# US 11,077,652 B2 · Method of forming a decorative wear resistant layer

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- Number: US 11,077,652 B2
- Document ID: US11077652B2
- Status: Granted
- Kind: B2
- Application number: 16/410,212
- Filed: 2019-05-13
- Published: 2019-08-29
- Granted: 2021-08-03
- Earliest claimed: 2013-10-23
- Assignees: Ceraloc Innovation AB
- Applicants: Ceraloc Innovation AB
- Inventors: Darko Pervan
- Web page: https://patentgrep.com/patent/US11077652B2

## CPC

- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B05D 5/02: to obtain a matt or rough surface
- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/08: of synthetic resin
- B32B 23/08: of synthetic resin
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/18: characterised by the use of special additives
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B32B 33/00: Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
- B32B 38/14: Printing or colouring
- B32B 38/145: {Printing}
- B44C 5/04: Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C 5/0476: {with abrasion resistant properties}
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B05D 1/12: Applying particulate materials (B05D1/06, B05D1/10 take precedence)
- B05D 1/26: performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
- B05D 7/04: to surfaces of films or sheets (producing layered products by applying coatings of pasty or pulverulent plastics B29C41/00)
- B32B 37/06: characterised by the heating method
- 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 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/26: Polymeric coating
- B32B 2262/067: Wood fibres
- B32B 2262/101: Glass fibres
- B32B 2264/04: Cellulosic particles, e.g. rayon
- B32B 2307/4023: on the layer surface, e.g. ink
- B32B 2307/412: Transparent
- B32B 2307/554: Wear resistance
- B32B 2307/732: Dimensional properties
- B32B 2307/75: Printability
- B32B 2419/04: Tiles for floors or walls
- B32B 2607/00: Walls, panels
- E04F 2290/042: with a facing or top layer for sound insulation
- Y10T 428/24802: Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T 428/24876: Intermediate layer contains particulate material [e.g., pigment, etc.]
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The disclosure relates to a method to form a digital print on a substrate including a polymer material by bonding particles in powder form to the surface of the substrate. A method of forming a decorative wear resistant layer, the method including: providing a substrate comprising a thermoplastic material and a transparent layer comprising a thermoplastic material, providing a continuous print layer comprising particles on the substrate or on the transparent layer, printing a digital image comprising colour pigments on the print layer, and bonding the print layer with the colour pigments to the transparent layer and to the substrate with heat and pressure such that the digital image is located between the transparent layer and the substrate.

## Claims

### Claim 1

A floor panel comprising
a core comprising a thermoplastic material,
a decorative layer arranged on the core, wherein the decorative layer comprises a thermoplastic material, and
a transparent layer arranged on the decorative layer, wherein the transparent layer comprises a thermoplastic material,
wherein the decorative layer comprises a print layer arranged under the transparent layer, the print layer comprising particles and colour pigments attached to said particles to form a digital print, the particles comprising at least one of mineral particles, fibers, or thermoplastic powder.

### Claim 2 (depends on 1)

The floor panel according to claim 1, wherein the particles comprise organic fibers or inorganic fibers.

### Claim 3 (depends on 1)

The floor panel according to claim 1, wherein the particles comprise cellulose fibres or at least partially bleached cellulose fibres.

### Claim 4 (depends on 1)

The floor panel according to claim 1, wherein the particles comprise a PVC powder.

### Claim 5 (depends on 1)

The floor panel according to claim 1, wherein the print layer is continuous.

### Claim 6 (depends on 1)

The floor panel according to claim 1, wherein the decorative layer is a thermoplastic foil and wherein the transparent layer is a thermoplastic foil.

### Claim 7 (depends on 1)

The floor panel according to claim 1, wherein the floor panel comprises a balancing layer applied on a rear side of the core.

### Claim 8 (depends on 1)

The floor panel according to claim 1, wherein the core comprises fillers.

### Claim 9 (depends on 1)

The floor panel according to claim 1, wherein the core comprises one or several layers of thermoplastic material.

### Claim 10 (depends on 9)

The floor panel according to claim 9, wherein said one or several layers comprises PVC mixed with 20-80% chalk or limestone fillers.

### Claim 11 (depends on 1)

The floor panel according to claim 1, wherein the print layer is bonded to the decorative layer or to the transparent layer with a binder.

### Claim 12 (depends on 1)

The floor panel according to claim 1, wherein the print layer has a thickness of 0.03-0.10 mm or a weight of about 10-30 g/m2.

### Claim 13 (depends on 1)

The floor panel according to claim 1, wherein a surface of the decorative layer is completely covered with the print layer.

### Claim 14 (depends on 1)

The floor panel according to claim 1, wherein the colour pigments are provided by a water-based ink.

### Claim 15 (depends on 1)

The floor panel according to claim 1, wherein the floor panel is an LVT floor panel.

### Claim 16 (depends on 1)

The floor panel according to claim 1, wherein the floor panel comprises a mechanical locking system.