EA045442B1 - FLOOR PANEL AND METHOD FOR MANUFACTURING THE FLOOR PANEL - Google Patents

Description

The present invention relates to a floor panel and a method for manufacturing a floor panel.

More particularly, the present invention relates to a floor panel of this type which comprises a backing comprising a thermoplastic material and a trim provided thereon, as well as on at least one pair of opposite edges connecting parts formed at least in part from the backing and allowing mechanical fixation, that is, without the use of glue, etc., between two such floor panels. This type of flooring panel allows you to create a waterproof floor covering in a simple and convenient way. This type of flooring can also be used without any problems in wet rooms such as bathrooms, unlike wood laminate flooring panels using, for example, a medium density fibreboard or high pressure fibreboard underlay which are less suitable for such applications.

Patent document WO 2013/026559 describes such a floor panel in which the backing contains one or more layers of soft or flexible polyvinyl chloride (PVC). However, such a floor panel has a number of problems. For example, it has a significant risk of exhibiting telegraphic effects. However, after a certain period of time, imperfections in the underlying surface or subfloor on which the panels are installed become visible on the surface of the panels. When installing the panels in a room with a lot of incident sunlight, such as a porch, etc., there is also a high risk of curled edges and/or gaps forming between the joined panels. This is a result of the expansion/shrinkage that the substrate undergoes when the temperature changes. Although the use of a layer of fiberglass can increase the dimensional stability of the floor panel, it is often still not enough to avoid the problems mentioned. Additionally, these panels are relatively flexible, meaning installation may not always go smoothly. In addition, the varnish layer present on the top side of the panel is generally not rated well in terms of wear resistance, scratch resistance, stain resistance, etc.

The floor panel, which is known from patent document WO 2014/006593, attempts to solve a number of the problems mentioned. It has a rigid backing layer formed by extrusion, which contains, on the one hand, high-density polyethylene (HDPE) or PVC, and on the other hand, bamboo, wood and/or cork powder. This backing layer is bonded to a veneer layer, such as a decorative vinyl layer. This floor panel already offers significantly higher resistance to telegraphic effects. Its rigidity also makes it easier to install. However, it also has disadvantages. Thus, the flatness of this floor panel cannot be guaranteed. There is a significant risk of warping. In addition, this floor panel appears to be susceptible to the formation of indentations in its upper surface, such as from the legs of a table or chair. Additionally, delamination problems can occur when the veneer layer separates from the backing layer.

The object of the present invention is to provide a solution to one or more of the above and/or other problems.

To this end, the present invention, in accordance with its first independent aspect, relates to a floor panel of the above-mentioned type, characterized in that the substrate contains a layer of rigid thermoplastic material, and a layer of glass fiber is present in the floor panel. The present inventor has found that the use of a glass fiber layer with a rigid backing layer is extremely advantageous. It provides a reduced risk of panels warping. It also reduces the risk of curled edges and/or gaps when installing panels on a porch, etc. Expansion/shrinkage still remains, but the disadvantages mentioned appear to be reduced. It should be noted that expansion is not inherently a problem since it can be countered by the necessary expansion spaces.

It should be noted that the term “underlay” means that part of the floor panel that is located under the trim or possible trim carrier.

The rigidity of the substrate layer is preferably derived from the rigidity of its thermoplastic material. This is possible by using a suitable amount of plasticizer or not using any plasticizer at all. If plasticizers are used, their amount is preferably less than 15 ppm. at 100 m.h. resin, less than 10 ppm at 100 m.h. resin or less than 5 parts per part. at 100 m.h. resin. It should be noted that the amount of plasticizers is less than 15 ppm. at 100 m.h. resin means that per 100 parts of thermoplastic synthetic material there are less than 15 parts of plasticizers. Examples of plasticizers that can be used are phthalate plasticizers such as di-isononyl phthalate (DINP) or dioctyl phthalate (DOP or DnOP), or alternatively for phthalate plasticizers, dioctyl terephthalate (DOTP) or di-isononyl phthalate. 1,2-cyclohexanedicarboxylate (DINCH).

The thermoplastic material of the rigid backing layer preferably contains one or more of the following thermoplastic synthetic materials: PVC, polyethylene, HDPE, polypropylene, polyester, polyethylene terephthalate (PET), polyurethane and/or elastomer. The most preferred synthetic material is PVC.

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The thermoplastic material of the rigid backing layer preferably contains some filler. Fillers contribute to the rigidity of the panels. Various types of fillers can be used, individually or in combination:

an inorganic filler such as chalk, lime and/or talc;

organic filler such as wood, bamboo and/or cork; and/or mineral filler.

It should also be noted that talc filler is particularly beneficial. Namely, this filler has been shown to have a positive effect on the dimensional stability of the panel.

The filler concentration is preferably 30-70% by weight or 45-65% by weight. It should be noted here that the weight percentage is determined by the total weight of the thermoplastic material in the support layer.

The filler proportion is preferably at least 40% by weight, more preferably at least 50% by weight and even more preferably at least 60% by weight or at least 70% by weight. This fairly high percentage of filler has been shown to increase the dimensional stability of the backing layer.

The thermoplastic material of the rigid support layer may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black.

It should also be noted that the thermoplastic material of the backing layer may be a recycled material.

Preferably, the rigid backing layer is non-foamed or substantially non-foamed. The present inventor has found that such a backing layer not only provides better resistance to telegraphic effects than foam layers, but also provides resistance to dents. It should also be noted that essentially non-foamed means that the density of the non-foamed thermoplastic material is reduced by foaming by a maximum of 10% and preferably by a maximum of 5% or a maximum of 2%. The density of the non-foamed or nearly non-foamed support layer is preferably 1300-2000 kg/m ³ or 1500-2000 kg/m ³ .

However, it is also possible that the hard backing layer may be foamed. In fact, the present inventor has found that foaming has a positive effect on dimensional stability. Preferably the density reduction is greater than 10%. This means that the density of the unfoamed thermoplastic material decreases by more than 10% when foamed.

The rigid support layer can be formed through various techniques such as sprinkling, extruding or calendering processes. The sprinkling process, which is essentially known from patent documents WO 2013/179261 and BE 2015/5572, is preferred. In fact, the flatness of the substrate layer can be better guaranteed by such a process.

The fiberglass layer may refer to, for example, fiberglass fleece, fiberglass fabric, or fiberglass mesh.

The glass fiber layer is preferably adjacent to the rigid backing layer. In this position, the fiberglass layer can best resist possible warping or dimensional deformation of the backing layer.

The glass fiber layer is preferably at least partially impregnated with the thermoplastic material of the rigid backing layer. This ensures that the fiberglass layer is well-filled, making it work more efficiently. The risk of delamination is also reduced.

It should also be noted that the fiberglass layer preferably refers to fiberglass fleece. This type of fiberglass layer bonds better to the backing layer. Better impregnation is also possible.

The substrate may comprise a second rigid substrate layer of thermoplastic material. This substrate layer may have one or more of the characteristics of the first mentioned substrate layer.

Preferably, the glass fiber layer is adjacent to the first mentioned as well as the second backing layer. Thus, a layer of glass fiber is located between two layers of substrate. This can be achieved in various ways.

Preferably, these two rigid backing layers are provided by a sprinkling treatment. In this case, one layer of support may be deposited, a layer of glass fiber may be provided on it, and another layer of support may be deposited on this complex. This complex can then be consolidated. Such a process is known per se from patent document WO 2013/179261. It has the advantage that a layer of fiberglass can be very well embedded between two layers of substrate.

Another possibility is one in which one support layer is provided by sprinkling treatment, a layer of glass fiber is provided on it, this complex is consolidated, and only then another support layer is provided on this consolidated complex. Such a process is known from patent document WO 2016/079225. It has the advantage that the risk of deformation and/or damage to the glass fiber layer can be minimized, since the press element of the possibly used pressing device can be in direct contact with the glass fiber layer.

Another support layer can be provided, for example, through a calendering technique.

Another possibility is to produce two rigid backing layers by extrusion. In this case, the extruded substrate layers and the glass fiber layer can be stacked on top of each other and then bonded to each other. The interlinking can be carried out in a pressing device, for example a single-plate or multi-plate press.

Another possibility is to form one support layer by extrusion, transport this extruded support layer and provide a glass fiber layer during said transport on said extruded support layer. The advantage of this process over the previous one is that it can be performed continuously. For example, one layer of substrate can be transported along the guide rollers, and a layer of glass fiber can be fed along with the substrate layer between these guide rollers. Another backing layer can be provided subsequently on the glass fiber layer. Alternatively, it is possible to provide this backing layer together with the glass fiber layer on the same backing layer during transport.

The fiberglass layer may be untreated. However, it is also possible for the glass fiber layer to be pre-treated. This may provide a better bond to the backing layer or layers adjacent to the fiberglass layer.

Pre-treatment may include providing a coating to the glass fiber layer or impregnating the glass fiber layer. The coating or impregnation material may be plastisol, preferably PVC plastisol. Pre-processing can be performed separately.

The density of the fiberglass layer can be 30-100 g/ ^m2 . However, it is preferably less than 65 g/m ² . This has the advantage that the fiberglass layer can be cast into the substrate more easily and quickly. In addition, such lighter glass fibers result in only a small (or no) reduction in dimensional stability, at least not as much as is the case with rigid backing layers, which is what the inventor of the present invention has quite surprisingly discovered.

A second layer of fiberglass is preferably present in the floor panel. Using more than one layer of fiberglass has been proven to be more effective than using a single layer of fiberglass. The second glass fiber layer may have one or more of the characteristics of the first glass fiber layer.

In particular, the first and second layers of glass fiber have a density of less than 65 or at most 50 g/m ² . This has a positive effect on processing speed and virtually no negative impact on dimensional stability, at least not in the case of applications with rigid backing layers.

The two layers of fiberglass are preferably placed on either side of the center of the floor panel. This way their effect is better distributed across the floor panel. Preferably, one layer of fiberglass is located in the lower half of the floor panel, while the other layer of fiberglass is located in the upper half.

The two layers of fiberglass are preferably spaced vertically apart by at least 1/5 or at least 1/4 of the thickness of the floor panels. This ensures that the effect of the fiberglass panels is well distributed throughout the thickness of the floor panel. Most preferably, they are located at a vertical distance from each other that is approximately 1/3 of the thickness of the floor panel.

Preferably, these two layers of glass fiber surround the first layer of substrate. Herein, the top side of this substrate layer is defined by one layer of glass fiber and its bottom side by another layer of glass fiber. The thickness of the first backing layer in this case is preferably at least 1/5, at least 1/4 or about 1/3 of the total thickness of the floor panel. The two layers of fiberglass are preferably positioned either side of the center of the floor panel, such that the center line of the floor panel in this case passes through the first layer of backing.

One glass fiber layer is preferably located between the first substrate layer and the second rigid thermoplastic material substrate layer, while the other substrate layer is preferably located between the first substrate layer and the third rigid thermoplastic material substrate layer. This results in a particularly balanced and stable multi-layer structure. The second and third substrate layers may have one or more characteristics of the first substrate layer. The first backing layer is preferably centered, that is, the center line of the floor panel passes through it, while the second and third backing layers are preferably centered such that the second backing layer is in the top half and the third backing layer is in the bottom half of the floor panel . The second and third support layers are preferably thinner than the first support layer, but preferably their thickness is at least 1/5 or at least 1/4 the thickness of the first support layer. The third backing layer is preferably made thicker than the second backing layer, but is preferably no more than 2.5 or 2 times thicker.

One or more rigid backing layers of thermoplastic material form the rigid portion of the floor panel. This rigid part preferably has a total thickness of at least 2 mm. Namely, the inventor of the present invention has found that, at this thickness, the resistance against telegraphic effects and the bending rigidity are very good. Even better, the total thickness of the rigid part is at least 2.5 mm or at least 3 mm. The total thickness of the rigid part is preferably a maximum of 8 mm, a maximum of 6 mm or a maximum of 4 mm. In this way, the weight of the panels can remain limited. The total thickness of the rigid part is preferably 2-8, 2-6 or 2-4 mm. The total thickness of the rigid portion is preferably at least 50%, at least 60%, or at least 65% of the total thickness of the floor panel.

The substrate preferably includes a backing layer that is more flexible or compressible than the first rigid backing layer. This more flexible backing layer has the advantage that the sound generated when walking on the installed floor panels can be muffled. Preferably, this flexible backing layer is located between the first backing layer and the trim. Preferably, this more flexible backing layer is located directly below the finish or possible finish carrier on which the finish is provided. In this case, it also facilitates the efficient production of deep relief structures on the upper side of the floor panel. To this end, it is actually desirable to deform the material under the finish, which is easier to do when the material is relatively flexible.

This more flexible backing layer is preferably made from a thermoplastic material, preferably PVC, but other synthetic materials such as polyethylene, polypropylene, polyester such as PET, polyurethane and/or elastomer may also be used. The flexibility of this backing layer is preferably obtained by realizing its thermoplastic material as soft or semi-rigid. This is possible by using a suitable amount of plasticizers, in particular when PVC is used as the thermoplastic synthetic material. The amount of plasticizers in the more flexible backing layer is preferably at least 15 ppm. at 100 m.h. resin and even better at least 20 ppm. at 100 m.h. resin.

Examples of plasticizers that can be used, particularly in the case of PVC, are phthalate-based plasticizers such as DINP or DOP, or alternatively DOTP or DINCH.

When implementing a more flexible backing layer, extrusion, calendering or sprinkling techniques can be used.

Preferably, the more flexible backing layer is bonded to the first or possibly second rigid backing layer by thermal lamination, which, compared to the use of adhesives or the like, limits the risk of delamination. Preferably this is carried out by means of a calendering process, for example by means of a calendering device consisting of more than two calendering rollers.

However, it is also possible that the more flexible backing layer may consist of a material other than the thermoplastic material. For example, it is possible for this backing layer to relate to a carpet layer or a textile layer in general, or to be made of rubber or cork. In these cases, it is preferred that the corresponding backing layer be bonded to the first or possibly second rigid backing layer by means of an adhesive or the like, preferably a waterproof adhesive such as hot melt adhesive. It should also be noted here that in the case of carpeting, for example, the finish is actually contained within that layer of carpeting.

The thickness of the more flexible substrate layer is preferably 0.5-3 mm, even better 0.5-2 mm and best of all 0.5-1 mm inclusive, since at these thicknesses the above-described advantages are particularly pronounced.

The substrate may comprise on its underside a backing layer that is preferably more flexible or more compressible than the first rigid backing layer. This type of underlay layer located on the underside of the underlay has the advantage that the noise generated when walking on the installed floor panels can be muffled. This backing layer may consist of a thermoplastic material, which may include the use of synthetic materials such as PVC, polyethylene, polypropylene, polyester such as PET, polyurethane and/or elastomer. The corresponding backing layer is preferably foamed as this can improve its sound absorption properties. A preferred embodiment of such a backing layer is one that contains XPE or cross-linked polyethylene foam.

When implementing said substrate layer located on the underside of the substrate, extrusion, calendering or sprinkling techniques can be used.

It is also possible to connect this backing layer to the first or possible third rigid backing layer by means of thermal lamination, which, compared to the use of glue or the like, limits the risk of delamination. However, it is possible that the corresponding backing layer is connected to the first or possible third backing layer in some other way, for example by means of an adhesive or the like, in which case a waterproof adhesive such as hot melt adhesive is preferably used.

It is also possible that the bottom layer consists of a material other than the thermoplastic material. For example, it is possible for this bottom layer to be a textile layer or to consist of cork or rubber. In these cases, it is preferable for this bottom layer to be bonded to the core by means of an adhesive or the like, preferably a waterproof adhesive such as hot melt adhesive.

The thickness of said substrate layer located on the underside of the substrate is preferably 1-4 mm, even better 1-3 mm, and best of all 1-2 mm inclusive, with a thickness of approximately 1.5 mm being ideal.

The finish preferably refers to an embossed or printed finish that preferably depicts a natural product such as wood or stone. In the case of wood, the finish may represent, for example, the layers and/or pores of the wood. Embossing or printing can use any of the following techniques: offset printing, gravure printing and digital printing, which uses, for example, a digital printing press or an inkjet printer.

The trim may be embossed or printed onto the trim carrier. Alternatively, the finish may be embossed or printed directly onto the substrate, in which case it is referred to as direct printing. It is also possible for the substrate to be provided with a primer or primer, possibly multiple layers of primer or primer, before embossing or printing.

When the finish is embossed or printed on the finish carrier, it preferably refers to a foil or film, which may be thermoplastic. This may apply, for example, to foil or film made of PVC, polyethylene, polypropylene, polyurethane or polyester such as PET.

It is also possible for the wear layer to be a cellulose-based layer, preferably impregnated with resin. For example, a cellulose-based layer refers to paper such as standard paper or kraft paper. The resin preferably contains melamine resin and/or phenolic resin.

It should also be noted that when the finishing carrier is a cellulose-based layer, there may also be one or more cellulose-based layers underneath, such as paper, which improves the rigidity of the floorboard. These one or more additional cellulose-based layers are preferably impregnated with a resin such as melamine and/or phenolic resin.

Alternatively, for an embossed or printed finish, a veneer of wood or stone can be provided on the substrate, for example, which then forms the finish. Preferably, this possible wood veneer is treated so that it is waterproof or substantially waterproof.

Preferably, the floor panel contains a wear and/or varnish layer provided on the finish to protect it and prevent it from wearing out. Preferably these layers are transparent or translucent so that the finish is visible.

The wear layer is preferably a foil or film, which is preferably thermoplastic. This may apply, for example, to foil or film made of PVC, polyethylene, polypropylene, polyurethane or polyester such as PET. The thickness of such foil or film is preferably 250-750 microns inclusive. This type of wear layer is preferably applied when the finish is embossed or printed on foil or film.

It is also possible that the wear layer is a cellulose-based layer, preferably impregnated with resin. For example, a cellulose-based wear layer refers to paper such as standard paper or kraft paper. The resin preferably contains melamine resin and/or phenolic resin. Preferably, the cellulose-based wear layer contains wear-resistant particles such as ceramic particles or corundum. This type of wear layer is preferably applied when the finish is embossed or printed on a cellulose-based layer.

The varnish layer is preferably based on urethane acrylates, polyester acrylates and/or epoxy acrylates. Preferably this refers to a varnish layer that can be cured by UV radiation or excimer radiation. The varnish layer may contain ceramic particles such as alumina and/or silica. A layer of varnish can be provided before or after any possible relief is formed on the top side of the floor panel. Of course, with a fairly deep relief, for example with a depth of more than 100 or 250 μm, it is advantageous to provide a layer of varnish before the formation of the relief, as described in patent document BE 2016/5732, since this helps to prevent breaks in the varnish layer. This is of course useful when applying high gloss wear layers, such as PVC wear layers, since in this way the formation of shimmering spots resulting on such wear layers, as described in patent document BE 2016/5732, can be avoided.

It should also be noted that multiple layers of varnish may be present over the finish. This is especially advantageous when the relief is provided on the upper side of the floor panel. IN

- 5 045442 in this case, the first layer of varnish can be provided before the formation of the relief so that the varnish layer does not have breaks and prevent the formation of flickering spots, and the second - after the formation of the relief, and for this second layer of varnish a harder varnish can be used, which is essentially known in principle from patent document BE 2016/5732.

It should also be noted that the present invention allows for the application of harder varnishes. The reason for this is the presence of a rigid backing layer. In fact, this backing layer can resist the shrinkage that the varnish undergoes and thus warping or deformation of the panel. The application of harder varnishes has the advantage that they are more effective and provide higher mechanical and chemical resistance.

The top side of the floor panel can have a relief that simulates the texture of a natural product such as wood, stone or ceramics. In the case of wood, the relief may model, among other things, the layers and/or pores of the wood. Possible bevels on one or more edges of the upper side of the floor panel do not belong to such a relief and are not considered to form part of the relief, taking into account the fact that they are not intended to simulate a natural texture, but rather to achieve a board effect. The relief can be provided by mechanical and/or chemical embossing.

The relief preferably has a maximum depth of greater than 100 µm, and even better greater than 200 or 250 µm. This deep relief helps the floor panel look natural. With such deep relief, it is particularly advantageous to use a more flexible backing layer, as described above herein. In fact, such a backing layer can easily be deformed or embossed to form a deep relief.

In the case where the relief is formed on the upper side of the floor panel, it is best that there is a wear layer in which the relief is created. It is possible for the deep relief to extend into the wear layer, but it is desirable for it to extend into the substrate, preferably into a possibly more flexible substrate layer.

The relief can be created simultaneously with the creation of the finish. Simultaneous creation has the advantage of resulting in a more natural-looking and tactile floor panel. Various techniques for implementing such a simultaneous embodiment are known, in particular, from the following patent documents: EP 2636524, EP 2447063 and EP 2447064.

It should be noted that when wood or stone veneer is provided over a substrate, the top side of the floor panel is automatically embossed with the texture of wood or stone, respectively.

The top side of the floor panel may include a bevel at one or more of its edges. This may refer to a bevel that is no deeper than the thickness of the eventual wear layer. However, it is possible for this bevel to have a depth greater than the thickness of the wear layer, for example extending into the substrate, in which case this bevel is preferably finished. This can be provided by a separate finish on the bevel, that is a finish separate from the main finish such as varnish, paint or foil. Alternatively, the main finishing can be carried out continuously along this bevel. In this case, it may refer to what is called a pressed bevel, where the bevel is formed by pressing the top side of the floor panel, including the trim, close to its edge.

The floor panel preferably has one or more of the following characteristics:

the floor panel bends under its own weight by less than 10 cm/m, and even better by less than 5 cm/m; and/or the floor panel has a modulus of elasticity or Young's modulus of at least 2000 N/mm ² , at least 3000 N/mm ² or at least 3500 N/mm ² .

The bend can be measured by clamping the floor panel at one end and measuring the bend of the remaining free part. In the case of an elongated rectangular panel, the clamped end can be, for example, one of its short sides.

The elastic modulus should be measured at room temperature equal to 25°C.

The overall thickness of the floor panel is preferably 3-10 mm, or 3-8 mm, or 3.5-8 mm, or 3.5-6 mm, or 4-6 mm inclusive, with the ideal thickness being approximately 4.5 mm.

The mechanical fixation effected by the connecting parts in the connected state of two such floor panels can be performed at least or exclusively in the horizontal direction, that is, in a plane of the connected floor panels that is perpendicular to the connected edges. This horizontal fixation can be realized by the interaction of the fixing surfaces. The area in which these locking surfaces interact is preferably located at least partially or entirely in the first, optionally second or optionally third rigid backing layer, which has the advantage of providing a strong lock and minimizing the formation of gaps. It is also possible to place a layer of fiberglass at the height of this zone, which improves the fixation strength.

The mechanical fixation effected by the connecting parts in the connected state of two such floor panels can be carried out at least or exclusively in the vertical direction, that is, perpendicular to the plane of the connected floor panels. This vertical locking may be achieved by the interaction of locking surfaces, the area in which these locking surfaces interact is preferably located at least partially or entirely in the first, optionally second or optionally third rigid backing layer, which has the advantage of providing strong locking and minimizing formation gaps It is also possible to place a layer of fiberglass at the height of this zone, which improves the fixation strength.

Preferably, both horizontal and vertical locking are present, preferably realized by the interaction of locking surfaces, the zone or zones in which the locking surfaces interact are preferably located at least partially in the first, optionally second or optionally third rigid substrate layer. The fiberglass layer may be located at the height of the zone in which the fixing surfaces interact. In the case where there are multiple zones in which the fixing surfaces interact, these layers of glass fibers, when multiple layers of glass fibers are used, or at least a portion of these layers of glass fibers can be located at the height of the above-mentioned zones.

The connecting parts can be implemented as a tongue-and-groove connection defined by an upper and lower shoulder. This connection preferably contains locking elements, for example in the form of a protrusion at the bottom side of the connection projection and a recess at the top side of the lower shoulder, which in the connected state resist movement of the projection and groove in the horizontal direction. Preferably, this tongue and groove connection has one or more of the following characteristics, provided they are not inconsistent with each other, all of which enhance the stability and strength of the fixation:

the upper bead is at least partially formed from a first or possibly a second rigid substrate layer;

the lower bead is at least partially formed from a first or possibly a third rigid substrate layer;

the center line through the protrusion is located in the first rigid layer of the substrate;

the innermost point of the groove is located in the first rigid layer of the substrate;

the area in which the upper side of the protrusion interacts with the lower side of the upper bead is located at least partially or completely in the first or possible second rigid substrate layers;

the zone in which possible fixing elements interact is located at least partially or completely in the first or possible third rigid substrate layer;

a layer of fiberglass is located at the height of the zone in which the upper side of the protrusion interacts with the lower side of the upper bead;

the fiberglass layer is located at the height of the zone in which possible fixing elements interact;

a layer of fiberglass is located on the center line through the protrusion;

the fiberglass layer is located at the height of the innermost point of the groove;

in the case where the area in which the upper side of the protrusion interacts with the underside of the upper flange is located in a different position than the area in which the possible locking elements interact, preferably at least two layers of glass fiber are present, and preferably one layer of glass fiber is located on the height of the zone in which the upper side of the protrusion interacts with the lower side of the upper bead, and the other layer of glass fiber is located at the height of the zone in which the possible fixing elements interact;

a layer of fiberglass extends continuously through the bottom bead or the top bead; and/or a layer of glass fiber extends continuously in at least one of the connecting parts.

The connecting parts implemented as a tongue and groove connection are preferably selected from the following types:

the type in which the connecting parts are configured in such a way that they allow the joining of two such floor panels at their respective edges by means of a rotary movement in which the tongue-and-groove floor panel, from an inclined position in which the projection is already partially located in the groove, is rotated downward to be fully inserted protrusion into the groove and connect the corresponding edges to each other;

the type in which the connecting parts are configured in such a way that they allow the connection of two such floor panels at their respective edges by substantially linear movement in the plane of the floor panels and substantially perpendicular to the respective edges, preferably with a snap action;

the type in which the connecting parts are configured in such a way that they allow the connection of two such floor panels at their respective edges, both through the rotational movement described above herein, and through substantially linear movement in the plane of the floor panels and substantially perpendicular to the respective edges, preferably with a snap action.

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It should also be noted that a tongue and groove joint, in the case where the floor panel is square or rectangular, can be applied on each pair of opposite edges of the floor panel.

Alternatively, the connecting parts can be implemented as hook-shaped parts consisting of, on the one hand, an upwardly directed fixing part in the form of a hook with a shoulder and an upwardly directed fixing element, and on the other hand of a downwardly directed part in the form of a hook with a shoulder and a downward direction hook-shaped parts, wherein these locking elements, in the connected state of two such floor panels, resist movement of the hook-shaped parts in the horizontal direction. The mechanical locking effected by these hook-shaped parts preferably also operates in the vertical direction, and for this purpose they can be provided with vertically active locking elements. Preferably, the hook-shaped portion has one or more of the following characteristics, all of which enhance the stability and strength of the fixation:

the flange of the downwardly directed hook-shaped portion is at least partially formed from a first or possibly a second rigid substrate layer;

the flange of the upwardly directed hook-shaped portion is at least partially formed from a first or possibly a third rigid substrate layer;

the region in which the upwardly directed locking element cooperates with the downwardly directed locking element to effect horizontal locking is located at least partially or completely in the first or possible third rigid substrate layer;

the zone or zones in which possible vertically active locking elements interact are located at least partially or completely in the first, possible second or possible third rigid substrate layer;

a layer of glass fiber is located at the height of the zone in which the upwardly directed locking element interacts with the downwardly directed locking element to effect horizontal fixation;

a layer of fiberglass is located at the height of the zone or zones in which possible vertical fixing elements interact;

in the case where the area in which the upwardly directed locking element interacts with the downward locking element to effect horizontal locking is located in a different position than the area in which possible vertically active locking elements interact, at least two layers of glass fiber are preferably present, wherein preferably one layer of glass fiber is located at the height of the zone in which the upwardly directed locking element interacts with the downward locking element to effect horizontal locking, and the other layer of glass fiber is located at the height of the zone in which possible vertically active locking elements interact;

the glass fiber layer extends continuously in the bead of the downwardly directed hook-shaped portion or in the bead of the upwardly directed hook-shaped portion; and/or a layer of glass fiber extends continuously in at least one of the hook-shaped portions.

The vertically active locking elements may comprise a separate insert, preferably an elastically deformable and/or movable insert, which is per se known, for example, from patent documents WO 2006/043893, WO 2008/068245 and WO 2009/066153. This insert has the advantage that the strength of the vertical fixation becomes largely independent of the floor panel material itself, and that stronger vertical fixation can be achieved compared to elements that are realized from the floor panel material itself. Thus, such an insert is useful in reducing the risk of gaps forming between the floor panels being joined.

This insert is preferably provided in a recess in the upwardly directed or downwardly directed hook-shaped portion. This recess is preferably located at least partially in the first rigid substrate layer.

In the case where such an insert is not used, the vertically active fixing elements are preferably realized from the floor panel material itself, and even better from the material of the first, possibly second or possible third rigid backing layer. The rigid nature of these backing layers ensures that these locking elements will also provide strong vertical fixation.

The hook-shaped parts can preferably engage each other through a substantially linear movement perpendicular to the plane of the connected floor panels or to the plane of the floor covering.

It should also be noted that hook-shaped pieces, in the case where the floor panel is square or rectangular, can be applied on each pair of edges of the floor panel.

Preferably, the floor panel is square or rectangular, and can be connected to adjacent floor panels using a fold-down laying technique. For this purpose this

- 8 045442 a floor panel contains, on the one hand, on one pair of opposite edges, connecting parts, which are implemented in the form of a tongue-and-groove connection, and which are of a type that allows this floor panel to be connected to an already installed similar floor panel, which is located in the previous one row, by means of a turning movement, and on the other hand, on the other pair of edges, connecting parts, which are implemented in the form of hook-shaped parts and which allow the corresponding floor panel to be connected by the same turning movement to an already installed similar floor panel located in the same very row. This fold-down laying technique has been shown to be excellent for installing the floor panel of the present invention.

It should also be noted that instead of a fiberglass layer, any reinforcing layer can be used. Preferably, this is a reinforcing layer that contains reinforcing fibers such as carbon fibers.

According to an independent second aspect, the present invention relates to a floor panel of the above type, characterized in that the backing comprises a rigid non-foamed backing layer of thermoplastic material. As a result, this floor panel is less sensitive to indentation effects, for example from chair and/or table legs, compared to floor panels with foam backing layers.

It should be noted that this advantage also occurs when the rigid substrate is lightly foamed, that is, when foaming reduces the density of the rigid substrate layer by a maximum of 10%.

According to an independent third aspect, the present invention relates to a floor panel of the above type, characterized in that the backing comprises a backing layer of thermoplastic material which is thermolaminated to a more flexible backing layer which is located between the trim and the rigid backing layer. This reduces the risk of delamination.

According to an independent fourth aspect, the present invention relates to a floor panel of the above type, characterized in that it contains at least two layers of glass fiber, each of which has a density of less than 65 g/ ^m2 or even at most 50 g/ ^m2 .

It should also be noted that each of the second through fourth aspects may be combined with one or more of the characteristics of the first aspect without requiring the floor panel to exhibit the characteristic of that first aspect.

In accordance with an independent fifth aspect, the present invention relates to a method for manufacturing a floor panel with a substrate containing a thermoplastic material and a finish provided thereon, which includes the following steps:

providing a first rigid substrate layer of thermoplastic material through a first pouring treatment;

providing a layer of fiberglass on the poured backing layer;

providing a second rigid substrate layer of thermoplastic material on the glass fiber layer through a second pouring treatment;

consolidation of the poured layers of substrate and layer of fiberglass under the influence of pressure and/or heat;

providing on the consolidated second substrate layer a more flexible or more compressible substrate layer of thermoplastic material by applying the thermoplastic material in a liquid state.

The peculiarity of this method is that the rigid substrate layers are consolidated, and only then a more flexible substrate layer is provided on them. This allows consolidation parameters, such as pressure and/or temperature, to be adjusted optimally depending on the thermoplastic material characteristics of the rigid backing layers, which differ from the material characteristics of the more flexible backing layer, taking into account the difference in stiffness/flexibility.

The thermoplastic material of the first and/or second support layer may be provided in the form of grains or powder. Preferably this material, or at least a part thereof, is poured in the form of granules, but it may be advantageous to pour it as a dry mixture, for example in the case where the material or part thereof is to be foamed. Such a dry mixture actually guarantees the characteristics of the foaming agents added to the material, as described in patent document BE 2015/5572, in the best possible way.

The consolidation can be carried out in a pressing device, preferably a double belt pressing device. This pressing device may include a tension roller which may provide calibration of the poured material.

Preferably, the more flexible backing layer is provided on the second backing layer by means of a calendering device. The calendering device preferably contains more than two calendering rollers.

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It will be appreciated that this method may also include providing a finish and possible wear and/or varnish layers.

The above layers preferably form a continuous web of material, which is finally divided into individual parts, for example by cutting, to form floor panels.

Once divided into separate parts, the floor panels may be provided along one or more edges with connecting parts that provide a mechanical connection between two such floor panels. These connecting parts are preferably made by means of cutting tools such as milling tools.

The floor panel produced in accordance with the present invention may further have one or more floor panel characteristics in accordance with the first, second, third and/or fourth aspects mentioned.

It should be noted that the present invention is not only applicable to floor panels. It can be applied advantageously to any type of panels such as wall panels, ceiling panels or door panels.

The present invention can also be applied more generally than just to panels. It can preferably be applied to any type of floor, wall, ceiling or door elements. Examples of this are roll-up flooring elements or floor covering elements such as floor covering vinyl.

It should also be noted that each of the mentioned ranges of values includes the specified limits, unless expressly stated otherwise.

To better demonstrate the characteristics of the present invention, hereinafter, by way of non-limiting examples, certain preferred embodiments are described with reference to the accompanying drawings, in which:

fig. 1 shows a floor panel in accordance with the present invention;

fig. 2 is a cross-section along line II-II shown in FIG. 1;

fig. 3 and 4 show how the edges shown in FIG. 2;

fig. 5 illustrates on an enlarged scale the area F5 shown in FIG. 2;

fig. 6 and 7 are variations of FIGS. 2;

fig. 14 and 15 show how the floor panels can be joined according to the fold-down laying technique;

fig. 16 represents connecting parts that can be used with such floor panels;

fig. 17-19 show variations of FIGS. 16;

fig. 20 represents a method in accordance with the present invention; and figs. 21 and 22 represent options.

Fig. 1 shows a floor panel 1 in accordance with the present invention. The presented floor panel 1 contains a finish 2, which refers to a printed wood finish. This refers to an elongated rectangular floor panel 1 which has a pair of long edges 3-4 and a pair of short edges 5-6. Each pair of edges is provided with connecting parts 7-8 and 9-10, respectively.

The shape of the connecting parts 7-8 is shown in FIG. 2. This refers to a tongue and groove connection comprising a tongue 11 and a groove 12 defined by an upper shoulder 13 and a lower shoulder 14. The lower shoulder 14 projects further than the upper shoulder 13. Additionally, this connection includes locking elements 15-16 in the form protrusion 15 on the lower side of the protrusion 11 and an upwardly directed locking element 16 in the part of the lower bead 14, which protrudes further than the upper bead 13, which, by interacting the locking surfaces 17-18, counteract the movement of the protrusion 11 and groove 12 in the horizontal direction H. The upper side 19 of the protrusion 11 cooperates with the underside 20 of the upper flange 13 to resist separation in the vertical direction V.

Fig. 3 and 4 show how the connecting parts 7-8 can be connected through a pivoting movement (FIG. 3) as well as a substantially horizontal snapping movement (FIG. 4).

Fig. 2 also shows the structure of the floor panel 1. It consists of a backing 21, a finishing carrier 22 with finishing 2, a wear layer 23 and a varnish layer 24.

The substrate 21 is composed of two substrate layers 21A and 21B made of PVC.

The substrate layer 21A is rigid. To this end, no plasticizers are present in this layer 21A, or plasticizers are present in an amount of less than 15 ppm. at 100 m.h. resin. Examples of plasticizers that can be used have already been mentioned. In addition, the substrate layer 21A contains a filler in an amount of 30 to 70 mass%. Preferably chalk, talc and/or lime are used, possibly supplemented with particles of wood, bamboo and/or cork. In addition, the substrate layer 21A may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The thickness T1 of the substrate 21A is at least 2 mm. As a result, the substrate layer 21A has high flexural rigidity. This is advantageous because it reduces to some extent the risk of the floor panel 1 warping and curling edges when exposed to sunlight.

This risk is further reduced to a large extent due to the presence of 25 fiberglass fleece. Although this does not appear to be able to prevent the substrate 21 from expanding/contracting as temperatures change, it does prevent warping or pushing out. This is actually the most important thing considering that expansion/contraction can essentially be counteracted by providing suitable spaces for expansion, which is also inherently known in the field of wood laminate flooring. Fiberglass fleece 25 is disposed between backing layers 21A and 21B. In this way, it can perform its function in the best possible way. The fiberglass fleece 25 may be at least partially impregnated with thermoplastic material of the backing layers 21A and/or 21B. This provides a strong seal in the substrate 21 so that it can perform its function even better. This position of the glass fiber layer 25 ensures that it extends continuously in both connecting parts 7-8. This is advantageous for its efficiency, in particular at the respective edges 3-4 of the panel 1.

The rigid substrate layer 21A is obtained through a sprinkling process. With such a process, a very good connection with the glass fleece 25 can be obtained. In such a process, the glass fleece 25 can also have a support function. The glass fleece 25 may also form a separation between the poured layer 21A and the layer 21B if the latter is also poured. This is definitely beneficial before consolidation as it prevents the poured material from different layers from mixing with each other.

Moreover, the substrate layer 21A is non-foamed. This provides better resistance against telegraphing and indentation effects compared to foam layers. The density of layer 21A is 1300-2000 kg/m ³ .

The area in which the upper side 19 of the projection and the lower side 20 of the upper bead interact is located entirely within the rigid substrate layer 21A, just like the area in which the locking elements 15-16 interact. This ensures the creation of a strong mechanical connection in which the formation of a gap is difficult. The upper bead 13 is partially formed from layer 17A, and the lower bead 14 is even completely formed. This reduces the risk of breakage of one or both beads 13-14. In particular, this is advantageous for the lower bead 14, since this bead 14 can avoid breaking due to possible bending to which it is subjected during joining of the edges 3-4. Otherwise the connection will be lost.

The substrate layer 21B is more flexible than the layer 21A. To this end, a greater amount of plasticizers is present in this layer 21B, namely at least 15 ppm. at 100 m.h. resin. This flexible layer 21B ensures that, regardless of the relatively rigid panel 1, there will be no clicking sound when walking on the panel 1. Thus, due to its soft nature, it has sound-absorbing properties. In addition, such a layer 21B is easier to deform in order to create a deep relief on the top side of the panel 1. The filler concentration in this layer 21B is 30-70 wt%. In addition, the substrate layer 21B may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The T2 thickness of the substrate layer 21B is 0.5-1 mm.

Layers 17A and 17B are bonded to each other by thermal lamination. This results in a reduced risk of delamination compared to using glue or the like.

The trim carrier 22 on which the trim is printed refers to a PVC film or foil.

The transparent wear layer 23 refers to a PVC layer with a thickness of 250-750 μm.

The total thickness T of the floor panel 1 is from 3.5 to 6 mm.

Fig. 5 shows in more detail a varnish 24 which is provided on the wear layer 23. This is a urethane acrylate based varnish. A relief 26 provided on the top side of the panel 1 is also visible.

Fig. 6 shows connecting parts 7-8 similar to those shown in FIG. 2, however, the substrate 21 has a different structure. Layer 21A is similar to layer 21A in FIG. 2, but is more subtle. A second rigid backing layer 21C is also present in the backing 21, and is also made of PVC. The support layer 21C does not contain plasticizers, or contains plasticizers in an amount of less than 15 parts by weight. at 100 m.h. resin. The support layer 21C also contains filler in an amount of from 30 to 70 wt.%. In addition, the support layer 21C may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The total thickness T1 of the substrate layers 21A and 21C is at least 2 mm. The result is that the combination of the backing layers 21A and 21C gives a high flexural rigidity of the panel 1, which is even increased by the presence of glass fleece 25 therein. The position of the glass fleece 25 is such that it extends continuously through both connecting parts 7-8 . In addition, it is located at the height of the center line of the projection 11 and extends through the innermost point of the groove 12. Thus, additional support is provided at these positions, which is beneficial for the strength of the projection 11 and groove 12.

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The rigid layers 21A and 21C are formed by a sprinkling process, which is known per se from the patent document WO 213/179261. This has the advantage that the glass fleece 25 can be very well molded into a rigid whole, resulting in a particularly stable sandwich.

The 21C rigid layer is also non-foamed.

Fig. 7 shows connecting parts 7-8 similar to those shown in FIG. 6, however, the substrate 21 has a different structure. The substrate layers 21A and 21C have a similar structure to the layers 21A and 21C in FIG. 6. However, there is a third rigid backing layer 21D, which is also made of PVC. The substrate layer 21D does not contain plasticizers, or contains plasticizers in an amount of less than 15 ppm. at 100 m.h. resin. In addition, the substrate layer 21D contains filler in an amount of 30 to 70 mass%. In addition, the substrate layer 21D may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The total thickness T1 of the substrate layers 21A, 21C and 21D is at least 2 mm. The result is that the combination of the backing layers 21A, 21C and 21D gives a high flexural rigidity of the panel 1, which is even increased by the presence of two glass fleece layers 25A and 25B therein. These two layers of glass fleece 25A and 25B are located off-center of the panel 1 at a distance D from each other that is at least 1/5 of the thickness T of the panel 1. The backing layers 21C and 21D are thinner than the central layer 21A, but have a thickness being at least 1/5 of the thickness of the central layer 21A. The result is a particularly balanced and stable multi-layer structure. The substrate layers 21A, 21C and/or 21D may inherently comprise multiple substrate layers and thus be multilayered. The substrate layer 21A, for example, may comprise multiple substrate layers, which may have mutually different compositions, such as mutually different concentrations of filler or plasticizer. The same applies to layers 21C and 21D, and more generally to all substrate layers mentioned in this document.

The two layers 25A and 25B of glass fleece have a density of less than 65 gsm ^. This has a positive effect on process speed and virtually no negative impact on dimensional stability, at least not in the case of applications with rigid backing layers.

Fig. 8 shows the embodiment shown in FIG. 7, in which the substrate 21 on its lower side includes a sound-absorbing XPE foam substrate layer 21E. The thickness of this layer 21E is 1-2 mm.

Fig. 9 shows the embodiment shown in FIG. 7, in which the glass fleece layers 25A-25B are arranged slightly differently. The glass fleece 25A extends centrally through the area in which the top side 19 of the projection 11 interacts with the underside 20 of the top bead 13, while the glass fleece 25 extends centrally through the area in which the locking elements 1516 interact. This provides excellent horizontal and vertical retention. .

Fig. 10 shows a variant of FIG. 9. The glass fleece 25A is arranged in a similar manner, however, the glass fleece 25B extends continuously in the connecting portion 8. It extends continuously through the lower bead 14. This is advantageous for the strength of this bead 14.

Fig. 11 shows a structure of the substrate 21 similar to that shown in FIG. 10, but here the connecting parts 7-8 have a different configuration. The lower side of the protrusion 11 is convex, while the upper side of the lower bead 14 is concave.

Fig. 12 and 13 show two further embodiments in which the lower side of the projection 11 and the upper side of the lower bead 14 comprise a flat portion.

Fig. 14 and 15 show how the floor panels 1 can be connected to each other using a fold-down laying technique.

For this purpose, the short pair of edges 5-6 of the panel 1 is provided with connecting parts 9-10 shown in FIG. 16. They are implemented in the form of a downward hook 27 and an upward hook 28. The downward hook 27 has a collar 29 with a downward locking element 30, while the up hook 28 has a collar 31 with an upward locking element 32. Locking elements 30 and 32 cooperate by locking surfaces 33-34 to resist horizontal movement of hooks 27-28. Hooks 27-28 are also provided with vertically active locking elements 35-36. The vertically active locking element 35 is formed as a separate insert which is provided in a recess 37 in the downwardly directed hook 27. This recess is located partially in the rigid layers 21A and 21C. It is also possible to provide an insert 35 in the upwardly directed hook 28.

The bead 29 is formed in part from rigid layers 21A and 21C. The bead 31 is formed entirely from rigid layers 21A and 21D. the area in which the locking elements 30 and 32 interact is located entirely within the rigid layer 21a. All these measures are beneficial for the strength of the fixation. The area in which the insert 35 interacts with the locking element 36 is located in the more flexible layer 21B. However, it is possible that this zone is located at least partially or completely in the rigid layers 21A and/or 21C.

The fiberglass layer 25A is positioned at the height of the recess 37. This provides additional stability where the floor panel is weakened by the recess 37.

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Claims (2)

The glass fiber layer 25A extends continuously in the bead 31 of the upwardly directed hook 28. Fig. 17 shows a variant of FIG. 16. Here, the insert 36 is provided in a recess 37 in the upwardly directed hook 28. However, the area in which the insert 36 interacts with the locking element 35 is actually located in the rigid substrate layer, namely the rigid layer 21A. This provides very good vertical support. Fig. 18 shows one embodiment of FIG. 16 and 17, in which the vertically active locking elements are implemented from the material of the panel 1. There are even two pairs of vertically active locking elements, namely locking elements 35-36, as well as locking surfaces 3334, which provide both horizontal and vertical locking. All vertical fixing elements are made from rigid layers 21A and 21C. In addition, the glass fleece is located at the height of the zone in which the fixing elements 35-36 interact. The glass fleece 25B passes continuously through the bead 31. This ensures that the bead 31 is very stable and the risk of damage, for example when the bead 31 is elastically flexed during joining, is very small, despite the recess provided on the underside of the bead. 31, which increases the bendability of the bead 31 and thus the ease of installation. Fig. 19 shows one embodiment of FIG. 18, in which vertically active locking elements 35-36 are located at the end of the bead 31. Glass fleece 25B extends through the entire bead. Fig. 20 represents a method in accordance with the fifth aspect of the present invention. This method can be used to obtain the structure of the panel substrate 1 shown, for example, in FIG. 7. By sprinkling, rigid substrate layers 21D, 21A and 21C are sequentially provided. Their rigid thermoplastic material is deposited onto the conveyor belt 39 by means of depositing devices 38. Glass fleece 25B and glass fleece 25A are provided on these deposited layers 21D and 21A, respectively. To this end, glass fleece 25A and 25B is unwinded from rollers 40 and provided on respective backing layers 21D and 21A. The formed complex is then transported to a two-belt press 41 where it is consolidated under pressure and/or heat. The pressing device 41 contains, in the direction of movement, thermocouples 42, tension roller 43 and cooling elements 44. Heating elements 42 heat the complex entering the pressing device 41, resulting in easier and better bonding of the individual layers to each other. The use of tension roller 43 is advantageous because it ensures the calibration of the respective layers. Cooling elements 44 finally cool the consolidated complex so that it can be processed more quickly. Thereafter, a more flexible substrate layer 21B is provided on this consolidated assembly by means of a calendering device 45, which consists of more than one calendering roller 46. It will be appreciated that a finishing carrier 22 with a finishing 2, a wear layer 23 and a varnish layer 24 may be applied in subsequent steps. Fig. 21 shows a variant of FIG. 20. Here, the glass fleece 25 is brought into contact with the press member in the press device 43. This is different from FIG. 20, where each glass fleece is sandwiched between rigid backing layers. Fig. 22 shows another alternative method of providing glass fleece 25 on a rigid backing layer. The reference numeral 47 indicates an extrusion device with which the rigid substrate layer 21A is produced. This substrate layer 21 is then transported between the guide rollers 48. The glass fleece 25 is unwinded from the roll 49, and after passing between the two guide rollers is placed on the substrate layer 21A. Obviously, the resulting complex can be further processed, and possibly supplemented with subsequent layers of support and/or glass fleece. It should also be noted that this technique can be advantageously applied to any type of thermoplastic material backing layer, whether it is a rigid, semi-rigid or flexible backing layer. The present invention is in no way limited to the embodiments described above herein; on the contrary, such methods, floor panels and carrier material can be implemented in accordance with various embodiments without departing from the scope of the present invention. CLAIM 1. A floor panel comprising a backing and a trim, wherein the backing comprises a rigid backing layer of thermoplastic material, wherein the rigid backing layer of thermoplastic material does not have a density reduction of more than 10% due to foaming compared to the thermoplastic material in an unfoamed state, wherein the rigid thermoplastic material the backing layer comprises a filler, wherein the backing layer includes a backing layer that is more flexible or compressible than the rigid backing layer, wherein the backing layer that is more flexible or compressible than the rigid backing layer is located between the rigid backing layer and the trim. 2. Floor panel according to claim 1, in which the filler is selected from the group of inorganic filler- -