Source: https://patents.google.com/patent/BE1023817B1/en
Timestamp: 2019-11-20 00:49:44
Document Index: 82374186

Matched Legal Cases: ['arts 12', 'arts 12', 'arts 12', 'arts 17', 'arts 17', 'arts 11', 'arts 12']

BE1023817B1 - Floor panel for forming a floor covering, and substrate for a panel - Google Patents
Floor panel for forming a floor covering, and substrate for a panel Download PDF
BE1023817B1
BE1023817B1 BE2016/5036A BE201605036A BE1023817B1 BE 1023817 B1 BE1023817 B1 BE 1023817B1 BE 2016/5036 A BE2016/5036 A BE 2016/5036A BE 201605036 A BE201605036 A BE 201605036A BE 1023817 B1 BE1023817 B1 BE 1023817B1
BE2016/5036A
BE1023817A1 (en
2016-01-15 Application filed by Unilin Bvba filed Critical Unilin Bvba
2016-01-15 Priority to BE2016/5036A priority Critical patent/BE1023817B1/en
2017-07-31 Publication of BE1023817A1 publication Critical patent/BE1023817A1/en
2017-08-01 Publication of BE1023817B1 publication Critical patent/BE1023817B1/en
Floor panel for forming a floor covering, wherein the floor panel (1) comprises a layer-shaped substrate (6), as well as a decorative top layer (7) located above the substrate (6); and wherein the substrate (6) comprises at least one layer (8) made on the basis of a composition comprising at least one thermoplastic plastic; characterized in that the composition comprises at least one or more elastomers in addition to the thermoplastic plastic; and that said thermoplastic plastic is thermoplastic polyester.
Floor panel for forming a floor covering, and substrate for a panel.
The present invention relates to a floor panel for forming a floor covering, as well as to a substrate for a panel.
More specifically, the invention relates to a floor panel for forming a floor covering of the type wherein the floor panel comprises a layer-shaped substrate, as well as a decorative top layer located above the substrate; and wherein the substrate comprises at least one layer made on the basis of a composition comprising at least one thermoplastic plastic.
The term "layer-shaped substrate" indicates that the substrate is made up of one or more layers, more specifically material layers.
It is also noted that the decorative top layer does not necessarily have to be directly connected to the substrate.
Such type of floor panel is known from, inter alia, documents WO 01/44669, WO 2011/085306, WO 2013/179260, WO 2013/179261, WO 2014/117887 and WO 2015/011049.
Various plastics are known from the aforementioned documents, on the basis of which the substrate of the floor panel can be designed. However, many of those plastics, such as polyvinyl chloride (PVC), are criticized. After all, they may pose environmental problems. For the production of soft PVC, for example, plasticizers should be used, such as plasticizers from the phthalates group. Such plasticizers are, however, critically assessed in recent legal regulations. WO 2014/111192 discloses a substrate for floor panels that is an alternative to substrates based on PVC. The substrate is made on the basis of a thermoplastic matrix material and a cross-linked pulverulent elastomer embedded in the matrix material. The thermoplastic matrix material is a polyolefin such as polypropylene (PP) or polyethylene (PE), or an olefin copolymer such as ethylene-propylene-diene monomer (EPDM) rubber.
A disadvantage of such PP or PE-based substrates is that they can deform under the influence of, for example, sunlight or underfloor heating to such an extent that cracks or gaps can arise between such floor panels coupled to each other. Moreover, the risk of such a crack or crack formation is greater than with PVC-based substrates.
Another drawback is that with such PP or PE-based substrates it is relatively difficult to make a solid and at the same time mechanically strong floor panel with respect to, for example, PVC-based substrates.
The aforementioned WO ‘049 mentions among others polyethylene terephthalate, abbreviated PET, as plastic that can be used to manufacture the substrate of the floor panel.
A drawback of such a PET-based substrate is that the fatigue in the substrate can be considerable under the influence of load. This is especially disadvantageous in the case that coupling parts such as snap profiles are made from the material of the substrate. After all, fatigue can lead to damage or breakage of these coupling parts.
Another drawback is that such PET-based substrate can be rather brittle.
A further disadvantage is that with such a PET-based substrate there is a relatively high risk of cracking or cracking between the coupled floor panels due to deformation under the influence of, for example, sunlight or underfloor heating.
The present invention aims in the first place at an alternative floor panel of the aforementioned type, wherein according to various preferred embodiments solutions are offered for problems with floor panels from the prior art.
To this end the invention relates to a floor panel for forming a floor covering of the aforementioned type, characterized in that the composition comprises at least one or more elastomers in addition to the thermoplastic plastic; and that said thermoplastic plastic is thermoplastic polyester.
An advantage of such a composition is that the relevant substrate layer can be made very strong. It thus offers the possibility of realizing a strong floor panel substrate from which coupling parts such as click profiles can be manufactured which allow to provide a strong and sturdy locking between the floor panels.
The inventor has furthermore established that the composition not only allows the substrate layer in question to be very strongly designed, but also allows the fatigue to be reduced under the influence of load. This is because the composition can provide the relevant substrate layer with the elasticity required for this purpose. Certainly in the case that coupling parts such as click profiles are provided in the substrate layer, this is advantageous since the risk of breakage or damage thereof can be minimized.
It has also been established that the composition allows a particularly robust and tough substrate layer to be realized. After all, the composition appears to be able to compensate for the sensitivity of thermoplastic polyester to hydrolysis, as well as to be able to reduce the associated decrease in viscosity, so that a less brittle substrate layer is obtained. One or more of the aforementioned advantages are particularly well expressed if the proportion of thermoplastic polyester in the composition is between 5 wt% and 50 wt%. More preferably, this proportion is between 10 wt% and 40 wt%, and even more preferably between 15 wt% and 35 wt%.
The thermoplastic polyester can be selected from the group consisting of the following substances: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), also known as polypropylene terephthalate (PTT), polyethylene naphthalate (PEN) and combinations thereof.
The thermoplastic polyester is preferably PET, given that the aforementioned advantages can be expressed particularly well when using PET. In addition, PET offers ecological advantages as it allows recycled PET to be used in the aforementioned composition. This recycled PET can then come from, for example, PET bottles or from PET-containing floor covering products such as PET-containing carpet or PET-containing floor panels according to the present invention.
In particular, the thermoplastic polyester may be present in the composition in the form of PET flakes such as colorful PET flakes. One or more of the aforementioned advantages are particularly noticeable if the proportion of elastomer in the composition is between 1 wt% and 35 wt%. This proportion is preferably between 1 wt% and 30 wt%, more preferably between 5 wt% and 30 wt% and even more preferably between 5 wt% and 25 wt%.
At least one elastomer may be selected from the group of elastomers with a Shore hardness greater than 20 Shore A and less than 90 Shore A or more preferably from the group of elastomers with a Shore hardness greater than 40 Shore A and less than 85 Shore D. The Shore hardness is measured according to the ISO 868 standard. In particular, the one or more elastomers are all selected from the aforementioned groups.
Preferably at least one elastomer is a thermoplastic elastomer. In case the composition comprises several elastomers, these are preferably all of the thermoplastic type.
The thermoplastic elastomer can be designed according to one of the following options.
According to a first possibility, the thermoplastic elastomer is based on propylene. In a first preferred embodiment according to this first possibility, it concerns an ethylene-propylene copolymer, the propylene being in particular isotactic propylene. For example, the elastomer can be essentially composed of repeat units of isotactic propylene with random distribution of ethylene. Examples of such ethylene-propylene copolymers are the commercially available Vistamaxx propylene-based elastomers from ExxonMobil, with Vistamaxx 3020FL and Vistamaxx 6202FL being preferred. In a second preferred embodiment according to the aforementioned first possibility, the elastomer based on propylene relates to a thermoplastic polyolefm (TPE-0 or TPO) or a composition of PP and non-contaminated EPDM rubber. An example of such a thermoplastic polyolefm is Q 100 F from LyondellBasell.
According to a second possibility, the thermoplastic elastomer is based on a styrene block copolymer such as styrene-butylene-styrene (SBS) or styrene-ethylene-butylene-styrene (SEBS). In a first preferred embodiment according to this second possibility, it is a block copolymer based on styrene and ethylene / butylene or styrene and ethylene / propylene. Examples of this are the commercially available Kraton G elastomers. In particular, it is a linear tri-block copolymer based on styrene and ethylene / butylene or linear SEBS, with the Kraton G1645 M elastomer being preferred. In a second preferred embodiment according to the aforementioned second possibility, the elastomer based on a styrene block copolymer is based on a composition of SEBS or SBS on the one hand and a polyolefm such as PP or PE on the other hand. Examples of these concern the commercially available Ensoft-S elastomers, with Ensoft-S SM-300-40A and Ensoft SX-241-50A-T2-000 being preferred. The Kraton G plastics can also be used in this second preferred embodiment, with the Kraton G1645 M being preferred.
According to a third possibility, the thermoplastic elastomer is a so-called polyolefin elastomer (POE). Such an elastomer is based on an ethylene-α-olefin copolymer such as an ethylene-octene or an ethylene-butene copolymer. Examples of such elastomers are the commercially available Engage elastomers from The Dow Chemical Company, with Engage 8180 and Engage 8402 being preferred. Another example is Queo 0203 from Borealis.
Each of the above-described embodiments for the thermoplastic elastomer is particularly advantageous since the described types of elastomers can very easily be processed together with a thermoplastic polyester such as PET into the relevant substrate layer of the floor panel.
In the case that the composition comprises several elastomers, each of these elastomers is preferably designed in accordance with one of the aforementioned possibilities, wherein several of the embodiments can be combined.
There are other embodiments for the thermoplastic elastomer that can be employed. For example, the elastomer can be a thermoplastic vulcanizate (TPV or TPE-V), such as a PPV based on PP and EPDM. According to yet another possibility, the elastomer is a thermoplastic polyether block amide (PEBA). Examples of such a PEBA elastomer are the commercially available Pebax elastomers. According to yet another alternative, the elastomer is a thermoplastic copolyester (COPE), of which the commercially available Ecdel elastomers from Eastman are exemplary. Another alternative to the elastomer is a thermoplastic urethane (TPU) such as the commercially available Estollan from BASF.
According to an alternative, at least one of the elastomers can be polychloroprene or neoprene.
Although the invention does not exclude that at least one of the elastomers is of the thermosetting type, this option is not preferred because of the more difficult processability of such elastomers and their negative impact on recyclability.
Preferably at least one of the elastomers is free from maleic anhydride or not grafted with maleic anhydride. In case the composition comprises several elastomers, these are preferably all free from maleic anhydride or not grafted with maleic anhydride.
Furthermore, the composition can at least be provided with mineral fiber structures such as fibers of glass, tal and / or wollastonite. These mineral fiber structures ensure that the degree of distortion that occurs under the influence of varying temperature can be limited by, for example, incident sunlight or underfloor heating. Thus, the associated risk of crack or crack formation between the coupled floor panels can be reduced. In other words, the mineral fiber structures increase the dimensional stability of the substrate layer in question and reduce the thermal shrinkage or expansion at varying temperatures. It is furthermore noted that the one or more elastomers appear to reinforce the positive influence of the mineral fiber structures on the dimensional stability. Together with the thermoplastic polyester, they form a flexible matrix in which the fiber structures prove to thrive. It has also been established that the composition of the fiber structures can be provided without the relevant substrate layer thereby becoming too stiff or too hard. This is remarkable in view of the already relatively high stiffness or hardness of a thermoplastic polyester such as PET.
The proportion of mineral fiber structures in the composition is preferably between 5 wt% and 40 wt%, more preferably between 10 wt% and 30 wt% and even more preferably between 15 wt% and 25 wt%.
At least one filler may be added to the composition, such as chalk, limestone and / or talc. Such a filler allows on the one hand to modify the mechanical properties of the substrate and, on the other hand, it can bring economic benefits. It has also been established that the filler can be added to the composition without the substrate layer concerned thereby becoming too stiff or too hard. This is remarkable in view of the already relatively high stiffness or hardness of a thermoplastic polyester such as PET.
The proportion of filler in the composition is preferably between 10 wt% and 80 wt%, more preferably between 20 wt% and 70 wt% and even more preferably between 20 wt% and 60 wt%. In one embodiment, the proportion of filler in the composition may be between 55 wt% and 70 wt%.
Although the composition is preferably free of plasticizers, the present invention does not exclude their use. In any case, the present invention allows the content of plasticizers to be reduced to a minimum. Examples of plasticizers that may be used are DOP, DINCH, DINP, DOTP or polyisobutenes such as Oppanol B.
The composition preferably further comprises at least one compatibilizer or coupling agent. The compatibilizer or coupling agent offers the advantage that the stability of the composition can be increased. This is in particular the case if the thermoplastic polyester shows little or no affinity for one of the one or more elastomers. In this regard, it is noted that elastomers produced according to the above-described first preferred embodiment of the second embodiment, in particular block copolymers based on styrene and ethylene / butylene or styrene and ethylene / propylene such as linear tri-block copolymers based on styrene and ethylene / butylene, such show affinity. For example, the aforementioned Kraton elastomers can already exhibit affinity with the thermoplastic polyester, which particularly concerns PET. In that case, therefore, a compatibilizer need not be used, but this is not excluded.
It is further noted that in the case of the composition comprising several elastomers, several compatibilizers or coupling agents can be used. The number of compatibilizers that are used here can depend on the number of elastomers that already show affinity for the thermoplastic polyester.
A suitable compatibilizer or coupling agent can be based on glycidyl methacrylate. An example of this is a copolymer of ethylene and glycidyl methacrylate such as the commercially available Lotader AX 8840. Still another example is a terpolymer of ethylene, acrylic ester and glycidyl methacrylate such as the commercially available Lotader AX 8900.
Yet another example of a suitable compatibilizer or coupling agent is an ethylene terpolymer, whether or not in combination with glycidyl methacrylate, such as the commercially available Elvaloy PTW from Dupont.
Another suitable compatibilizer may be formed by PP grafted with maleic anhydride. The commercially available Orevac CA100, Polybond 3200, Polyram Bondyram 1001 and 1101 are examples of this.
The proportion of compatibilizer or coupling agent in the composition is preferably less than 10 wt%, more preferably less than 5 wt% and even more preferably less than 2.5 wt%.
The composition may further comprise at least so-called melt enhancers, the proportion of which in the composition is preferably less than 5 wt%, more preferably less than 2.5 wt% and even more preferably less than 1 wt%. The melt enhancers contribute to the robustness and toughness of the substrate layer in question. After all, they reduce the viscosity drop of the thermoplastic polyester that can be caused by its hydrolysis.
In addition to the components or components already mentioned above, the composition can also comprise at least one thermoplastic plastic other than a thermoplastic polyester. The fact that the composition also comprises a thermoplastic plastic other than thermoplastic polyester, hereinafter referred to as "additional thermoplastic plastic", has the advantage that an additional freedom is created for modifying the properties of the substrate layer.
The additional thermoplastic plastic preferably relates to PP. This offers the advantage that the stiffness of the relevant substrate layer can still be reduced, so that the degree of fatigue can be limited under the influence of load. Certainly in the case that coupling parts such as click profiles are provided in the substrate layer, this is advantageous since the risk of breakage or damage thereof can still be minimized. Moreover, by using PP as an additional thermoplastic plastic, the robustness and toughness of the relevant substrate layer can be further increased.
Although isotactic polypropylene is preferably used as an additional thermoplastic plastic, the invention does not exclude the use of atactic polypropylene. The use of atactic polypropylene can, after all, help to achieve a higher filler content.
In another possibility, the additional thermoplastic plastic relates to polystyrene or a combination of PP and polystyrene.
It is further noted that the most advantageous values for at least the proportion of thermoplastic polyester, elastomer and any filler present in the composition depend on the type of elastomer used as described below.
In the first embodiment of the elastomer described above, the composition preferably satisfies one or more of the following characteristics: the proportion of thermoplastic polyester in the composition is between 20 wt% and 30 wt%; the proportion of elastomer in the composition is between 5 wt% and 15 wt%; and / or - the proportion of filler in the composition is between 40 wt% and 50 wt%.
In the second embodiment of the elastomer described above, the composition preferably satisfies one or more of the following characteristics: the proportion of thermoplastic polyester in the composition is between 15 wt% and 25 wt%; the proportion of elastomer in the composition is between 5 wt% and 15 wt%; and / or - the proportion of filler in the composition is between 45 wt% and 55 wt%.
In the third embodiment of the elastomer described above, the composition preferably satisfies one or more of the following characteristics: the proportion of thermoplastic polyester in the composition is between 25 wt% and 35 wt%; - the proportion of elastomer in the composition is between 15 wt% and 25 wt%; and / or - the proportion of filler in the composition is between 25 wt% and 35 wt%.
The relevant substrate layer may still be foamed. The advantage of this is that the density of the substrate layer can be reduced. This way, savings on raw materials and energy can be achieved. The substrate layer can also be assigned new properties such as in terms of comfort and dimensional stability.
To this end, the composition may comprise a blowing agent. The blowing agent can, according to a first possibility, be a chemical blowing agent such as azoisobutyronitrile or azodicarbonamide. In a second possibility, the blowing agent is an expandable microsphere. Examples of such expandable microspheres are the commercially available Expancel expandable microspheres. According to a third possibility, the blowing agent relates to a physical blowing agent.
It is further noted that several of the blowing agents described above can be combined.
In order to reduce the density of the substrate layer or for economic benefits, the composition may further comprise at least one density-reducing filler such as perlite, vermiculite and / or silicate. The filler relates in particular to an expanded, foamed, porous or hollow filler. In the case of such an expanded filler, reference is made here to a filler that has already been expanded before it is added to the composition. In particular, the expanded filler relates to an already expanded microsphere such as the commercially available already expanded Expancel microspheres.
The layer-shaped substrate can be provided with a reinforcement layer such as a glass fiber cloth or a glass fiber, which may or may not be present in the relevant substrate layer. The reinforcement layer can increase the dimensional stability of the floor panel and thus reduce the thermal shrinkage or expansion at varying temperatures, which limits the risk of cracking or cracking with coupled floor panels.
The thickness of the floor panel is preferably substantially, that is to say half or more, formed by the layer-shaped substrate. More specifically, the layer-shaped substrate forms a support for the decorative top layer above it.
The thickness of the layer-shaped substrate is preferably between 1 and 6 mm and more preferably between 2 and 5 mm. This allows the floor panel to be made sufficiently thin, while still showing sufficient strength and stability.
It is further noted that the respective substrate layer can be manufactured according to different possibilities. For example, the substrate layer can be produced by scattering, extrusion, injection molding, calendering and / or coating techniques.
The layer-shaped substrate can be made up of several layers. In that case, at least one of the layers is based on the composition described above. The one or more other layers can be made on the basis of a composition as described above, which, although not necessarily identical to the composition of the at least one layer. However, it is possible that the one or more other layers are designed differently and not on the basis of a composition as described above.
The top layer comprises at least one decor, as well as preferably a transparent or translucent wear layer located above the decor.
The decor of the top layer preferably comprises a motif or pattern that is applied to a carrier sheet in the form of a print. The decor may, for example, exhibit a wood motif or pattern, a stone motif, a ceramic motif, or the like. The carrier sheet may be a resin-impregnated paper sheet or a plastic film. An example of a resin-coated paper sheet is a melamine-impregnated paper sheet. Examples of plastic films are polyvinyl chloride films, polyurethane films, polypropylene films, polyethylene terephthalate films and polyethylene films. Such printed carrier sheet is preferably connected to the substrate or another layer of the top layer via a thermal laminating process. The printed carrier sheet may or may not be connected together with one or more other layers of the top layer to the substrate.
According to an alternative but also preferred embodiment, the decor is a so-called "direct print" or "Direktdruck". The decor is applied directly to an underlying layer of the floor panel or to a primer or primer provided on this underlying layer. The underlying layer can relate to the substrate, but also to another layer of the top layer. With such a direct print, a printer can be used which is preferably a digital printer such as a digital inkjet printer.
According to yet another alternative, the decor relates to a print applied to the underside of the wear layer.
According to a first possibility, the wear layer relates to a paper sheet soaked in resin. An example of such a paper sheet is a melamine impregnated paper sheet. The paper sheet is preferably provided with hard particles such as corundum particles. Such particles increase the wear resistance of the floor panel. The paper sheet soaked in resin may or may not be applied to the substrate or other layer of the top layer together with the aforementioned printed paper sheet, for example by means of a thermal laminating process.
According to a second possibility, the wear layer relates to a plastic-based wear layer which is applied either as a film, whether or not together with the aforementioned printed film, for example by means of a thermal laminating process, or is applied in liquid form and subsequently applied to the substrate or another layer of the top layer has cured. If the wear layer comprises a film, it is preferably a thermoplastic film, in particular a polyvinyl chloride film, a polyurethane film, a polypropylene film, a polyethylene terephthalate film or a polyethylene film.
The top layer may comprise a back layer which comprises at least one thermoplastic plastic. The backing layer may be bonded to the substrate under the influence of pressure and temperature, whether or not together with the aforementioned printed carrier sheet and / or the wear layer, or may be applied in liquid or pasty form by calendering or otherwise applying it on the substrate.
The backing layer is preferably designed on the basis of a flexible thermoplastic. Such a flexible backing layer has the advantage that the flexibility of the floor panels can be increased. Such flexibility can contribute to the ease of installation of the floor panels, as well as, for example, to a reduction in the noise production of the floor panels, for example when stepping over the floor panels.
The top layer can be finished with a lacquer layer, which is applied as a liquid layer on the aforementioned wear layer and / or the aforementioned decor and is subsequently cured. It is preferably a lacquer layer that can be cured by UV light or excimer radiation or a layer that can be cured by raising the temperature. This latter layer can, for example, use blocked isocyanates as a crosslinker. Preferably a lacquer layer is applied on top of the optional wear layer, but according to an alternative the lacquer layer can function as a wear layer.
The top layer can still be provided with indentations that may or may not be in register with the decor. For this purpose a roller can be used as described per se in PCT / IB2015 / 055826. The impressions provide the floor panels with a relief such that they can better simulate a natural structure such as a wood structure. The impressions can for instance be made according to a wood grain pattern.
In addition to the substrate and the top layer, the floor panel can also comprise a counter layer which is located below the substrate, but does not have to connect directly to this. The counter layer can for instance be made on the basis of cork or on the basis of a thermoplastic plastic, which is preferably flexible. Such a rather soft counter layer can assign new properties to the floor panel, for example in terms of comfort and sound absorption. In particular, such a counter layer forms a layer with acoustic properties. The counter layer can, for example, contribute to the reduction of the sound production of the floor panel, for example when walking across the floor panel.
The floor panel is preferably provided with mechanical coupling means or coupling parts on at least two opposite edges, which allow two of such floor panels to be coupled to each other. The coupling means or coupling parts can in this case effect a locking in a direction perpendicular to the plane of the coupled floor panels or in a direction perpendicular to the coupled edges and in the plane of the coupled floor panels. The coupling means or coupling parts preferably effect a locking in both aforementioned directions.
The coupling means or coupling parts preferably have one or a combination of the following characteristics: - the characteristic 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 being mainly responsible for locking in the aforementioned direction perpendicular to the plane of the coupled floor panels, and wherein the tongue and groove are provided with additional locking parts, mainly responsible for locking in said direction perpendicular to the coupled edges and in the plane of the coupled floor panels . The locking members preferably comprise a protrusion on the underside of the tooth and a recess in the lower lip of the groove. Such coupling means and locking parts are known, for example, from WO 97/47834; - the characteristic 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 characteristic that the mechanical coupling means or coupling parts allow coupling on the basis of a horizontal, or almost horizontal, sliding movement of the panels towards each other; - the feature that the mechanical coupling means or coupling parts allow coupling on the basis of a rolling movement along the relevant edges; - the characteristic that the mechanical coupling means or coupling parts allow 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, preferably around such floor panels according to the so-called " install fold-down principle, as known from WO 01/75247; the feature that the mechanical coupling means or coupling parts, or at least the associated upper edge, is realized on the basis of a milling operation with rotating milling tools; and / or - the characteristic that the mechanical coupling means or coupling parts make use of a separate locking element or an insert, as described per se in, inter alia, the documents WO 2006/043893 A1, WO 2008/068245 A1 and WO 2009/066153 A2.
The aforementioned coupling means or coupling parts, or at least at least a part of these coupling means or coupling parts, are preferably arranged in the material of the substrate, more particularly in the material of the substrate layer made on the basis of the above-described composition. The substrate layer has excellent properties for this purpose, such as in terms of mechanical strength and flexibility. The coupling means or coupling parts can be provided by means of milling operations with rotating milling tools.
The floor panel is preferably an elongated rectangular or a square floor panel which is provided on its two pairs of opposite edges with coupling means or coupling parts as described above.
However, it is not excluded that the floor panel is free of coupling means or coupling parts at its edges, wherein the floor panel is then intended to be glued or installed separately with its underside against a surface.
It is further noted that the present invention also relates to a substrate for a panel, more particularly a floor panel, wherein the substrate is layer-shaped, and comprises at least one layer which is designed on the basis of a composition comprising at least one thermoplastic plastic, with characterized in that the composition comprises at least one or more elastomers in addition to the thermoplastic plastic; and that said thermoplastic plastic is thermoplastic polyester. The substrate and the composition can further be embodied as already described above.
It is further noted that each of the aforementioned value intervals includes the aforementioned limits, unless explicitly stated otherwise.
With the insight to better demonstrate the characteristics of the invention, a few preferred embodiments are described below as an example without any limiting character, with reference to the accompanying drawings, in which: figure 1 shows a top view of a floor panel according to the invention; and - figure 2 represents a cross-section according to the line II-II in figure 1.
Figure 1 shows a floor panel 1 according to the present invention in top view. The floor panel 1 here is elongated and rectangular. It includes a pair of long sides 2-3 and a pair of short sides 4-5.
Figure 2 shows a cross-section according to line II-II in Figure 1. It is clear from the cross-section that the floor panel 1 is composed of a layer-shaped substrate 6 and a decorative top layer 7 located above the substrate 6.
In the example, the substrate 6 comprises one layer 8 which is designed on the basis of a composition as described above. The composition here more particularly comprises PET, a thermoplastic elastomer, a compatibilizer or coupling agent, glass fibers, calcium carbonate and melt enhancers. Three practical examples of such a composition are described below. EXAMPLE 1
The PET is present in the form of PET flakes, the proportion of which in the composition is 25 wt%. The elastomer is designed in accordance with the first embodiment described above. It is therefore a thermoplastic elastomer based on propylene and more particularly concerns an ethylene-propylene copolymer, in particular Vistamaxx 6202FL. This elastomer is present in a share of 8 wt%. The compatibilizer or coupling agent is a terpolymer of ethylene, acrylic ester and glycidyl methacrylate, namely Lotader AX8900, which is present in the composition in a 1.8 wt% proportion. Furthermore, the glass fibers, the calcium carbonate and the melt enhancers are present in a proportion of 20 wt%, 45 wt% and 0.2 wt%, respectively. EXAMPLE 2
The PET is present in a share in the composition of 20 wt%. The elastomer is designed in accordance with the second embodiment described above. It is therefore a thermoplastic elastomer based on a styrene block copolymer and is more specifically carried out on the basis of a composition of a SEBS block copolymer and a polyolefm such as PP, in particular Ensoft SX-241-50A-T2-000. This elastomer is present in a share of 8 wt%. The compatibilizer is a copolymer of ethylene and glycidyl methacrylate, namely Lotader AX8840, which is present in the composition in a share of 1.8 wt%. Furthermore, the glass fibers, the calcium carbonate and the melt enhancers are present in a proportion of 20 wt%, 50 wt% and 0.2 wt%, respectively. EXAMPLE 3
The PET is present in a share in the composition of 30 wt%. The elastomer is designed in accordance with the third embodiment described above and thus relates to a polyolefin elastomer. More specifically, it is an ethylene-octene copolymer, in particular Engage 8180. This elastomer is present in a proportion of 18 wt%. The compatibilizer is Sukano TA52-10 MB02, which is present in the composition in a share of 1.8 wt%. Furthermore, the glass fibers, the calcium carbonate and the melt enhancers are present in a proportion of 20 wt%, 30 wt% and 0.2 wt%, respectively.
The substrate 6 here has a thickness T which makes up more than half the total thickness T1 of the floor panel 1.
In the example, the decorative top layer 7 comprises a decor 9, as well as a transparent or translucent wear layer 10 located above the decor 9. Here, the decor 9 and the wear layer 10 can be designed as described above. The decor comprises, as schematically shown in Figure 1, a wood pattern 11.
It is to be noted that, for the sake of clarity, the decorative top layer 7 is shown here larger than in reality.
The floor panel 1 is here provided with mechanical coupling parts 12 on at least the sides 2-3. The coupling parts 12 allow two of such floor panels 1 to be coupled to each other such that a locking occurs in both a direction V perpendicular to the plane of the coupled floor panels 1 as in a direction H perpendicular to the coupled sides 2-3 and in the plane of the coupled floor panels 1.
The coupling parts 12 shown are essentially designed as a tooth 13 and a groove 14 which are responsible for locking in the direction V. The groove 14 is herein provided with an upper lip 15 and a lower lip 16 extending beyond the distal end of the upper lip 15 protrudes.
The tooth 13 and the groove 14 are also provided with locking parts 17-18 which are responsible for locking in the direction H. In the example, the locking parts 17-18 consist of a protrusion 17 on the underside of the tooth 13 and one in the coupled state cooperating recess 18 in the lower lip 16 of the groove 14.
In the example shown, the coupling parts 11-12 are substantially realized in the substrate layer 8. This can be done on the basis of milling operations, for example with rotating milling tools.
The contour of the side 2 shown in dotted line makes it clear that the coupling parts 12 in the example allow at least one coupling on the basis of a turning movement W along the relevant sides 2-3.
The present invention is by no means limited to the embodiments described above, but such floor panels and substrates can be realized according to different variants without departing from the scope of the present invention.
Floor panel for forming a floor covering, wherein the floor panel (1) comprises a layer-shaped substrate (6), as well as a decorative top layer (7) located above the substrate (6); and wherein the substrate (6) comprises at least one layer (8) made on the basis of a composition comprising at least one thermoplastic plastic; characterized in that the composition comprises at least one or more elastomers in addition to the thermoplastic plastic; and that the aforementioned thermoplastic plastic is thermoplastic polyester.
Floor panel according to claim 1, wherein the proportion of thermoplastic polyester in the composition is between 5 wt% and 50 wt%, preferably between 10 wt% and 40 wt%, and even more preferably between 15 wt% and 35 wt% .
Floor panel according to claim 1 or 2, wherein the thermoplastic polyester is polyethylene terephthalate (PET).
Floor panel according to claim 3, wherein the thermoplastic polyester is present in the composition in the form of PET flakes.
Floor panel according to one of the preceding claims, wherein the proportion of elastomer in the composition is between 1 wt% and 35 wt%, preferably between 1 wt% and 30 wt%, even more preferably between 5 wt% and 30 wt%, and most preferably between 5 wt% and 25 wt%.
Floor panel according to one of the preceding claims, wherein at least one elastomer has a Shore hardness that is greater than 20 Shore A and smaller than 90 Shore A, and preferably greater than 40 Shore A and smaller than 85 Shore D , where the Shore hardness is measured according to the ISO 868 standard.
Floor panel according to one of the preceding claims, wherein at least one of the elastomers is a thermoplastic elastomer.
Floor panel according to one of the preceding claims, wherein at least one elastomer based on propylene is designed; and wherein the propylene-based elastomer preferably has one of the following characteristics: it is an ethylene-propylene copolymer; or it is a thermoplastic polyolefin (TPO) or a composition of polypropylene and cross-linked ethylene-propylene-diene monomer (EPDM) rubber.
Floor panel according to one of the preceding claims, wherein at least one elastomer based on a styrene block copolymer such as styrene-butylene-styrene (SBS) or styrene-ethylene-butylene-styrene (SEBS) is designed; and wherein the elastomer based on styrene block copolymer preferably has one of the following characteristics: it is a block copolymer based on styrene and ethylene / butylene or styrene and ethylene / propylene, more particularly a linear tri-block copolymer based on styrene and ethylene / propylene or linear SEBS; or - it is based on a composition of SEBS or SBS on the one hand and a polyolefin such as polypropylene or polyethylene on the other.
Floor panel according to one of the preceding claims, wherein at least one elastomer is a polyolefin elastomer (POE), and preferably an ethylene-octene copolymer.
Floor panel according to one of the preceding claims, wherein the composition still comprises at least mineral fiber structures such as glass fibers, the proportion of which in the composition is preferably between 5 wt% and 40 wt%, more preferably between 10 wt% and 30 wt%, and even more preferably between 15 wt% and 25 wt%.
Floor panel according to one of the preceding claims, wherein the composition further comprises at least one filler such as chalk, limestone and / or talc, the proportion of which in the composition is preferably between 10 wt% and 80 wt%, more preferably between 20 wt% and 70 wt%, and even more preferably between 20 wt% and 60 wt%.
Floor panel according to one of the preceding claims, wherein the composition further comprises at least one compatibilizer or a coupling agent, wherein the compatibilizer or coupling agent is preferably selected from the group comprising the following substances: a copolymer of ethylene and glycidyl methacrylate, a terpolymer of ethylene, acrylic ester and glycidyl methacrylate and a polypropylene grafted with maleic anhydride.
Floor panel according to claim 13, wherein the proportion of compatibilizer or coupling agent in the composition is less than 10 wt%, preferably less than 5 wt% and more preferably less than 2.5 wt%.
Floor panel as claimed in any of the foregoing claims, wherein the composition still comprises at least so-called melt enhancers, the proportion of which in the composition is preferably smaller than 5 wt%, more preferably smaller than 2.5 wt%, and even more at preferably less than 1 wt%.
Floor panel according to one of the preceding claims, wherein the composition comprises, in addition to the components or components already mentioned above, at least one thermoplastic plastic other than thermoplastic polyester, which preferably relates to polypropylene or polystyrene or a combination of both.
Floor panel according to one of the preceding claims, wherein the decorative top layer (7) comprises a decor (9), as well as a transparent or translucent wear layer (10) located above the decor (9).
A floor panel according to any one of the preceding claims, wherein the floor panel (1) further comprises a counter layer located below the substrate (6).
Floor panel according to one of the preceding claims, wherein the floor panel (1) is provided with mechanical coupling means or coupling parts (12) on at least two opposite edges (2-3), said coupling means or coupling parts (12) allowing two of such floor panels (1) can be coupled to each other such that a locking is created in both a direction (V) perpendicular to the plane of the coupled floor panels (1) and in a direction (H) perpendicular to the coupled edges (2-3) and in the plane of the coupled floor panels (1).
Substrate for a panel, more particularly a floor panel (1), wherein the substrate (6) is layer-shaped, and comprises at least one layer (8) which is designed on the basis of a composition comprising at least one thermoplastic plastic, characterized by in addition to the thermoplastic plastic, the composition also comprises at least one or more elastomers; that the aforementioned thermoplastic plastic is thermoplastic polyester; and that the composition is preferably carried out according to one of claims 2 to 16.
BE2016/5036A 2016-01-15 2016-01-15 Floor panel for forming a floor covering, and substrate for a panel BE1023817B1 (en)
BE2016/5036A BE1023817B1 (en) 2016-01-15 2016-01-15 Floor panel for forming a floor covering, and substrate for a panel
CN201780006448.6A CN108474213A (en) 2016-01-15 2017-01-12 It is used to form the floor panel of floor cover and the substrate for panel
EP17704300.7A EP3402942A1 (en) 2016-01-15 2017-01-12 Floor panel for forming a floor covering, and substrate for a panel
PCT/IB2017/050161 WO2017122149A1 (en) 2016-01-15 2017-01-12 Floor panel for forming a floor covering, and substrate for a panel
CA3010403A CA3010403A1 (en) 2016-01-15 2017-01-12 Floor panel for forming a floor covering, and substrate for a panel
US16/068,909 US20190032342A1 (en) 2016-01-15 2017-01-12 Floor panel for forming a floor covering, and substrate for a panel
BE1023817A1 BE1023817A1 (en) 2017-07-31
BE1023817B1 true BE1023817B1 (en) 2017-08-01
ID=55456515
US (1) US20190032342A1 (en)
EP (1) EP3402942A1 (en)
CN (1) CN108474213A (en)
BE (1) BE1023817B1 (en)
CA (1) CA3010403A1 (en)
WO (1) WO2017122149A1 (en)
BRPI0804498A2 (en) * 2007-03-01 2011-08-30 Prs Mediterranean Ltd process for producing compatible polymeric blends
2016-01-15 BE BE2016/5036A patent/BE1023817B1/en active IP Right Grant
2017-01-12 CA CA3010403A patent/CA3010403A1/en active Pending
2017-01-12 WO PCT/IB2017/050161 patent/WO2017122149A1/en active Application Filing
2017-01-12 CN CN201780006448.6A patent/CN108474213A/en active Search and Examination
2017-01-12 US US16/068,909 patent/US20190032342A1/en active Pending
2017-01-12 EP EP17704300.7A patent/EP3402942A1/en active Pending
WO2017122149A1 (en) 2017-07-20
BE1023817A1 (en) 2017-07-31
CA3010403A1 (en) 2017-07-20
US20190032342A1 (en) 2019-01-31
EP3402942A1 (en) 2018-11-21
CN108474213A (en) 2018-08-31
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