Source: https://patents.google.com/patent/US20030033777
Timestamp: 2018-02-22 17:12:10
Document Index: 471840905

Matched Legal Cases: ['arts 10', 'arts 10', 'arts 10', 'arts 10', 'arts 10', 'art 24']

US20030033777A1 - Floor panel and method for the manufacture thereof - Google Patents
US20030033777A1
US20030033777A1 US10216821 US21682102A US2003033777A1 US 20030033777 A1 US20030033777 A1 US 20030033777A1 US 10216821 US10216821 US 10216821 US 21682102 A US21682102 A US 21682102A US 2003033777 A1 US2003033777 A1 US 2003033777A1
US10216821
US8196366B2 (en )
Floor panel of the type comprising a hard top layer (3) forming a decorative surface, from which, together with other identical or similar floor panels (1), a floor covering can be formed, wherein this floor panel (1) includes at least one sound-absorbing layer (4) which is integrated into the floor panel (1) and is located between other layers of this floor panel (1).
The present invention aims at a floor panel of the above-mentioned type, in other words, a floor panel comprising a hard top layer forming a decorative surface, which floor panel is realized such that an optimization or at least a considerable improvement of the sound absorption is provided, notwithstanding the presence of the hard or relatively hard surface to be walked on.
By integrating one or more sound-absorbing layers into the floor panel, more particularly at a distance above the underside, as well as at a distance below the top surface, it is obtained that, on one hand, such sound-absorbing layer, independent from the thickness of the floor panel, can be positioned relatively close to the upper surface, whereas, on the other hand, the global structure of such floor panel still can be kept relatively thick and stable. Tests have shown that by integrating the sound-absorbing layer, better results are obtained, on one hand, as the thickness of the material situated thereabove, in which the sound substantially propagates, is reduced and, on the other hand, in that a multilayer construction is created, which obviously also contributes to the desired effect in an advantageous manner.
Preferably, the floor panel, apart from the sound-absorbing layer and the top layer, then also at least comprises one structural basic layer. Although various structural basic layers can be incorporated into the floor panel, this latter, according to an important preferred form of embodiment, will comprise only one structural basic layer, which contributes to the constructive simplicity of the whole.
In the most preferred form of embodiment, the construction even is such that the floor panel, with the exception of possible adhesive layers or the like, and with the exception of an insulating layer possibly provided at the underside of the floor panel, exclusively consists of the structural basic layer, the sound-absorbing layer provided on top thereof, and the top layer provided on top of this sound-absorbing layer.
In a preferred form of embodiment, the floor panels are provided with coupling parts at two or more of their edges. In a simple form of embodiment, these coupling parts may consist of a traditional tongue and groove. More particularly, however, use shall be made of coupling parts of the type providing for a vertical, as well as horizontal locking, for example, as described in the international patent application WO 97/47934.
Regardless whether the coupling parts are manufactured from the material of a structural basic layer of from another material, it is always preferred that these coupling parts are situated substantially, and preferably entirely, outside of the sound-absorbing layer or layers, in other words, that these coupling parts and the sound-absorbing material, viewed in the height, are situated at different levels in the floor panels. This offers the advantage that, when, as described in the following, the sound-absorbing layer or layers are realized in a material which offers little strength and/or are realized in a material which is difficult to process, the strength of the coupling parts and/or the degree of difficulty of forming them is not or only minimally influenced in a disadvantageous manner due to the presence of the sound-absorbing layer. This latter is in particular valid for embodiments in which the sound-absorbing layer consists of synthetic material and in which the coupling parts are formed by means of a milling process. Milling in the synthetic material indeed may cause problems in respect to cooling, and preferably, the cutting surface through the synthetic material thus will be restricted to a minimum, which, as aforementioned, is possible by situating the coupling parts to be formed outside of the sound-absorbing layer.
cork is waterproof, as a result of which a water-repelling effect is created, in particular if it is provided above a material layer, such as MDF or HDF, which is sensitive in respect to water;
According to a particular characteristic, the sound-absorbing layer is formed of a material layer which can be wound up in itself, to which aim, for example, a thin layer of cork or a thin layer of synthetic material can be applied. Such windable material offers the advantage that it is easy to utilize in a production process, in particular in a continuous process, whereby the sound-absorbing layer systematically must be provided on and/or between plate-shaped structural basic layers. The sound-absorbing material then can be unwound systematically onto the underlying structural basic layer and can be attached thereto.
as a laminate layer constructed of material sheets, more particularly a so-called “laminated sheet material”;
According to a particular form of embodiment, the sound-absorbing layer will be integrated into the top layer, which, of course, is possible in different ways. So, for example, this can be realized by taking up a particularly thin cork layer, when forming the HPL or the like, between two of the material layers of which the HPL is formed.
It is clear that the different layers of the floor panels of the invention can be attached to each other in any manner. This may be performed, for example, by means of appropriate kinds of glue or other adhesive materials, by having certain layers cure on top of each other or by fixing them upon each other by melting, or by providing thin double sided adhesive layers in between them.
[0058]FIG. 1 represents a floor panel according to the invention;
[0059]FIG. 2 represents a cross-section according to line II-II in FIG. 1;
[0060]FIG. 3 represents another embodiment of the floor panel according to the invention;
[0061]FIG. 4, at a larger scale, represents a possible embodiment of the part indicated by F4 in FIG. 3;
FIGS. 5 to 8 represent views analogous to that of FIG. 4, however, for four variants;
[0063]FIG. 9 in cross-section represents a part of another variant.
As represented in FIGS. 1 and 2, the invention relates to a floor panel 1 which is provided with a hard or relatively hard top layer 3 at the upper side 2.
[0070]FIGS. 2 and 3 show that, when the floor panels 1 are equipped with such coupling parts 10-11, the sound-absorbing layer 4 preferably is situated outside of these coupling parts 10-11, with which it is meant that this layer 4 is not situated at the level of the tongue-shaped and groove-shaped parts formed by these coupling parts 10-11. In this manner, it is guaranteed that the sound-absorbing layer 4, in the proximity of the edges 6-7 and/or 8-9 provided with coupling parts 10-11, during the formation of the profile of these edges, is cut through exclusively vertical or substantially vertical. Hereby, the advantage is obtained that, as explained in the introduction, the strength of the coupling parts 10-11, and in particular the strength of the tongue-shaped parts, is not disadvantageously affected by the presence of the material of the sound-absorbing layer 4. Also, the distance over which the applied machinery tools must cut through the material of the sound-absorbing layer 4, thereby is restricted to a minimum.
[0079]FIG. 4 only is a schematic representation, and of course, the relations between the thicknesses of the different layers can be chosen different. In a practical application, the basic-layer 15, for examples will-have a thickness of approximately 5 mm, whereas the sound-absorbing layer 4 has a thickness of 2 mm and the top layer 3 has a thickness of 1 mm. Of course, according to different variants, values can be applied which totally deviate from the abovesaid.
[0080]FIG. 5 shows a part of a floor panel 1 with a construction which can be compared to that of the floor panel 1 of FIG. 4, with the sole difference that an additional covering layer 18 is provided between the sound-absorbing layer 4 and the basic layer 15, on the upper side of the basic layer 15. Of course, this layer construction, too, can be realized in different manners. One possibility consists, for example, in that first the basic layer 15 is provided with the covering layer 17 and the backing layer 16, by means of classic DPL techniques (Direct Pressure Laminate), after which, by means of adhesives, the sound-absorbing layer 4 and the top layer 3 are attached thereupon.
[0085]FIG. 8 shows a part of a floor panel 1 with a similar structure as that from FIG. 4, however, with the difference that at the underside of the floor panel 1, an additional layer 22 is provided which is formed by a compressible material, whether or not with thermal or sound-insulating features, which offers the advantages that during installation, unevennesses are levelled. This layer 22 consists, for example, of synthetic foam.
In FIG. 9, another variant is represented whereby the floor panel 1, at one or more of its upper edges 23, is provided with a bevelled part 24 or the like, more particularly a so-called chamfer, whereby the bevelled part at least partially extends through the sound-absorbing layer 4. In order to prevent that the layer structure becomes visible in an annoying manner, a decorative covering 25 is provided on the bevelled part. The covering 25 consists, for example, of a print obtained by means of transfer print, for example, as described in the international patent application PCT/BE01/00008, or another printing technique. Also, a covering strip, lacquer or the like can be provided on the bevelled part.
Although in the figures only embodiments with one sound-absorbing layer 4 are represented, it is clear that according to variants, also several sound-absorbing layers 4 can be integrated in such floor panel 1. Also the structural basic layers 15-18-19 in their turn can be composed of several layers, whether or not provided with more or less covering layers or backing layers.
1. Floor panel of the type comprising a hard top layer (3) forming a decorative surface, from which, together with other identical or similar floor panels (1), a floor covering can be formed, characterized in that this floor panel (1) comprises at least one sound-absorbing layer (4) which is integrated into the floor panel (1) itself and to this aim is located between other layers of this floor panel (1).
2. Floor panel according to claim 1, characterized in that said sound-absorbing layer (4), viewed according to the thickness (T) of the floor panel (1), extends at least up into the upper half of the floor panel (1).
3. Floor panel according to claim 1 or 2, characterized in that said sound-absorbing layer (4), viewed according to the thickness (T) of the floor panel (1), is situated entirely in the upper half.
4. Floor panel according to any of the preceding claims, characterized in that the sound-absorbing layer (4), viewed according to the thickness (T) of the floor panel (1), is situated at a distance (D2) below the upper side (2) of this floor panel (1) which is smaller than 4 mm, and even better is smaller than or equal to 2 mm.
5. Floor panel according to any of the preceding claims, characterized in that it comprises only one sound-absorbing layer (4) integrated between other layers.
6. Floor panel according to any of the preceding claims, characterized in that, apart from the sound-absorbing layer (4) and the top layer (3), it moreover comprises at least one structural basic layer (15-18-19).
7. Floor panel according to claim 6, characterized in that the floor panel (1) comprises exclusively one one-piece structural basic layer (15).
8. Floor panel according to any of the preceding claims, characterized in that the top layer (3) is fixed directly on top of the sound-absorbing layer (4), more particularly without the intermediary of structural basic layers (15-18-19).
9. Floor panel according to claims 6 or 7 and according to claim 8, characterized in that it comprises at least one structural basic layer (15-19) which is situated below the sound-absorbing layer (4), whether or not directly therebelow.
10. Floor panel according to claim 9, characterized in that this panel, with the exception of possible adhesive layers or the like, and with the exception of an insulating layer (22) possibly provided at the underside (5) of the floor panel (1), exclusively consists of the structural basic layer (15), the sound-absorbing layer (4) provided on top thereof, and the top layer (3) provided on top of this sound-absorbing layer (4).
11. Floor panel according to any of the claims 1 to 7, characterized in that at least a structural basic layer (18) is present between the sound-absorbing layer (4) and the top layer (3).
12. Floor panel according to any of the claims 1 to 6, characterized in that the sound-absorbing layer (4) is located between two structural basic layers (18-19).
13. Floor panel according to claim 11 or 12, characterized in that the top layer (3) is fixed directly on top of the upper structural basic layer (15-18).
14. Floor panel according to any of the preceding claims, characterized in that it comprises at least one backing layer (16-20).
15. Floor panel according to claim 14, characterized in that such backing layer (16) is provided at least at the underside (5) of the floor panel (1).
16. Floor panel according to claim 14 or 15, characterized in that it comprises covering layers (21) and/or backing layers (16-20) which are integrated in the floor panel (1), more particularly, are situated at the upper side and/or underside of structural basic layers (15-18-19) which form part of the floor panel (1).
17. Floor panel according to any of the claims 6 to 16, characterized in that one or more of said structural basic layers (15-18-19) consist of a board material made of wood or being wood-based, more particularly board material formed of compressed wood-containing material.
18. Floor panel according to claim 17, characterized in that one or more of the structural basic layers (15-18-19) consist of board material formed by MDF and/or HDF.
19. Floor panel according to claim 17 or 18, characterized in that all structural basic layers (15-18-19) applied herein consist of MDF and/or HDF.
20. Floor panel according to any of the claims 6 to 19, characterized in that the floor panel (1), at two or more of its edges (6-7-8-9), is provided with coupling parts (10-11) and that these coupling parts (10-11) are formed at least partially of one or more of said structural basic layers (15-18-19).
21. Floor panel according to any of the preceding claims, characterized in that this floor panel (1), at two or more of its edges (6-7-8-9), is provided with coupling parts (10-11), whereby the sound-absorbing layer (4), sound-absorbing layers, respectively, are situated outside of the coupling parts (10-11).
22. Floor panel according to claim 21, characterized in that it is provided, at two or more of its edges (6-7-8-9), with coupling parts (10-11), whereby the sound-absorbing layer (4) is situated above the coupling parts (10-11).
23. Floor panel according to any of the claims 20 to 22, characterized in that said coupling parts (10-11) consist of coupling parts of the type providing for a vertical, as well as horizontal mechanical locking.
24. Floor panel according to any of the preceding claims, characterized in that the sound-absorbing layer (4) consists of cork or of a cork-based material.
25. Floor panel according to any of the claims 1 to 23, characterized in that the sound-absorbing layer (4) consists of a sound-absorbing synthetic material, preferably polyurethane.
26. Floor panel according to any of the preceding claims, characterized in that the sound-absorbing layer (4) is formed of a material layer which can be wound up in itself.
27. Floor panel according to any of the preceding claims, characterized in that the sound-absorbing layer (4) has a thickness of less than 2 mm.
28. Floor panel according to any of the preceding claims, characterized in that the top layer (3) has a thickness of less than 1 mm.
29. Floor panel according to any of the preceding claims, characterized in that the top layer (3) is realized according to any of the following possibilities:
HPL (High Pressure Laminate) or the like;
DPL (Direct Pressure Laminate), LPL (Low Pressure Laminate), or the like;
a plate, realized as a so-called compact laminate;
so-called formica or the like;
a laminate based on resin or on supports, such as lengths of paper, impregnated with resin;
30. Floor panel according to any of the claims 1 to 7, characterized in that the sound-absorbing layer (4) is integrated into the top layer (3).
31. Floor panel according to any of the preceding claims, characterized in that it is provided with a bevelled part (24) or the like at its upper edge, more particularly a so-called chamfer, whereby the bevelled part (24) at least partially extends through the sound-absorbing layer (4); and that on this bevelled part (24), a decorative covering (25) is provided, more particularly printed thereon, preferably by means of transfer printing.
32. Floor panel according to any of the preceding claims, characterized in that a layer (26), formed by a compressible material, whether or not with thermally insulating or sound-insulating qualities, is provided against the underside (5) of this floor panel (1).
33. Method for manufacturing a floor panel (1) according to any of the claims 1 to 32, whereby first, composed plates of a larger size are manufactured, from which subsequently each time several floor panels (1) are formed, characterized in that said plates are manufactured at least by supplying one or more board-shaped structural basic layers, supplying material, wound up in rolls, for forming said sound-absorbing layer (4), and unwinding this material from those rolls, as well as supplying the top layer (3) or the material for forming such top layer (3), whereby the respective composed layers are provided on top of each other.
US10216821 2001-08-14 2002-08-13 Floor panel and method for the manufacture thereof Active 2025-01-04 US8196366B2 (en)
BE200100547A BE1014345A3 (en) 2001-08-14 2001-08-14 Floor panel and method for manufacturing it.
US13339987 US8234829B2 (en) 2001-08-14 2011-12-29 Floor panel and method for the manufacture thereof
US13534091 US8484920B2 (en) 2001-08-14 2012-06-27 Floor panel and method for the manufacture thereof
US13534061 US8356452B2 (en) 2001-08-14 2012-06-27 Floor panel and method for the manufacture thereof
US13339987 Continuation US8234829B2 (en) 2001-08-14 2011-12-29 Floor panel and method for the manufacture thereof
US20030033777A1 true true US20030033777A1 (en) 2003-02-20
US8196366B2 US8196366B2 (en) 2012-06-12
US10216821 Active 2025-01-04 US8196366B2 (en) 2001-08-14 2002-08-13 Floor panel and method for the manufacture thereof
US13339987 Active US8234829B2 (en) 2001-08-14 2011-12-29 Floor panel and method for the manufacture thereof
US13534061 Active US8356452B2 (en) 2001-08-14 2012-06-27 Floor panel and method for the manufacture thereof
US13534091 Active US8484920B2 (en) 2001-08-14 2012-06-27 Floor panel and method for the manufacture thereof
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Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:THIERS, BERNARD;HOCHEPIED, PETER JOZEF;REEL/FRAME:013335/0284