Panel for forming a floor covering, method for manufacturing such panels and granulate applied herewith

Patent metadata

Field	Value
Publication number	US-10619357-B2
Application number	US-201715671754-A
Country	US
Kind code	B2
Filing date	Aug 8, 2017
Priority date	Jun 1, 2012
Publication date	Apr 14, 2020
Grant date	Apr 14, 2020

Abstract

A method for manufacturing panels with at least a substrate and a top layer. The method having the steps of providing a granulate having thermoplastic material and having an average particle size of less than 1 millimeter, forming a substrate layer by strewing the granulate, consolidating the layer between the belts of a continuous press device, and providing the top layer on the substrate.

First claim

The invention claimed is:

1. A method for manufacturing panels with at least a substrate and a top layer; said substrate comprising one or more substrate layers and said top layer comprising a printed decor; said method at least comprising:
providing thermoplastic material in the form of a granulate, said granulate having an average particle size of less than 1 millimeter;
forming a substrate layer by strewing said granulate;
consolidating said layer between the belts of a continuous press device;
providing said top layer on said substrate.

2. The method of claim 1 , wherein said average particle size is larger than 25 micrometers.

3. The method of claim 1 , wherein said granulate further comprises at least 50 percent by weight of fillers.

4. The method of claim 1 , wherein said providing a granulate comprises breaking down larger particles.

5. The method of claim 1 , wherein said providing a granulate comprises solidifying thermoplastic material by quenching in a liquid.

6. The method of claim 1 , wherein said thermoplastic material is soft PVC.

7. The method of claim 1 , wherein said providing said top layer comprises melting said substrate layer at least at the surface together with at least a decor film comprising said printed decor.

8. The method of claim 1 , wherein said strewing comprises depositing said granulate on the belts of said continuous pressing device.

9. The method of claim 1 , wherein said method further comprises levelling said substrate by means of a plastisol.

10. The method of claim 1 , wherein said method further comprises levelling said substrate by grinding.

Assignees

• Unilin Bvba

Inventors

• Segaert Martin
• Naeyaert Christophe

Classifications

• B32B2419/00

  Buildings or parts thereof · CPC title

• B29C43/48

  Endless belts · CPC title

• E04F15/02038

  characterised by tongue and groove connections between neighbouring flooring elements · CPC title

• B32B2315/085

  Glass fiber cloth or fabric · CPC title

• B29L2031/732

  Floor coverings (piles carpets B29L2031/7652; for vehicles B29L2031/3017) · CPC title