# US 11,993,939 B2 · Floor panel

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- Number: US 11,993,939 B2
- Document ID: US11993939B2
- Status: Granted
- Kind: B2
- Application number: 17/205,475
- Filed: 2021-03-18
- Published: 2021-08-19
- Granted: 2024-05-28
- Earliest claimed: 2016-11-10
- Assignees: Unilin BV
- Applicants: Ivc BV
- Inventors: Kristof Van Vlassenrode; Paul Brusseel; Nick Vanhulle; Jochen Bossuyt
- Web page: https://patentgrep.com/patent/US11993939B2

## CPC

- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- B29C 70/08: comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
- B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)}
- B29D 99/0057: {Producing floor coverings}
- 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 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/02: comprising animal or vegetable substances {, e.g. cork, bamboo, starch}
- B32B 9/045: {of synthetic resin}
- B32B 25/08: of synthetic resin
- B32B 27/065: {of foam}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/22: using plasticisers
- 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 27/36: comprising polyesters
- B32B 27/40: comprising polyurethanes
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B44C 5/0407: {containing glass elements}
- 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}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B29K 2027/06: PVC, i.e. polyvinylchloride
- B29K 2105/04: cellular or porous
- B29K 2309/08: Glass
- B29L 2031/732: {Floor coverings (piles carpets B29L2031/7652; for vehicles B29L2031/3017)}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2264/0242: Vinyl halide, e.g. PVC, PVDC, PVF or PVDF (co)polymers
- B32B 2264/067: Wood particles
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/107: Ceramic
- B32B 2264/108: Carbon, e.g. graphite particles
- B32B 2266/0235: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2266/025: Polyolefin
- B32B 2307/102: Insulating
- B32B 2307/412: Transparent
- B32B 2307/51: Elastic
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2419/04: Tiles for floors or walls
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2607/00: Walls, panels
- E04F 2201/0146: with snap action of the edge connectors
- 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 2201/0552: adapted to be rotated around an axis parallel to the joint edge
- E04F 2290/042: with a facing or top layer for sound insulation
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- 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)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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)}
- 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

## Abstract

A floor panel with a substrate, including thermoplastic material, a decor provided thereon, and, on at least one pair of opposite edges, coupling parts realized at least partially from the substrate. The coupling parts allow a mechanical locking between two of such floor panels, where the substrate includes a rigid, non-foamed substrate layer of thermoplastic material.

## Claims

### Claim 1

A floor panel comprising:
a substrate formed from thermoplastic material;
a decor provided on the substrate; and,
on at least one pair of opposite edges of the substrate, coupling parts realized at least partially from the substrate,
wherein said coupling parts are configured to effect a mechanical locking between two of such floor panels,
wherein the substrate comprises a rigid, non-foamed substrate layer formed by extrusion of a composition consisting essentially of a thermoplastic material, an amount of filler and one or more of an impact modifier, a stabilizer and a color pigment;
wherein said rigid, non-foamed substrate layer is free from plasticizers or comprises an amount of less than 5 phr of plasticizers;
wherein said amount of filler is at least 60 percent by weight and said thermoplastic material is polyvinyl chloride;
wherein a density of the rigid, non-foamed substrate layer is at least 1300 kg/m3;
wherein a thickness of said rigid, non-foamed substrate layer is at least 65% of an overall thickness of said floor panel;
wherein said overall thickness of said floor panel is between 3 and 10 mm, the floor panel showing a modulus of elasticity or Young's modulus of at least 2000 N per square millimeter.

### Claim 2 (depends on 1)

The floor panel according to claim 1, wherein the thickness of said rigid non-foamed substrate layer is between 2 and 6 mm.

### Claim 3 (depends on 1)

The floor panel according to claim 1, wherein said decor is printed directly on one or a plurality of base coats provided on said substrate.

### Claim 4 (depends on 1)

The floor panel according to claim 1, wherein said decor is printed on a decor carrier, wherein said decor carrier is a thermoplastic film or a paper layer impregnated with a melamine resin.

### Claim 5 (depends on 1)

The floor panel according to claim 1, wherein said decor is a veneer of wood or stone.

### Claim 6 (depends on 1)

The floor panel according to claim 1, wherein said floor panel comprises a transparent or translucent wear and/or lacquer layer provided on said decor.

### Claim 7 (depends on 6)

The floor panel according to claim 6, wherein said wear layer is a thermoplastic foil having a thickness between 350 and 750 micrometers, or a paper layer impregnated with melamine resin.

### Claim 8 (depends on 1)

The floor panel according to claim 1, wherein a relief is formed in an upper side of said floor panel, wherein said relief reaches deeper than 100 microns, wherein said relief is provided by means of mechanical and/or chemical embossing.

### Claim 9 (depends on 8)

The floor panel according to claim 8, wherein said relief extends into said substrate.

### Claim 10 (depends on 1)

The floor panel according to claim 1, wherein said mechanical locking is operative in both a horizontal and a vertical direction, wherein said locking is realized by cooperating locking surfaces, wherein the zones in which the locking surfaces cooperate are situated at least partially in said rigid substrate layer.

### Claim 11 (depends on 1)

The floor panel according to claim 1, wherein said filler is an inorganic filler.

### Claim 12 (depends on 1)

The floor panel according to claim 1, wherein the rigid substrate layer has a first portion and a second portion opposite the first portion, the second portion being a greater distance from the decor than the first portion and having a greater rigidity than the first portion.

### Claim 13 (depends on 1)

The floor panel according to claim 1, wherein the filler comprises wood, bamboo and/or cork.

### Claim 14 (depends on 1)

The floor panel according to claim 1, wherein the thickness of said rigid non-foamed substrate layer is 8 mm.

### Claim 15 (depends on 1)

The floor panel according to claim 1, wherein the decor comprises a melamine and/or a phenolic resin.

### Claim 16 (depends on 1)

The floor panel according to claim 1, wherein the density of the rigid, non-foamed substrate layer is in a range of 1300 to 2000 kg/m3.

### Claim 17 (depends on 1)

The floor panel according to claim 1, wherein the thermoplastic material of the rigid substrate layer comprises an amount of filler of at least percent by weight.

### Claim 18

A floor panel comprising:
a substrate and a decor provided on the substrate; and,
on at least one pair of opposite edges of the substrate, coupling parts realized at least partially from the substrate, wherein said coupling parts are configured to, in a coupled condition of two such floor panels, effect a mechanical locking at said one pair of opposite edges, wherein said mechanical locking is operative in both a horizontal direction and a vertical direction, said coupling parts being realized as a tongue and groove connection, the groove being bordered by an upper and a lower lip, wherein said tongue and groove connection comprises locking elements in the form of a protrusion at a lower side of the tongue and a recess in an upper side of the lower lip, which, in a coupled condition, counteract a moving apart of the tongue and the groove in a horizontal direction, wherein said mechanical locking is realized by cooperating locking surfaces of said tongue and groove and said locking elements;
wherein the substrate comprises a rigid, non-foamed substrate layer formed by extrusion of a composition consisting essentially of a thermoplastic material, an amount of inorganic or mineral filler and one or more of an impact modifier, a stabilizer and a color pigment;
wherein said rigid, non-foamed substrate layer is free from plasticizers or comprises an amount of less than 5phr of plasticizers;
wherein said amount of inorganic or mineral filler is at least 60 percent by weight and said thermoplastic material is polyvinyl chloride;
wherein a density of the rigid, non-foamed substrate layer is at least 1300 kg/m3;
wherein a thickness of said rigid, non-foamed substrate layer is at least 65% of an overall thickness of said floor panel;
wherein said overall thickness of said floor panel is between 3 and 10 mm, the floor panel showing a modulus of elasticity or Young's modulus of at least 2000 N per square millimeter;
wherein said upper lip and said lower lip are at least partially realized from said rigid, non-foamed substrate layer;
wherein a center line through said tongue is in said rigid, non-foamed substrate layer and wherein said groove comprises a most inwardly located point, said point being situated in said rigid, non-foamed substrate layer;
wherein zones in which the locking surfaces cooperate are situated at least partially in said rigid substrate layer.

### Claim 19 (depends on 18)

The floor panel according to claim 18, wherein the thickness of said rigid non-foamed substrate layer is between 2 and 6 mm.

### Claim 20 (depends on 19)

The floor panel according to claim 19, wherein said decor is chosen from a list consisting of:
a decor printed directly on one or a plurality of base coats provided on said substrate;
a decor printed on a decor carrier, wherein said decor carrier is a thermoplastic film or a paper layer impregnated with a melamine resin; and
a decor being a veneer of wood or stone.

### Claim 21 (depends on 20)

The floor panel according to claim 20, wherein said floor panel comprises a transparent or translucent wear and/or lacquer layer provided on said decor.

### Claim 22 (depends on 21)

The floor panel according to claim 21, wherein said wear layer is a thermoplastic foil having a thickness between 350 and 750 micrometers, or a paper layer impregnated with melamine resin.

### Claim 23 (depends on 22)

The floor panel according to claim 22, wherein a relief is formed in an upper side of said floor panel, wherein said relief reaches deeper than 100 microns, wherein said relief is provided by means of mechanical and/or chemical embossing.

### Claim 24 (depends on 23)

The floor panel according to claim 23, wherein said relief extends into said substrate.

### Claim 25 (depends on 22)

The floor panel according to claim 22, wherein the thermoplastic material of the rigid substrate layer comprises an amount of filler of at least 70 percent by weight.

### Claim 26 (depends on 22)

The floor panel according to claim 22, wherein said modulus of elasticity or Young's modulus is at least 3000 N per square millimeter.

### Claim 27 (depends on 26)

The floor panel according to claim 26, wherein said modulus of elasticity or Young's modulus is at least 3500 N per square millimeter.

### Claim 28 (depends on 26)

The floor panel according to claim 26, wherein said coupling parts allow bringing two of such floor panels in said coupled condition by means of a turning movement as well as by means of a substantially horizontal snap movement.

### Claim 29 (depends on 28)

The floor panel according to claim 28, wherein said lower lip is subjected to bending during said bringing said two of such floor panels in said coupled condition, wherein said lower lip is not broken.