Patent Description:
Laminated panels comprise a core layer onto which a decorative top structure is applied having a printed decorative image which typically has the appearance of a wood pattern. The decorative image is covered by a transparent layer to preserve and protect said the image. In order to improve the optical and haptic appearance of the decorative image of the decorative top structure, impressions can be realized in the transparent layer, this in order to obtain an e.g., imitation of wood pores and other unevennesses which can be present at the surface of real wood. Often PVC is used as main constituent for composing the core. Often, the decorative image is digitally printed onto a PVC film, wherein said printed PVC film is affixed to said core. Although the digital printing techniques are constantly improving, leading to more realistic natural appearances, there is also a trend of leading flooring manufacturers to develop more environmental-friendly decorative panels which are more composed of natural materials rather than of synthetic, in particular thermoplastic, materials, such as PVC. To this end, flooring panels have been developed which use a cork layer, rather than a PVC film, to bear a printed décor image. Although this solution constitutes an improvement from an environmental point of view, it has been found that cork is rather expensive and it is practically impossibly to reach to same panel quality compared to panels wherein PVC are used to bear the decorative image, in terms of image quality and panel stability.

The document <CIT> discloses a decorative panel according to the preamble of claim <NUM>.

It is therefore a first objective of the invention to provide a relatively environmental-friendly, high-quality decorative panel.

It is therefore a second objective of the invention to provide a relatively environmental-friendly decorative panel comprising a high-quality décor image.

It is therefore a third objective of the invention to provide an environmental-friendly, inexpensive decorative panel.

At least one of these objective can be met by providing a decorative panel according to claim <NUM>.

Preferably, the decorative panel is an interlockable panel configured to interlock with adjacent panels. To this end, the decorative panel comprises a first panel edge comprises a first coupling profile, and a second panel edge, preferably opposite to the first panel edge, comprising a second coupling profile being designed to engage interlockingly with said first coupling profile of an adjacent panel, both in horizontal direction and in vertical direction.

The intermediate layer is a non-human collagen based layer. Skin, or animal hide, is formed primarily of collagen, a fibrous protein, and serves as source for composed at least a part of said intermediate layer. Collagen is a generic term for a family of at least <NUM> distinct collagen types; animal skin is typically type I collagen, although other types of collagen may be used in forming leather. Collagens are characterized by repeating triplets of amino acids, -(Gly-X-Y) n -, so that approximately one-third of the amino acid residues are in collagen are glycine. X is typically proline and Y is typically hydroxyproline. The structure of collagen may consist of twined triple units of peptide chains of differing lengths. Different animals may produce different amino acid compositions of the collagen, which may result in different properties (and differences in the resulting leather). Collagen fiber monomers may be produced from alpha-chains of about <NUM> amino acids long, so that the triple helix takes the form of a rod of about <NUM> long, with a diameter of <NUM>. Triple helices can be bound together in bundles called fibrils, and fibril bundles come together to create fibers. Fibers typically divide and join with each other throughout an animal skin layer. Variations of the crosslinking or linking may provide strength to the material. Fibers may have a range of diameters depending on the type of animal hide. In addition to type I collagen, skin (hides) may include other types of collagen as well, including type III collagen (reticulin), type IV collagen, and type VII collagen. Leather derived from animal mainly consists of collagen type I when hides are obtained from adult animals, and significant proportion of collagen types III and IV, together with collagen type I when skins are derived from young animals. The composition and ratio of collagen types affect the physical properties of leather, a younger hide with proper tanning provides the softest leather.

The use of non-human collagen, and (bonded) leather in particular, is not only technically driven, but also environmentally and morally driven. The global leather industry slaughters more than a billion animals per year. The leather skin resulting from this slaughtering process is often and largely treated as waste, which is typically burned afterwards. By reusing this leather at least partially the amount of waste is reduced and a more circular production cycle can be realised. Moreover, these leather residues, typically offered as bonded leather, is relatively inexpensive, and therefore more attractive than other natural materials, such as cork, which may be used for this purpose.

Moreover, the application of a non-human collagen and/or leather based intermediate layer for supporting the decorative top structure is favourable since, this intermediate layer is well-suitable for adhesion of a primer layer and/or a digital print layer of the decorative top structure. Moreover, due to the flexible (elastic) nature of the intermediate layer, the intermediate layer is typically configured to compensate differences in the temperature and/or moisture expansion coefficient of the core and at least a part of the decorative top structure. This prevents delamination of the panel, which is in favour of the lifetime of the panel. An additional advantage of the intermediate layer is it capability to be sawn, milled, and edged, which is favourable when profiling the panel to realising coupling profiles. Furthermore, the intermediate layer provide the panel additional strengthening. Additionally, the presence of one or more intermediate layer provides the panel improved acoustic dampening properties. Since at least the edges of at least one intermediate layer are typically exposing to the surrounding atmosphere, it is additionally favourable that the intermediate layer(s) has/have a relatively good resistance against cleaning agents. Due to the above properties it can be advantageous that (i) at least one intermediate layer is situated in between the core and the decorative top structure, and preferably affixed, either directly or indirectly, to the upper side of the core, and/or that (ii) at least one intermediate layer is embedded in the core, and/or that (iii) at least one intermediate layer is affixed, either directly or indirectly, to the lower side of the core.

The non-human collagen present in the intermediate layer is preferably derived from cows, water buffaloes, horses, deers, crocodiles, or goats, as the tear strength of this leather types are relatively high, in particular higher than <NUM> N/mm. Hence, the intermediate layer(s) preferably comprise(s) bovine leather, which is typically preferred over ovine leather, also because there is a correlation between leather strength and fibril diameter in bovine leather. In bovine leather, the collagen fibrils are more aligned than in ovine skin, and it was found that where tissue contains highly aligned fibrils, the fibril diameter becomes a significant determinant of strength. In tissues where the fibrils are not well aligned, the influence of fibril alignment on strength is greater than that of fibril diameter. Therefore, in leather and skin, larger fibrils may lead to stronger material, but for weaker leathers, fibril diameter is secondary to fibril alignment for strength. Preferably, the fibril length is at least <NUM>, which is typical for cows and horses.

Preferably, the amount of (genuine) leather is preferably situated between <NUM> and <NUM>% and more preferably approximately <NUM>% by weight of the intermediate layer. Although it is imaginable that the intermediate layer is entirely (<NUM>%) composed of leather, this will commonly be considered as a rather expensive solution compared to a composite material which comprises further to leather also one or more other materials.

Preferably, at least one intermediate layer is at least partially or entirely composed of bonded leather, also referred to as reconstituted leather or blended leather. Bonded leather is at least partially composed of (genuine) leather particles bonded by means of a binding material, wherein the amount of binding material is preferably situated between <NUM> and <NUM>% and more preferably approximately <NUM>% by weight of the intermediate layer. Examples of suitable binding material are natural rubber, such as latex, and polyurethane. Preferably, bonded leather comprises a layered structure of a carrier layer onto which leather particles are bonded by means of said binding material. The carrier layer may, for example, be composed of a paper, fabric, cork, wood, and/or a, preferably natural polymer, such as natural rubber (latex). The carrier layer may be either a woven or non-woven layer. Preferably, the binding material is partially penetrated into the carrier layer. It is conceivable that the binding material is partially penetrated into the core and/or at least one other adjacent layer. Since the collagen of the intermediate layer typically has a porous structure, it typically allows penetration of other materials. It is therefore imaginable that the decorative top structure is partially penetrated into at least one intermediate layer situated in between the top structure and the core. More in particular, it is imaginable that a primer layer of the top structure, is partially penetrated into at least one intermediate layer situated in between the top structure and the core. Penetration of layers into each other typically increases the bonding strength between said layers.

Preferably, at least one intermediate layer comprises between <NUM>-<NUM>%, more preferably at least <NUM>% and/or less than <NUM>%, most preferably approximately <NUM>% (+/-<NUM>%), by weight of natural leather fibres. Preferably, at least one intermediate layer comprises between <NUM>-<NUM>%, more preferably at least <NUM>% and/or less than <NUM>%, and most preferably approximately <NUM>% (+/- <NUM>%), by weight of synthetic polymer and/or natural polymer, in particular natural latex. Preferably, at least one intermediate layer comprises between <NUM>-<NUM>%, more preferably at least <NUM>% and/or less than <NUM>%, and most preferably approximately <NUM>% (+/- <NUM>%), by weight of fat, in particular natural fat. Preferably, at least one intermediate layer comprises between <NUM>-<NUM>%, more preferably at least <NUM>% and/or less than <NUM>%, and most preferably approximately <NUM>% (+/- <NUM>%), by weight of water and/or vegetable additive, such as vegetable tanning agent, and/or at least one other additive.

Preferably, at least one intermediate layer comprises at least one natural fat, such as fatty tissue derived from animals and/or vegetable oil, in particular rapeseed oil, wherein the amount of natural fat is preferably situated between <NUM> and <NUM>%, and more preferably approximately <NUM>% by weight of the intermediate layer. Typically, such a natural fat, such as natural oil, in particular rapeseed oil, acts as lubricant within the intermediate layer. The presence of one or more lubricants modulates or controls fibril-fibril bonding during dehydration to leather which improves the strength of the intermediate layer. Other suitable lubricants include surfactants, anionic surfactants, cationic surfactants, cationic polymeric surfactants, anionic polymeric surfactants, amphiphilic polymers, fatty acids, modified fatty acids, non-ionic hydrophilic polymers, non-ionic hydrophobic polymers, poly acrylic acids, poly methacrylic, acrylics, natural rubbers, amphiphilic anionic polymer and copolymers, amphiphilic cationic polymer and copolymers and mixtures thereof as well as emulsions or suspensions of these in water, alcohol, ketones, and other solvents. In case a polymeric substance is used as lubricant, preferably a natural (bio)polymeric substance is used.

Furthermore, at least one intermediate layer comprises at least one additive, such as, preferably vegetable, tanning agent and/or water, wherein the amount of additive is preferably situated between <NUM> and <NUM> % and more preferably <NUM>% by weight of the intermediate layer. Examples of vegetable tanning agents are pyrogallol- or pyrocatechin-based tannins, such as valonea, mimosa, ten, tara, oak, pinewood, sumach, quebracho and chestnut tannins; chromium tanning agents include chromium salts like chromium sulphate; aldehyde tanning agents include glutaraldehyde and oxazolidine compounds, syntans include aromatic polymers, polyacrylates, polymethacrylates, copolymers of maleic anhydride and styrene, condensation products of formaldehyde with melamine or dicyandiamide, lignin and natural flours.

The intermediate layer(s) may comprise at least one filler, preferably an inorganic filler, such and calcium carbonate and/or clays. These fillers may fill the interstitial spaces in loose leathers and in between leather particles, and make the looseness less pronounced, and hence the intermediate as such more robust.

Preferably, at least one intermediate layer comprises synthetic particles, in particular synthetic fibres, in particular polymer fibres. These particles may e.g. be formed by glass particles, carbon particles, silicon particles or other types of polymer fibres.

It is imaginable that at least one intermediate layer has a textured upper surface, preferably an artificially textured upper surface. This increases the contact surface between the intermediate layer and an adjacent layer, which typically increases the bonding strength in between these layers. Moreover, this textured upper surface could contribute to a texture of the upper side of the panel.

Preferably, the density of at least one intermediate layer is between <NUM> and <NUM>/cm<NUM>, preferably between <NUM> and <NUM>/cm<NUM>, more preferably approximately <NUM> (+/- <NUM>) g/cm<NUM>. The density is preferably measured by using ISO <NUM>.

Preferably, the thickness of at least one intermediate layer is between <NUM> and <NUM>, preferably between <NUM> and <NUM>, more preferably approximately <NUM> (+/- <NUM>) mm. The thickness is preferably measured by using ISO2589.

Typically, each non-human collagen comprising intermediate layer is a flexible layer. This layer may be manufactured and marketed separately, preferably in a rolled up condition, prior to manufacturing of the panel according to the invention.

The core may be flexible, semi-rigid or substantially rigid. The core may be solid or at least partially foamed. The core is preferably at least partially, and more preferably entirely composed, of a natural material, such as wood or mineral. It is preferred that the core is at least partially, and more preferably entirely composed, of high-density fibreboard (HDF) or medium-density fibreboard (MDF). Alternatively, it could be preferred that the core is preferably at least partially, and more preferably entirely composed, of magnesium oxide and/or magnesium hydroxide. It is also imaginable that the core is formed by another type of mineral board, such as a cement board, in particular a fiber cement board. Alternatively, the core may comprise at least one polymer selected 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. The polymer may be a virgin polymer, a recycled polymer, or a combination of virgin polymer and recycled polymer. The core may comprise at least one wood-based material. The core may comprise at least one composite material of at least one polymeric material and at least one non-polymeric material. The at least one non-polymeric material is preferably selected from the group consisting of: talc, chalk, wood, calcium carbonate, leather, and a mineral filler. The non-polymeric material may be, for example, in the form of fibers and/or in the form of dust. The material of the core as such may also be free of any non-human collagen material. This latter doesn't mean that it is not imaginable to embed at least one non-human collagen based intermediate layer into the core. In this embodiment the core and the embedded intermediate layer(s) are considered as separate layer. It is possible though that core material, such as polymeric core material, at least partially penetrates the embedded intermediate layer(s).

As said, the decorative top structure preferably comprises at least one primer layer applied onto at least one intermediate layer. The primer layer is intended to securely bond the ink of the décor image. The primer layer preferably comprises at least one acryl resin and/or at least one acrylate. The primer layer preferably has a white or whitish colour. The décor image may be directly printed on the primer layer, or directly onto the intermediate layer in case a separate primer layer is omitted.

It is imaginable that the décor image is directly printed onto a(n) (alternative) carrier layer, such as a paper sheet and/or polymeric film, wherein said carrier layer is affixed to at least one intermediate layer and/or onto at least one primer layer of the decorative structure.

Preferably, at least one transparent and/or translucent protective layer is formed by a wear layer. It is imaginable and often preferred that a plurality of the wear layers is applied. Preferably, at least one transparent and/or translucent protective layer is formed by a top coating, such as a UV hardened top coating, preferably applied on top of at least one wear layer of the decorative top structure. One or more transparent and/or translucent protective layers may be applied by printing, in particular digital printing.

The decorative top structure preferably comprises at least one decorative layer and at least one transparent wear layer covering said decorative layer. The decorative top structure may additionally comprise at least one back layer (also referred to as backing layer) situated in between said decorative layer and the core, wherein said back layer is preferably at least partially made of a vinyl compound, another polymer, wood, paper, textile, leather, such as cotton and/or recycled jeans (denim), and/or combinations thereof. The one or more materials used in said at least one back layer may virgin materials, recycled materials, and combinations thereof. Here, it is for example imaginable and even preferred that the back layer comprises a mixture of wood, cotton, preferably recycled cotton, more preferably recycled cotton based upon recycled jeans (denim), and/or virgin cotton; and at least one binding agent. The recycled cotton can be post-consumer recycled cotton, being a type of cotton that comes from garments which have been sold to and used by the consumer, such as jeans. Additionally or alternatively, the recycled cotton can be pre-consumer recycled cotton (cutting waste), which is a type of cotton that comes from the waste that is produced in the manufacturing process. Preferably, the back layer comprises wood in an amount of <NUM>-<NUM>% by weight of the back layer, and a cotton based material, such as recycled jeans and/or raw cotton (virgin cotton), in an amount of <NUM>-<NUM>% by weight of the back layer, and at least one binding agent, preferably in an amount of <NUM>-<NUM>% by weight of the back layer. The back layer may be free of PVC and/or any other synthetic polymer. Optionally, the back layer may act as decorative layer (which does not require a separate decorative layer on top).

A lacquer layer or other protective layer may be applied on top of said wear layer. The protective layer and/or wear layer preferably comprises silicon oxide (SiO2). Preferably, said protective layer is an UV cured protective layer, which is preferably applied, more preferably by using hot-coating, in liquid state prior to curing. A finishing layer, which may be an UV cured layer, may be applied in between the decorative layer and the wear layer. The decorative layer will be visible and will be used to provide the panel an attractive appearance. To this end, the decorative layer may have a design pattern, which can, for example be a wood grain design, a mineral grain design that resembles marble, granite or any other natural stone grain, or a colour pattern, colour blend or single colour to name just a few design possibilities. It is imaginable and may even be preferred that the decorative layer comprises at least one recycled material and/or at least one natural material, such as e.g. wood, coffee (e.g. coffee grounds, and/or ground coffee, and/or coffee powder, and/or coffee chaff), textile, cotton, in particular recycled jeans material, and/or mixtures thereof, for example a mixture of wood and a coffee based material. In this latter embodiment, the decorative layer may e.g. comprise wood in an amount of <NUM>-<NUM>% by weight of the decorative layer, and a coffee based material, such as coffee grounds and/or coffee chaff, in an amount of <NUM>-<NUM>% by weight of the decorative layer, and at least one binding agent, preferably in an amount of <NUM>-<NUM>% by weight of the decorative layer. The decorative layer may be free of PVC and/or any other synthetic polymer. Additionally or alternatively, the decorative layer comprises a film, such as a polymer film, for example a PVC film, and/or a paper film, onto which at least one décor image is printed, preferably digitally printed. Customized appearances, often realized by digital printing during the panel production process, are also imaginable. The decorative top structure may also be formed by a single layer. In an alternative embodiment, the decorative top structure is omitted, thus not applied, in the panel according to the invention. In this latter embodiment, the upper side of the core constitutes the upper side of the panel.

The top surface of the decorative top structure, which defines the top surface of the panel, may be provided by a provided with a texture, which is preferably aligned in register with at least a part of at least one décor image of the decorative top structure. Preferably, the texture is a result of digital printing of one or more layers of the decorative top structure.

In a preferred embodiment, the first coupling profile and the second coupling profile are preferably configured such that two of such panels can be coupled to each other by means of a lowering movement (fold-down movement) and/or turning movement. In case the panel is rectangular, then the first panel edge and second panel edge are typically situated at opposite short edges of the panel. The panel preferably also comprises at least one third coupling profile and at least one fourth coupling profile located respectively at a third panel edge and a fourth panel edge, wherein the third coupling profile comprises: a sideward tongue extending in a direction substantially parallel to the upper side of the core, 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 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 panels can be coupled to each other by means of a turning movement (angling down movement), wherein, in coupled condition: at least a part of the sideward tongue of a first panel is inserted into the third groove of an adjacent, second panel, and wherein at least a part of the upward locking element of said second panel is inserted into the second downward groove of said first panel.

Preferably, the panel comprises a back layer (also referred to as underlay) which is affixed, either directly or indirectly, to a lower side of the core. As mentioned above, such a back layer may be formed by one of said intermediate layers. It is also imaginable that the back layer is formed by, for example, a polymer layer, a cork layer, preferably a high density cork layer (typically having a density of at least <NUM>/m3), a linoleum layer, and/or a composite layer, such as cork-linoleum composite layer. Also other materials, which may optionally be expanded (low density) or compressed (high density), may be used as backing layer. The backing layer is typically glued to the core. It is also imaginable that the backing layer and the core are fused together.

It is further preferred that the panel according to the invention has a thickness in the range of <NUM> to <NUM>, preferably in the range of <NUM> to <NUM>. The panel according to the invention, is preferably of a rectangular, parallelogrammatic, or hexagonal shape. The panel preferably has an oblong shape.

The invention also relates to a panel covering, in particular floor covering, ceiling covering, or wall covering, consisting of a plurality of, preferably mutually coupled, panels according to the invention. These layers, embodiments of which have been described above and below in more detail, may be manufactured (and optionally separately marketed) separately and prior to the manufacturing of the decorative panels according to the invention.

The invention will be elucidated on the basis of non-limitative exemplary embodiments shown in the following figures.

<FIG> shows a rectangular floor panel <NUM> according to the present invention. The panel <NUM> is interconnectable with similar panels for forming a covering, as will be shown in further figures. The floor panel <NUM> can be made of any material, though typical materials are wood, in particular HDF, MDF, and LDF, and plastic, in particular thermoplastic, more in particular PVC. Commonly, the floor panel <NUM> is made of a laminate comprising a central layer (core layer) enclosed by a backing structure and a top structure (not shown). The top structure commonly comprises a decorative layer, which may be printed onto the central layer, on top of which a protective layer is applied. The panel <NUM> comprises a centrally located core <NUM> provided with an upper side <NUM> and a lower side <NUM>. The core <NUM> is integrally connected with a first pair of opposite edges, in particular a first edge <NUM> and a complementary second edge <NUM>, located at the long lateral sides of the panel <NUM>. The core is also integrally connected with a second pair of opposite edges, in particular a third edge <NUM> and a complementary fourth edge <NUM>, located at the short sides of the panel <NUM> in this exemplary embodiment.

<FIG> is a cross-sectional view indicated by section A-A in <FIG>. In this cross-section, the shape of the complementary first edge <NUM> and second <NUM> edge are shown in detail. The first edge <NUM> comprises a sideward tongue <NUM> which is integrally connected to the core <NUM>. By means of the vertical dashed line the border between the sideward tongue <NUM> and the core <NUM> is visualised. A front region 9a of the sideward tongue <NUM> is provided with a rounded bottom surface <NUM>. An outer end of the rounded bottom surface <NUM> adjoins an inclined locking surface <NUM>. An opposite end of the rounded bottom surface <NUM> adjoins a bearing surface <NUM> making part of a back region 9b of the sideward tongue <NUM>. The second edge <NUM> of the panel <NUM> comprises an upper lip <NUM> and a lower lip <NUM> defining a recess <NUM>. Both lips <NUM>, <NUM> are integrally connected to the core <NUM>. By means of the vertical dashed line the border between the lips <NUM>, <NUM> and the core is visualised. As shown in <FIG>, the width of the upper lip <NUM> is substantially smaller than the width of the lower lip <NUM>. The recess <NUM> has a shape which is complementary to the shape of the sideward tongue <NUM>. More in particular, a top surface <NUM> of a back region 14a of the lower lip <NUM> has a (complementary) rounded shape, configured to co-act with the rounded front region 9a of the sideward tongue <NUM>, while a front region 14b of the lower lip <NUM> is provided with a upwardly protruding shoulder <NUM>, configured to co-act with the bearing surface <NUM> of the sideward tongue <NUM>. A lower surface <NUM> of the upper lip <NUM> is inclined and corresponds to the locking surface <NUM> of the sideward tongue <NUM>. Locking at the first edge <NUM> and the second edge <NUM> of adjacent panels <NUM> by insertion of the sideward tongue <NUM> of a panel <NUM> to be coupled into the recess <NUM>, wherein said panel <NUM> is initially held in an inclined position. After insertion of the sideward tongue <NUM> into the recess, the panel <NUM> to be coupled will be pivoted (angled) in downward direction about an axis parallel to the first edge <NUM> until both panels <NUM> are positioned in the same - commonly horizontal - plane, wherein the locking surface <NUM> of the sideward tongue <NUM> will engage the locking surface of the upper lip <NUM>, and wherein at least a bottom front part is accommodated substantially form-fittingly in the recess <NUM>, and wherein the bearing surface <NUM> is supported by the shoulder <NUM>. Locking at the first edge <NUM> and the second edge <NUM> leads to locking of the connected panels <NUM> in both horizontal direction and vertical direction. The angling down locking principle of the first and second edges <NUM>, <NUM> is a relatively easy locking principle which facilitates mutual coupling of panels at these edges <NUM>, <NUM> tremendously. Further details relating to this locking mechanism are visualised in <FIG> and <FIG>.

<FIG> is a cross-sectional view indicated by section B-B in <FIG>. In this cross-section, the shape of the complementary third edge <NUM> and second <NUM> edge are shown in detail. The third edge <NUM> comprises an upward tongue <NUM>, an upward flank <NUM> and an upward groove <NUM> formed between upward tongue <NUM> and upward flank <NUM>. The upward tongue <NUM> is connected to the core <NUM> by means of a bridge <NUM>, which is preferably resilient to some extent. A side 19a of upward tongue <NUM> facing toward upward flank <NUM> extends in the direction of the normal N1 of the upper side <NUM> of the core <NUM>. The tangent R1 and the normal N1 of the upper side <NUM> of the core <NUM> are thus directed toward each other (converging orientation), wherein the angle enclosed by R1 and N1 is preferably between <NUM> and <NUM> degrees in this exemplary embodiment. Due to the converging orientation of the upward flank <NUM> and the side 19a of the upward tongue <NUM> facing toward to the upward flank <NUM>, the upward groove <NUM> is a closed groove, which is only accessible to a complementary counterpart by deformation of the upward tongue <NUM> and/or bridge <NUM>. Another side 19b of upward tongue <NUM> facing toward upward flank <NUM> forms an aligning edge enabling facilitated realization of a coupling to an adjacent floor panel <NUM>. As shown, this side 19b functioning as aligning edge is directed away from the normal N1 of upper side <NUM> of the core <NUM>. An upper side 19d of upward tongue <NUM> does however extend in the direction of the normal N1 of the upper side <NUM> of the core <NUM>, and runs inclining downward in the direction of the side 19e of upward tongue <NUM> facing away from upward flank <NUM>. This chamfering provides the option of giving the complementary fourth edge <NUM> a more robust and therefore stronger form. A part of the side 19e of upward tongue <NUM> facing away from upward flank <NUM> is oriented substantially vertically and is moreover provided with an outward bulge <NUM>. A lower part 20a of upward flank <NUM> is oriented diagonally, while an upper part 20b of upward flank <NUM> is shown to be substantially vertical and forms a stop surface for fourth edge <NUM>. In between the inclined part 20a and the substantially vertical part 20b of the upward flank an additional coupling element, in particular an additional bulge <NUM>, is provided. A lower wall part 21a of upward groove <NUM> is oriented substantially horizontally in this exemplary embodiment.

The fourth edge <NUM> is substantially complementary to third edge <NUM>. The fourth edge <NUM> comprises a downward tongue <NUM>, a downward flank <NUM> and a downward groove <NUM> formed between downward tongue <NUM> and downward flank <NUM>. The downward tongue <NUM> is connected to the core <NUM> by means of a bridge <NUM>, which is preferably resilient to some extent. A side 25a of downward tongue <NUM> facing toward downward flank <NUM> lies in the direction of the normal N2 of the lower side <NUM> of the core <NUM>. This means that a tangent R2 of side 25a of downward tongue <NUM> and the normal of the lower side <NUM> of the core <NUM> are mutually converging, wherein the angle enclosed by R2 and N2 is preferably between <NUM> and <NUM> degrees in this exemplary embodiment. More preferably, the inclination of R1 is identical to the inclination of R2; hence, R1 and R2 are preferably parallel. Due to the converging orientation of the downward flank <NUM> and the side 25a of the downward tongue <NUM> facing toward to the downward flank <NUM>, the downward groove <NUM> is a closed groove, which is only accessible for the upward tongue <NUM> of an adjacent panel <NUM> by deformation of the downward tongue <NUM> and/or bridge <NUM>, as a result of which the entrance of the downward groove can be widened (temporary).

A side 25b of the downward tongue <NUM> facing away from downward flank <NUM> is diagonally oriented, but has a flatter orientation than the complementary side 20a of upward flank <NUM>, whereby a gap (air space) will be formed in the coupled position, which will generally facilitate coupling between two floor panels <NUM>. The inclining side 25b of downward tongue <NUM> also functions as aligning edge for the purpose of further facilitating coupling between two floor panels <NUM>. Another side 25c facing away from downward flank <NUM> takes a substantially vertical form, though is provided with a small cavity <NUM> configured to co-act with the additional bulge <NUM> of another panel <NUM>. A top part of the side 25c facing away from downward flank <NUM> forms a complementary stop surface for stop surface 20b of upward flank <NUM> (of an adjacent floor panel). Downward flank <NUM> is oriented substantially vertically and is provided with a recess <NUM> adapted to receive the outward bulge <NUM> of the upward tongue <NUM> (of an adjacent floor panel).

<FIG> show different views of the successive steps for interconnecting multiple floor panels <NUM> according to <FIG> for forming a floor covering <NUM>. <FIG> relate to the first step of the installation process, wherein a first row of floor panels <NUM> is generated by connecting the third edge <NUM> of a panel <NUM> to the fourth edge <NUM> of an adjacent panel, by pressing - in a substantially vertical direction (as indicated by the arrow) - the fourth edge <NUM> of a panel <NUM> to be coupled onto and into the third edge <NUM> of an already installed panel <NUM>. Due to the vertical displacement, the third edge <NUM> and/or the fourth edge <NUM> will be deformed slightly, such that the downward tongue <NUM> will be pushed into the upward groove <NUM>, and the upward tongue <NUM> will be pushed into the downward groove <NUM>. Moreover, the bulges <NUM>, <NUM> will be positioned in the corresponding recesses <NUM>, <NUM> to better secure the floor panels <NUM> with respect to each other. Due to this temporary deformation, wherein both the upward groove <NUM> and the downward grove <NUM> will be widened temporary for the insertion of the downward tongue <NUM> and the upward tongue <NUM> respectively, both edges <NUM>, <NUM> will snap into each other.

<FIG> relate to the second step of the installation process, wherein a second row of floor panels <NUM> is created which is connected to the first row of floor panels. To this end, a first edge <NUM> of a floor panel <NUM> to be coupled is positioned in an inclined orientation against a second edge <NUM> of an already installed panel <NUM>, such that the sideward tongue <NUM> is at least partially inserted in the complementary recess <NUM> of the second profile <NUM>. After this partial insertion the inclined panel is pivoted (angled) down - see arrow - around an axis parallel to the first edge <NUM>, until the panel <NUM> is located in the same plane as defined by the first row of panels, as a result of which the sideward tongue <NUM> will be locked into the recess <NUM> both in at least one horizontal direction and in vertical direction.

The first two steps as shown in <FIG> are preparatory steps for installation of one or more subsequent panels <NUM> which are to be coupled at multiple edges instead of only at a single edge. Installation of a subsequent floor panel <NUM> is visualised in <FIG>. Again, a floor panel <NUM> to be coupled is held at inclined position, wherein the sideward tongue <NUM> of the floor panel <NUM> is inserted partially into the corresponding recess <NUM> of a second edge of at least one floor panel already installed. The fourth edge <NUM> of the floor panel <NUM> to be installed is positioned substantially above the third edge <NUM> of the panel <NUM> already installed in the second row, wherein the fourth edge <NUM> and the third edge <NUM> mutually enclose an angle (being the inclination angle of the panel to be coupled). During angling down of the panel <NUM> to be coupled (see arrow) both the first edge <NUM> and the fourth edge <NUM> of the panel <NUM> will be connected to adjacent panels <NUM>. More in particular, during angling down of the panel <NUM>, the front region of the sideward tongue <NUM> will be accommodated in the recess <NUM>, and will be held in position by means of the limiting shoulder <NUM> and the limiting locking surface <NUM> of the upper lip <NUM> of the second edge <NUM> of the panel(s) already installed in the first row. Moreover, simultaneously the fourth edge <NUM> of the panel <NUM> to be coupled will make a downward scissoring movement with respect to the underlying third edge <NUM> and will zip (snap) into the third edge <NUM> and vice versa, leading to a firm and durable connection between the panels <NUM>.

<FIG> show different embodiments of the first and second edges of a floor panel according to the invention. In <FIG> the embodiment according to <FIG> is shown, while in <FIG> alternative embodiments of these edges are shown. More in particular, <FIG> shows a first and second edge <NUM>, <NUM> of a floor panel <NUM>, wherein, instead of a smoothly rounded bottom portion a more hooked (segmented rounded) bottom portion is shown. In <FIG>, an embodiment of a floor panel <NUM> is shown which is almost identical to the floor panel shown in <FIG>, though wherein the first and second edges <NUM>, <NUM> are provided with horizontal locking surfaces 44a, 45b instead of inclined locking surfaces. In <FIG>, an alternative embodiment of a floor panel <NUM> is shown, wherein the first and second edges <NUM>, <NUM> are shaped such that a bottom contact portion between the two edges <NUM>, <NUM> is partially smoothly rounded and partially discontinuously rounded (segmented rounded). Locking surfaces <NUM>, <NUM> of a sideward tongue <NUM> of the first edge <NUM> and of an upper lip <NUM> of the second edge have a substantially horizontal orientation. In <FIG>, an embodiment of a floor panel <NUM> almost identical to the floor panel <NUM> as shown in <FIG> is shown, with the difference that a front bottom part 54a of a sideward tongue <NUM> is not smoothly rounded, but flat giving a bottom portion of the sideward tongue <NUM> as such a segmented rounded (hooked) shape.

<FIG> shows a different embodiment of the third and fourth edges of a floor panel <NUM> according to the invention. Floor panel <NUM> comprises a core <NUM> provided with an upper side 58a and a lower side 58b, and coupling parts <NUM>, <NUM> positioned on opposite longitudinal sides of core <NUM> and connected integrally to core <NUM>. A first coupling part <NUM> comprises an upward tongue <NUM>, an upward flank <NUM> and an upward groove <NUM> formed between upward tongue <NUM> and upward flank <NUM>. A side 61a of upward tongue <NUM> facing toward upward flank <NUM> is inclined and extends in the direction of the normal N1 of the upper side 58a of core <NUM>. The tangent R1 and the normal N1 of upper side 58a of core <NUM> are thus directed toward each other (converging orientation), wherein the angle enclosed by R1 and N1 amounts to <NUM>-<NUM> degrees. On top of side 61a, a substantially flat upward aligning edge 61b of the upward tongue <NUM> is positioned, which faces toward upward flank <NUM> and which enables facilitated realization of a coupling to an adjacent floor panel. The inclined surface 61a, acting as locking surface, and the adjoining upward aligning edge 61b together form the inner side surface of the upward tongue <NUM>. As shown, this side 61b functioning as upward aligning edge is substantially flat and, moreover, directed away from the normal N1 of upper side 58a of the core. A (single) upper side 61d of upward tongue <NUM> does however extend in the direction of the normal N1 of upper side 68a of core <NUM>, and runs inclining downward in the direction of the side 61e of upward tongue <NUM> facing away from upward flank <NUM>. The angle of inclination is about <NUM> degrees. This chamfering provides the option of giving the complementary second coupling part <NUM> a more robust and therefore stronger form, as will be elucidated below. The side 61e of upward tongue <NUM> facing away from upward flank <NUM> is oriented substantially vertically and is moreover provided with an outward bulge <NUM> which clearly extends with respect to vertically oriented parts of the outer side wall <NUM> of the upward tongue <NUM>. A lower part 62a of upward flank <NUM> is oriented diagonally, while an upper part 62b of upward flank <NUM> is shown to be substantially vertical and forms a stop surface for second coupling part <NUM>. A lower wall part 63a of upward groove <NUM> is oriented substantially horizontally in this exemplary embodiment. A bridge <NUM> lying between lower wall part 63a of upward groove <NUM> and a lower side 59a has a somewhat elastic nature and is adapted to allow upward tongue <NUM> to slightly pivot relative to upward flank <NUM>, this resulting in a (temporary) widening of upward groove <NUM>, whereby coupling of floor panel <NUM> to an adjacent floor panel can be facilitated. Second coupling part <NUM> is substantially complementary to first coupling part <NUM>. Second coupling part <NUM> comprises a downward tongue <NUM>, a downward flank <NUM> and a downward groove <NUM> formed between downward tongue <NUM> and downward flank <NUM>. A side 66a of downward tongue <NUM> facing toward downward flank <NUM> is inclined and extends in the direction of the normal N2 of the lower side 58b of core <NUM>. This means that a tangent R2 of side 66a of downward tongue <NUM> and the normal of the lower side 58b of core <NUM> are mutually converging. In this exemplary embodiment the tangent R2 and the normal N2 enclose a mutual angle of <NUM>-<NUM> degrees. A side 66b facing away from downward flank <NUM> is diagonally oriented, but has a flatter orientation than the complementary side 62a of upward flank <NUM>, whereby a gap (air space) will be formed in the coupled position, which will generally facilitate coupling between two floor panels <NUM>. The inclining side 66b of downward tongue <NUM> also functions as aligning edge for the purpose of further facilitating coupling between two floor panels <NUM>. Another side 66c facing away from downward flank <NUM> takes a substantially vertical form and forms a complementary stop surface for stop surface 62b of upward flank <NUM> (of an adjacent floor panel). Downward tongue <NUM> is further provided with a small aligning edge 66d which is facing toward downward flank <NUM>. Because upper side 61d of upward tongue <NUM> has an inclining orientation, an upper side 68a of downward groove <NUM> likewise can be given, and in this embodiment has, a corresponding inclining orientation, whereby the (average) distance between upper side 68a of downward groove <NUM> and an upper side 60a of second coupling part <NUM> is sufficiently large to impart sufficient strength to second coupling part <NUM> as such. Downward flank <NUM> is oriented substantially vertically and is provided with a recess <NUM> adapted to receive the outward bulge <NUM> of upward tongue <NUM> (of an adjacent floor panel).

A bridge <NUM> lying between upper side 68a of downward groove <NUM> and upper side 60a has a somewhat elastic nature due its reduced thickness close to the downward tongue <NUM> (and possibly also due to material characteristics), and is adapted to allow downward tongue <NUM> to slightly pivot relative to downward flank <NUM>, this resulting in a (temporary) widening of downward groove <NUM>, whereby coupling of floor panel <NUM> to an adjacent floor panel can be facilitated. This pivoting point (point of deformation) is typically formed by the weakest point in the bridge <NUM>, which is indicated by the sign "P". The shown floor panel <NUM> can form a parquet floor panel, a plank, a laminated floor panel and/or a plastic floor panel. The coupling parts <NUM>, <NUM> and the core <NUM> are preferably integrally connected.

<FIG> shows a detailed cross-sectional view of a panel <NUM> according to one of <FIG> and/or which can be combined (integrated) with a panel as shown in one the previous figures. The panel <NUM> shown in <FIG> comprises a core <NUM>, wherein said core <NUM> comprises an upper side 58a and a lower side 58b. According to this non-limitative embodiment of the panel <NUM> the upper side 58a of the core <NUM> is provided with at least one intermediate layer <NUM>, on top of which intermediate layer <NUM> a decorative top structure <NUM> is provided. It is conceivable that said core layer <NUM> is optionally provided with a further intermediate layer <NUM> that is embedded in the core <NUM>, said further intermediate layer <NUM> may function as reinforcement of the core. The optional intermediate layer <NUM> may, for example, be a woven or non-woven glass fibre layer. Another, yet further intermediate layer <NUM> may optionally be affixed to the lower side 58b of the core <NUM>, and as such function as a damping or sound absorbing layer. Said intermediate layers <NUM>, <NUM>, <NUM> comprise at least a non-human collagen and/or leather, more preferably bonded leather. It is conceivable that at least one, or all intermediate layers <NUM>, <NUM>, <NUM> comprise a layered structure having at least a carrier layer, onto which carrier layer particles, such as leather particles, are bonded by means of a binding material. It is conceivable that said carrier layer may be composed out of a paper, fabric, and/or a polymer layer and may either be woven or non-woven. In order to adhere the leather particles to said carrier layer, the binding material may partially penetrate into the carrier layer. At least one intermediate layer <NUM>, <NUM>, <NUM> may in particular comprise between <NUM>-<NUM>% by weight of genuine leather fibres, preferably <NUM>% of genuine leather fibres, between <NUM>-<NUM>% by weight of natural latex, preferably <NUM>% by weight of natural latex, preferably additionally between <NUM>-<NUM>% by weight of natural fat, preferably <NUM>% by weight of natural fat, and preferably between <NUM>-<NUM>% by weight of miscellaneous raw material, preferably <NUM>% by weight of miscellaneous raw material. Said raw material may as a non-limited example be a vegetable tanning agent, water, or the like.

The encircled portion, A, of the panel <NUM> is enlarged for the sake of clarity to further elucidate the structure of the layers <NUM>, <NUM>, <NUM>, <NUM>, <NUM> provided onto the upper side 58a of the core <NUM>. At least one carrier layer provided with leather particles <NUM> (which is a specific embodiment of the intermediate layer <NUM>), as described above, is affixed directly onto the upper side 58a of the core <NUM>. The carrier layer with leather particles <NUM> may optionally be referred to as a bonded leather layer <NUM>. The side of the carrier layer comprising the leather particles preferably faces away from said upper side 58a. A primer <NUM> is provided onto said carrier layer provided with leather particles <NUM>. Preferably, said primer layer <NUM> partially penetrates the intermediate layer <NUM>, <NUM>, and a digital print layer <NUM> may as a result be affixed sufficiently to said intermediate layer <NUM>, <NUM>. However, optionally, it is conceivable that said print layer <NUM> is, preferably digitally, printed directly on top of the intermediate layer <NUM>, <NUM> and/or primer layer <NUM>. To protect the bonded leather layer <NUM> and the print layer <NUM> it is conceivable that at least one wear layer <NUM> is provided over at least a part of the print layer <NUM>, preferably covering essentially the entire panel <NUM>. Although in this figure only one wear layer <NUM> is depicted, the skilled person would realise that a plurality of wear layers <NUM> may be provided. A top coating <NUM> essentially entirely covers the wear layer <NUM>, which top coating <NUM> may for example be a lacquer or the like.

Although the intermediate layers <NUM>, <NUM>, <NUM> and the decorative top structure <NUM> are only depicted in this particular figure, it may be realized that said layers, either in this particular non-limitative configuration or separately, may be applicable to any of the embodiments according to the preceding figures. That is, all the layers elucidated in this figure, may be combined separately of one another in various embodiments according to the present invention.

The ordinal numbers used in this document, like "first", "second", "third", and "fourth" are used only for identification purposes. Hence, the use e.g. of the expressions "third locking element" and "second locking element" does therefore not necessarily require the co-presence of a "first locking element". The decorative panels according to the invention may also be referred to as decorative tiles. By "complementary" coupling profiles is meant that these coupling profiles can cooperate with each other. However, to this end, the complementary coupling profiles do not necessarily have to have complementary forms. By locking in "vertical direction" is meant locking in a direction perpendicular to the plane of the panel. By locking in "horizontal direction" is meant locking in a direction perpendicular to the respective coupled edges of two panels and parallel to or falling together with the plane defined by the panels.

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.

Claim 1:
Decorative panel (<NUM>), in particular a floor panel, ceiling panel or wall panel wherein a first panel edge (<NUM>) preferably comprises a first coupling profile (<NUM>), and a second panel edge (<NUM>), preferably opposite to the first panel edge (<NUM>), preferably comprises a second coupling profile (<NUM>) being designed to engage interlockingly with said first coupling profile (<NUM>) of an adjacent panel, both in horizontal direction and in vertical direction, wherein said decorative panel (<NUM>) further comprises :
- a core (<NUM>) provided with an upper side (58a) and a lower side (58b),
- a decorative top structure (<NUM>) affixed, directly or indirectly, on said upper side (58a) of the core, said decorative top structure (<NUM>) comprising:
o at least one, preferably digitally printed, decorative layer (<NUM>) forming at least one décor image, and
o at least one transparent and/or translucent protective layer (<NUM>) covering said decorative layer;
characterized in that said decorative panel (<NUM>) also comprises:
- at least one intermediate layer (<NUM>,<NUM>) comprising non-human collagen, wherein said at least one intermediate layer (<NUM>, <NUM>) is positioned underneath said decorative top structure (<NUM>).