Source: https://patents.google.com/patent/BE1024734B1/en
Timestamp: 2019-12-14 13:39:51
Document Index: 757798095

Matched Legal Cases: ['art 44', 'art 45', 'art 44', 'art 45', 'art 44', 'art 45', 'art 25', 'art 45', 'art 44', 'art 44', 'art 45', 'art 44', 'art 45', 'art 45', 'art 44', 'art 25', 'art 44']

BE1024734B1 - Floor panel and method for manufacturing a floor panel - Google Patents
BE1024734A1 (en
2018-06-11 Publication of BE1024734A1 publication Critical patent/BE1024734A1/en
2018-06-19 Publication of BE1024734B1 publication Critical patent/BE1024734B1/en
Floor panel (1) with a substrate (2) and a decoration (3) applied to it, characterized in that the substrate (2) comprises at least one foamed layer (4) of thermoplastic material and at least one reinforcement layer (8). The invention further relates to a method for manufacturing such floor panels (1).
More specifically, the invention relates to a floor panel with a substrate and a decoration applied to it. Such floor panels are well known per se, for example in the form of MDF or HDF panels with a printed decoration, such as the laminate panels of WO 97/47834, in the form of vinyl panels, such as in WO 2013/026559, or in the form of so-called WPG (Wood Plastic Composite) panels with a vinyl top layer, such as in WO 2014/065953.
In the case of WO 2013/026559, these are water-resistant floor panels with a substrate of soft or flexible polyvinyl chloride or PVC. Moreover, the decoration and the finishing layer made from PVC offer a pleasant walking comfort without pronounced ticking noise, as can be the case with laminate panels. However, there is a risk of telegraphic effects with floor panels from WO'559. Irregularities in the substrate hereby become visible on the surface of the floor covering over time, which is unattractive. In addition, such a floor panel is relatively difficult to install, because it is easily bent or deformed because of the flexibility of the carrier. The soft substrate is sensitive to dimensional changes in temperature fluctuations. Problems can arise with local heating of the floor covering, for example with direct sunlight coming in at a window. Expansion of the elements can take place at these locations. The limited rigidity of the floor panels ensures that the floor covering can curl locally. The possible coupling means, such as a locking tongue and groove, have only a limited strength. The soft finishing layer is scratch and stain sensitive, even when a superficial UV-cured lacquer layer is applied above the PVC finishing layer. Such a superficial lacquer layer has limited effectiveness, since it may have already ended in the first years of use.
WO 2013/026559 offers to some extent a solution to the problems with the dimensional stability of a substrate of soft PVC. By using a reinforcement layer soaked in PVC, more particularly a fiberglass mat soaked in soft PVC with a weight of 65 grams per square meter, an improved interaction between the substrate and the glass fiber layer is obtained, and a limited improvement of the dimensional stability in temperature fluctuations .
In the case of WO 2014/006593 it concerns floor panels with a substrate from an extruded plastic composite with a veneer layer, for example a vinyl top layer, as a decoration. The plastic composite can for instance be obtained from high density polyethylene (HDPE) or PVC on the one hand and bamboo, wood and / or cork dust on the other hand. The substrate is stiff and provides a reduced risk of the aforementioned telegraphic effects. In addition, any coupling parts can be provided in this stronger substrate. Such extruded substrates, however, tend to deform or curve and the dimensional stability is of the same level as the vinyl panels from the aforementioned WO 559.
The present invention aims in the first place at an alternative floor panel, wherein according to the preferred embodiments a solution is offered for one or more problems with the floor panels from the prior art.
To this end, according to a first independent aspect thereof, the invention relates to a floor panel with a substrate and a decoration arranged thereon, characterized in that the substrate comprises at least one foamed layer of thermoplastic material and at least one reinforcement layer. The inventor has determined that a foamed layer has better dimensional stability than a non-foamed layer of the same thermoplastic material. Moreover, a reinforcement layer with a foamed layer has a more effective result for limiting possible dimensional expansions in the event of temperature fluctuations.
It is noted that, within the scope of the present invention, "substrate" refers to all parts of the floor panel that are below the aforementioned decoration. By a foamed layer is meant a layer containing cavities, preferably in an amount that the density of the material is reduced by at least 10%, and preferably even at least 25%. Preferably the so-called "closed cell" foam. By non-foamed layer is meant a layer without cavities, or at least with a share of cavities such that the density of the material does not, or not more than 10%, decrease, and preferably not even more than 2% .
It is generally noted that, within the scope of the invention, a foamed layer does not necessarily have to be foamed in a uniform manner. It is possible that through its thickness the foamed layer comprises a varying proportion of cavities. For example, the highest proportion can be achieved centrally in the layer, while fewer foamed or even non-foamed zones may be present on one or more of the surfaces of such a layer.
The foamed layer in question is preferably positioned centrally in the substrate, or, in other words, forms at least one substrate portion present in the center of the thickness of the substrate.
The foamed layer in question preferably forms at least 30 percent of the thickness of the aforementioned substrate. It preferably even forms 40 percent or more of the thickness of the substrate.
It is clear that it is not excluded that several foamed layers would be present in the aforementioned substrate. The total thickness of the foamed layers is preferably between 30 and 70 percent of the thickness of the floor panel, or between 25 and 65 percent of the thickness of the substrate.
Preferably, said foamed layer relates to a foamed polyvinyl chloride (PYC) layer. It is preferably so-called rigid PVC, namely PVC that is free from plasticizers, or contains a plasticizer content of 12phr or less. The softener content is preferably between 1 and 6 phr. The rigidity of a layer of such rigid foam is comparable to that of a non-foamed layer, but because of its lower weight offers ergonomic advantages during installation. It goes without saying that the invention is not limited to foamed layers of PVC, but is equally well applied in floor panels where the foamed layer is formed from another thermoplastic material, such as from a phenolic foam, polyurethane foam, polypropylene foam, polyethylene foam or polyethylene terephthalate foam.
Preferably the foamed layer comprises filler materials, such as lime or talc. The inventor has established that talc also gives rise to increased dimensional stability. Preferably at least 30 phr mineral fillers are used in the aforementioned foamed layer.
The foamed layer can be obtained in various possible ways, the three main options of which are listed below.
According to a first possibility, the foamed layer is obtained at least by means of a mechanical foaming process. This means that cavities are formed in the relevant layer by pushing the thermoplastic material away by means of a foreign substance. For example, it may involve the use of expanding beads in a PVC-based layer. More specifically, use can be made of the microspheres known from WO 2013/178561. It goes without saying that a floor panel obtained at least according to this first possibility will have the property that the foamed layer contains cavities whose walls are covered by the walls of the respective expanded granules.
According to a second possibility, the foamed layer is obtained at least by means of a chemical foaming process. This means that cavities are formed in the relevant layer by means of a gaseous reaction product. For example, use can be made of azodicarbonamide. This substance releases nitrogen gas when heated, which remains in the foamed layer in the form of bubbles.
According to a third possibility, the foamed layer is obtained at least by means of fillers, wherein these fillers per se comprise one or more cavities. Here, for example, use can be made of the expanded state of the previously mentioned microspheres.
The aforementioned reinforcement layer preferably relates to a glass fiber layer, such as a woven or non-woven glass fiber layer. Preferably, the same reinforcement layer or fiber optic layer has a weight of at least 30 g / m2, and preferably less than 100 g / m2. More preferably, the weight of the reinforcement layer or glass fiber layer is between 35 and 65 grams per square meter, with 50 g / m2 being a good value.
The aforementioned reinforcement layer is preferably located on one of the surfaces of the foamed layer. At this position it can limit the risk of perforation or deformation of the relevant surface of the foamed layer, and gives rise to an increased resistance to the curvature of the relevant surface. The respective reinforcement layer is preferably located on the surface of the foamed layer which is directed towards the aforementioned decoration. In this way an increased resistance to indentation is obtained, for example by chair or table legs.
According to the most preferred embodiment, the aforementioned substrate further encloses a second reinforcement layer. The two reinforcement layers preferably enclose at least a portion of the aforementioned foamed layer and thus provide the aforementioned distortion resistance effects on both surfaces. The two reinforcement layers are preferably of the same nature, for example both glass fiber layers with a weight of between 30 and 75 grams per square meter. Contrary to his expectations, the inventor has determined that, in order to improve dimensional stability, it is more important to use two reinforcement layers than to choose the weight or strength of the individual reinforcement layers as high as possible. It is therefore possible to work with two reinforcement layers of a limited weight, which is economically advantageous. For example, it is possible to work with two fiberglass layers of 50 grams per square meter, or about 50 grams per square meter.
In general it is further noted that in case more than one reinforcement layer is present in the floor panel, the total weight of the reinforcement layers present is preferably less than 150 grams per square meter.
According to an important embodiment, the aforementioned substrate preferably further comprises at least one non-foamed layer of thermoplastic material. Such non-foamed layer is preferably located in the substrate in such a position that it is completely out of center. As mentioned, it is, preferably, the foamed layer that is positioned centrally in the substrate. The availability of a non-foamed layer in a floor panel which further comprises, according to the invention, a foamed layer and a reinforcement layer forms a barrier against telegraphic effects, and can lead to various other advantages depending on the position of this non-foamed layer.
Preferably, the aforementioned non-foamed layer connects to one of the surfaces of the aforementioned foamed layer and / or to the reinforcement layer which may be provided on that surface with the foamed layer. In the case where the surface in question faces the aforementioned decoration, additional resistance to indentation is obtained on the basis of the aforementioned non-foamed layer. Because the decoration is applied in this way on a more stable underlay, the impact resistance of the floor panel as a whole increases.
As mentioned, the non-foamed layer is preferably positioned out of the center of the substrate. In this way an increased bending stiffness of the substrate, and thus the entire floor panel, is obtained.
Preferably, the aforementioned non-foamed layer contains the same thermoplastic material as the aforementioned foamed layer, or is based on the same thermoplastic material. It can, of course, comprise a different content of additives, such as plasticizers and / or fillers.
Preferably, the aforementioned non-foamed layer is free of plasticizers, or it comprises a plasticizer content that is less than 12 phr, and more preferably less than 7 phr.
Suitable plasticizers for polyvinyl chloride include DINP, DOTP and DINCH, among others.
According to an important embodiment, the aforementioned substrate further comprises at least one second non-foamed layer of thermoplastic material, the relevant non-foamed layers enclosing at least a portion of the aforementioned foamed layer. According to this embodiment, an interesting composition of the substrate is obtained that is light and yet has a high bending stiffness. Moreover, such construction leads to a stable substrate or substrate portion. Preferably, the aforementioned substrate further comprises at least one third non-foamed layer of thermoplastic material, this third non-foamed layer being located between the decoration and at least one of the aforementioned first and second non-foamed layers. The third non-foamed layer is preferably located between the decoration and the whole of the foamed layer and the first and second non-foamed layers. The properties of the aforementioned third non-foamed layer, and more particularly its softness or compressibility, can be tailored to the desired function of this third non-foamed layer. For example, it may comprise a plasticizer content that is higher than the plasticizer content optionally present in the aforementioned first and / or second non-foamed layer. When such a layer is in a position between the decoration and the whole of the foamed layer and the first and second non-foamed layers, it can bring about a certain sound damping which increases walking comfort, and it offers production-technical advantages. For example, impressions that are applied to the surface of the floor panel can extend into this third non-foamed layer, whereby impressions can be obtained with a depth of more than 0.1 mm or even of 0.4 mm or more. In such a case, the aforementioned third non-foamed layer is preferably immediately below the aforementioned decoration, or at least still at least at a distance less than 0.15 mm below the decoration. With such impressions, the aforementioned decoration itself is also brought out of the plane, whereby very vivid imitations of, for example, wood or stone surfaces can be obtained.
In general, the aforementioned substrate preferably further comprises at least one further layer of thermoplastic material, said thermoplastic material comprising plasticizer having a content greater than the optional content of plasticizer in said foamed layer. This may concern the aforementioned third non-foamed layer. However, it is clear that such a layer is also interesting when the aforementioned first and / or second non-foamed layer are not present. Moreover, the layer with the higher plasticizer content may possibly be foamed, but not necessarily. Preferably, the aforementioned layer with the greater plasticizer content is located between the aforementioned foamed layer and the aforementioned decoration. In this way, the advantages of soundproofing and the production-technical advantages mentioned above in connection with the third non-foamed layer can also be achieved here. Preferably, the aforementioned layer with the greater plasticizer content contains the same thermoplastic material as the aforementioned foamed layer, namely, preferably, polyvinyl chloride (PVC). Preferably, the aforementioned layer with the greater plasticizer content is not foamed.
According to a most preferred embodiment, the substrate comprises a foamed layer of thermoplastic material, preferably of PVC with a plasticizer content of less than 12 phr or without plasticizer, the substrate further showing one or more non-foamed layers on both surfaces of the foamed layer , also preferably in each case from PVC with a plasticizer content of less than 12 phr, the ratio of the thickness of all non-foamed layers on one surface to the thickness of the non-foamed layers on the other surface of the foamed layer being between 0.75 and 1.33. By providing this whole of non-foamed layers below and above the foamed layer about the same thickness, or at least with a comparable thickness within the aforementioned ratio, a stable sandwich is created. Preferably, the whole of non-foamed layers on the lower surface is thinner, but within the aforementioned ratio, than the whole of non-foamed layers on the upper surface of the foamed layer. In such a case, the average plasticizer content of the non-foamed layers on the upper surface is higher than the average plasticizer content of the non-foamed layers on the lower surface. It is clear that the substrate according to the invention still encloses at least one reinforcement layer. At least two reinforcement layers are preferably used, namely preferably one in each case of the aforementioned foamed layer. These reinforcement layers then preferably each time form the separation between the foamed layer and the aforesaid healed of non-foamed layers.
The aforementioned decoration preferably comprises a printed motif. Such printed motif can be applied to a thermoplastic film, for example a PVC film. In the context of the present invention, such foil is, where appropriate, seen as part of the aforementioned decoration, and thus not as a substrate portion. Instead of a foil, it is also possible to work with a printing which is carried out on the substrate, with the intervention of primer layers, for example obtained from white PVC plastic, wherein these primer layers in the context of the present invention and, where appropriate, , therefore be seen as part of the aforementioned decoration.
The printed motif preferably relates to a pattern of wood grain and / or stone. The floor panel preferably has the motif of just one wood plank.
Although preference is given to printed motifs, it is not excluded that the decoration could be formed by, for example, real wood veneer or real stone veneer, or by a consolidated mixture of powders, for example PVC powders or PVC granulates.
Preferably, the floor panel further comprises a translucent or transparent wear layer that is applied above the aforementioned decoration. Such a wear layer preferably consists essentially of thermoplastic material, preferably PVC. Such a wear layer, however, preferably also has a superficial lacquer layer. Examples of usable lacquer layers are lacquer layers based on urethane acrylates, polyester acrylates and / or epoxide acrylates. It preferably concerns lacquer layers which are cured on the basis of UV radiation or excimer radiation. The lacquer layer in question can comprise hard particles, for example of aluminum oxide and / or silica, in order to obtain an increased wear resistance.
It is noted that the embodiments of the present invention wherein one or more layers with a layer of plasticizer content between or without the plasticizer are located between the reinforcement layer and the decoration offer particular advantages as regards the choice of the lacquer layer. A more effective lacquer layer can be chosen, while the risk of unwanted side effects remains limited. This is because more effective lacquer layers exhibit a certain shrinkage and can therefore lead to raised edges in the case that soft substrates are used. The presence of the layers without a plasticizer or with a limited plasticizer content, for example less than 12 phr or less than 7 phr close to the surface of the floor panel limits this risk. A good choice for an effective lacquer is a urethane acrylate-based lacquer with a hard particle content, such as aluminum oxide and / or silica, of more than 15% by weight, or even of 25% by weight or more. The lacquer layer can be made thicker than usual, for example with a thickness greater than 20 microns, so that it remains effective for longer. A greater thickness of the lacquer layer also makes it possible to use coarser hard particles, which in turn is advantageous for the wear resistance. Hard particles are preferably used with an average particle size of more than 10 microns.
Preferably, the floor panel, and preferably the substrate, comprises, viewed in thickness, at least 2 millimeters of thermoplastic material that is free of plasticizer, or has a plasticizer content of less than 12 phr, or more preferably, of less than 7 phr. The inventor has determined that this amount of hard thermoplastic material is sufficient to exclude the most important telegraphy effects. It is clear that, according to the invention, this thickness can be formed by foamed or non-foamed layers.
The floor panel preferably comprises, viewed in thickness, at most 5 or more preferably at most 3 millimeters of foamed thermoplastic material. The foamed layer of the invention preferably has a thickness of at most 4 millimeters, said foamed layer then, as mentioned above, preferably being present centrally in the substrate.
The aforementioned substrate preferably consists of at least 40 percent of its thickness in the aforementioned foamed layer, the remaining substrate material preferably being non-foamed. Alternatively, the substrate may have an additional foamed layer near its underside, irrespective of the thickness of the first foamed layer, which, preferably, as mentioned above, is positioned centrally in the substrate. The aforementioned additional foamed layer preferably also comprises thermoplastic material. Although it is not excluded that it consists of the same thermoplastic material as the foamed layer, it is preferably, independently of the material of the foamed layer, based on polyethylene. For example, it can be a layer of cross-linked or cross-linked polyethylene (XPE) with a thickness of 0.7 to 3 mm.
The different substrate layers can be realized in many different ways, and can be attached to each other by means of a thermal lamination process. If the substrate still has an additional foamed layer on its underside, it is preferably attached to the other substrate portions by means of an adhesive connection.
Preferably, one or more of the thermoplastic layers of the substrate has been obtained by scattering and consolidating at least the aforementioned thermoplastic material, whether or not in granulate form. Spreading operation for the manufacture of floor panels are known per se, for example from WO 2013/179261.
The floor panels of the invention can preferably be used to realize a floating floor covering. For this purpose they can be provided with profiles on one or more edges. The layer structure of the floor panels of the invention can have various synergistic effects with the concrete design of such profiles. A number of preferred features of such profiles are listed below.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means that allow two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a vertical direction perpendicular to the plane of the panels, wherein at least one of the aforementioned edges is provided with a groove, the deepest point of which is in the aforementioned foamed layer. The design of the groove at least partially in the foamed material offers advantages in terms of dimensional stability. Preferably, the aforementioned reinforcement layer extends uninterruptedly in one of the lips that defines the aforementioned groove. In case the substrate has two reinforcement layers, they preferably each extend in at least a portion of one of these lips, namely one in the upper groove lip and one in the lower groove lip. Preferably, the reinforcement layers are at least uninterrupted up to the groove opening, namely where the distal end of the shortest of the respective lips is located. According to this last possibility, a very stable vertical locking is achieved between the floor panels, and the risk of raised edges on the surface of the floor panel is minimized. It is clear that the groove in question preferably cooperates with a tooth on an opposite edge of a similar floor panel or with a separate connecting piece that also cooperates with an opposite edge of a similar floor panel. In both cases, in a coupled state of two such floor panels, preferably one or more pairs of vertically active locking surfaces arise. At least one such pair is preferably located in the aforementioned groove, namely on one or both groove lips, the aforementioned reinforcement layer or reinforcement layers then preferably extending uninterruptedly below the relevant pair of vertically active locking surfaces. Preferably, at least one of the aforementioned pairs, and more preferably, both pairs of vertically active locking surfaces are formed on the material of the aforementioned foamed layer. Use can be made of some tension on the respective contact surfaces, whereby a very stable connection is obtained. The potential tension can be prevented by a good choice of the position of the reinforcement layer or layers and the possible non-foamed layers from propagating to the surface of the floor panel.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means which enable two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a horizontal direction in the plane of the panels and perpendicular to the edges, wherein at least one of the aforementioned edges is provided with an upwardly directed hook-shaped locking portion, wherein said locking portion extends at least partially in a portion of the substrate that is free of said foamed layer. A well-defined horizontal locking is achieved on the basis of this characteristic. This is because non-foamed layers can be processed with greater accuracy.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means that allow two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a vertical direction perpendicular to the plane of the panels, wherein at least one of the aforementioned edges is provided with a groove, wherein this groove is flanked by an upper lip and a lower lip and wherein the upper surface of the lower lip is formed at least partially in the aforementioned foamed layer. It is advantageous to provide the lower lip in this material because, as mentioned above, it exhibits good dimensional stability. This feature leads to an improved mechanical coupling in which the risk of cracking between the coupled edges is limited. It is, of course, not excluded that the aforementioned upper surface of the lower lip is also at least partially formed in a portion of the substrate that is free from the aforementioned foamed layer, for example a portion of the upper surface that participates in a possible locking in horizontal direction.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means that allow two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a vertical direction perpendicular to the plane of the panels, wherein at least one of the aforementioned edges is provided with a groove, wherein this groove is flanked by an upper lip and a lower lip and wherein the lower surface of the upper lip is formed at least partially in the aforementioned foamed layer.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means that allow two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a vertical direction perpendicular to the plane of the panels, wherein at least one of the aforementioned edges is provided with a groove, wherein this groove is flanked by an upper lip and a lower lip and wherein the lower surface of the upper lip is formed at least partially in a portion of the substrate that is free from the aforementioned foamed layer.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means that allow two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a vertical direction perpendicular to the plane of the panels, as well as in a horizontal direction in the plane of the floor panels and perpendicular to the relevant edges, wherein said locking is provided in vertical direction by at least a pair of cooperating contact surfaces formed in said foamed layer, while said locking is in horizontal direction is formed by at least a pair of cooperating contact surfaces by a portion of the substrate that is free from the aforementioned foamed layer.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means that allow two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a vertical direction perpendicular to the plane of the panels, as well as in a horizontal direction in the plane of the floor panels and perpendicular to the relevant edges, wherein said locking is provided in vertical direction by two pairs of cooperating contact surfaces, a first pair being formed in said foamed layer, a second pair is formed by a portion of the substrate that is free from said foamed layer.
The floor panel of the invention is preferably characterized in that it is provided on at least two opposite edges with coupling means that allow two of such floor panels to be coupled to each other, whereby a locking is effected at the relevant edges at least in a vertical direction perpendicular to the plane of the panels, wherein at least one of the aforementioned edges is provided with a groove, wherein this groove is flanked by an upper lip and a lower lip and wherein said reinforcement layer extends in the aforementioned upper lip.
In general, it is clear that the invention is preferably applied to floor panels which are provided with mechanical coupling means on at least one pair of edges that allow two of such floor panels to be coupled to each other such that a locking occurs both in a vertical direction perpendicular to the plane of the coupled panels, as in a horizontal direction perpendicular to the coupled edge and in the plane of the panels. The coupling means preferably have one or a combination of two or more of the following properties: the property that the mechanical coupling means or coupling parts are essentially designed as a tooth and a groove bounded by an upper lip and a lower lip, said tongue and groove mainly are responsible for locking in said vertical direction, and wherein the tongue and groove are provided with additional locking parts, mainly responsible for locking in said horizontal direction. The locking parts preferably comprise a locking groove on the underside of the edge with the tooth and a hook-shaped part provided on the lower groove lip. Such coupling means and locking parts are known, for example, from WO 97/47834; the property that the mechanical coupling means or coupling parts press the coupled floor panels against each other, for example in that these mechanical coupling means are designed with so-called pre-stress, as is known per se from EP 1 026 341. The tension force with which the floor panels touch each other or towards each other pressed, for example, in combination with the above characteristic, can be obtained by means of a lower lip bent in coupled position which presses against the underside of the tooth in an attempt to spring back; - the property that the mechanical coupling means allow coupling on the basis of a horizontal, or almost horizontal, sliding movement of the panels towards each other; the property that the mechanical coupling means allow a coupling on the basis of a turning movement W along the relevant edges; the property that the mechanical coupling means permit a coupling on the basis of a downwardly directed movement of a male coupling part, for example with a tooth, into a female coupling part, for example with a groove; - the property that the mechanical coupling means, or at least the corresponding top edge, is realized on the basis of a milling operation with rotating milling tools.
The substrate of the floor panel of the invention preferably has a thickness of 4 to 8 millimeters.
For the same purpose as in the first aspect, the invention, according to an independent second aspect thereof, relates to a method for manufacturing a floor panel, said floor panel comprising at least one substrate and a decoration applied to it, the method for forming the substrate comprises at least the following steps: - the step of providing a prefabricated sheet, preferably a glass fiber layer; - the step of providing thermoplastic material; - the step of foaming the aforementioned thermoplastic material to form a foamed substrate or substrate portion, wherein the foaming takes place in the presence of the aforementioned prefabricated sheet.
Because foaming takes place in the presence of the aforementioned prefabricated sheet, various advantageous effects can be achieved depending on the nature of the prefabricated sheet and its position with respect to the foaming material.
Preferably, said step of providing thermoplastic material comprises at least one scattering operation. The spreading operation is preferably carried out with a so-called dry blend, rather than with granulates.
For foaming it is possible to work with the previously reported mechanical foaming as well as with chemical foaming.
The foaming step is preferably carried out between the press belts of a continuous press. In this way, the thickness of the obtained substrate or substrate portion can be somewhat controlled.
The step of foaming preferably also results in a consolidation of the material of the layer in question and / or the prefabricated sheet is connected to the relevant substrate or substrate part.
Preferably, at least the foaming and consolidation takes place in the same pressing operation.
As mentioned above, it is prefabricated preferably a glass fiber layer. This can be a woven or non-woven. The reinforcement layer or glass fiber layer preferably has a weight of at least 30 grams per square meter, but preferably less than 100 grams per square meter.
The prefabricated sheet can perform various possible functions in the method of the second aspect, some of which are listed below without wanting to be exhaustive.
According to a first possibility, the aforementioned prefabricated sheet forms a carrier for the relevant thermoplastic material and / or for the thermoplastic material of another substrate portion. The prefabricated sheet in this way allows a simple production, which can possibly be done in a continuous manner.
According to a second possibility, the aforementioned prefabricated sheet forms a separation between the aforementioned thermoplastic material of the foamed layer and a further layer of thermoplastic material. This embodiment is of particular importance when one or more of these layers are provided by a spreading operation or in a liquid phase. The prefabricated sheet prevents at least to some extent the mixing of the material from the layers that it separates. This is relevant for the reliable adjustment of the thickness of the substrate portions above and below the relevant prefabricated sheet, and for maintaining the possibly different compositions of the relevant substrate portions. Preferably, both the foamed layer and the aforementioned further layer are originally provided as a scattered thermoplastic material, and are consolidated together in the presence of the prefabricated sheet. As aforementioned, the composition of the thermoplastic material of the aforementioned further layer may differ from the composition of the aforementioned foamed layer.
According to a third possibility, the aforementioned prefabricated sheet relates to a reinforcement layer, which is in particular the case with a glass fiber layer.
According to a special embodiment of the method of the invention, the aforementioned prefabricated sheet is connected to the aforementioned thermoplastic material under tension. Because the sheet is under tension, various beneficial effects can be achieved in production. For example, when foaming, consolidating and / or joining, a shrinkage may occur at least in the aforementioned foamed layer. Such shrinkage leads to a compression of the prefabricated sheet, such that with a possible expansion of the substrate due to temperature fluctuations this sheet only becomes active when the compression has been canceled out. The prefabricated sheet thus only becomes active with delay and not with the first expansion. By applying a tension according to the present special embodiment, the prefabricated sheet can already become active with a smaller expansion of the substrate. Preferably, the aforementioned stress in the prefabricated sheet results in an elongation in this sheet that is at least 20% of the aforementioned shrinkage. In this way it is ensured that the prefabricated sheet is already active as a stabilizer in the obtained substrate or substrate portion upon the occurrence of stretching that amounts to 80% of the aforementioned shrinkage. The higher the tension in the sheet during production, the faster the prefabricated sheet, preferably a glass fiber layer, can become active.
Preferably, the method further comprises the step of providing at least one further substrate layer of thermoplastic material, wherein this thermoplastic material contains plasticizer with a content greater than the possible content of plasticizer in said foamed layer. Preferably, the relevant substrate layer is applied to the aforementioned already formed substrate portion with the foamed layer.
Preferably the method of the second aspect further comprises the step of providing a decoration on said substrate or substrate portion. Such a decoration can for instance comprise a printed foil.
It is clear that the method of the second aspect can be pre-eminently used for manufacturing the floor panels of the first aspect and the preferred embodiments thereof. It is therefore furthermore clear that the composition of the different substrate parts from the first aspect can correspond to the composition of the thermoplastic material from the second aspect.
Figure 1 represents a floor panel with the features of the invention;
Figure 2 represents a section on a larger scale according to the line II-II indicated in Figure 1;
Figure 3 shows on the same scale the coupled state of two such floor panels;
Figures 4 to 10 represent variants in a similar view;
Figure 11 shows on a larger scale a section following the line XI-XI indicated on Figure 1;
Figures 12 to 14 show similar variants; and
Figure 15 schematically shows a few steps in a method according to the invention.
Figure 1 shows a rectangular floor panel 1.
Figure 2 clearly shows that the floor panel 1 comprises a substrate 2 and a decoration 3 applied to it.
The substrate 2 comprises a foamed layer 4 of thermoplastic material, in this case polyvinyl chloride (PVC). This foamed layer 4 is positioned such that it is present at least centrally in the substrate 2, namely on the central line C. In this case, the thickness T1 of the foamed layer constitutes more than 40 percent of the thickness T2 of the substrate. For the rest, the substrate 2 in this case only comprises non-foamed layers 5-6-7.
The substrate 2 of the floor panel 1 from the example of figures 1 and 2 comprises a first and a second reinforcement layer 8-9, in this case glass fiber layers, more particularly glass fiber mats (non-woven). A first reinforcement layer 8 is located on the surface 10 of the foamed layer 4 facing the decoration 3 and encloses the foamed layer 4 together with the second reinforcement layer 9. The aforementioned second reinforcement layer 9 is then located on the opposite surface 11 of the foamed layer 4.
The aforementioned decoration 3 comprises a printed motif and represents a single wooden board. The printed motif is applied to a thermoplastic foil 12, namely a PVC foil. The floor panel 1 furthermore has a transparent or transparent wear layer 13 which is applied above the aforementioned decoration 3.
In the example, the aforementioned non-foamed layers 5-6-7 comprise a first non-foamed layer 5 and a second non-foamed layer 6 which in each case connect to the aforementioned surfaces 10-11 of the foamed layer 4, and, in this case, also at the reinforcement layers 8-9 present there. These first and second non-foamed layers 5-6 consist of the same thermoplastic material, namely PVC, as the foamed layer 4, but preferably contain a higher content of fillers, such as lime or talc. The floor panel of figure 2 forms an example of a substrate 2, in which the relevant non-foamed layers 5-6 enclose the foamed layer 4.
The substrate 2 from figure 2 further comprises a third non-foamed layer 7 of thermoplastic material. This third non-foamed layer 7 is located between the decoration 3 and the aforementioned first non-foamed layer 5, and contains a plasticizer content that is greater than the plasticizer content possibly present in the foamed layer 4 and / or is greater than the any plasticizer content present in the first and / or second non-foamed layer 5-6.
Preferably, the non-foamed layer 6 on the lower surface 11 of the foamed layer 4, namely the second non-foamed layer 6, is thicker than the aforementioned first foamed layer 5 on the upper surface 10 of the foamed layer 4, for example with a thickness T6 greater than 1.5 times the thickness T5 of the first non-foamed layer 5. Preferably, the sum of the thickness T5 of the first non-foamed layer 5 and the thickness T7 of the third non-foamed layer 7 is approximately equal, equal or greater than the thickness T6 of the second non-foamed layer 6, preferably at least 10 percent larger, but less than 50 percent larger. In this way the second foamed layer 6 can optimally counteract any residual stresses in the first and third foamed layer 5-7.
The substrate 2 of the floor panel 1 of Figure 4 is an example of the most preferred embodiment mentioned in the introduction, wherein the substrate 2 comprises a foamed layer 4 of thermoplastic material, preferably of PVC with a plasticizer content of less than 12 phr or without plasticizer. and wherein the substrate 2 furthermore has one or more non-foamed layers 5-6-7 on both surfaces 10-11 of the foamed layer 4, also in each case preferably from PVC with a plasticizer content of less than 12 phr. The ratio of the total thickness of all non-foamed layers 6 on one surface 11 to the thickness of the non-foamed layers 5-7 on the other surface 10 of the foamed layer 4 is between 0.75 and 1.33, namely in this case about 0.8. The whole of non-foamed layers 6 is, in this case, thinner at the lower surface 11, but within the aforementioned ratio, than the whole of non-foamed layers 5-7 on the upper surface 10 of the foamed layer 4. The average plasticizer content of the non-foamed layers 5-7 on the upper surface 10 is higher than the average plasticizer content of the non-foamed layers 6 on the lower surface 11, because the aforementioned third non-foamed layer 7 contains a higher plasticizer content than the possible plasticizer content in the first and second non-foamed layer 5-6. In the example, the aforementioned reinforcement layers 8, 9 each form the separation between the foamed layer 4 and the aforementioned set of non-foamed layers.
The floor panel 1 of the example is provided at least on the two opposite long edges 14-15 with coupling means 16 which allow two of the same floor panels 1 to be coupled to each other, wherein, as Figure 3 shows, a locking at the relevant edges 14-15 is effected both in a vertical direction V perpendicular to the plane of the panels 1, and in a horizontal direction H perpendicular to the respective edges 14-15 and in the plane of the panels 1. To this end, the panel 1 is at least one of its long edges 15 provided with a groove 17, the deepest point 18 of this groove 17 being in the aforementioned foamed layer 4. The groove 17 is, in this case, provided to co-act with a tooth 19 on the opposite edge 14, and is bounded by an upper lip 20 and a lower lip 21, the lower lip 21 extending beyond the upper lip 20 in a distal direction, or in other words beyond the groove opening 22. Figure 2 shows that the tooth 19 can be inserted into the groove 18 by means of a turning movement W around the respective edges 14-15.
The upper surface 23 of the lower lip 21 is in this case completely formed from the material of the aforementioned foamed layer 4, and the lower lip 21 is provided near its distal end 24 with a hook-shaped locking portion 25, which in this case is also completely made of material of the foamed layer 4 exists. The hook-shaped portion 25 is intended to cooperate in a coupled state with a locking groove 26 on the underside of the edge 14 provided with the aforementioned tooth 19, and establishes the aforementioned locking in the horizontal direction H. To this end, a pair of horizontally active contact surfaces 27-28 are formed between the aforementioned hook-shaped portion 25 and the locking groove 26. The contact surfaces 27-28 are formed on the material of the foamed layer 4.
In the example, the bottom surface 29 of the upper lip 20 is practically completely formed in a portion of the substrate 2 that is free from the aforementioned foamed layer 4. In coupled condition, a first pair of vertically active contact surfaces 30-31 is formed on this portion that is free of the material of the foamed layer 4. A second pair of vertically active contact surfaces 32-33 is formed on the upper surface 23 of the lower lip 21 and on the material of the foamed layer 4. In this case, the second pair of vertically active contact surfaces 32- 33 extends at least partially below the upper lip 20, namely in the actual groove 17, i.e. proximal to the groove opening 22. One of the reinforcement layers 9 extends continuously in the aforementioned lower lip 21, while the second of the aforementioned reinforcement layers 8 extends into the material of the aforementioned tooth 19. In this way, material portions protruding at the edges 14-15 are extra exposed supported. The presence of a part of a non-foamed layer 5-6-7 both in the tooth 19 and in the lower lip 21 is also advantageous here. The stability of the upper lip 20 is ensured by the non-foamed layers 5-7 present there.
The foamed layer 4, as well as the first and second non-foamed layers 5-6 are free of plasticizer or contain a plasticizer content of less than 12 phr. The third non-foamed layer 7 also contains a plasticizer content of less than 12 phr. Thus, the substrate 2 consists entirely of layers 4-5-6-7 with a plasticizer content of less than 12 phr, if plasticizer would already be present in the relevant layers 4-5-6.
The layers of the substrate 2 shown here are attached to each other by means of a thermal lamination process. The foamed layer 4 and the first and second non-foamed layers 5-6 have been obtained by scattering and consolidating thermoplastic material, whether or not in the form of granules or so-called dry-mix.
Figure 4 shows an example of a floor panel 1 according to the invention which has the same layer structure as the floor panel 1 of figures 1 to 3, with the exception of an additional foam layer 34 on the underside of the substrate. This is a foam layer 34 of cross-linked or cross-linked polyethylene (XPE) which is attached by means of glue to the other substrate parts, in particular to the non-foamed layer 6. This is a soft foam in this case.
Figure 4 further clearly shows that, in this case, the bottom surface 29 of the upper lip 20 is completely formed from the foamed layer 4, including the pair of vertically active contact surfaces 30-31 present there. In the coupled state, in this example, a space 35 is present on the underside of the tooth 19 extending at least from the tip of the tooth 19 beyond the upper lip 20. The reinforcement layers 8, 9 are located both in the upper lip 20 and in the lower lip 21 and extend continuously in it.
Both in the case of Fig. 3 and Fig. 4, the locking groove 26 extends into the upper substrate half, namely above the level C. Preferably, the substrate 2 comprises at least one reinforcement layer 8 which, as is the case here, extends uninterruptedly above the aforementioned locking groove 26, while any other of the reinforcement layers 9 is missing or removed at least at the location of the aforementioned locking groove 26.
Figure 5 gives an example with similar substrate sections as the figure 4. However, the edge profiling is carried out differently. The upper surface 23 of the lower lip 21 is formed in part both in the material of the foamed layer 4 and in the material of the underlying non-foamed layer 6. Hereby, the reinforcement layer 9 on the lower surface 11 of the foamed layer 4 is interrupted at that location of the deepest zone 36 in the aforementioned upper surface 23. Preferably, as shown here, at least at least half the thickness of the whole of non-foamed layers 6 on the lower surface 11 is retained at the location of this deepest zone 36. The horizontally active contact surfaces 27-28 are for the most part formed on the material of the foamed layer 4, but also for a part formed on the material of the underlying non-foamed layer 6. The reinforcement layer 9 is interrupted in the aforementioned lower lip 20 but intersects the aforementioned horizontally active contact surfaces 27-28.
In the example of Figure 5, the lower surface 29 of the upper lip 20 is practically completely formed in the foamed portion 4 of the substrate 2. In coupled condition, a first pair of vertically active contact surfaces 30-31 is formed on this portion. A second pair of vertically active contact surfaces 32-33 is formed on the upper surface 23 of the lower lip 20, also on the material of the foamed layer 4. In this case, the second pair of vertically active contact surfaces 32-33 is at least partially, and here even completely, below the upper lip 21, namely in the actual groove 17, or in other words proximal to the groove opening 22.
Figure 6 shows for substrate 2 a layer structure similar to that of Figures 4 and 5. In this case, above the decoration 3, a wear layer 13 is used which also comprises a superficial lacquer layer 37. Any residual stresses in the respective lacquer layer 37 hardly have any effect on the upper lip 21, since these portions of non-foamed layers have 5-7 that are free of plasticizer, or have a plasticizer content lower than 12phr, or even better lower than 7 phr. Moreover, a reinforcement layer 8 extends continuously in this upper lip 20.
It goes without saying that a superficial lacquer layer 37 can form part of the wear layer 13 of any embodiment of floor panels 1 according to the present invention.
In the case of Figure 6, the edge profiling comprises coupling means 16 with a convex underside on the tooth side 14, and a concave upper surface 23 of the lower lip 20 on the groove side 15 cooperating therewith. At the location of the horizontally active contact surfaces 27-28 there is an overlap 38 provided in the contour of the coupling means 16, such that in the coupled state a voltage is created at least on these horizontally active contact surfaces 27-28. At the vertically active contact surfaces 30-31 on the upper side of the tooth 19 and the lower side of the upper lip 20, a tension can also arise, either by a local overlap in the contour at this position, or because the aforementioned overlap 38 at the location of the horizontally active contact surfaces 27-28 creates a stress which takes effect on the vertically active contact surfaces 30-31. The latter is preferably achieved by slightly inclining the vertically active contact surfaces 30-31, as is the case here. Preferably, these vertically active contact surfaces 30-31, in such a case and globally, close an angle A in the range of 2 ° to 15 °.
It is clear that such inclination of the first pair of vertically active contact surfaces 30-31 can be applied to any floor panel 1 with the features of the invention, regardless of whether or not there is an overlap 38 in the contour of the coupling means 16 applied. Figures 1 to 9 are moreover all examples of the use of a slight inclination, namely of less than 10 °. In the example of Figure 10, a stronger inclination than 10 ° is applied, but still less than 45 °, namely about 30 ° in the example.
Furthermore, it is clear that an overlap 38 at the location of the horizontally active contact surfaces 27-28 can also be used in any floor panel 1 with the features of the present invention.
Figure 7 shows an example in which the substrate 2 is constructed in a similar way as in Figure 6, but with the exception of the additional foamed layer 34 on the underside of the substrate 2. While in Figure 6 the vertically active contact surfaces 30-31 and the horizontally active contact surfaces 27-28 are formed on the material of the foamed layer 4, in the case of Figure 7, the vertically active contact surfaces 30-31 are formed on a non-foamed layer 5 present on the upper surface 10 of the foamed layer 4. While in Figure 6, the reinforcement layer 9 in the lower lip 21 is interrupted, it extends uninterruptedly in the lower lip 21 of the embodiment of Figure 7. The overlap 38 of the contours realized on the hook-shaped portion 25 in Figure 7 is more limited than in the case of Figure 6.
Figure 8 shows an example with approximately the same substrate portions as the example of Figure 2, but wherein the third foamed layer 7 mentioned there has been omitted. The edge profiles have the same shape as those of Figure 4, but are designed here such that the upper surface 23 of the upper lip 20 is for the most part formed in the non-foamed layer 6 present on the lower surface 11 of the foam layer 4. The horizontally active contact surfaces 27-28 on the hook-shaped portion 25 are formed both in the material of the aforementioned foam layer 4 and in the material of the underlying non-foamed layer 6. The reinforcement layer 9 is interrupted in the aforementioned lower lip 21, but cuts the aforementioned horizontally active contact surfaces 27-28, in this case, approximately in the middle. Preferably, as shown here, at the location of the deepest zone 36 in the upper surface 23 of the lower lip 21, at least half the thickness of the whole of non-foamed layers 6 remains on the lower surface 11 of the foamed layer 4. saved.
Figure 9 shows an example in which the substrate 2 comprises a foamed layer 4 with a reinforcement layer 8 situated on the upper surface 10 of the foamed layer 4, and wherein the substrate 2 furthermore comprises a non-foamed layer 7A on the above-mentioned upper surface 10. In this In this case, the non-foamed layer 7A used has the composition of the third non-foamed layer 7 mentioned in the context of the preceding examples, namely a plasticizer content higher than the possible plasticizer content in the foamed layer 4. In this case, the foamed layer 4 is obtained by consolidating and foaming scattered powders of thermoplastic material, while the non-foamed layer 7A has been obtained by the liquid application or calendering of thermoplastic material on the already formed foamed layer 4. The substrate 2 has only one reinforcement layer 8, namely on the upper surface 10 of the aforementioned foamed layer 4.
The edge profiles shown in the example of Fig. 9 are for the most part formed in the foamed layer 4. In the coupled state, in this example, a space 35 is present on the underside of the tooth 19 which extends at least from the tip of the tooth 19 extends beyond the upper lip 20. The reinforcement layer 8 is located in the upper lip 20. At the upper surface 23 of the lower lip 20, but more distantly than the upper lip 21, namely beyond the groove opening 22, there are vertically active contact surfaces 32-33 . In this case, even the upper surface of the hook-shaped portion 25 forms a vertically active contact surface 39. The latter is not necessarily so.
Figure 10 shows another embodiment in which a similar construction of the substrate 2 is applied as in Figure 9, but in which the, in this case only, reinforcement layer 8 is embedded in the foamed layer 4, in this case centrally or approximately centrally, in the foamed layer 4.
In the edge profiles of Figure 10, a pair of vertically active contact surfaces 30-31 on the underside 29 of the upper lip 20 are partly formed on the aforementioned foamed layer 4, and partly on the aforementioned non-foamed layer 6. In the coupled state in this example, a space 35A is provided on the underside of the tooth 19 extending from the tip of the tooth 19 to a position below the upper lip 21. On the upper surface 23 of the lower lip 21 there is a pair of vertically active contact surfaces 32-33 is formed which extends from the actual groove 17 to beyond the upper lip 20. A space 40 is provided between this pair of vertically active contact surfaces 32-33 and the horizontally active contact surfaces 27-28 formed on the hook-shaped portion 25.
Figure 10 furthermore shows that deep impressions 41 can be formed on the surface of the floor panel 1. In this case it concerns at least impressions 41 with a depth D of approximately 0.4 mm to form a chamfer. Figure 10 clearly shows that the non-foamed layer 7A absorbs a portion of the indentation 41, because in this case a non-foamed layer 7A with a softener content greater than the foamed layer 4 has been chosen. The decoration 3 present follows the impression. 41.
In connection with the contour flaps 38 shown in Figs. 6 and 7, it is again noted that similar contour flaps are of course possible in all embodiments. In the coupled state of two such floor panels, such contour flaps 38 can give rise to the presence of a bent lower lip 21, as stated in the introduction, or to a material compression at least at the location of the horizontally active contact surfaces 27-28.
In all examples, the depth G of the groove 17 is less than the thickness T1 of the foamed layer 4. Such profiling is preferred in view of stability of the coupling and, in particular, of the upper lip 20, but is not necessary . This is particularly important when working with a superficial lacquer layer 37 as part of the wear layer 13.
As previously mentioned, in all examples, the vertically active contact surfaces 30-31 on the top of the tooth 19 and the bottom surface 29 of the upper lip 20 are inclined. In the case of figures 1 to 9 rather limited, namely with an angle between 2 ° and 15 °, or even between 2 and 7 ° in the cases of figures 1 to 8. In the case of figure 10, an inclination is applied which is greater than 15 °, namely, in this case, approximately 30 °.
In all examples, the lower lip 21 of the groove 17 extends beyond the upper lip 20 over a distance E which is at least twice the thickness T1 of the foamed layer A. Although the lower lip 21 does not necessarily have to protrude, and coupling means 16 can also be used with a shorter or equally long lower lip, such as, for example, the coupling means from WO 97/47834 or WO 01/98603, a projecting lower lip 21 is preferred. The degree of projection of the lower lip, or the distance E, is preferably at least once the thickness T1 of the foamed layer 4, and more preferably at least twice the thickness T1 of the foamed layer 4. The degree of projection is preferably less than one and a half times the total thickness T of the floor panel 1, and preferably more than half the thickness T of the floor panel 1, as is the case here in all examples.
Although in the figures a chamfer is always shown in the form of a chamfer on the upper edge of the floor panels 1, this is not necessary in the context of the invention. The respective top edges can also be made without chamfer or with another type of chamfer. According to a special embodiment, it is possible to work with a chamfer carried out through the aforementioned decoration 3 into the underlying substrate portion. The relevant substrate part can then optionally be provided with a matching or possibly contrasting uniform coloring, or the surface of the chamfer can be provided with a separate decorative coating, for example a lacquer layer or a print. For examples of such chamfers, reference is made to WO 2012/004701.
Figure 11 shows the short edges 42-43 of the floor panel 1 of Figures 1 to 3. Hereby an edge profiling with a male part 44 and a female part 45 is used which allows two of such floor panels 1 to be coupled to the relevant edges 42- 43 by means of a downward movement M of the male part 44 in the female part 45, wherein in in the coupled state a locking is effected both in a horizontal direction H and in a vertical direction V. The combination of a rotatable profile on the long edges 14-15, for example according to one of the figures 2 to 10, and a downwardly connectable profile on the short edges 44-45, for example according to one of the figures 11 to 14, leads to the emergence of a floor panel 1 which can be coupled by means of a so-called fold-down movement. Hereby the long edges 14-15 are arranged in each other with a turning movement W, whereby this turning movement W creates a downward movement M at the short edges 42-43 which applies the male part 44 present therein to the female part 45.
The example of such downwardly connectable profiling shown here is designed in one piece with the material of the floor panel 1 and comprises, for bringing about the locking, a cooperating snap hook 46 and undercut 47, as well as a hook-shaped part 25 on the lower lip 21 which , also has an undercut 47A in this case. The undercut 47A on the hook-shaped portion 25 is designed such that it forms an angle A1 with the vertical from 1 ° to 10 °, and preferably about 5 °. The locking groove 26 cooperating with the aforementioned hook-shaped portion 25 is fully positioned below the reinforcement layer 8 on the upper surface 10 of the foamed layer 4.
The aforementioned cooperating snap hook 46 and undercut 47 show vertically active contact surfaces 30-31 cooperating in the coupled state, which surfaces are partly formed in the foamed layer 4 and partly in the non-foamed layer 5 located above it. The horizontally, as well as vertically, active contact surfaces 27A-28A of the hook-shaped portion 25 are made entirely of the material of the foamed layer 4.
The upper surface 23 of the lower lip 21 consists entirely of material of the foamed layer 4. In the coupled state, the edge profiles still have vertically active contact surfaces 32-33 formed on this upper surface 23. Between these vertically active contact surfaces 32-33 and horizontally active contact surfaces 27A- 28A, a space 40 is present. The lower reinforcement layer 9 extends in one piece in the lower lip 21, and the upper reinforcement layer 8 extends in one piece over the aforementioned locking groove 26.
A recess 48 is formed on the underside of the lower lip 21 which at least partially extends below the aforementioned space 40. This provides a smoother coupling, even with the overlap 38 shown in the contours.
Figure 12 shows a variant of profiles which can be coupled together with a downward movement M, the snap hook 46 being located at the distal end 24 of the lower lip 21 of the female part 45, while the undercut 47 is provided in the male part 44. Also here, the upper surface 23 of the lower lip 21 is completely formed from the material of the foamed layer 4, and, in coupled condition, the edge profiles have vertically active contact surfaces 32-33 formed on this upper surface 23. Between these vertically active contact surfaces 32-33 and horizontally active contact surfaces 27A-28A, a space 40 is present. The lower reinforcement layer 9 extends in one piece in the lower lip 21, and the upper reinforcement layer 8 extends in one piece over the aforementioned locking groove 26.
Also in the example of Fig. 12, the hook-shaped portion 25 is formed with an undercut 47A, this undercut 47A being designed such that it forms an angle A1 with the vertical from 1 ° to 10 °, and preferably about 5 °. It goes without saying that, in both Figure 11 and Figure 12, such undercutting 47A at the location of the horizontally active contact surfaces 27A-28A on the hook-shaped portion 25 is not necessary and that contact surfaces 27-28 which are equally effective can be used are vertically inclined or less steeply inclined than the vertical, for example with an inclination comparable to that of the horizontally active contact surfaces 27-28 of Figs. 1 to 10, namely an inclination where the relevant contact surfaces 27-28 enclose an angle with the horizontal from 45 ° to 90 °.
Figure 13 shows a variant of downwardly connectable profiles, the snap hook 46 being formed by a separate insert 49, which, in this case, is arranged in the male part 44. Such individual insert 49 is preferably also formed from thermoplastic material, for example at least from PVC or ABS (acrylonitrile-butadiene-styrene), and in the coupled state preferably exhibits, as here, a vertically active contact surface 50 with the material of a non-ferrous material. foamed layer 7 of the female part 45. In this way, an accurate vertical positioning of the male part 44 in the female part 45 can be obtained. The aforementioned individual insert 49 is located, in this example, in a seat with upper walls 51 formed from non-foamed material and lower walls 52 formed from foamed material.
Figure 14 shows yet another example of sections that can be coupled downwards into each other, wherein in this example the undercut 47 is formed by a separate insert 49, which for this purpose, in this case, is arranged in the female part 45. Such individual insert 49 is preferably also formed from thermoplastic material, for example at least from PVC or ABS (acrylonitrile-butadiene-styrene), and in the coupled state preferably exhibits, as here, a vertically active contact surface 50 with the material of a foamed layer of the male part 44. The aforementioned individual insert 49 is located in a seat with upper walls 51 formed of non-foamed material and lower walls 52 formed of foamed material.
With regard to figures 13 and 14, it is further noted that it is advantageous to have non-foamed material above the seat of the individual insert 49, preferably with a plasticizer content of less than 12 phr, and more preferably of less than 7 phr. This is because in this way it is achieved that the risk of deformation of the upper surface of the floor panels 1 is minimized by force action during coupling or in the coupled condition.
It is clear that the hook-shaped part 25, or the cooperating locking groove 26 on the male part 44, in the examples of figures 11 to 14 in each case extends into the upper substrate half, thus above the level C.
It is clear that the edge profiles of Figures 11 to 14 can be designed in various alternative ways, wherein the contact surfaces present can be designed on different substrate sections, similar to the abovementioned possibilities for teeth and / or grooves mentioned above in the introduction, but with the tooth 19 is replaced by a snap hook 46, which may or may not be one piece, and the groove 17 is formed by an undercut 47, whether or not provided by a separate insert 49.
It is furthermore clear that the edge profiles from figures 2 to 10 can also be applied to the short edges 42-43, with or not the same profile on the long edges 14-15, as well as on the short edges 42- 43 is applied.
It is further noted that profiles such as those of figures 11 to 14 can of course also be used in other substrates 2 with the characteristics of the invention, for example in the substrates 2 of figures 4 to 6 and 8 to 10.
Figure 15 schematically shows a few steps in a possible method for manufacturing floor panels 1.
The method comprises the step S1 of providing a thermoplastic material 53. In this case, this step S1 is performed three times on the basis of three separate spreading operations 54A-54B-54C. The method furthermore comprises the step S2 of providing a prefabricated sheet, in this case two glass fiber mats 8-9, which are each situated between two of the aforementioned three scattered materials.
In a first spreading operation 54A, the material for a first non-foamable layer is scattered. In a second spreading operation 54B, the material for a first layer to be foamed is sprinkled. In a third spreading operation 54C, the material for a second non-foamable layer is scattered. It is clear that the composition applied via the second spreading operation 54B is at least different from that of the first and third spreading operations 54A-54C. The aforementioned glass webs 8-9 form an effective separation between these materials. In addition, they carry the scattered material together with the underlying conveyor belt 55 throughout the continuous production process.
It is clear that the spreading operations 54A-54B-54C described above can be used to obtain a substrate portion with a central foamed layer 4 which is provided on both surfaces 10-11 with a glass fiber mat 8-9 and an adjacent non-foamed layer 5-6, similar to the foamed layer 4, reinforcement layers 8-9 and a first and second non-foamed layer 5-6 from the examples of figures 2 to 8 and 11 to 14.
In a next step S3, at least the material from the second spreading operation 54B is foamed in the presence of the aforementioned glass fiber mats 8-9. This is done between the bands of a double band press 56. The double band press 56 is heated in a first section 57, and cooled in a second section 58. The resulting foam can have an impact on the heat transfer in the press, since this can act as an insulator. To avoid too great an impact on the line speed, the scattered material is preferably preheated before being treated in the press.
Following the pressing operation, on the surface of the obtained substrate portion 59, in a step S4, a further substrate layer 60 can be applied in liquid form, for example by means of a so-called calender operation 61. With reference to Figs. 2 to 7, it is further noted that this further substrate layer 60 may, for example, be the third non-foamed layer 7 mentioned there.
It is noted that, in a step not further shown here, the method can be continued with the application of a decoration 3, optionally in the form of a printed foil 12, and a wear layer 13, which may optionally comprise a lacquer layer 37.
As described in the introduction, it is possible to connect one or more of the prefabricated sheets, namely the glass fiber mats 8-9, to the thermoplastic material 53 under tension, for example by pulling them in the longitudinal direction.
The present invention is by no means limited to the embodiments described above, but such floor panels and methods can be realized in various ways without departing from the scope of the present invention.
Floor panel with a substrate (2) and a decoration (3) arranged thereon, characterized in that the substrate (2) comprises at least one foamed layer (4) of thermoplastic material and at least one reinforcement layer (8).
Floor panel according to claim 1, characterized in that said foamed layer (4) is a foamed PVC layer.
Floor panel according to claim 2, characterized in that the aforementioned PVC is free from plasticizers, or contains a plasticizer content of 12phr or less.
Floor panel according to one of the preceding claims, characterized in that the foamed layer (4) is obtained at least by means of a mechanical foaming process.
Floor panel according to one of the preceding claims, characterized in that the foamed layer (4) is obtained at least by means of a chemical foaming process.
Floor panel according to one of the preceding claims, characterized in that the aforementioned reinforcement layer (8) is a glass fiber layer with a weight of at least 30 gr / m2, and preferably less than 100 gr / m2.
Floor panel according to one of the preceding claims, characterized in that the aforementioned reinforcement layer (8) is located on one of the surfaces (10) of the foamed layer (4).
Floor panel according to one of the preceding claims, characterized in that the aforementioned substrate (2) further encloses a second reinforcement layer (9), the relevant reinforcement layers (8-9) comprising at least a part of the aforementioned foamed layer (4) Enclose.
Floor panel according to one of the preceding claims, characterized in that the aforementioned substrate (2) further comprises at least one non-foamed layer (5-6) of thermoplastic material.
Floor panel according to claim 9, characterized in that the aforementioned non-foamed layer (5-6) adjoins one of the surfaces (10-11) of the aforementioned foamed layer (4) and / or the reinforcement layer (8-9) ) which may be provided on that surface (10-11).
Floor panel according to claim 9 or 10, characterized in that the aforementioned non-foamed layer (5-6) contains the same thermoplastic material as the aforementioned foamed layer (4).
Floor panel according to one of claims 9 to 11, characterized in that the aforementioned non-foamed layer (5-6) is free of plasticizers, or comprises a plasticizer content that is less than 12phr.
Floor panel according to one of claims 9 to 12, characterized in that the aforementioned substrate (2) further comprises at least one second non-foamed layer (5-6) of thermoplastic material, the relevant non-foamed layers (5) -6) enclose at least a portion of the aforementioned foamed layer (4).
Floor panel according to claim 13, characterized in that the aforementioned substrate (2) further comprises at least one third non-foamed layer (7) of thermoplastic material, said third non-foamed layer (7) being located between the decoration ( 3) and at least one of the aforementioned first and second non-foamed layers (5-6).
Floor panel according to one of the preceding claims, characterized in that the aforementioned substrate (2) further comprises at least one further layer (7) of thermoplastic material, wherein this thermoplastic material contains plasticizer with a content greater than the possible content of plasticizer in the aforementioned foamed layer.
Floor panel according to claim 15, characterized in that said layer (7) with the greater plasticizer content is located between said foamed layer (4) and said decoration (3).
The floor panel according to claim 15 or 16, characterized in that said layer (7) with the greater plasticizer content contains the same thermoplastic material as said foamed layer (4).
The floor panel according to any of claims 15 to 17, characterized in that the said layer (7) with the greater plasticizer content is not foamed.
Floor panel according to one of the preceding claims, characterized in that the aforementioned decoration (3) comprises a dipped design.
Floor panel according to claim 19, characterized in that the aforementioned printed motif is applied to a thermoplastic foil (12).
Floor panel according to one of the preceding claims, characterized in that the floor panel (1) further comprises a translucent or transparent wear layer (13) which is arranged above the aforementioned decoration (3).
Floor panel according to claim 21, characterized in that said wear layer (13) comprises a superficial lacquer layer (37).
Floor panel according to one of the preceding claims, characterized in that the relevant floor panel (1) is provided on at least two opposite edges (14-15) with coupling means (16) that allow two of such floor panels (1) to be coupled to each other wherein a locking is effected at the relevant edges (14-15) at least in a vertical direction (V) perpendicular to the plane of the panels (1), wherein at least one of the aforementioned edges (15) is provided with a groove (17 ), the deepest point (18) of which is located in the aforementioned foamed layer (4).
Floor panel according to one of the preceding claims, characterized in that the relevant floor panel (1) is provided on at least two opposite edges (14-15) with coupling means (16) that allow two of such floor panels (1) to be coupled to each other wherein a locking is effected at the respective edges (14-15) at least in a horizontal direction (H) in the plane of the panels (1) and perpendicular to the edges (14-15), wherein at least one of the aforementioned edges ( 14-15) is provided with an upwardly directed hook-shaped locking portion (25), wherein said locking portion (25) extends at least partially in a portion of the substrate (2) that is free from said foamed layer (4).
Floor panel according to one of the preceding claims, characterized in that the relevant floor panel (1) is provided on at least two opposite edges (14-15) with coupling means (16) that allow two of such floor panels (1) to be coupled to each other wherein a locking is effected at the relevant edges (14-15) at least in a vertical direction (V) perpendicular to the plane of the panels (1), wherein at least one of the aforementioned edges (14-15) is provided with a groove (17), wherein said groove (17) is flanked by an upper lip (20) and a lower lip (21) and wherein the upper surface (23) of the lower lip (21) is formed at least partially in the aforementioned foamed layer (4) .
The floor panel according to claim 25, characterized in that said upper surface (23) of the lower lip (21) is also at least partially formed in a portion of the substrate (2) that is free from said foamed layer (4).
27. - Floor panel according to one of the preceding claims, characterized in that the relevant floor panel (1) is provided on at least two opposite edges (14-15) with coupling means (16) which allow two of such floor panels (1) to be coupled to each other wherein a locking is effected at the relevant edges (14-15) at least in a vertical direction (V) perpendicular to the plane of the panels (1), wherein at least one of the aforementioned edges (14-15) is provided with a groove (17), wherein said groove (17) is flanked by an upper lip (20) and a lower lip (21) and wherein the lower surface (29) of the upper lip (20) is formed at least partially in the aforementioned foamed layer (4).
Floor panel according to one of the preceding claims, characterized in that the floor panel (1) in question is provided on at least two opposite edges (14-15) with coupling means (16) that allow two of such floor panels (1) to be coupled to each other wherein a locking is effected at the relevant edges (14-15) at least in a vertical direction (V) perpendicular to the plane of the panels (1), wherein at least one of the aforementioned edges (14-15) is provided with a groove (17), wherein said groove (17) is flanked by an upper lip (20) and a lower lip (21) and wherein the lower surface (29) of the upper lip (20) is formed at least partially in a portion of the substrate (2) ) that is free from the aforementioned foamed layer (4).
29. - Floor panel according to one of the preceding claims, characterized in that the relevant floor panel (1) is provided on at least two opposite edges (14-15) with coupling means (16) which allow two of such floor panels (1) to be coupled to each other wherein a locking is effected at the relevant edges (14-15) at least in a vertical direction (V) perpendicular to the plane of the panels (1), as well as in a horizontal direction (H) in the plane of the floor panels (1) and perpendicular to the respective edges (14-15), wherein said locking in vertical direction (V) is provided by at least one pair of cooperating contact surfaces (30-31) formed in said foamed layer (4), while said locking provided in the horizontal direction (H) is formed by at least a pair of cooperating contact surfaces (27-28) by a portion of the substrate (2) that is free from said foamed layer (4).
Floor panel according to one of the preceding claims, characterized in that the floor panel in question is provided on at least two opposite edges (14-15) with coupling means (16) which allow two of such floor panels (1) to be coupled to each other, whereby to the concerning edges (14-15) a locking is effected at least in a vertical direction (V) perpendicular to the plane of the panels (1), as well as in a horizontal direction (H) in the plane of the floor panels (1) and perpendicularly on the respective edges (14-15), wherein said locking in vertical direction (V) is provided by two pairs of cooperating contact surfaces (30-31, 32-33), a first pair (32-33) being formed in the said foamed layer (4), while a second pair (30-31) is formed by a portion of the substrate (2) that is free from said foamed layer (4).
Floor panel according to one of the preceding claims, characterized in that the floor panel (1) in question is provided on at least two opposite edges (14-15) with coupling means (16) that allow two of such floor panels (1) to be coupled to each other wherein a locking is effected at the relevant edges (14-15) at least in a vertical direction (V) perpendicular to the plane of the panels (1), wherein at least one of the aforementioned edges (14-15) is provided with a groove (17), wherein said groove (17) is flanked by an upper lip (20) and a lower lip (21) and wherein said reinforcement layer (9) extends into said upper lip (20).
Floor panel according to one of the preceding claims, characterized in that the floor panel (1), viewed in thickness, comprises at least 2 millimeters of thermoplastic material that is free of plasticizer, or has a plasticizer content of less than 12 phr.
Floor panel according to one of the preceding claims, characterized in that the floor panel (1), when viewed in thickness, comprises at most 4 millimeters of foamed thermoplastic material.
Floor panel according to one of the preceding claims, characterized in that the said substrate (2) consists of at least 40 percent of its thickness (T2) from the aforementioned foamed layer (4), the remaining substrate material preferably being foamed.
Floor panel according to one of the preceding claims, characterized in that the relevant layers of the substrate (2) are attached to each other by means of a thermal laminating process.
Floor panel according to one of the preceding claims, characterized in that one or more of the thermoplastic layers of the substrate (2) have been obtained by scattering and consolidating at least the aforementioned thermoplastic material (53), whether or not in granulate form .
Floor panel according to one of the preceding claims, characterized in that the substrate (2) has an additional foam layer (34) on its underside.
38. - Method for manufacturing a floor panel, wherein this floor panel comprises at least one substrate (2) and a decoration (3) applied to it, wherein the method for forming the substrate (2) comprises at least the following steps: - the step (S2) providing a prefabricated sheet, preferably a glass fiber layer (8-9); - the step (S1) of providing thermoplastic material (53); - the step (S3) of foaming the thermoplastic material (53) to form a foamed substrate or substrate portion (59), wherein foaming takes place in the presence of the aforementioned prefabricated sheet (8-9).
The method according to claim 38, characterized in that said step (S1) of providing thermoplastic material comprises at least one spreading operation (54B).
Method according to claim 39, characterized in that the aforementioned prefabricated sheet (8-9) forms a support for the scattered thermoplastic material.
Method according to one of claims 39 or 40, characterized in that the aforementioned prefabricated sheet (8-9) forms a separation between the aforementioned scattered thermoplastic material and a further layer of thermoplastic material.
Method according to claim 41, characterized in that the said further layer also consists of scattered thermoplastic material.
Method according to one of claims 41 or 42, characterized in that the composition of the thermoplastic material (53) of the said further layer differs from the composition of the said foamed layer.
The method according to any of claims 38 to 43, characterized in that the aforementioned prefabricated sheet (8-9) is a reinforcement layer.
The method according to any of claims 38 to 44, characterized in that said prefabricated sheet (8-9) is connected under tension to said thermoplastic material (53).
The method according to claim 45, characterized in that when foaming, consolidating and / or joining, a shrinkage occurs at least in the aforementioned foamed layer (4), and in that the said tension in the prefabricated sheet (8-9) leads to a stretch in this sheet which is at least 20% of the aforementioned shrinkage.
A method according to any one of claims 38 to 46, characterized in that the method further comprises the step (S4) of providing at least one further substrate layer (60) of thermoplastic material, said thermoplastic material containing plasticizer having a content greater than the possible content of plasticizer in the aforementioned foamed layer.
The method according to claim 47, characterized in that said substrate layer (60) is applied to the said substrate portion (59) in liquid form.
The method according to any of claims 38 to 48, characterized in that it further comprises the step of providing a decoration (3) on said substrate or substrate portion (59).
The method according to claim 49, characterized in that said decoration (3) comprises a printed foil (12).
The method according to any of claims 38 to 50, characterized in that it is used to manufacture a floor panel (1) with the features of one of claims 1 to 37.
BE20165869A 2016-11-10 2016-11-22 Floor panel and method for manufacturing a floor panel BE1024734B1 (en)
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EA201991148A EA201991148A1 (en) 2016-11-10 2017-11-03 Floor panel and method for producing a floor panel
CONC2019/0007200A CO2019007200A2 (en) 2016-11-10 2019-07-03 Floor panel and methods for manufacturing a floor panel
BE1024734A1 BE1024734A1 (en) 2018-06-11
BE1024734B1 true BE1024734B1 (en) 2018-06-19
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BE1024723B1 (en) 2018-06-11