Panel suitable for assembling a waterproof floor or wall covering, method of producing a panel

Patent metadata

Field	Value
Publication number	US-9745758-B2
Application number	US-201514856590-A
Country	US
Kind code	B2
Filing date	Sep 17, 2015
Priority date	Sep 18, 2014
Publication date	Aug 29, 2017
Grant date	Aug 29, 2017

Abstract

The invention relates in a first aspect, to a panel suitable for assembling a waterproof floor or wall covering by interconnecting a plurality of said panels with each other, wherein the panel has a substantially planar top surface, and a substantially planar bottom surface, at least four substantially linear side edges comprising at least one pair of opposite side edges which are provided with interconnecting coupling means for interconnecting one panel within another. The invention also relates to a method of producing a panel according to the invention.

First claim

The invention claimed is:

1. A panel suitable for assembling a waterproof floor or wall covering by interconnecting a plurality of said panels with each other,
wherein the panel has a substantially planar top surface, and a substantially planar bottom surface, at least four substantially linear side edges of which at least one pair of opposite side edges which are provided with interconnecting coupling means for interconnecting one panel within another, the panel having a sandwich structure which comprises a core layer composed of at least a thermoplastic material, a rigid top layer and a reinforcing layer situated in between the core layer and the top layer, said reinforcing layer being substantially made of at least one thermoplastic material, wherein the core layer is provided with at least a part of the interconnecting coupling means, wherein the panel has an overall rigidity between 35 and 45 N/mm 2 , and wherein the rigid top layer comprises at least two plies of cellulose-based layer and a cured resin.

2. The panel according to claim 1 , comprising two pairs of opposite side edges which are provided with interconnecting coupling means.

3. The panel according to claim 1 , 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 the other side edge of the same pair of opposite side edges.

4. The panel according to claim 1 , wherein the interconnecting coupling means have an interlocking feature which substantially avoids play between interconnected panels.

5. The panel according to claim 1 , wherein the core layer and the reinforcing layer are made of substantially the same thermoplastic material.

6. The panel according to claim 1 , wherein the thermoplastic material of the core layer comprises polyvinyl chloride (PVC) and/or polyethylene (PE) and/or acrylonitrile butadiene styrene (ABS).

7. The panel according to claim 1 , wherein the thermoplastic material of the reinforcing layer comprises polyvinyl chloride (PVC) and/or polyethylene (PE).

8. The panel according to claim 1 , wherein at least a part of the thermoplastic material of the core layer has a foam structure.

9. The panel according to claim 8 , wherein the thermoplastic material both at a top surface and a bottom surface of the core layer forms a crust layer enclosing the foam structure.

10. The panel according to claim 9 , wherein the thickness of each crust layer is between 0.01 and 1 mm.

11. The panel according to claim 1 , wherein the thickness of the core layer is between 2 and 20 mm.

12. The panel according to claim 1 , wherein the reinforcing layer is a hard layer.

13. The panel according to claim 1 , wherein the hardness of the reinforcing layer is between 30 and 90 Shore D.

14. The panel according to claim 1 , wherein the thermoplastic material of the reinforcing layer is a high density thermoplastic.

15. The panel according to claim 14 , wherein the density of the reinforcing layer is between 1000 and 2000 kg/m 3 .

16. The panel according to claim 1 , wherein the thickness of the reinforcing layer is between 0.2 and 2 mm.

17. The panel according to claim 1 , wherein the reinforcing layer is directly attached to the core layer.

18. The panel according to claim 17 , wherein the reinforcing layer is welded to the core layer.

19. The panel according to claim 1 , wherein the reinforcing layer is attached to the core layer by an adhesive.

20. The panel according to claim 1 , wherein the cellulose-based layer is paper.

21. The panel according to claim 1 , wherein the cured resin comprises a melamine resin and/or a phenolic resin.

22. The panel according to claim 1 , wherein the panel comprises a rigid bottom layer attached to a bottom surface of the core layer.

23. The panel according to claim 22 , plies of the rigid top layer and/or plies of the rigid bottom layer form a laminate which is obtained by lamination under high pressure.

24. The panel according to claim 1 , wherein the rigid top layer comprises seen from the upper surface of the panel, a first and second ply of cellulose-based layer and a cured resin, wherein the cellulose-based layer of the second ply has a decorative surface.

25. The panel according to claim 24 , wherein the rigid top layer comprises seen from the upper surface of the panel, a third and fourth ply of cellulose-based layer and a cured resin, wherein the cellulose-based layer of the third ply contains fibres oriented in a first main direction, wherein the cellulose-based layer of the fourth ply contains fibres oriented in a second main direction, wherein the first main direction of the cellulose-based layer of the third ply differs from the second main direction of the cellulose-based layer of the fourth ply by an angle in the range of 45 to 135 degrees.

26. The panel according to claim 1 , wherein the first ply of the rigid top layer contains abrasion resistant particles, and/or its top surface is provided with a relief pattern.

27. The panel according to claim 1 , wherein the core layer basically composed of a thermoplastic material contains one or more filler materials chosen from the group comprising calcium carbonate, wood dust, bamboo dust, rubber, cork, straw, fibres, fiberglass, and paper.

28. A waterproof floor or wall covering composed of a plurality of interconnected panels according to claim 1 .

Assignees

• Champion Link Int Corp

Inventors

• Baert Thomas Luc Martine
• Drevet Anthony
• Van Poyer Tom

Classifications

• E04F13/0894

  with tongue and groove connections · CPC title

• B29C66/748

  to natural products or their composites, not provided for in groups B29C66/742 - B29C66/746 · CPC title

• E04F15/206

  Layered panels for sound insulation · CPC title

• E04F13/18

  of organic plastics with or without reinforcements or filling materials (of plastic-bound fibres or chips E04F13/16 ){or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles (E04F13/0864 takes precedence)} · CPC title

• E04F15/105

  of organic plastics with or without reinforcements or filling materials · CPC title