Method for manufacturing a panel including a reinforcement sheet, and a floor panel

A method for manufacturing a panel including a reinforcement sheet, comprising the steps of:

• providing a first layer of thermoplastic material,
• providing a reinforcement sheet having a thickness,
• providing a second layer of thermoplastic material,
• combining the reinforcement sheet and the first layer by laying the reinforcement sheet on the first layer, or alternatively, by performing the step of providing the first layer of thermoplastic material by applying the thermoplastic material of the first layer onto the reinforcement sheet,
• after the step of combining the reinforcement sheet and the first layer, applying the second layer of thermoplastic material onto the reinforcement sheet at a side of the reinforcement sheet facing away from the first layer,
• at least partially melting the thermoplastic material of the first layer to form an at least partially melted first layer,
• at least partially melting the thermoplastic material of the second layer to form an at least partially melted second layer,
• adhering the at least partially melted first layer, the at least partially melted second layer and the reinforcement sheet to each other so as to form the panel,
• wherein the reinforcement sheet and the first layer are adhered to each other by pressing them together after the step of at least partially melting the thermoplastic material of the first layer,
• wherein an applied pressure during the step of pressing the reinforcement sheet and the first layer together and a rate of melting the thermoplastic material of the first layer during the step of at least partially melting the thermoplastic material of the first layer are selected such that the reinforcement sheet is impregnated by the thermoplastic material of the first layer over at least 80% of its thickness,
• wherein the step of providing the first layer of thermoplastic material comprises spreading granular thermoplastic material prior to the step of at least partially melting the thermoplastic material of the first layer,
• wherein the step of providing the second layer of thermoplastic material comprises providing the second layer in the form of a sheet or a film, and
• wherein the reinforcement sheet and the second layer are adhered to each other after the step of at least partially melting the thermoplastic material of the second layer, while the thermoplastic material of the second layer is still at least partially melted, and separately from the step of pressing the reinforcement sheet and the first layer together, by pressing the at least partially melted second layer onto the reinforcement sheet,
• wherein, in the panel, a thickness of the first layer is between 1 and 3.5 mm and the reinforcement sheet is located at a middle of the panel in a thickness direction or at a position in the thickness direction other than the middle, and
• wherein the panel has a total product thickness between 1.5 and 6.5 mm.