	US 12,371,379 B2
	Panel and method for producing a panel
Thomas Luc Martine Baert, Sint-Martens-Latem (BE); Tom Van Poyer, Jiaxing (CN); and Sven Boon, Jiaxing (CN)
Assigned to Champion Link International Corporation, The Valley (AI)
Filed by Champion Link International Corporation, The Valley (AL)
Filed on Jul. 6, 2023, as Appl. No. 18/347,758.
Application 18/347,758 is a continuation of application No. 16/951,002, filed on Nov. 18, 2020, granted, now 11,724,537.
Application 16/951,002 is a continuation in part of application No. 16/896,343, filed on Jun. 9, 2020, granted, now 11,624,192, issued on Apr. 11, 2023.
Claims priority of application No. 2025684 (NL), filed on May 26, 2020.
Prior Publication US 2023/0347685 A1, Nov. 2, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. C04B 28/10 (2006.01); B28B 1/52 (2006.01); B28B 11/00 (2006.01); B28B 19/00 (2006.01); B32B 3/06 (2006.01); B32B 5/14 (2006.01); B32B 9/02 (2006.01); B32B 13/02 (2006.01); B32B 13/04 (2006.01); B32B 13/10 (2006.01); B32B 13/12 (2006.01); B32B 21/14 (2006.01); B44C 5/04 (2006.01); C04B 18/26 (2006.01); C04B 28/30 (2006.01); C04B 28/32 (2006.01); C04B 40/02 (2006.01); E04B 2/00 (2006.01); E04B 5/02 (2006.01); E04C 2/04 (2006.01); E04C 2/06 (2006.01); E04F 15/08 (2006.01); E04F 15/10 (2006.01); B28B 3/02 (2006.01); B32B 13/08 (2006.01); B32B 29/06 (2006.01); C04B 18/24 (2006.01); C04B 111/00 (2006.01); E04C 2/00 (2006.01); E04F 15/02 (2006.01)

CPC C04B 28/105 (2013.01) [B28B 1/522 (2013.01); B28B 1/525 (2013.01); B28B 11/001 (2013.01); B28B 19/0092 (2013.01); B32B 3/06 (2013.01); B32B 5/145 (2013.01); B32B 9/02 (2013.01); B32B 13/02 (2013.01); B32B 13/04 (2013.01); B32B 13/10 (2013.01); B32B 13/12 (2013.01); B32B 21/14 (2013.01); B44C 5/04 (2013.01); C04B 18/26 (2013.01); C04B 28/30 (2013.01); C04B 28/32 (2013.01); C04B 40/0259 (2013.01); E04C 2/04 (2013.01); E04C 2/06 (2013.01); E04C 2/46 (2013.01); E04C 2/50 (2013.01); E04F 15/08 (2013.01); E04F 15/107 (2013.01); B28B 3/02 (2013.01); B32B 13/08 (2013.01); B32B 29/06 (2013.01); B32B 2260/026 (2013.01); B32B 2260/028 (2013.01); B32B 2260/046 (2013.01); B32B 2262/065 (2013.01); B32B 2262/067 (2013.01); B32B 2262/08 (2013.01); B32B 2307/546 (2013.01); B32B 2307/722 (2013.01); B32B 2307/732 (2013.01); B32B 2419/04 (2013.01); B32B 2451/00 (2013.01); B32B 2607/00 (2013.01); C04B 18/248 (2013.01); C04B 2111/00612 (2013.01); E04C 2002/004 (2013.01); E04F 15/02038 (2013.01); Y02W 30/91 (2015.05); Y10T 428/24777 (2015.01); Y10T 428/24942 (2015.01); Y10T 428/2495 (2015.01); Y10T 428/24967 (2015.01); Y10T 428/24992 (2015.01)]

20 Claims

1. A floor, wall, or ceiling panel, comprising:

at least one core layer, the core layer comprising an upper core surface and a lower core surface and at least one pair of opposite side edges;

wherein the at least one core layer has a density in a range of 1350 kg/m³to 1550 kg/m³and comprises a cement comprising magnesium oxide and having a crystal structure expressed as a ternary system of magnesium oxide, a magnesium salt, and water;

wherein the at least one core layer further comprises at least 20 wt % natural fibers disperse in said cement;

wherein the natural fibers comprise fibers encapsulated by the cement and form an interconnected matrix with the cement crystals in the core layer;

wherein the natural fibers form a reinforcing network across the entire volume of the core layer; and

wherein the density of the core layer is substantially constant over the entire volume of the core layer, wherein the spatial variation of density is below 10% over the entire volume of the core layer.