Floor panel

Patent metadata

Field	Value
Publication number	US-9783995-B2
Application number	US-201615045389-A
Country	US
Kind code	B2
Filing date	Feb 17, 2016
Priority date	May 10, 2010
Publication date	Oct 10, 2017
Grant date	Oct 10, 2017

Abstract

A floor panel may include a substrate having a top side and a bottom side. A top layer may be provided on the substrate. The top layer may consist of a printed thermoplastic film and a thermoplastic transparent or translucent layer provided on the printed thermoplastic film. The top layer may be directly applied to the substrate using a glue layer available between the printed thermoplastic film and the top side of the substrate. The substrate may be an extruded synthetic material board including a filler selected from the group consisting of chalk, wood and sand. The substrate at least at two opposite edges may include coupling means provided in the extruded synthetic material board. The floor panel may have a thickness of 5 to 10 millimeters.

First claim

What is claimed is:

1. A floor panel comprising:
a substrate having a top side and a bottom side; and
a top layer provided on the substrate;
wherein the top layer consists of a printed thermoplastic film and a thermoplastic transparent or translucent layer provided on the printed thermoplastic film;
wherein the top layer is directly applied to the substrate using a glue layer available between the printed thermoplastic film and the top side of the substrate;
wherein the substrate is an extruded synthetic material board including a filler selected from the group consisting of chalk, wood and sand;
wherein the substrate at least at two opposite edges includes coupling means provided in the extruded synthetic material board;
wherein the floor panel has a thickness of 5 to 10 millimeters;
wherein the floor panel is rectangular and oblong;
wherein the coupling means is a tongue provided on one opposite edge and having a lower side with a recess, and a groove provided on the other opposite edge and having a lower groove lip with an upstanding part; and
wherein, when two floor panels are coupled together at respective edges, the cooperation of the tongue and the groove creates
(1) at least two pairs of vertically active locking surfaces that are formed from the material of the substrate, including a first pair of vertically active locking surfaces between an upper side of the tongue and a lower side of an upper groove lip, and a second pair of vertically active locking surfaces between the lower side of the tongue and an upper side of the lower groove lip, and
(2) at least two pairs of horizontally active locking surfaces, including a first pair of horizontally active locking surfaces that are formed from the material of the substrate and positioned on the upstanding part of the lower groove lip and a surface of the recess, and a second pair of horizontally active locking surfaces positioned next to the floor surface, at the location where the top layers of the coupled floor panels flank each other, the second pair of horizontally active locking surfaces being at least partially formed from the material of the top layer.

2. The floor panel of claim 1 , wherein the substrate is foamed.

3. The floor panel of claim 2 , wherein the substrate has a locally higher density at the top side or at the bottom side as compared to the density of the substrate in a central layer.

4. The floor panel of claim 3 , wherein the locally higher density is at least 5 percent higher than an average density of the substrate.

5. The floor panel of claim 2 , wherein the substrate is of the closed cell type.

6. The floor panel of claim 1 , wherein the substrate has an average density of 450 to 900 kilograms per cubic meter.

7. The floor panel of claim 1 , wherein the top layer has a thickness of 0.5 to 3 millimeters.

8. A floor panel comprising:
a substrate having a top side and a bottom side; and
a top layer provided on the substrate;
wherein the top layer consists of a printed thermoplastic film and a thermoplastic transparent or translucent layer provided on the printed thermoplastic film;
wherein the substrate is a synthetic material board including a filler selected from the group consisting of chalk, wood and sand;
wherein the substrate at least at two opposite edges includes coupling means provided in the synthetic material board;
wherein the coupling means enable a locking with a similar floor panel at the respective edges; the locking preventing separation of the locked floor panels in a horizontal direction perpendicular to the edges using locking parts provided in each other whereby at least one pair of horizontally active locking surfaces is created, the horizontally active locking surfaces being oriented at an angle A of more than 90 degrees with the horizontal direction; the locking preventing separation of the locked floor panels in a vertical direction perpendicular to the plane of the locked floor panels;
wherein the floor panel is rectangular and oblong;
wherein the two opposite edges are the short pair of edges;
wherein the substrate at the two longitudinal opposite edges includes longitudinal coupling means in the form of a tongue provided on one longitudinal opposite edge and having a lower side with a recess, and a groove provided on the other longitudinal opposite edge and having a lower groove lip with an upstanding part; and
wherein, when two floor panels are coupled together at the longitudinal edges, the cooperation of the tongue and the groove creates
(1) at least two pairs of vertically active locking surfaces that are formed from the material of the substrate, including a first pair of vertically active locking surfaces between an upper side of the tongue and a lower side of an upper groove lip, and a second pair of vertically active locking surfaces between the lower side of the tongue and an upper side of the lower groove lip, and
(2) at least two pairs of horizontally active locking surfaces, including a first pair of horizontally active locking surfaces that are formed from the material of the substrate and positioned on the upstanding part of the lower groove lip and a surface of the recess, and a second pair of horizontally active locking surfaces positioned next to the floor surface, at the location where the top layers of the coupled floor panels flank each other, the second pair of horizontally active locking surfaces being at least partially formed from the material of the top layer.

9. The floor panel of claim 8 , wherein the locking parts include an upstanding part at a bottom lip of a first one of the edges and a cooperating therewith recess at the bottom side of a second one of the edges.

10. The floor panel of claim 9 , wherein the bottom lip in a locked condition is bent.

11. The floor panel of claim 8 , wherein the locking parts are formed from the material of the substrate.

12. The floor panel of claim 8 , wherein the coupling means allow a coupling by use of a downwardly directed movement of a second one of the edges into a first one of the edges.

13. A floor panel comprising:
a substrate having a top side and a bottom side; and
a top layer provided on the substrate;
wherein the top layer includes a primer layer provided directly on the top side of the substrate, a print provided directly on the primer layer, and a thermoplastic transparent or translucent layer provided on the print;
wherein the substrate is a synthetic material board including a filler selected from the group consisting of chalk, wood and sand;
wherein the substrate at least at two opposite edges includes coupling means provided in the synthetic material boards
wherein the floor panel is rectangular and oblong;
wherein the coupling means is a tongue provided on one opposite edge and having a lower side with a recess, and a groove provided on the other opposite edge and having a lower groove lip with an upstanding part; and
wherein, when two floor panels are coupled together at respective edges, the cooperation of the tongue and the groove creates
(1) at least two pairs of vertically active locking surfaces that are formed from the material of the substrate, including a first pair of vertically active locking surfaces between an upper side of the tongue and a lower side of an upper groove lip, and a second pair of vertically active locking surfaces between the lower side of the tongue and an upper side of the lower groove lip, and
(2) at least two pairs of horizontally active locking surfaces, including a first pair of horizontally active locking surfaces that are formed from the material of the substrate and positioned on the upstanding p

Assignees

• Flooring Ind Ltd Sarl

Inventors

• Meersseman Laurent
• Segaert Martin
• Thiers Bernard
• Clement Benjamin
• Maesen Christophe

Classifications

• B32B2255/102

  synthetic resin or rubber layer being a foamed layer · CPC title

• B32B7/027

  Thermal properties · CPC title

• B32B2255/26

  Polymeric coating · CPC title

• B32B2307/7265

  Non-permeable · CPC title

• B44C1/24

  Pressing or stamping ornamental designs on surfaces · CPC title