Floor panel

Patent metadata

Field	Value
Publication number	US-9080330-B2
Application number	US-201514627197-A
Country	US
Kind code	B2
Filing date	Feb 20, 2015
Priority date	May 10, 2010
Publication date	Jul 14, 2015
Grant date	Jul 14, 2015

Abstract

A floor panel includes a substrate and a top layer provided on the substrate. The top layer is composed of a print and a transparent thermoplastic layer having a thickness of 0.5 mm or less and being situated above said print. The floor panel, at least on two opposite edges, is provided with a straight or curved chamfer extending to below the global level of the print.

First claim

The invention claimed is:

1. Floor panel having a rectangular and oblong shape with a pair of longitudinal opposite edges and a pair of short opposite edges, said floor panel comprising a substrate and a top layer provided on said substrate;
wherein said top layer comprises from bottom to top a thermoplastic back layer located on the substrate, a print provided on a synthetic material film, and a transparent thermoplastic layer based on polyvinylchloride situated above said print; the synthetic material film being located between the back layer and the transparent thermoplastic layer, and the print being provided between the transparent thermoplastic layer and the synthetic material film; said top layer forming a decorative side of said floor panel wherein said print shows a wood pattern with a pore direction extending in the direction of said pair of longitudinal opposite edges;
wherein said substrate is based on a thermoplastic material chosen from the list consisting of polyvinylchloride, polyethylene, polypropylene and polyurethane; said substrate having an overall thickness which is larger than half of the thickness of the entire panel;
wherein said floor panel at least at said pair of longitudinal opposite edges is provided with coupling parts allowing to couple two such floor panels to each other, such that, in a coupled condition, said two floor panels are locked to each other at the respective edge 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 panels;
wherein said coupling parts are formed as a tongue and a groove, wherein the contour of said tongue and groove is substantially realized in said substrate with said back layer extending above a horizontal level determined by a center line of said tongue and groove;
wherein said floor panel has a length of more than 118 centimeters, a width between 8 and 22 centimeters and a thickness of more than 5 millimeters.

2. The floor panel of claim 1 , wherein said floor panel has a length of more than 180 centimeters, a width of more than 14 centimeters and a thickness between 7 and 10 millimeters.

3. The floor panel of claim 1 , wherein said floor panel bends under its own weight by an amount of less than 50 centimeter per meter length of the floor panel.

4. The floor panel of claim 1 , further comprising means for limiting the bending comprise at least one profile embedded in the substrate material, wherein the profile globally extends in the longitudinal direction of the floor panel; said profile being based on synthetic material or metal.

5. The floor panel of claim 4 , wherein the profile is situated closer to said tongue than to said groove.

6. The floor panel of claim 1 , further comprising means for limiting the bending comprise at least one glass fiber layer underneath said print.

7. The floor panel of claim 6 , wherein said glass fiber layer is embedded in the substrate material.

8. The floor panel of claim 6 , wherein said glass fiber layer is located outside of the center of said substrate.

9. The floor panel of claim 6 , wherein said glass fiber layer is located outside of the center of said substrate.

10. The floor panel of claim 6 , wherein said glass fiber layer is situated closer to the decorative side than to the lower side of the substrate.

11. The floor panel of claim 1 , wherein said substrate is waterproof.

12. The floor panel of claim 1 , further comprising for limiting the bending comprise at least one layer within the floor panel having a density of more than 650 kilograms per cubic meter.

13. The floor panel of claim 1 , wherein said floor panel has a maximum thickness of 10 millimeters and a material density of more than 450kilograms per cubic meter.

14. The floor panel of claim 13 , wherein said foamed synthetic material board is of the closed-cell type.

15. The floor panel of claim 1 , wherein said substrate comprises thermoplastic material and fillers.

16. The floor panel of claim 1 , wherein said substrate is a foamed synthetic material board.

17. The floor panel of claim 1 , wherein said top layer comprises an annealed thermoplastic layer having a thickness between 0.5 and 3 millimeters.

18. The floor panel of claim 1 , wherein this floor panel has a length of more than 180 centimeters.

19. The floor panel of claim 18 , wherein said print is a wood grain print extending in the longitudinal direction of said decorative side; wherein said print is free from repetitions over the entire length of said decorative side.

20. The floor panel of claim 1 , wherein the back layer is a layer of polyvinylchloride.

21. The floor panel of claim 20 , wherein the polyvinylchloride of the back layer is filled with chalk.

22. The floor panel of claim 1 , wherein the back layer has a higher density than the transparent thermoplastic layer.

23. The floor panel of claim 1 , wherein the back layer covers a thickness of more than 45% of the overall thickness of the top layer.

24. The floor panel of claim 23 , wherein the top layer has a thickness of 1 to 2millimeters.

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Meersseman Laurent
• Vanhastel Luc

Classifications

• B32B27/08

  of synthetic resin · CPC title

• B32B2307/712

  Weather resistant · CPC title

• B32B2471/00

  Floor coverings (B32B2419/04 takes precedence) · CPC title

• B32B2260/021

  Fibrous or filamentary layer · CPC title

• 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