# US 11,299,893 B2 · Panel for forming a floor covering, method for manufacturing such panels and granulate applied herewith

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- Number: US 11,299,893 B2
- Document ID: US11299893B2
- Status: Granted
- Kind: B2
- Application number: 16/808,874
- Filed: 2020-03-04
- Published: 2020-06-25
- Granted: 2022-04-12
- Earliest claimed: 2012-06-01
- Assignees: Flooring Industries Limited, Sarl
- Applicants: Flooring Industries Limited, Sarl
- Inventors: Martin Segaert; Christophe Naeyaert
- Web page: https://patentgrep.com/patent/US11299893B2

## 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 for forming a floor covering, where this panel includes a substrate including at least a layer of thermoplastic material, where the panel, above the layer, comprises at least also a printed décor and a translucent or transparent wear layer. The layer also includes at least individual fibers having a length greater than 1 millimeter, where the individual fibers are loose and freely distributed within the layer of thermoplastic material.

## Claims

### Claim 1

A panel for forming a floor covering, wherein the panel comprises:
a substrate including at least a layer of thermoplastic material,
wherein the panel, above said layer, comprises at least a printed decor and a translucent or transparent wear layer,
wherein said layer also comprises at least individual fibers having a length greater than 1 millimeter, said individual fibers are moisture resistant fibers, wherein said individual fibers are loose and freely distributed within said layer of thermoplastic material.

### Claim 2 (depends on 1)

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

### Claim 3 (depends on 1)

The panel according to claim 1, wherein said layer of thermoplastic material is situated at least halfway in the thickness of the panel.

### Claim 4 (depends on 1)

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

### Claim 5 (depends on 1)

The panel according to claim 1, wherein said moisture resistant fibers are glass fibers, steel fibers, carbon fibers, aramid fibers, polyethylene fibers or cellulose fibers being coated or treated by means of acetylation.

### Claim 6 (depends on 1)

The panel according to claim 1, wherein said moisture resistant fibers on average have a diameter situated between 1 to 100 μm.

### Claim 7 (depends on 1)

The panel according to claim 1, wherein said individual fibers are provided with a coating or a treatment which improves the adherence to the thermoplastic material.

### Claim 8 (depends on 1)

The panel according to claim 1, wherein said layer also comprises at least a glass fiber cloth or glass fiber fleece.

### Claim 9 (depends on 1)

The panel according to claim 1, wherein this panel comprises at least two such layers on the basis of thermoplastic material.

### Claim 10 (depends on 1)

The panel according to claim 1, wherein said thermoplastic material relates to soft polyvinyl chloride with a percentage of plasticizer of 12 percent by weight or more.

### Claim 11 (depends on 1)

The panel according to claim 1, wherein said thermoplastic material further comprises fillers.

### Claim 12 (depends on 1)

The panel according to claim 1, wherein said individual fibers on average have a diameter situated between 5 and 25 micrometers.

### Claim 13 (depends on 1)

The panel according to claim 1, wherein said individual fibers have an average length of more than 3 mm.

### Claim 14

A panel for forming a floor covering, wherein the panel comprises:
a substrate including at least a layer of thermoplastic material, wherein the panel, above said layer, comprises at least a printed decor and a translucent or transparent wear layer,
wherein said layer also comprises at least individual fibers, wherein said individual fibers are loose and freely distributed within said layer of thermoplastic material, said panel being provided with coupling means, said coupling means having a thickness of at least 2.5 mm.

### Claim 15 (depends on 14)

The panel according to claim 14, wherein said coupling means having a thickness of at least 3 mm.

### Claim 16 (depends on 14)

The panel according to claim 14, wherein said panel having a thickness of less than 4 mm.

### Claim 17 (depends on 14)

The panel according to claim 14, wherein said layer also comprises at least individual fibers having a length greater than 1 millimeter, said individual fibers are moisture resistant fibers, wherein said individual fibers are loose and freely distributed within said layer of thermoplastic material.

### Claim 18 (depends on 17)

The panel according to claim 17, wherein said substrate has a thickness of 1.3 to 10 millimeters.

### Claim 19 (depends on 17)

The panel according to claim 17, wherein said layer of thermoplastic material is situated at least halfway in the thickness of the panel.

### Claim 20 (depends on 17)

The panel according to claim 17, wherein said thermoplastic material is chosen from the list consisting of polyvinyl chloride, polypropylene, polyethylene and polyurethane.

### Claim 21 (depends on 17)

The panel according to claim 17, wherein said moisture resistant fibers are glass fibers, steel fibers, carbon fibers, aramid fibers, polyethylene fibers or cellulose fibers being coated or treated by means of acetylation.

### Claim 22 (depends on 17)

The panel according to claim 17, wherein said moisture resistant fibers on average have a diameter situated between 1 to 100 μm.

### Claim 23 (depends on 14)

The panel according to claim 14, wherein said individual fibers are provided with a coating or a treatment which improves the adherence to the thermoplastic material.

### Claim 24 (depends on 14)

The panel according to claim 14, wherein said layer also comprises at least a glass fiber cloth or glass fiber fleece.

### Claim 25 (depends on 14)

The panel according to claim 14, wherein the panel comprises at least two such layers on the basis of thermoplastic material.

### Claim 26 (depends on 14)

The panel according to claim 14, wherein said thermoplastic material relates to soft polyvinyl chloride with a percentage of plasticizer of 12 percent by weight or more.

### Claim 27 (depends on 14)

The panel according to claim 14, wherein said thermoplastic material further comprises fillers.

### Claim 28 (depends on 14)

The panel according to claim 14, wherein said individual fibers on average have a diameter situated between 5 and 25 micrometers.

### Claim 29 (depends on 14)

The panel according to claim 14, wherein said individual fibers have an average length of more than 3 mm.