Panel for forming a floor covering and such floor covering

Patent metadata

Field	Value
Publication number	US-11053696-B1
Application number	US-202016778570-A
Country	US
Kind code	B1
Filing date	Jan 31, 2020
Priority date	Jan 31, 2020
Publication date	Jul 6, 2021
Grant date	Jul 6, 2021

Abstract

Provided is a panel suitable for forming a floor covering. The panel has a substantially planar top side, a substantially planar bottom side, and at least four substantially linear side edges. The linear side edges have at least one pair of opposite side edges. The linear side edges may be provided with a locking means.

First claim

What is claimed is:

1. A floor panel comprising at least one core layer, a planar top side, and a planar bottom side, at least four linear side edges having at least one pair of opposite side edges, at least one core layer comprising a magnesium crystal structure having a whisker phase and a flake crystal phase, wherein a ratio of the whisker phase to the flake crystal phase is higher than 1, and wherein the core layer comprises at least one organic compound comprising at least two hydroxyl groups.

2. The panel according to claim 1 , wherein the magnesium crystal structure is a magnesium oxysulfate crystal structure.

3. The panel according to claim 2 , wherein at least a number of magnesium oxysulfate whiskers have an average diameter of 0.2 to 1.0 micrometre.

4. The panel according to claim 2 , wherein at least a number of magnesium oxysulfate whiskers have an average length of 1 to 50 micrometres.

5. The panel according to claim 2 , wherein the core layer comprises at least 55% by weight of magnesium oxysulfate whiskers.

6. The panel according to claim 2 , wherein the core layer comprises at least 60% by weight of magnesium oxysulfate whiskers.

7. The panel according to claim 1 , wherein said organic compound comprising at least two hydroxyl (—OH) groups is an acid selected from the group consisting of oxalic acid, citric acid, phosphoric acid and boric acid.

8. The panel according to claim 1 , wherein the core layer comprises an upper part and a lower part and a reinforcing layer situated between said upper part and said lower part of the core layer.

9. The panel according to claim 8 , wherein the reinforcing layer comprises fiberglass.

10. The panel according to claim 9 , wherein the upper reinforcing layer comprises a fiberglass mesh.

11. The panel according to claim 10 , wherein the core layer comprises an intermediate part and a further reinforcing layer, wherein a first reinforcing layer is situated between said upper part and said intermediate part of the core layer, and a second reinforcing layer is situated between said intermediate part and said lower part of the core layer.

12. The panel according to claim 11 , comprising two pairs of opposite side edges which are provided with interconnecting coupling means.

13. The panel according to claim 12 , wherein the interconnecting coupling means comprise a tongue and a groove, wherein the tongue is provided on one side edge of one pair of opposite side edges and the groove is provided on an opposing side edge of a same pair of opposite side edges.

14. The panel according to claim 1 , wherein the core layer further comprises at least one binder.

15. The panel according to claim 1 , comprising at least one top layer, wherein the top layer comprises at least one of a decorative layer and a protective layer.

16. The panel according to claim 1 , comprising at least one backing layer for improved balance and acoustical performance.

17. A floor covering comprising multiple floor panels according to claim 1 .

18. The panel according to claim 1 , wherein the magnesium crystal structure is a magnesium oxychloride crystal structure.

19. The panel according to claim 1 , wherein the core layer comprises 0.05% to 5% by weight of at least one organic compound comprising at least two hydroxyl groups.

Assignees

• Champion Link Int Corp

Inventors

• Baert Thomas Luc Martine
• Van Poyer Tom
• Boon Sven

Classifications

• B32B2419/04

  Tiles for floors or walls · CPC title

• B32B2266/049

  Water-setting material, e.g. concrete, plaster or asbestos cement · CPC title

• B32B13/10

  of wood; of wood particle board · CPC title

• B32B13/04

  comprising such {water setting} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06)} · CPC title

• B32B13/14

  next to a fibrous or filamentary layer · CPC title