# US 12,110,695 B2 · Floor panel and method of producing such a floor panel

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- Number: US 12,110,695 B2
- Document ID: US12110695B2
- Status: Granted
- Kind: B2
- Application number: 16/624,509
- Filed: 2018-06-22
- Published: 2020-04-23
- Granted: 2024-10-08
- Earliest claimed: 2017-06-22
- Assignees: Champion Link International Corporation
- Applicants: Champion Link International Corporation
- Inventors: Thomas Luc Martine Baert; Anthony Drevet
- Web page: https://patentgrep.com/patent/US12110695B2

## CPC

- E04F 15/02: Flooring or floor layers composed of a number of similar elements (of webs E04F15/16)
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- 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 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/045: {of synthetic resin}
- B32B 9/047: {made of fibres or filaments}
- B32B 9/06: of paper or cardboard
- B32B 13/12: of synthetic resin
- B32B 13/14: next to a fibrous or filamentary layer
- B32B 27/08: of synthetic resin
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 29/005: {next to another layer of paper or cardboard layer}
- C04B 28/32: Magnesium oxychloride cements, e.g. Sorel cement
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/02188: {for use in wet rooms}
- E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins}
- B32B 2250/05: 5 or more layers
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/26: Polymeric coating
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
- B32B 2262/067: Wood fibres
- B32B 2262/101: Glass fibres
- B32B 2307/102: Insulating
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/554: Wear resistance
- B32B 2307/584: Scratch resistance
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2307/7265: Non-permeable
- B32B 2307/732: Dimensional properties
- B32B 2307/734: Dimensional stability
- B32B 2419/04: Tiles for floors or walls
- B32B 2607/00: Walls, panels
- C04B 2111/00612: {as one or more layers of a layered structure}
- C04B 2111/60: Flooring materials
- 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 2201/023: with a continuous tongue or groove
- E04F 2201/043: with tongues and grooves being formed by projecting or recessed parts of the panel layers
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

The invention relates to a floor panel, in particular a magnesium oxide based floor panel, which is preferably provided with interconnecting coupling parts for mutually connecting adjacent floor panels to each other. The invention also relates to a method of producing a floor panel, in particular a magnesium oxide based floor panel.

## Claims

### Claim 1

A floor panel or wall panel, comprising a laminate of:
a magnesium oxide based core layer comprising magnesium oxide and magnesium sulphate and/or magnesium chloride, wherein magnesium oxide and magnesium sulphate and/or magnesium chloride comprise 60-90% of the total mineral content of the core layer, wherein the core layer further comprises wood fibres;
at least one magnesium oxide based upper crust layer positioned on top of said core layer, said upper crust layer comprising wood fibres;
at least one magnesium oxide based lower crust layer positioned underneath the core layer;
at least one upper reinforcing layer situated in between said core layer and said at least one upper crust layer;
at least one backing layer situated on an underside of the lower crust layer; and
at least one decorative layer and at least one wear layer attached to a top surface of the upper crust layer;
wherein the density of said upper crust layer is at least 8% larger than the density of the core layer; and
wherein the weight content of wood fibres in the core layer is larger than the weight content of wood fibres in the upper crust layer.

### Claim 2 (depends on 1)

The panel according to claim 1, further comprising a first pair of opposite edges, said first pair of opposite edges comprising complementary coupling parts allowing to mutually couple of plurality of floor panels to each other.

### Claim 3 (depends on 2)

The panel according to claim 2, further comprising a second pair of opposite edges, wherein both pairs of opposite edges comprise coupling parts allowing to mutually couple a plurality of floor panels to each other.

### Claim 4 (depends on 1)

The panel according to claim 1, wherein the upper crust layer comprises magnesium sulphate and/or magnesium chloride.

### Claim 5 (depends on 1)

The panel according to claim 1, wherein both the core layer and the upper crust layer comprise water, and wherein the weight content of water in the core layer is larger than the weight content of water in the upper crust layer.

### Claim 6 (depends on 1)

The panel according to claim 1, wherein the upper reinforcing layer comprises a fiberglass mesh.

### Claim 7 (depends on 6)

The panel according to claim 6, wherein the fiberglass mesh has a mesh size of at least 5×5 mm.

### Claim 8 (depends on 6)

The panel according to claim 6, wherein the fiberglass mesh has an area weight of at least 90 g/m2.

### Claim 9 (depends on 6)

The panel according to claim 6, wherein the fiberglass mesh is provided with a coating.

### Claim 10 (depends on 1)

The panel according to claim 1, wherein the density of the core layer is between 1000 and 1800 kg/m3.

### Claim 11 (depends on 1)

The panel according to claim 1, wherein the density of the upper crust layer is between 1100 and 2000 kg/m3.

### Claim 12 (depends on 1)

The panel according to claim 1, wherein the density of said at least one lower crust layer is larger than the density of the core layer; and, the floor panel further comprises
at least one lower reinforcing layer situated in between said core layer and said at least one lower crust layer.

### Claim 13 (depends on 12)

The panel according to claim 12, wherein the laminate comprises a plurality of lower reinforcing layers stacked on top of each other.

### Claim 14 (depends on 13)

The panel according to claim 13, wherein the laminate comprises a plurality of lower crust layers, wherein at least one lower crust layer is positioned in between at least two lower reinforcing layers, and wherein at least one lower crust layer is positioned underneath a lowest, lower reinforcing layer.

### Claim 15 (depends on 12)

The panel according to claim 12, wherein the density of the lower crust layer is between 1100 and 2000 kg/m3.

### Claim 16 (depends on 12)

The panel according to claim 12, wherein the lower crust layer comprises magnesium sulphate and/or magnesium chloride.

### Claim 17 (depends on 12)

The panel according to claim 12, wherein the lower crust layer is free of wood fibres.

### Claim 18 (depends on 12)

The panel according to claim 12, wherein both the core layer and the lower crust layer comprise water, and wherein the weight content of water in the core layer is larger than the weight content of water in the lower crust layer.

### Claim 19 (depends on 12)

The panel according to claim 12, wherein the lower reinforcing layer comprises a fiberglass mesh.

### Claim 20 (depends on 19)

The panel according to claim 19, wherein the fiberglass mesh has a mesh size of at least 5×5 mm.

### Claim 21 (depends on 19)

The panel according to claim 19, wherein the fiberglass mesh has an area weight of at least 90 g/m2.

### Claim 22 (depends on 19)

The panel according to claim 19, wherein the fiberglass mesh is provided with a coating.

### Claim 23 (depends on 1)

The panel according to claim 1, wherein the laminate comprises a top structure attached to the upper crust layer comprising the decorative layer and the wear layer covering said decorative layer.

### Claim 24 (depends on 1)

The panel according to claim 1, wherein the laminate comprises a urea-formaldehyde impregnated, decorative paper layer, attached to the upper crust layer.