Panel for forming a floor covering and method for manufacturing such panels

Patent metadata

Field	Value
Publication number	US-10480201-B2
Application number	US-201815924869-A
Country	US
Kind code	B2
Filing date	Mar 19, 2018
Priority date	Jun 1, 2012
Publication date	Nov 19, 2019
Grant date	Nov 19, 2019

Abstract

A panel that includes at least a substrate of thermoplastic material and a top layer with a printed decor and a translucent or transparent wear layer. The substrate substantially consists of three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material. Additionally, the thermoplastic material of the lower most layer and the uppermost layer is more rigid than the thermoplastic material of the central layer.

First claim

The invention claimed is:

1. A panel comprising at least a substrate of thermoplastic material and a top layer with a printed decor and a translucent or transparent wear layer,
wherein said substrate substantially consists of three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material, and
wherein the thermoplastic material of the lower most layer and the uppermost layer is more rigid than the thermoplastic material of the central layer,
wherein said lowermost and said uppermost layer comprise less than 5 percent by weight of plasticizer or no plasticizer, and
wherein said central layer comprises 12 percent by weight or more of plasticizer.

2. The panel according to claim 1 , wherein said thermoplastic material is chosen from the group consisting of polyvinylchloride, polypropylene, polyethylene and polyurethane.

3. The panel according to claim 2 , wherein said lowermost layer is on the basis of hard or semi-rigid polyvinylchloride, said central layer is on the basis of soft polyvinylchloride, and said uppermost layer is on the basis of hard or semi-rigid polyvinylchloride.

4. The panel according to claim 1 , wherein said lowermost layer and said uppermost layer are thinner than said central layer.

5. The panel according to claim 1 , wherein said panel is a floor panel for a floating floor covering and at two or more opposite edges comprises coupling parts with which two of such floor panels can be coupled at said edges in such a manner that they are mutually locked in a horizontal direction perpendicular to the respective edge and in the plane of the floor panels, as wall as in a vertical direction perpendicular to the plane of the floor panels.

6. The panel according to claim 1 , wherein said substrate has a thickness of 1.3 to 10 millimeters.

7. The panel according to claim 1 , wherein said panel has a thickness situated between 2 and 6 millimeters.

8. The panel according to claim 1 , wherein said decor consists of a print performed on a synthetic material film, wherein said film is a printed polyvinylchloride film, a polyurethane film, a polypropylene film or a polyethylene film.

9. The panel according to claim 1 , wherein said wear layer also comprises a thermoplastic material, wherein said thermoplastic material is hard or soft polyvinylchloride, polyurethane, polypropylene or polyethylene.

10. The panel according to claim 1 , wherein the thickness of the panel is for more than one half formed by said substrate.

11. The panel according to claim 1 , wherein said top layer comprises a backing layer located underneath the printed decor.

12. A panel comprising at least a substrate of thermoplastic material having a thickness of 1.3 to 10 millimeter, and a top layer with a printed decor and a translucent or transparent wear layer, wherein said thermoplastic material is chosen from the list comprising of polyvinylchloride, polypropylene, polyethylene and polyurethane and wherein said substrate forms more than one half the thickness of the panel, said panel being a floor panel for a floating floor covering and comprising at two or more opposite edges coupling parts with which two of such floor panels are able to be coupled at said edges in such a manner that they are mutually locked in a horizontal direction perpendicular to the respective edge and in the plane of the floor panels, as well as in a vertical direction perpendicular to the plane of the floor panels, wherein said substrate substantially consists of three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material, wherein the thermoplastic material of the lowermost layer and the uppermost layer is more rigid than the thermoplastic material of the central layer,
wherein said lowermost and said uppermost layer comprise less than 5 percent by weight of plasticizer or no plasticizer, and
wherein said central layer comprises 12 percent by weight or more of plasticizer.

13. The panel according to claim 12 , wherein said decor consists of a print performed on a synthetic material film, wherein said film is a printed polyvinylchloride film, a polyurethane film, a polypropylene film or a polyethylene film.

14. The panel according to claim 13 , wherein said wear layer also comprises a thermoplastic material, wherein said thermoplastic material is hard or soft polyvinylchloride, polyurethane, polypropylene or polyethylene.

15. The panel according to claim 14 , wherein said lowermost layer is on the basis of hard or semi-rigid polyvinylchloride, said central layer is on the basis of soft polyvinylchloride, and said uppermost layer is on the basis of hard or semi-rigid polyvinylchloride.

Assignees

• Unilin Bvba

Inventors

• Segaert Martin
• Naeyaert Christophe

Classifications

• E04F15/107 Primary

  composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04) · CPC title

• B32B37/1027

  Pressing using at least one press band · CPC title

• E04F2201/023

  with a continuous tongue or groove · CPC title

• B32B2305/08

  Reinforcements · CPC title

• B29C70/506

  and impregnating by melting a solid material, e.g. sheet, powder, fibres (B29C70/508 takes precedence) · CPC title