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

Patent metadata

Field	Value
Publication number	US-9758973-B2
Application number	US-201314402011-A
Country	US
Kind code	B2
Filing date	May 30, 2013
Priority date	Jun 1, 2012
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

Panel for forming a floor covering, wherein this panel comprises at least a layer of thermoplastic material, wherein said layer also comprises at least individual fibers having a length greater than 1 millimeter.

First claim

The invention claimed is:

1. A panel for forming a floor covering, wherein this panel comprises:
a substrate layer having a thickness of 1.3 to 10 millimeters, said substrate layer being substantially formed by one or more layers of thermoplastic material,
wherein this panel, above said one or more layers of thermoplastic material, comprises at least also a printed decor and a translucent or transparent wear-layer,
with at least one said layers of thermoplastic material situated at least halfway in the thickness of the panel, wherein said thermoplastic material is chosen from the list consisting of polyvinyl chloride, polypropylene, polyethylene, and polyurethane,
wherein each of said one or more layers of thermoplastic material also comprises at least individual glass fibers having a length greater than 1 millimeter, and wherein said individual glass fibers are loose and freely distributed within each of said layers of thermoplastic material, and
wherein said panel at one or more edges comprises mechanical coupling parts allowing to couple two of such panels to each other; said coupling parts being substantially realized in said substrate layer.

2. The panel of claim 1 , wherein said individual glass fibers are provided with a coating or a treatment which improves the adherence to the thermoplastic material.

3. The panel of claim 1 , wherein said layer of thermoplastic material also comprises at least a glass fiber cloth or glass fiber fleece.

4. The panel of claim 1 , wherein this panel comprises at least two such layers on the basis of thermoplastic material.

5. The panel of claim 1 , wherein said thermoplastic material relates to soft polyvinyl chloride with a percentage of plasticizer of 12 percent by weight or more.

6. The panel of claim 1 , wherein said thermoplastic material further also comprises fillers.

7. The panel of claim 1 , wherein said individual glass fibers on average have a diameter situated between 5 and 25 micrometers.

8. The panel of claim 1 , wherein said individual fibers have an average length of more than 3 mm.

9. A panel for forming a floor covering, wherein this panel comprises:
a substrate having a thickness of 1.3 to 10 millimeters, said substrate being substantially formed by one or more layers of thermoplastic material,
wherein this panel, above said one or more layers of thermoplastic material, comprises at least also a printed decor and a translucent or transparent wear-layer,
with at least one said layers of thermoplastic material situated at least halfway in the thickness of the panel, wherein said thermoplastic material is chosen from the list consisting of polyvinyl chloride, polypropylene, polyethylene, and polyurethane,
wherein each of said one or more layers of thermoplastic material also comprises at least individual glass fibers having a length greater than 1 millimeter, and wherein said individual glass fibers are loose and freely distributed within each of said layers of thermoplastic material,
wherein said panel at one or more edges comprises mechanical coupling parts allowing to couple two of such panels to each other; said coupling parts being substantially realized in said substrate, and
wherein said wear-layer has a thickness of 0.2 to 0.4 millimeters.

10. A method for manufacturing panels, wherein said method comprises at least the step of:
providing a substrate having a thickness of 1.3 to 10 millimeters by at least forming one or more layers of thermoplastic material on the basis of a strewn granulate of said thermoplastic material,
wherein said one or more layers of thermoplastic material is situated at least halfway in the thickness of the panel, wherein said thermoplastic material is chosen from the list consisting of polyvinyl chloride, polypropylene, polyethylene, and polyurethane,
wherein each of the formed one or more layers comprises individual fibers having a length greater than 1 mm, wherein said individual glass fibers are loose and freely distributed within each of said layers of thermoplastic material, and
forming a printed décor and a translucent or transparent wear layer above said layer of thermoplastic material, and
wherein at one or more edges of said panel, mechanical coupling parts are formed allowing to couple two of such panels to each other, said coupling parts being substantially realized in said substrate layer.

11. The method of claim 10 , wherein said strewn layer is consolidated between the belts of a continuous press device.

12. The method of claim 11 , wherein said granulates comprise at least a portion of said individual glass fibers.

13. The method of claim 10 , wherein said thermoplastic material relates to soft PVC and wherein said individual fibers are provided with a coating or a treatment which improves the adherence to the thermoplastic material.

14. The method according to claim 10 , wherein the aforementioned granulate has an average particle size of less than 1 mm.

15. The method of claim 14 , wherein for the granulate, it is started from a granulate with an average particle size of 350 micrometers or less.

16. The method according to claim 10 , wherein said granulate, apart from said thermoplastic material, also comprises glass fibers having a length greater than 1 mm.

Assignees

• Unilin Bvba

Inventors

• Segaert Martin
• Naeyaert Christophe

Classifications

• B32B2315/085

  Glass fiber cloth or fabric · CPC title

• B32B2305/30

  Fillers, e.g. particles, powders, beads, flakes, spheres, chips · CPC title

• E04F15/102

  of fibrous or chipped materials, e.g. bonded with synthetic resins · CPC title

• B32B37/1027

  Pressing using at least one press band · CPC title

• E04F15/105

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