Floor panel for forming a floor covering

Patent metadata

Field	Value
Publication number	US-12180720-B2
Application number	US-202318446690-A
Country	US
Kind code	B2
Filing date	Aug 9, 2023
Priority date	Sep 14, 2015
Publication date	Dec 31, 2024
Grant date	Dec 31, 2024

Abstract

Floor panel for forming a floor covering, where the floor panel includes a carrier on the basis of a thermoplastic material and a top layer provided on the carrier. The thermoplastic material is free from plasticizers or includes a plasticizer in an amount up to maximum 20 phr, where the thermoplastic material is foamed or expanded, and where the carrier is provided with a reinforcement layer.

First claim

The invention claimed is:

1. A floor panel for forming a floor covering, wherein the floor panel comprises:
a carrier with at least a first layer comprising a first thermoplastic material; wherein said first thermoplastic material is polyvinyl chloride free from plasticizers or polyvinyl chloride comprising a plasticizer in an amount up to maximum 20 phr;
wherein said carrier forms at least 40 percent of the thickness of said floor panel;
a top layer fused to the carrier, the top layer including at least a decor film with a print and at least a wear layer, wherein said wear layer comprises a polyvinyl chloride film with a provided thereon lacquer layer solidified at least by means of excimer radiation;
wherein said floor panel is provided on at least two opposite edges with coupling means which allow that two of such floor panels can be coupled to each other in such a manner that a locking is obtained in a vertical direction perpendicular to the plane of the coupled panels as well as in a horizontal direction perpendicular to the coupled edges and in the plane of the floor panel; wherein the coupling means are provided substantially in said carrier.

2. The floor panel of claim 1 , wherein said first thermoplastic material comprises plasticizer in an amount between 5 and 15 phr.

3. The floor panel of claim 1 , wherein said top layer comprises a further thermoplastic layer.

4. The floor panel of claim 1 , wherein said decor film is a printed synthetic material film.

5. The floor panel of claim 3 , wherein said further thermoplastic layer is a thermoplastic backing layer based on one or a combination of polyvinyl chloride, polyethylene, polypropylene and/or polyurethane.

6. The floor panel of claim 1 , wherein said first thermoplastic material has a Fikentscher K-value of 85 or below.

7. The floor panel of claim 1 , wherein said print has a wood pattern representing the image of a single wooden plank.

8. The floor panel of claim 7 , wherein said top layer comprises embossments providing a relief simulating a wood texture.

9. The floor panel of claim 1 , wherein said carrier consists of said first layer.

10. A method for manufacturing a floor panel, wherein said method at least comprises:
the step of providing a carrier, wherein said carrier has at least a first layer comprising a first thermoplastic material; wherein said first thermoplastic material is polyvinyl chloride free from plasticizers or polyvinyl chloride comprising a plasticizer in an amount up to maximum 20 phr;
the step of providing a top layer to said carrier, wherein said top layer includes at least a decor film with a print and at least a wear layer; wherein said wear layer comprises a polyvinyl chloride film; wherein a lacquer layer is provided on said polyvinyl chloride film and said lacquer layer is solidified at least by means of excimer radiation;
the step of providing said floor panel by means of a milling operation on at least two opposite edges with coupling means which allow that two of such floor panels can be coupled to each other in such a manner that a locking is obtained in a vertical direction perpendicular to the plane of the coupled panels as well as in a horizontal direction perpendicular to the coupled edges and in the plane of the floor panel; wherein the coupling means are provided substantially in said carrier.

11. The method of claim 10 , wherein said first thermoplastic material comprises plasticizer in an amount between 5 and 15 phr.

12. The method panel of claim 10 , wherein said top layer comprises a further thermoplastic layer.

13. The method of claim 10 , wherein said decor film is a printed synthetic material film.

14. The method of claim 12 , wherein said further thermoplastic layer is a thermoplastic backing layer based on one or a combination of polyvinyl chloride, polyethylene, polypropylene and/or polyurethane.

15. The method of claim 10 , wherein said first thermoplastic material has a Fikentscher K-value of 85 or below.

16. The method of claim 10 , wherein said print has a wood pattern representing the image of a single wooden plank.

17. The method of claim 16 , wherein said method further comprises the step of providing embossments in said top layer; said embossments providing a relief simulating a wood texture.

18. The method of claim 10 , wherein said carrier consists of said first layer and wherein said carrier forms at least 40 percent of the thickness of said floor panel.

Assignees

• Flooring Ind Ltd Sarl
• Unilin Bv

Inventors

• Van Vlassenrode Kristof
• Bossuyt Filip

Classifications

• B32B27/32

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B3/04

  characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} · CPC title

• B32B37/1027

  Pressing using at least one press band · CPC title