# US 10,480,201 B2 · Panel for forming a floor covering and method for manufacturing such panels

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- Number: US 10,480,201 B2
- Document ID: US10480201B2
- Status: Granted
- Kind: B2
- Application number: 15/924,869
- Filed: 2018-03-19
- Published: 2018-07-26
- Granted: 2019-11-19
- Earliest claimed: 2012-06-01
- Assignees: Unilin, Bvba
- Applicants: Unilin, Bvba
- Inventors: Martin Segaert; Christophe Naeyaert
- Web page: https://patentgrep.com/patent/US10480201B2

## CPC

- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B27N 3/06: Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
- B29C 43/006: {Pressing and sintering powders, granules or fibres}
- B29C 43/30: Making multilayered or multicoloured articles {(B29C43/26 takes precedence)}
- B29C 43/305: {Making multilayered articles}
- B29C 43/48: Endless belts
- B29C 70/0035: {comprising two or more matrix materials}
- B29C 70/081: {Combinations of fibres of continuous or substantial length and short fibres}
- B29C 70/506: {and impregnating by melting a solid material, e.g. sheet, powder, fibres (B29C70/508 takes precedence)}
- B32B 5/024: {Woven fabric}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 37/1027: {Pressing using at least one press band}
- B32B 37/24: with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence)
- B32B 38/145: {Printing}
- D06N 3/0022: {Glass fibres}
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/08: only of stone or stone-like material, e.g. {ceramics}, concrete; of glass {or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass (E04F15/02005 takes precedence)}
- E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- B29C 2043/483: {cooperating with a second endless belt, i.e. double band presses}
- B29K 2101/12: Thermoplastic materials
- B29K 2309/08: Glass
- B29L 2031/732: {Floor coverings (piles carpets B29L2031/7652; for vehicles B29L2031/3017)}
- B32B 37/0015: {to avoid warp or curl}
- B32B 2305/08: Reinforcements
- B32B 2305/10: Fibres of continuous length
- B32B 2305/22: Fibres of short length
- B32B 2305/30: Fillers, e.g. particles, powders, beads, flakes, spheres, chips
- B32B 2307/412: Transparent
- B32B 2307/414: Translucent
- B32B 2307/7242: Non-permeable
- B32B 2307/734: Dimensional stability
- B32B 2309/105: Thickness
- B32B 2315/08: Glass
- B32B 2315/085: Glass fiber cloth or fabric
- B32B 2327/06: PVC, i.e. polyvinylchloride
- B32B 2398/20: Thermoplastics
- B32B 2419/00: Buildings or parts thereof
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- E04F 2201/0153: by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
- E04F 2201/0161: with snap action of the edge connectors
- E04F 2201/023: with a continuous tongue or groove
- Y10T 428/24868: Translucent outer layer
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A panel that includes at least a substrate of thermoplastic material and a top layer with a printed decor and a translucent or transparent wear layer. The substrate substantially consists of three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material. Additionally, the thermoplastic material of the lower most layer and the uppermost layer is more rigid than the thermoplastic material of the central layer.

## Claims

### Claim 1

A panel comprising at least a substrate of thermoplastic material and a top layer with a printed decor and a translucent or transparent wear layer,
wherein said substrate substantially consists of three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material, and
wherein the thermoplastic material of the lower most layer and the uppermost layer is more rigid than the thermoplastic material of the central layer,
wherein said lowermost and said uppermost layer comprise less than 5 percent by weight of plasticizer or no plasticizer, and
wherein said central layer comprises 12 percent by weight or more of plasticizer.

### Claim 2 (depends on 1)

The panel according to claim 1, wherein said thermoplastic material is chosen from the group consisting of polyvinylchloride, polypropylene, polyethylene and polyurethane.

### Claim 3 (depends on 2)

The panel according to claim 2, wherein said lowermost layer is on the basis of hard or semi-rigid polyvinylchloride, said central layer is on the basis of soft polyvinylchloride, and said uppermost layer is on the basis of hard or semi-rigid polyvinylchloride.

### Claim 4 (depends on 1)

The panel according to claim 1, wherein said lowermost layer and said uppermost layer are thinner than said central layer.

### Claim 5 (depends on 1)

The panel according to claim 1, wherein said panel is a floor panel for a floating floor covering and at two or more opposite edges comprises coupling parts with which two of such floor panels can be coupled at said edges in such a manner that they are mutually locked in a horizontal direction perpendicular to the respective edge and in the plane of the floor panels, as wall as in a vertical direction perpendicular to the plane of the floor panels.

### Claim 6 (depends on 1)

The panel according to claim 1, wherein said substrate has a thickness of 1.3 to 10 millimeters.

### Claim 7 (depends on 1)

The panel according to claim 1, wherein said panel has a thickness situated between 2 and 6 millimeters.

### Claim 8 (depends on 1)

The panel according to claim 1, wherein said decor consists of a print performed on a synthetic material film, wherein said film is a printed polyvinylchloride film, a polyurethane film, a polypropylene film or a polyethylene film.

### Claim 9 (depends on 1)

The panel according to claim 1, wherein said wear layer also comprises a thermoplastic material, wherein said thermoplastic material is hard or soft polyvinylchloride, polyurethane, polypropylene or polyethylene.

### Claim 10 (depends on 1)

The panel according to claim 1, wherein the thickness of the panel is for more than one half formed by said substrate.

### Claim 11 (depends on 1)

The panel according to claim 1, wherein said top layer comprises a backing layer located underneath the printed decor.

### Claim 12

A panel comprising at least a substrate of thermoplastic material having a thickness of 1.3 to 10 millimeter, and a top layer with a printed decor and a translucent or transparent wear layer, wherein said thermoplastic material is chosen from the list comprising of polyvinylchloride, polypropylene, polyethylene and polyurethane and wherein said substrate forms more than one half the thickness of the panel, said panel being a floor panel for a floating floor covering and comprising at two or more opposite edges coupling parts with which two of such floor panels are able to be coupled at said edges in such a manner that they are mutually locked in a horizontal direction perpendicular to the respective edge and in the plane of the floor panels, as well as in a vertical direction perpendicular to the plane of the floor panels, wherein said substrate substantially consists of three layers, including a lowermost layer, a central layer and an uppermost layer, all made from thermoplastic material, wherein the thermoplastic material of the lowermost layer and the uppermost layer is more rigid than the thermoplastic material of the central layer,
wherein said lowermost and said uppermost layer comprise less than 5 percent by weight of plasticizer or no plasticizer, and
wherein said central layer comprises 12 percent by weight or more of plasticizer.

### Claim 13 (depends on 12)

The panel according to claim 12, wherein said decor consists of a print performed on a synthetic material film, wherein said film is a printed polyvinylchloride film, a polyurethane film, a polypropylene film or a polyethylene film.

### Claim 14 (depends on 13)

The panel according to claim 13, wherein said wear layer also comprises a thermoplastic material, wherein said thermoplastic material is hard or soft polyvinylchloride, polyurethane, polypropylene or polyethylene.

### Claim 15 (depends on 14)

The panel according to claim 14, wherein said lowermost layer is on the basis of hard or semi-rigid polyvinylchloride, said central layer is on the basis of soft polyvinylchloride, and said uppermost layer is on the basis of hard or semi-rigid polyvinylchloride.