into/onto the channel-shaped recess. Preferably, the top section of the decorative top structure is at least partially glossy, while the bottom section of the decorative top structure and/or — if applied — a coating applied into/onto the channel-shaped recess has a relatively matt appearance. This difference in glossiness between the top surface of the top section of the decorative top structure commonly improves the aesthetical appearance of the tile panel as such, wherein the look and possibly feel of an actual grout line (and/or bevel) can be realistically imitated.

Preferably, the upwardly facing recess surface is at least partially concavely curved, preferably gradually concavely curved, across the width direction of the recess. This means that the curvature is a continuous curvature. This prevents the presence of sharp ridges (discontinuities) on the surface recess, which improves the appearance of the curved recess surface. Preferably, the upwardly facing recess surface is substantially completely concavely curved across the width direction of the channel-shaped recess.

A deepest point of at least one channel-shaped recess, defining the maximum depth of the recess (with respect to the (highest) top surface of the top section), could be situated at the side edge or at a distance from the side edge. In this latter case a more or less parabolically shaped recess surface is present. It is imaginable that at least one channel-shaped recess has a deepest point at a distance from the respective side edge, wherein said deepest point is located closer to the side edge than to the top surface of the tile panel.

Preferably, at least one back layer of the bottom section of the decorative top structure comprises thermoplastic material, preferably PVC material. Additionally or alternatively, at least one back layer comprises at least one polymer, chosen from the group consisting of: ethylene vinyl acetate (EVA), polyurethane (PU), polyethylene (PE), polypropylene (PP), polystyrene (PS), polyvinylchloride (PVC), polyethylene terephthalate (PET), polyisocyanurate (PIR), or mixtures thereof.

Preferably, the polymer, in particular thermoplastic material, used in at least one (exposed) back layer comprises a pigment to colour the back layer as to resemble actual imitation grout lines or traditional bevels. Preferably, the back layer comprises at least one non-polymeric material and/or at least one filler. More details and preferred embodiments have been described below.

It may be preferred that the back layer comprises a matrix material, such as a thermoplastic material, and wear-resisting anti-slip particles embedded in said matrix material. The anti-slip particles typically provide a texture to the upper surface of the channel-shaped recess to closely represent the look and feel of an actual grout line. Moreover, although the upper surface of the imitation grout line is normally situated at a lower level than the (remaining) top surface of the tile panel,

the presence of anti-slip particles may improve the anti-slip properties of the tile panel as such to some extent. it is imaginable that the bottom section of the decorative top structure comprises a laminate of a plurality of back layers. Different back layers may have different functionalities. For example, one of the back layer may act as pigmented layer to colour the upper surface of the channel-shaped recess, while another back layer may e.g. act as reinforcement layer. This reinforcement layer may e.g. be a glass fibre layer (woven or non-woven) and/or an EVA layer, which typically reinforces the tile panel as such. The reinforcement layer may be embedded into a thermoplastic comprising (other) back layer. Preferably, the reinforcement layer (if applied) is embedded into a lower half and/or in the center of the back layer. This relatively low positioning of the reinforcement layer is typically preferred as locally cutting away an upper portion of the back layer to form the channel-shaped recess(es) will not damage (and therefore not weaken), and will not expose the reinforcement layer, which secures a uniform colouring of the channel-shaped recess at the location of the exposed back layer portion.

This laminate of back layers also facilitates to firstly prepare the bottom section and atleast a part of the top section, including the decorative layer, of the decorative top structure, before applying this pre-prepared laminated film onto the core layer.

Preferably, at least one back layer and the core layer comprise the same thermoplastic material. This allows the back layer and the core layer to be fused together.

Preferably at least one tile panel layer, more preferably the core layer and/or the back layer, comprises at least one polymer material in particular at least one polymer matrix which is at least partially be composed of a polymer that is selected from the group consisting of: polypropylene (PP), polyurethane (PU), thermoplastic polyurethane (TPU), polystyrene (PS), polyethylene (PE), polyethylene terephthalate (PET), and polyvinyl chloride (PVC).

The at least one polymer material, in particular the at least one polymer matrix, of the core layer, and/or the back layer, and/or another tile panel layer, can at least partially be composed of a polymer formed by at least one virgin polymer material, by at least one recycled polymer material, or by a mixture of virgin polymer material and recycled polymer material. The at least one polymer matrix can be enriched with at least one additive, preferably at least one additive chosen from the group consisting of: talc, chalk, wood, graphene, graphite, calcium carbonate, titanium dioxide, calcined clay, porcelain, iron oxide, at least one fatty acid salt, glass particles, glass fibres, carbon particles, silicon particular, a(nother) mineral filler, rice, a{nother) natural filler, a(nother) (auxiliary) polymer, such as an elastomer and/or latex. It is also imaginable that rubber and/or elastomeric parts (particles) are dispersed within the composite to improve the flexibility and/or impact resistance at least to some extent. The core layer and/or the back layer may (thus) be rigid, semi-flexible, or flexible, and so can be the tile panel as such.

In case the back layer comprises at least one polymer material, such as PVC, enriched with one or more additives, the back layer may be provided with improved properties, such as an improved rigidity and/or toughness and/or a reduced shrinkage rate and/or a reduced warping rate. This could improve the heat stability of the back layer, which allows direct printing of the decorative layer onto the back layer. Here, the decorative layer could be formed solely by at least one ink layer. A separate carrier layer to carry the ink can be omitted in this case, as this function has been taken over by the back layer. Optionally, a primer layer, preferably a white primer layer is applied, which is preferably situated in between the back layer and the at least one ink layer.

In order to improve the anti-warp properties (and hence to reduce the warping rate), the back layer (and/or the core layer and/or another tile panel layer) preferably comprises at least one polymer, preferably at least one thermoplastic polymer, such as PVC, which comprises at least one iron oxide and at least one fatty acid salt. Preferably, the iron oxide(s) and the fatty acid(s) form a composite additive, wherein the weight content of the iron oxide within the composite additive is preferably at least 10%. Preferably, the iron oxide is selected from at least one iron oxide chosen from the group consisting of: FeO, Fe203, Fe304, Fe203-H20,

Fe203 or Fe203.H20. The preferred content of the iron oxide accounts for 30-90% of the weight of the composite additive, such as 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75% , 80%, 85%, more preferably 70-90%, most preferably 75-85%.

The particle size range of the iron oxide(s) is preferably 30-500 nm, more preferably 50-200 nm, even more preferably 100-150 nm. Preferably, the fatty acid salt is selected from at least one fatty acid chosen from the group consisting of: alkali metal stearate or alkaline earth metal stearate, preferably magnesium stearate, zinc stearate, calcium stearate, lithium stearate, stearic acid sodium, more preferably sodium stearate. Research demonstrated, for example, that in case the weight ratio of iron oxide Fe203 or Fe203-H20 and sodium stearate is 4:1, the warping rate can be reduced by about 80%.

The filler(s) preferably incorporated in the core layer and/or the back layer {and/or another tile panel layer) may e.g. be formed by fibres, such as glass fibres or synthetic or genuine leather fibres, and/or may be formed by dust-like particles and/or platelets or other particles. Here, the expression “dust” is understood as small dust-like particles (powder), like bamboo dust, wood dust, cork dust, or non- wood dust, like mineral dust, glass powder, stone powder, in particular cement, and combinations thereof. The average particle size of the dust is preferably between 14 and 20 micron, more preferably between 16 and 18 micron. The primary role of this kind of filler is to provide the core layer and/or the back layer, and the tile panel as such, sufficient hardness and/or to decrease the cost price of the core layer and/or the back layer, and hence of the tile panel. Moreover, this kind of filler will typically also improve the impact strength of the core layer and/or the back layer and of the tile panel as such. Preferably, the filler content in the composite material of the core layer and/or the back layer is between 30 and 75% by weight of the composite material of the core layer and/or the back layer, more preferably between 50 and 60% by weight of the composite material of the core layer and/or the back layer. Preferably, the polymer content in the composite material of the core layer and/or the back layer is between 25 and 70% by weight of the composite material of the core layer and/or the back layer, more preferably between 40 and 50% by weight of the composite material of the core layer and/or the back layer.

The polymer can either be foamed or unfoamed. Preferably, the composite of the core layer and/or the back layer comprises at least one filler selected from the group consisting of: a salt, a stearate salt, calcium stearate, and zinc stearate.

Stearates have the function of a stabilizer, and lead to a more beneficial processing temperature, and counteract decomposition of components of the composite during processing and after processing, which therefore provide long-term stability.

Instead of or in addition to a stearate, for example calcium zinc may also be used as stabilizer. The weight content of the stabilizer(s) in the composite will preferably be between 1 and 5%, and more preferably between 1.5 and 4%. The composite of the core layer and/or the back layer preferably comprises at least one impact modifier comprising at least one alkyl methacrylate, wherein said alkyl methacrylate is preferably chosen from the group consisting of: methyl methacrylate, ethyl methacrylate, propyl methacrylate, isopropyl methacrylate, t-butyl methacrylate and isobutyl methacrylate. The impact modifier typically improves the product performance, in particular the impact resistance. Moreover, the impact modifier typically toughens the core layer and/or the back layer and can therefore also be seen as toughening agent, which further reduces the risk of breakage. Often, the modifier also facilitates the production process, for example, as already addressed above, in order to control the formation of the foam with a relatively consistent (constant) foam structure. The weight content of the impact modifier in the composite will preferably be between 1 and 9%, and more preferably between 3 and 6%. At least one plastic material used in the core layer and/or the back layer is preferably free of any (toxic) plasticizer in order to increase the desired rigidity of the core layer and/or the back layer, which is, moreover, also favourable from an environmental point of view. The core layer and/or the back layer and/or another tile panel layer of the tile panel may comprise wood-based material, for example,

MDF, HDF, wood dust, bamboo, prefabricated wood, more particularly so-called engineered wood. This wood-based material may be part of a composite material of the core.

It may be preferred that the decorative layer of the top section of the decorative top structure comprises a carrier layer bearing at least one decorative ink layer. This allows the decorative ink layer to be printed onto the carrier layer without being dependent on the material properties of the back layer, and hence without having the risk that the back layer will warp during the printing process (during application of the at least one decorative ink layer). As the carrier layer, such as white polymer film or white paper, (having a typically thickness of about 0.07 mm) is typically substantially thinner than the coloured back layer (having a typical thickness of 0.3- 0.4 mm), a sound printing of the decorative ink layer(s) onto the relatively thin carrier layer can be secured while printing of the decorative ink layer(s) onto the relatively thick back layer could affect the print quality. This latter is mainly due to different stretching properties and/or thermal printing properties of the relatively thick back layer compared to the carrier layer, which in particular is a risk in case the relatively thick back layer is substantially composed of a polymer material, in particular a thermoplastic material, such as PVC. Hence, performing the printing step first on the relatively thin carrier layer before laminating the carrier layer onto the back layer secures a constant print quality and allows that existing print equipment can be used. This embodiment obviously does not exclude that printing of the decorative ink layer(s) can be performed directly onto the back layer and/or onto a, preferably white, primer layer applied on the back layer, without using a separate carrier layer. In this case, the back layer is preferred enriched with one or more additives, such as fillers, in particular inert fillers and/or one or more toughening agents, to provide the back layer with sufficient toughness and/or rigidity and/or sufficient thermal properties to be subjected to the printing process.

The carrier layer may be a paper film. Preferably, the carrier layer comprises a thermoplastic material, like PVC. More preferably, the back layer and the carrier layer comprise the same thermoplastic material. This allows the back layer and the carrier layer to be fused together. The carrier layer is preferably a white layer, which improves the colour authenticity of the decorative layer. Alternatively, the carrier layer may be provided by a primer layer, preferably a white primer layer. The decorative ink layer represents a décor. The layer may be a continuous layer or fragmented (interrupted) layer, dependent on the intended décor to be visualized.

The printed décor image(s) of the decorative layer(s) may be based on the CMYK colour principle where the white colour is typically provided by the surface of the white base coat (if applied) and/or a white thermoplastic film and/or a white paper film. This is a 4-colour setup comprising cyan, magenta, yellow and black. Mixing these together will give a colour space/gamut, which is relatively small. To increase specific colour or the total gamut spot colours may be added. A spot colour may be any colour. One or more additional colours may be applied, such as at least one additional colour selected from the group consisting of: orange, green, blue, red, white, light grey, light magenta, and light cyan. These colours may be used separately or in combinations. The colours are typically mixed and controlled by a combination of software and hardware (print engine/print heads).

The at least one wear layer is preferably transparent or translucent to allow the decorative layer to remain visible through said wear layer. At least one wear layer, and preferably each wear layer in case a plurality of wear layers would be applied, is preferably made of transparent or translucent polyurethane or, alternatively, polyvinylchioride, polypropylene, or any another suitable transparent or translucent polymer. Typically, at least one layer of the decorative top structure is cured by using UV curing, and at least one, preferably other, layer of the decorative top structure is cured by using electron-beam (EB) curing. Preferably, the thickness of the wear layer is at least 0.05 mm, in particular at least 0.3 mm, and is preferably situated in between and including 0.3 and 0.75 mm, more preferably between and including 0.3 and 0.5 mm, such as 0.3 mm or 0.5 mm. A plurality of wear layers, on top of each other, may also be applied. A protective lacquer coating may be applied onto the decorative layer and/or onto at least one wear layer.

Instead of or in addition to the application of a printed decorative layer covered by at least one wear layer, it is also imaginable that the top section of the decorative top structure comprises or is entirely formed by at least one tile. This tile may be made of sliceable natural stone, marble, concrete, limestone, granite, slate, glass, ceramics, wood, or a composite material. Particular preferred are ceramic materials of a type selected from the group consisting of Monocuttura ceramic, Monoporosa ceramic, porcelain ceramic, or multi-casted ceramic. This tile may be a relatively thin tile (veneer tile) as this tile is attached to the core layer, with a preferred thickness of less than 1 cm, preferably less than 7.5 mm, more preferably less than 5 mm.

Preferably, at least one pair of opposing first and second side edges is respectively provided with first and second coupling profiles, configured such that the first coupling profile of the first side edge of a first tile panel can be coupled to the second coupling profile of the second side edge of a second tile panel, wherein the first side edge is provided with a channel-shaped recess, wherein an outer portion of said channel-shaped recess defines and/or connects to a substantially vertical plane, wherein at least a part of the first coupling profile, preferably the entire first coupling profile, extends with respect to said substantially vertical plane over a horizontal distance which is preferably larger than the width of the channel-shaped recess, and which is preferably smaller than three times, preferably smaller than two times, the width of channel-shaped recess.

In a preferred embodiment, a first tile panel edge comprises a first coupling profile, and a second tile panel edge, preferably opposite to the first tile panel edge, comprising a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, in horizontal direction and/or in vertical direction, preferably in both directions, wherein the first coupling profile and the second coupling profile are preferably configured such that two of such tile panels can be coupled to each other by means of a fold-down movement (vertical movement).

The first coupling profile preferably comprises: . an upward tongue, = at least one upward flank lying at a distance from the upward tongue, . an upward groove formed in between the upward tongue and the upward flank wherein the upward groove is adapted to receive at least a part of a downward tongue of a second coupling profile of an adjacent tile panel, and . optionally at least one first locking element, preferably provided at a distant side of the upward tongue facing away from the upward flank and/or at the upward flank, and wherein the second coupling profile preferably comprises: . a first downward tongue, . at least one first downward flank lying at a distance from the downward tongue, . a first downward groove formed in between the downward tongue and the downward flank, wherein the downward groove is adapted to receive at least a part of an upward tongue of a first coupling profile of an adjacent tile panel, and . optionally at least one second locking element adapted for co-action with a first locking element of an adjacent tile panel, said second locking element preferably being provided at the downward flank and/or at a distant side of the downward tongue facing away from the downward flank.

Preferably, the first and second coupling profiles are configured to realize a drop- lock coupling, wherein the first coupling profile holds or secures the second coupling profile and preferably vice versa. To this end, it may be favourable that at least a part of an inside of the upward tongue, facing the upward flank, is upwardly inclined towards the upward flank and/or that a least a part of the inside of the downward tongue, facing the downward flank, is downwardly inclined towards the downward flank. Such a system is also referred to as a closed-groove system, wherein each groove of a tile panel holds or secures a complementary tongue of an adjacent tile panel, which results in a horizontal and vertical locking effect. An inverted embodiment, an open-groove system, is also imaginable in this case. The one or more first locking elements and the one or more second locking elements may further improve the mutual locking of interconnected tile panels.

Preferably, the channel-shaped recess connects to the upward flank. This positioning of the channel-shaped recess is preferred as this does not weaken the first coupling profile. Moreover, the second tile panel edge is preferably free of a channel-shaped recess, as a result of which the second coupling profile is not weakened by the channel-shaped recess either. This secures sufficient robustness of the coupling profiles to allow interlocking of adjacent tile panels in a durable and reliable manner.

Itis typically preferred that at least one pair of opposing third and fourth side edges is respectively provided with third and fourth coupling profiles, configured such that the third coupling of the third side edge of a tile panel can be coupled to the fourth coupling profile of the fourth side edge of another tile panel, wherein the fourth side edge is provided with a channel-shaped recess, wherein an outer portion of said channel-shaped recess defines and/or connects to a substantially vertical plane, wherein at least a part of the fourth coupling profile extends with respect to said substantially vertical plane over a horizontal distance which is preferably larger than the width of the channel-shaped recess, and which is preferably smaller than three times, preferably smaller than two times, the width of channel-shaped recess.

Preferably, a third tile panel edge comprises a third coupling profile, and a fourth tile panel edge, preferably opposite to the fourth tile panel edge, comprising a fourth coupling profile being designed to engage interlockingly with said third coupling profile of an adjacent tile panel, in horizontal direction and/or in vertical direction, preferably in both directions, wherein the third coupling profile and the fourth coupling profile are preferably configured such that two of such tile panels can be coupled to each other by means of an angling down movement or turning movement.

Preferably, the tile panel comprises at least one third coupling profile and at least one fourth coupling profile located respectively at a third tile panel edge and a fourth tile panel edge, wherein the third coupling profile comprises: . a sideward tongue extending in a direction substantially parallel to the upper side of the core layer, © at least one second downward flank lying at a distance from the sideward tongue, and . a second downward groove formed between the sideward tongue and the second downward flank, wherein the fourth coupling profile comprises: « a third groove configured for accommodating at least a part of the sideward tongue of the third coupling profile of an adjacent tile panel, said third groove being defined by an upper lip and a lower lip, wherein said lower lip is provided with an upward locking element, wherein the third coupling profile and the fourth coupling profile are configured such that two of such tile panels can be coupled to each other by means of a turning movement or angling down movement, wherein, in coupled condition: at least a part of the sideward tongue of a first tile panel is inserted into the third groove of an adjacent, second tile panel, and wherein at least a part of the upward locking element of said second tile panel is inserted into the second downward groove of said first tile panel.

Preferably, the upper lip is provided with a channel-shaped recess. Preferably, the third tile panel edge is free of a channel-shaped recess. Typically, the upper lip is the most preferred location for the channel-shaped recess as this location is often less vulnerable than the location right above the sideward tongue. This secures that the third and fourth coupling profiles can be realized in a robust manner, which is in favour of realizing a reliable and durable connection between adjacent tile panels.

As indicated above, a top portion of the channel-shaped recess may be provided with a chamfered edge positioned in between the top surface of the tile panel and a vertical or concavely curved part of the channel-shaped recess. This is also called a (micro)bevel. This chamfered edge is typically flat and thus uncurved. The chamfered edge preferably encloses an angle with a plane defined by the tile panel which is situated in between 5 and 50 degrees, preferably in between 5 and 45 degrees. Typically, these (micro)bevel(s) are applied in order to create a smooth transition between the top surface and the vertical part and/or concavely curved part and/or remaining part of the recess, and often also to compensate small height differences between the tile panels and to prevent the presence of unwanted sharp edges as much as possible, in order to improve look and feel of a tile panel covering consisting of a plurality of tile panels according to the invention. The width of this chamfered edge is typically situated in between 0.05 and 2 mm, and is preferably approximately 1 mm.

In a preferred embodiment, the tile panel according to the invention is substantially made from one or more plastic composites, such as wood plastic composite and/or stone plastic composite. These materials have proven a highly suitable and feasible alternative to a traditional tile material such as marble, stone, ceramic or wood.

The tile panel according to the invention, has a preferred thickness in the range from 3.5 mm up to 12.0 mm. When the tile panel comprises a core layer and a decorative top structure, the decorative top structure may have a total thickness in the range of 0.30 up to 1.20 mm, while the core layer may have a thickness in the range of 3 mm up to 11 mm. In case the decorative top structure is formed by one or more tiles, the overall thickness of this decorative top structure and of the tile panel as such will typically be larger.

Preferably, at least two opposing tile panel edges are parallel to each other, preferably the tile panel having a rectangular or hexagonal format. Other polygonal shapes, like an octagonal shape, or non-polygonal shapes are also imaginable.

The invention also relates to a decorative laminated film to be attached to a core layer for realizing a tile panel according to the invention, wherein said laminated film comprises at least one back layer, and a decorative layer attached to said back layer, and optionally at least one, at least partially transparent or translucent wear layer covering said decorative layer at least partially. This film may be produced and even separately shipped and/or marketed, apart from the core layer.

Preferably, the decorative layer comprises a carrier layer with an decorative ink layer (digitally) printed on top of said carrier layer. The decorative ink layer is preferably printed onto said carrier layer before laminating said carrier layer with the (uppermost) back layer. This prevents warping of the back layer during the printing process, which can easily occur in case the back layer comprises a (substantial amount of) thermoplastic material. In case the back layer can be provided with sufficient thermal stability, for example by incorporating one or more fillers in the back layer and/or by incorporating at least one reinforcement layer in the back layer, a separate carrier layer may be omitted. A white primer layer may be applied onto the carrier layer (if applied) or onto the back layer (in case the carrier layer is not applied) to make the ink colours of the decorative ink layer(s) look more realistic. Laminating of the back layer with the decorative layer may be realized by means of fusion and/or gluing.

The invention further relates to a decorative surface covering, in particular for a floor, ceiling or wall surface, which is constructed by a multitude of neighbouring tile panels according to the invention. Preferably, the decorative surface covering is constructed by a multitude of neighbouring interconnected tile panels according to one of the foregoing claims.

The invention moreover relates to a method of manufacturing a decorative tile panel according to the invention, comprising the steps of:

A) preparing a decorative layer, preferably by printing a décor onto a carrier layer,

B) adhering the decorative layer onto a back layer resulting in a decorative laminated film,

C) adhering said back layer, in particular said decorative laminated film, onto a core layer,

D) applying at least one wear layer onto the decorative layer, and

E) locally removing the wear layer and decorative layer, and optionally a part of the back layer, as to form at least one channel-shaped recess, preferably at least one imitation grout line and/or at least one bevel, wherein an exposed top surface of the channel-shaped recess is at least partially defined by said back layer.

Preferably, steps A) and B) are separate, subsequent steps. This eliminates the risk that the back layer will warp and/or that the print quality will be affected during the printing process according to step A). However, steps A) and B) may be integrated steps, wherein the decorative ink layer(s) is directly printed onto the back layer. The back layer is preferably a coloured layer with a colour which corresponds to a desired colour of (at least a part of) the channel-shaped recess, such as grey or brown, to resemble actual imitation grout lines or traditional bevels. Step A) is preferably performed by using digital printing of ink, in particular coloured ink. More in particular, step A) is preferably performed by digitally printing a décor onto the carrier layer. The carrier layer is preferably relatively thin compared to the back layer. Preferably, the carrier layer thickness is generally 0.05-0.1 mm, and may for example be 0.6, 0.7, 0,8, or 0.9 mm.

During step A) heat may be generated during curing and/or drying the printed ink layer, which could cause warping of the back layer, in particular in case the back layer is relatively thick, such as for example at least 0.3 mm. This warping effect of the back layer leads to undesired quality issues during the production of the tile panel. Hence, for this reason the printing step to realize the decorative layer is preferably carried out before laminating the decorative layer with the back layer. As indicated above, the back layer preferably comprises thermoplastic material, such as PVC, which allows fusion with the relatively thin carrier layer of the decorative layer. To this end, the carrier layer preferably comprises the same thermoplastic material, preferably PVC, as the back layer. Preferably, during step B) the decorative layer and the back layer are mutually fused by applying heat and pressure onto both layers, wherein preferably use is made of heated calendering rollers.

Step D) could be applied after step C) and/or prior to step C). The preferred order typically depends on the material of the wear layer and/or the application method used during step D).

Preferably, step D) is applied prior to step E). However, it is also imaginable that step D) is applied after step E) to protect the channel-shaped recess with at least one wear layer. A combination of both options is also possible.

Preferably, during step C) the decorative laminated film and the core layer are mutually fused by applying heat and pressure onto both layers, wherein preferably use is made of heated calendering rollers.

Step B) and step C) may overlap in time. Additionally or alternatively, step C) may be performed prior to step B).

Preferably, step E) is performed by locally milling or cutting away material (or alternatively removing material) of the wear layer and decorative layer, and optionally a part of the back layer.

In a preferred embodiment, the method comprises step F), comprising profiling at least two side edges of the tile panel to provide these side edges with coupling profiles allowing adjacent panels to interlock. Step F) and step E) may overlap in time.

Preferably, step E) is performed prior to step C). This allows the production of a separate decorative top structure provided with one or more channel-shaped recesses to be laminated — at a later stage and optionally at another location — with the core layer. The laminated decorative top structure may be marketed as semi- finished product (intermediate product) before lamination of said decorative top structure to the core layer.

The invention will be further elucidated by several non-limitative embodiments according to the present invention, wherein: - Figure 1 schematically shows a top view of a decorative tile panel according to the invention; - Figure 2a schematically show a cross-sectional view of a decorative tile panel according to the invention along line A-A’ of figure 1; - Figure 2b schematically show a cross-sectional view of a decorative tile panel according to the invention along line B-B’ of figure 1;

- Figure 3a-3b schematically show a cross-sectional view of coupled decorative tile panels of respectively figure 2a and figure 2b; - Figure 4 schematically shows a method to manufacture decorative tile panels according to the present invention; and - Figure 5 schematically shows another method to manufacture decorative tile panels according to the present invention.

Within these figures, similar reference numbers correspond to similar or equivalent elements or features.

Figure 1 shows a top view of a decorative tile panel 1 according to the invention.

The decorative tile panel 1 comprises a decorative top structure 3 and a plurality of tile panel edges 11-14. The tile panel 1 has an oblong rectangular shape, it is however also imaginable that the tile panel 1 has another shape such as a square, a diamond, or else. The shown tile panel 1 is provided with two channel-shaped recesses 9, 10. A first channel-shaped recess 9 is provided on a side edge 14 of the core layer. It is imaginable that a channel-shaped recess 9 is provided on a plurality of side edges 11-14 of the core layer. In a preferred embodiment both a short side edge 11, 12 and a long side edge 13, 14 are provided with a channel- shaped recess 9. In this embodiment, the side edges 11-14 of the core layer form the panel edges 11-14 of the tile panel 1. The tile panel 1 further comprises a second channel-shaped recess 10 provided on a side edge 16 of the decorative top structure 3. Therewith, the second channel-shaped recess 10 (optically) divides the decorative top structure 3 of the tile panel 1. It is imaginable that a channel-shaped recess 10 is provided on a plurality of side edges 16 of the decorative top structure 3. Dotted line A-A’ indicates a cross-section of the tile panel 1 which is depicted in figure 2a. Dotted line B-B’ indicates a cross-section of the tile panel 1 which is depicted in figure 2b.

Figures 2a-2b show a cross-sectional view of a decorative tile panel 1 according to the present invention. The tile panel 1 comprises a core layer 2 and a decorative top structure 3 affixed to the core layer 2. The decorative top structure 3 is affixed to an upper side of the core layer 2. A backing layer 15 is affixed to a bottom side of the core layer 2. The decorative top structure 3 comprises a bottom section 4 and a top section 5. The bottom section 4 is directly or indirectly affixed to the core layer 2. The bottom section 4 comprises at least one back layer 4a. The top section 5 comprises at least one decorative layer 5a and at least one wear layer 5b. The decorative layer ba comprises a carrier layer 5c preferably bearing a decorative ink layer.

Figure 2a shows a cross-sectional view of a decorative tile panel 1 along dotted line A-A’ of figure 1. The decorative tile panel 1 comprises a first tile panel edge 11 and a second tile panel edge 12. The first tile panel edge 11 and the second tile panel edge 12 are opposing tile panel edges 11, 12. The channel- shaped recess 10 is provided on a side edge 16 of the decorative top structure 3.

Therewith, the channel-shaped recess 10 (optically) divides the decorative top structure 3 at least into two portions 31, 32. It is imaginable that the tile panel 1 comprises a plurality of channel-shaped recesses 10 in the decorative top structure 3. Therewith, (optically) dividing the decorative top structure 3 into a multitude of portions. The channel-shaped recess 10 is formed by a cut-away portion of the top section 5 of the decorative top structure 3. The channel-shaped recess 10 is parabolically shaped. Other shapes are also imaginable, such as a V-shaped recess 10. The distance from the deepest point 10a of the channel-shaped recess 10 to the core layer 2 is smaller than the distance from the deepest point 10a of the channel-shaped recess 10 to the top surface of the tile panel 1. The channel- shaped recess 10 comprises an exposed top surface 10a at least partially defined by the bottom section 4 of the decorative top structure 3. The exposed top surface 10a may have a different colour than the top section 5, preferably to form an imitation grout line in the tile panel 1. In the shown embodiment the exposed top surface 10a is formed by the back layer 4a of the bottom portion 4 of the decorative top structure 3. The channel-shaped recess 10 is partially defined by three side walls 10a-10c. A part of at least one side wall 10a is defined by the bottom section 4 of the decorative top structure 3. The side walls 10b, 10c are provided as a chamfered edge positioned between the top surface of the tile panel 1 and the concavely curved part of the channel-shaped recess 10. The bottom section 4 has a nominal thickness T,, wherein the thickness Te of the bottom section 4 below the channel-shaped recess 10 is smaller than the nominal thickness Tx. It is imaginable that the thickness T. of the bottom section 4 below the channel-shaped recess 10 is substantially equal to the normal thickness T, of the bottom section 4. The first tile panel edge 11 comprises a first coupling profile 6. The first coupling profile 6 comprises an upward tongue 61, at least one upward flank 62 and an upward groove 63 formed in between the upward tongue 61 and the upward flank 62. The first coupling profile 6 further comprises at least one first locking element 64. The first locking element 64 of the shown embodiment is provided at a distant side of the upward tongue 61 facing away from the upward flank 62. The second tile panel edge 12 opposes the first side edge 11 of the tile panel 1. The second side edge 12 comprises a second coupling profile 7. The second coupling profile 7 comprises a first downward tongue 71, at least one first downward flank 72 and a first downward groove 73 formed in between the downward tongue 71 and the downward flank 72.

The second coupling profile 7 further comprises at least one second locking element 74. The second locking element 74 of the shown embodiment is provided at the downward flank 72. Preferably, the first locking element 64 and the second locking element 74 are complementary locking elements such that upon coupling of two of such tile panels 1 the locking elements 64, 74 engage interlockingly in horizontal direction and/or in vertical direction.

Figure 2b shows a cross-sectional view of a decorative tile panel 1 along dotted line B-B’ of figure 1. The tile panel 1 comprises a third panel tile edge 13 and a fourth panel tile edge 14. The decorative tile panel 1 further comprises a channel- shaped recess 9. The tile panel 1 comprises a channel-shaped recess 9 at the side of the fourth tile panel edge 14. However, another location of the channel-shaped recess 9 is imaginable. The channel-shaped recess 9 can for example be formed at or near any of the tile panel edges 11-14. The channel-shaped recess 9 is formed by a cut-away portion of the top section 5 of the decorative top structure 3. The channel-shaped recess 9 comprises an exposed top surface 9a at least partially defined by the bottom section 4 of the decorative top structure 3. The exposed top surface 9a may have a different colour than the top section 5, preferably to form an imitation grout line between coupled decorative tile panels 1. In the shown embodiment the exposed top surface 9a is formed by the back layer 4a of the bottom portion 4 of the decorative top structure 3. The channel-shaped recess 9 is partially defined by two side walls 9a-9b. A part of at least one side wall 9a is defined by the bottom section 4 of the decorative top structure 3. The side wall 9b is provided with a chamfered edge positioned in between the top surface of the tile panel 1 and a vertical part of the channel-shaped recess 9. The bottom section 4 has a nominal thickness T,, wherein the thickness T. of the bottom section 4 below the channel-shaped recess 9 is smaller than the nominal thickness Ts. It is imaginable that the thickness T. of the bottom section 4 below the channel-shaped recess 9 is substantially equal to the normal thickness Ty, of the bottom section 4.

The third tile panel edge 13 comprises a third coupling profile 9. The third coupling profile 9 comprises a sideward tongue 91, at least one second downward flank 92 and at least one second downward groove 93 formed between the sideward tongue 91 and the second downward flank 92. The fourth tile panel edge 14 comprises a fourth coupling profile 8. The fourth coupling profile 8 comprises a third groove 83, an upper lip 81 and a lower lip 82. As can be observed, the upper lip 81 is provided with the channel-shaped recess 9. Additionally, the third tile panel edge 13 is free of a channel-shaped recess 9.

Figures 3a-3b show a cross-sectional view of two coupled decorative tile panels according to the present invention.

Figure 3a shows two coupled decorative tile panels according to figure 2a.

The first coupling profile 6 and the second coupling profile 7 are configured such that two of such tile panels can be coupled to each other by means of a fold-down movement. The side edge 16 of the decorative top structure 3 is provided with a channel-shaped recess 10 forming at least one imitation grout line and/or at least one (micro)bevel, connecting the side edges 16 of the decorative top structure 3.

The channel-shaped recess 10 is formed at a distance from a tangent line formed by the shown line of contact of two coupled tile panels. The channel-shaped recess 10 is particularly formed at a distance from each of the coupling profiles 6, 7 and/or at a distance from each of the panel side edges 11, 12. Therewith, the channel- shaped recess 10 (optically) divides the decorative top structure 3 of the tile panel into decorative top structure portions 31- 33. An outer portion of said channel- shaped recess 10 defines and/or connects to a substantially vertical plane V. At least a part of the first coupling profile 6, preferably the entire first coupling profile 6, extends with respect to said substantially vertical plane V over a horizontal distance

D which is larger than the width W of the channel-shaped recess 10.

Figure 3b shows two coupled decorative tile panels 1 according to figure 2b.

The third coupling profile 9 and the fourth coupling profile 8 are configured such that two of such tile panels can be coupled to each other by means of an angling down movement or turning movement. The fourth tile panel edge 14 is provided with a channel-shaped recess 9. Upon coupling of two tile panels at least one imitation grout line and/or at least one (micro)bevel is formed, connecting the side edges 13, 14 of the tile panels. The channel-shaped recess 9 is formed at the tangent line formed by the line of contact of the two coupled tile panels. The channel-shaped recess 9 is particularly formed near at least one of the coupling profiles 6, 7 and/or near at least one of the panel side edges 11, 12. An outer portion of said channel-shaped recess 9 defines and/or connects to a substantially vertical plane V. At least a part of the fourth coupling profile 8, preferably the entire fourth coupling profile 8, extends with respect to said substantially vertical plane V over a horizontal distance D which is larger than the width W of the channel-shaped recess 9. Here, the vertical plane V is equal to the tangent line formed by the line of contact of the two coupled tile panels. The upwardly facing recess surface of the channel-shaped recess 9 is at least partially concavely curved, preferably gradually concavely curved, across the width direction W of the channel-shaped recess 9.

Figure 4 shows a method for manufacturing a decorative tile panel 1 according to the present invention. In step A) a decorative layer 5a is prepared. In this embodiment, the decorative layer 5a is prepared by printing a décor onto a carrier layer 5c. The décor is printed onto the carrier layer 5c by means of a (digital) printer 40. Subsequently, the printed ink layer is cured and/or dried (not shown).

Thereafter, in step B) the decorative layer 5a is adhered onto a back layer 4a resulting in a decorative laminated film 3. The decorative layer 5a is adhered onto the back layer 4a by means of a roller 41. However, other methods for adhering a decorative layer ba onto the back layer 4a are possible such as calendaring and/or applying pressure on both the back layer 4a and the decorative layer 5a. In step C) the back layer 4a, in particular the decorative laminated film 3, is adhered to a core layer 2. The back layer 4a and the core layer 2 are adhered by applying heat and pressure P on both the back layer 4a and the core layer 2. In this embodiment, the decorative laminated film 3 and the core layer 2 are adhered by applying heat and pressure P on both the decorative laminated film 3 and the core layer 2. it is imaginable that in step C) use is made of heated calendaring rollers (not shown). In step D) a wear layer 5b is applied on the upper surface of the decorative laminated film 3, in particular on the decorative layer 5a. The wear layer 5b can be applied onto the upper surface of the decorative laminated film 3 by spraying the wear layer 5b on the upper surface by means of a spraying device 42. However, various other methods can be applied to apply a wear layer 5b onto the upper surface of the decorative laminated film 3, such as dipping the upper surface in a wear layer material comprising bath or by printing the wear layer 5b onto the upper surface of the decorative film layer 3, in particular of the decorative layer 5a. The decorative laminated film 3 comprises a top section 5 and a bottom section 4. The top section comprises the carrier layer 5c, the decorative layer 5a and the wear layer 5b. The bottom section 4 comprises the back layer 4a. In step E) the wear layer 5b, the decorative layer 5a and the carrier layer 5c are locally removed. In the shown 5 embodiment, also a part of the back layer 4a is removed. Step E) forms at least one channel-shaped recess 9, preferably at least one imitation grout line and/or at least one (micro)bevel, wherein an exposed top surface 9a of the channel-shaped recess 9 is at least partially defined by said back layer 4a. Step E) is performed by removing material of the top section 5 of the decorative film layer 3. Optionally, a part of the bottom portion 4 is removed. Step E) can be performed by locally milling or cutting away material, for example by usage of a milling device 43.

Figure 5 shows another method for manufacturing a decorative tile panel 1 according to the present invention. It is possible that, the decorative laminated film is manufactured by means of co-extrusion in step B). The co-extruder 50 comprises two extruders 52, 53 each providing one sublayer 62, 63 respectively to be co- extruded. The first extruder 52 discharges a first sublayer 62 comprising a slab of viscous or paste-like back layer material. The second extruder 53 discharges a second sublayer 63 comprising a slab of viscous or paste-like decorative layer material. The colour of the decorative layer material preferably differs from the colour of the back layer. Subsequently, the two sublayers 62, 63 are fed into three (heated) calendaring rolls 59, 60, 61. These calendaring rolls 59, 60, 61 mutually adhere the two sublayers 62, 63 together into a coextruded layer 63. The coextruded layer 63 subsequently forms a decorative laminated film 3, comprising a back layer 4a and a decorative layer 5a. In step A), the decorative layer 5a can be prepared by (digitally) printing a décor onto the decorative layer material of the decorative laminated film 3 by means of a (digital) printer 40. It is possible that the colour of the decorative layer material is substantially white before preparing a décor. Optionally, the second extruder 53 discharges a second sublayer 63 comprising a décor forming a decorative layer 5a. In that case, it is possible that step A) and B) are performed simultaneously and a (digital) printer 40 is not needed. In step C) the back layer 4a is adhered to the core layer 2. In step C) the back layer 4a, in particular the decorative laminated film 3, is adhered to a core layer 2. The back layer 4a and the core layer 2 are adhered by applying heat and pressure P on both the back layer 4a and the core layer 2. In this embodiment, the decorative laminated film 3 and the core layer 2 are adhered by applying heat and pressure P on both the decorative laminated film 3 and the core layer 2. lt is possible that step C) is performed by means of co-extrusion. The co-extruder 50 then comprises extruders 52, 53 each providing one sublayer 62, 63 respectively to be co-extruded. The first extruder 52 discharges a first sublayer 62 comprising a slab of viscous or paste-like core layer material. The second extruder 53 discharges a second sublayer 63 comprising a slab of viscous or paste-like back layer material. The colour of the back layer material 4a differs from the colour of the core layer 2. Subsequently, the two sublayers 62, 63 are fed into three calendaring rolls 59, 60, 61. These calendaring rolls 59, 60, 61 mutually adhere the two sublayers 62, 63 together into a coextruded layer. In step A) a decorative layer 5a is prepared, for example by printing a décor onto a carrier layer, such as shown in figure 4. Subsequently, the decorative layer 5a is adhered to the back layer 4a in step B). It is optional to print a décor onto a carrier layer before adhering the decorative layer 5a onto the back layer 4a. In yet another embodiment, step A) to step C) are performed by making use of a co-extruder 50 that comprises three extruders (not shown). Then, the co-extruder 50 comprises three extruders each providing one sublayer respectively to be co-extruded. The first extruder 52 discharges a first sublayer 62 comprising a slab of viscous or paste-like back layer material. The second extruder 53 discharges a second sublayer 63 comprising a slab of viscous or paste-like decorative layer material. The third extruder discharges a third sublayer (not shown) comprising a slab of core layer material.

The third extruder would be located at the lower side of the first extruder 52. The three sublayers could subsequently be fed into the (heated) calendaring rolls 59, 60, 61 and mutually adhered into a coextruded layer comprising a core layer 2, back layer 4a and decorative layer 5a. Optionally, a decorative layer 5a is prepared by (digitally) printing a décor onto the side of the decorative material layer of the coextruded layer. In step F) at least two side edges of the tile panel are profiled to provide the side edges with coupling profiles 54, 55 to allow adjacent panels to interlock upon coupling. The profiling of the side edges can for example be performed by (laser) cutting the core layer 2. In step D) at least one wear layer 5b is applied onto the decorative layer 5a. In step E) the wear layer 5b and decorative layer 5a are locally removed, for example by means of cutting or milling. In the shown embodiment, the material is removed by means of a milling machine 43.

Additionally, part of material of the back layer 4a is removed in step E). Thereby,

forming at least one channel-shaped recess 9, preferably at least one imitation grout line and/or at least one (micro)bevel, wherein an exposed top surface 9a of the channel-shaped recess 9 is at least partially defined by said back layer 4a. Step

F) can be performed prior to step D) and/or E). Step F) can also be performed after step D) and/or E).

The above-described inventive concepts are illustrated by several illustrative embodiments. It is conceivable that individual inventive concepts may be applied without, in so doing, also applying other details of the described example. It is not necessary to elaborate on examples of all conceivable combinations of the above- described inventive concepts, as a person skilled in the art will understand numerous inventive concepts can be (re)combined in order to arrive at a specific application.

It will be apparent that the invention is not limited to the working examples shown and described herein, but that numerous variants are possible within the scope of the attached claims that will be obvious to a person skilled in the art.

The ordinal numbers used in this document, like “first”, “second”, “third” and “fourth”, are used only for identification purposes. Hence, the use of the expression “third coupling profile” does therefore not necessarily require the co-presence of a “first coupling profile”.

The verb “comprise” and conjugations thereof used in this patent publication are understood to mean not only “comprise”, but are also understood to mean the phrases “contain”, “substantially consist of”, “formed by” and conjugations thereof.

Claims

Conclusions

1. Decorative tile panel suitable for covering a floor, ceiling or wall surface, which tile panel comprises: eo at least one core layer, and ° at least one decorative top structure, applied directly or indirectly to said core layer, the decorative top structure defining an upper surface of the tile panel, said decorative top structure comprising: 0 a bottom section comprising at least one underlayer, and Oo a top section comprising a decorative layer and at least one, at least partially transparent or translucent wear layer at least partially covering said decorative layer,

. a plurality of side edges at least partly defined by said core layer and/or by said decorative top structure, the decorative top structure being provided with at least one channel-shaped recess, preferably at least one imitation joint line and/or at least one bevel, connecting different side edges, preferably opposite side edges, of the tile panel, said at least one channel-shaped recess being at least partly formed by a cut-out portion of the top section of the decorative top structure, and an exposed upper surface of the channel-shaped recess being at least partly defined by the bottom section, in particular at least one sub-layer, of the decorative top structure.

2. A tile panel as claimed in claim 1, wherein said at least one channel-shaped recess is formed in part by a cut-out portion of the bottom section of the decorative top structure.

3. Tile panel according to claim 1 or 2, wherein the bottom section has a nominal thickness T, the thickness Te of the bottom section below the channel-shaped recess being less than the nominal thickness Th.

4. Tile panel according to claim 3, wherein the thickness Ts of the bottom section under the channel-shaped recess satisfies the following formula: Ta > Tc 2 0.6T,.

5. A tile panel as claimed in any preceding claim, wherein the channel-shaped recess is defined in part by a side wall, a portion of said side wall being defined by the bottom section of the decorative top structure.

6. Tile panel according to any of the preceding claims, wherein the channel-shaped recess is defined by at least one side wall and said upper surface, the transition between the side wall and the upper surface being continuous, preferably smoothly continuous.

7. A tile panel according to any preceding claim, wherein an exposed upper surface of the channel-shaped recess is at least partly formed by an exposed portion of the bottom section, in particular at least one underlayer, of the decorative top structure.

8. A tile panel according to any preceding claim, wherein an exposed surface of the channel-shaped recess is at least partially covered with at least one coating.

9. Tile panel according to any of the preceding claims, wherein the upper surface of the channel-shaped recess is at least partially concavely curved, preferably fully curved in the width direction of the channel-shaped recess.

10. A tile panel as claimed in any preceding claim, wherein an exposed upper surface of the channel-shaped recess is at least partially textured.

11. A tile panel according to any preceding claim, wherein the underlayer comprises a pigment corresponding to an intended visual appearance of said channel-shaped recess.

12. Tile panel according to any of the preceding claims, wherein the underlayer comprises thermoplastic material, preferably PVC material.

13. A tile panel according to any preceding claim, wherein the underlayer comprises a matrix material, such as a thermoplastic material, and at least one filler or additive, such as wear-resistant anti-slip particles, embedded in said matrix material.

14. Tile panel according to any of the preceding claims, wherein the decorative layer comprises a carrier layer provided with a decorative ink layer.

15. Tile panel according to claim 14, wherein the base layer and the carrier layer comprise the same thermoplastic material.

16. Tile panel according to claim 14 or 15, wherein the underlayer and the carrier layer are fused.

17. Tile panel according to any of claims 14-16, wherein the carrier layer is a white layer.

18. Tile panel according to any of the preceding claims, wherein the thickness of the underlayer is at least 0.2 mm, and preferably lies between and comprises 0.3 and 1 mm.

19. Tile panel according to any of the preceding claims, wherein the thickness of the wear layer is at least 0.05 mm, and preferably between 0.05 and 0.75 mm, and more preferably 0.3, 0.4 or 0.5 mm.

20. Tile panel according to any of the preceding claims, wherein the underlayer and the core layer comprise the same thermoplastic material.

21. Tile panel according to any of the preceding claims, wherein the underlayer and the core layer are fused.

22. A tile panel according to any preceding claim, wherein said channel-shaped recess has a deepest point at a distance from the respective side edge, the deepest point preferably being closer to said side edge than to the upper surface of the tile panel.

23. A tile panel according to any preceding claim, wherein the width of the channel-shaped recess is at least three times the maximum depth of said channel-shaped recess relative to the upper surface of the tile panel.

24. A tile panel according to any preceding claim, wherein one side edge of the tile panel is provided with a channel-shaped recess, while an opposite side edge is not provided with an imitation joint line.

25. A tile panel according to any preceding claim, wherein at least one pair of opposite first and second side edges are provided with first and second coupling profiles respectively, arranged such that the first coupling of the first side edge of a first tile panel can be coupled to the second coupling profile of the second side edge of a second tile panel, the first side edge being provided with a channel-shaped recess, an outer portion of the channel-shaped recess defining and/or connecting to a substantially vertical plane, at least a portion of the first coupling profile, preferably the entire first coupling profile, extending relative to said substantially vertical plane over a horizontal distance which is preferably greater than the width of the channel-shaped recess, and which is preferably less than three times, preferably less than two times, the width of the channel-shaped recess.

26. Tile panel according to any of the preceding claims, wherein a first tile panel edge comprises a first coupling profile, and a second tile panel edge, preferably opposite the first tile panel edge, comprises a second coupling profile designed to interlockingly engage with said first coupling profile of an adjacent tile panel, in a horizontal direction and/or in a vertical direction, the first coupling profile and the second coupling profile preferably being arranged such that two such tile panels can be coupled to each other by means of a downward folding movement.

27. Tile panel according to claim 25 or 26, wherein the first coupling profile comprises: . an upward tongue,

. at least one upward flank spaced from the upward tongue, . an upward groove formed between the upward tongue and the upward flank, the upward groove being adapted to receive at least a portion of a downward tongue of a second coupling profile of an adjacent panel, and . optionally at least one first locking element, preferably provided on a remote side of the upward tongue facing away from the upward flank, and wherein the second coupling profile comprises: . a first downward tongue, . at least one first downward flank spaced from the downward tongue, . a first downward groove formed between the downward tongue and the downward flank, the downward groove being adapted to receive at least a portion of an upward tongue of a first coupling profile of an adjacent panel, and . optionally at least one second locking element suitable for cooperation with a first locking element of an adjacent panel, the second locking element preferably being provided on the downward flank.

28. Tile panel according to claim 27, wherein the channel-shaped recess connects to the upward flank.

29. A tile panel as claimed in claim 27 or 28, wherein the second edge of the tile panel is free from a channel-shaped recess.

30. A tile panel according to any preceding claim, wherein at least one pair of opposite third and fourth side edges are provided with third and fourth coupling profiles respectively, arranged such that the third coupling of the third side edge of a tile panel can be coupled to the fourth coupling profile of the fourth side edge of another tile panel, wherein the fourth side edge is provided with a channel-shaped recess, wherein an outer part of the channel-shaped recess defines and/or adjoins a substantially vertical plane, wherein at least a part of the fourth coupling profile extends relative to said substantially vertical plane over a horizontal distance which is preferably greater than the width of the channel-shaped recess, and which is preferably less than three times, preferably less than twice, the width of the channel-shaped recess.

31. Tile panel according to any one of the preceding claims, wherein a third tile panel edge comprises a third coupling profile, and a fourth tile panel edge, preferably opposite the fourth tile panel edge, comprises a fourth coupling profile designed to interlockingly engage with said third coupling profile of an adjacent tile panel, in a horizontal direction and/or in a vertical direction, wherein the third coupling profile and the fourth coupling profile are preferably arranged such that two such tile panels can be coupled to each other by means of a downward angular movement.

32. Tile panel according to any of the preceding claims, wherein the tile panel comprises at least one third coupling profile and at least one fourth coupling profile located at a third tile panel edge and a fourth tile panel edge respectively, the third coupling profile comprising:

. a lateral tongue extending in a direction substantially parallel to the top of the core layer,

. at least one second downward flank located at a distance from the lateral tongue, and « a second downward groove formed between the lateral tongue and the second downward flank, the fourth coupling profile comprising:

. a third groove adapted to receive at least a portion of the lateral tongue of the third coupling profile of an adjacent tile panel, the third groove being defined by an upper lip and a lower lip, said lower lip being provided with an upward locking element, the third coupling profile and the fourth coupling profile being adapted to couple two such tile panels together by means of a pivoting movement, wherein, in the coupled state: at least a portion of the lateral tongue of a first tile panel is inserted into the third groove of an adjacent second tile panel, and at least a portion of the upward locking element of said second tile panel is inserted into the second downward groove of said first tile panel.

33. Tile panel according to claim 32, wherein the upper lip is provided with a channel-shaped recess.

34. A tile panel as claimed in claim 32 or 33, wherein the third tile panel edge is free from a channel-shaped recess.

35. Tile panel according to any of the preceding claims, wherein the width of the channel-shaped recess is less than 4.5 mm.

36. Tile panel according to any of the preceding claims, wherein the maximum depth of the channel-shaped recess is 0.1 - 1.5 mm, preferably 0.2 - 0.8 mm, more preferably 0.2 - 0.3 mm.

37. A tile panel as claimed in any preceding claim, wherein an upper portion of the channel-shaped recess is provided with a bevelled edge located between the upper surface of the tile panel and a vertically or concavely curved portion of the channel-shaped recess.

38. Tile panel according to any of the preceding claims, wherein the core layer of the tile panel is at least partly made of one or more plastic composites, such as wood plastic composite and/or stone plastic composite and/or mineral plastic composite.

39. Tile panel according to any of the preceding claims, wherein the tile panel has a thickness in the range of 4.0 mm to 12.0 mm.

40. Tile panel according to any of the preceding claims, wherein the thickness of the underlayer is at least four times the thickness of the wear layer.

41. Tile panel according to any of the preceding claims, wherein at least one reinforcement layer is bonded to and/or embedded in at least one substrate.

42. Tile panel according to claim 41, wherein the at least one reinforcement layer is located in the lower half and/or the middle of at least one sub-layer.

43. A tile panel according to any preceding claim, wherein at least two opposing tile panel edges are parallel to each other, the tile panel preferably having a rectangular or hexagonal shape.

44. Decorative laminated film for attachment to a core layer for realizing a tile panel according to any of the preceding claims, wherein the laminated film comprises at least one substrate, and a decorative layer attached to the substrate, and optionally at least one at least partially transparent or translucent wear layer at least partially covering the decorative layer.

45. Decorative surface covering, in particular for a floor, ceiling or wall surface, which is constructed from a plurality of adjacent tile panels according to any one of claims 1 to 43.

46. A decorative surface covering as claimed in claim 43 which is constructed from a plurality of adjacent, interconnected tile panels as claimed in any preceding claim.

47. Method for manufacturing a decorative tile panel according to any one of claims 1 to 43, comprising the steps of: A) preparing a decorative layer, preferably by printing a decor on a carrier layer, B) adhering the decorative layer to a substrate resulting in a decorative laminated film, C) adhering said substrate, in particular said decorative laminated film, to a core layer,

D) applying at least one wear layer on the decorative layer, and E) locally removing the wear layer and decorative layer, and optionally a portion of the underlayment, to form at least one channel-shaped recess, preferably at least one imitation joint line and/or at least one chamfer, an exposed upper surface of the channel-shaped recess being at least partially defined by said underlayment.

48. The method of claim 47, wherein step D) is at least partially performed after step C).

49. A method according to claim 47 or 48, wherein step D) is performed prior to step E).

50. A method according to any one of claims 47 to 49, wherein step D) is at least partially performed prior to step C).

51. A method according to any one of claims 47 to 50, wherein the base layer comprises thermoplastic material and at least one filler embedded in the thermoplastic material.

52. Method according to any one of claims 47 to 51, wherein step A) is carried out by digitally printing a decor on the carrier layer.

53. A method according to any one of claims 47 to 52, wherein said carrier layer is used during step A), said carrier layer and said underlayer each comprising the same thermoplastic material, and said carrier layer and said underlayer are fused during step B).

54. A method according to any one of claims 47 to 53, wherein during step B) the decorative layer and the base layer are fused by applying heat and pressure to both layers, preferably using heated calender rolls.

55. A method according to any one of claims 47 to 54, wherein during step C) the laminated film and the core layer are mutually fused by applying heat and pressure to both layers, preferably using heated calender rolls.

56. Method according to any one of claims 47 to 55, wherein step B) and step C) overlap in time.

57. Method according to any one of claims 47 to 56, wherein step E) is carried out by locally milling away material from the wear layer and decorative layer, and optionally a part of the underlayer.

58. Method according to any of claims 47 to 57, wherein the method comprises step F), comprising profiling at least two side edges of the tile panel to provide these side edges with coupling profiles to enable locking of adjacent panels.

59. A method according to any one of claims 47 to 58, wherein step C) is performed prior to step B).

60. A method according to any one of claims 47 to 58, wherein step E) is performed prior to step C).

61. A method according to any one of claims 47 to 59, wherein the decorative layer and the base layer are made by co-extrusion, and wherein the base layer and the core layer are made by co-extrusion.