# US 12,179,468 B2 · Decorative panel and method for producing a panel

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 12,179,468 B2
- Document ID: US12179468B2
- Status: Granted
- Kind: B2
- Application number: 17/657,811
- Filed: 2022-04-04
- Published: 2023-07-27
- Granted: 2024-12-31
- Earliest claimed: 2022-01-07
- Assignees: Champion Link International Corporation
- Applicants: Champion Link International Corporation
- Inventors: Thomas Luc Martine Baert; Tom Van Poyer; Sven Boon
- Web page: https://patentgrep.com/patent/US12179468B2

## CPC

- B29C 48/022: {characterised by the choice of material}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B29C 44/022: {Foaming unrestricted by cavity walls, e.g. without using moulds or using only internal cores}
- B29C 44/3415: {Heating or cooling}
- B29C 44/505: {extruding the compound through a flat die (in general B29C48/03)}
- B29C 48/0012: {combined with shaping by internal pressure generated in the material, e.g. foaming}
- B29C 48/07: Flat, e.g. panels
- B29C 48/21: the layers being joined at their surfaces
- B29C 48/87: Cooling
- B29C 48/92: Measuring, controlling or regulating
- 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 5/20: foamed in situ
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- E04F 13/0866: {composed of several layers, e.g. sandwich panels or layered panels (layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence)}
- E04F 13/0894: {with tongue and groove connections}
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B29C 2948/92704: Temperature
- B29C 2948/92876: Feeding, melting, plasticising or pumping zones, e.g. the melt itself
- B29K 2101/12: Thermoplastic materials
- B29K 2105/043: {Skinned foam}
- B29K 2105/16: Fillers
- B29K 2509/00: Use of inorganic materials not provided for in groups {B29K2503/00 - B29K2507/00,} as filler
- B29K 2509/02: Ceramics
- B29L 2031/104: {Tiles}
- B32B 2264/1021: Silica
- B32B 2264/1027: Clay
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2264/107: Ceramic
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/0235: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2266/025: Polyolefin
- B32B 2266/0264: Polyester
- B32B 2307/72: Density
- B32B 2307/722: Non-uniform density
- B32B 2419/04: Tiles for floors or walls
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2607/02: Wall papers, wall coverings
- 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
- 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
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- 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

The invention relates to a floor or wall panel and to a method of producing such panel. The panel comprise at least one core layer comprising at least one composite material, said composite material comprising at least one mineral filler, and at least one thermoplastic binder, which are present in a preferred ratio and composition such that a relatively light weight and rigid panel is obtained.

## Claims

### Claim 1

A floor or wall panel comprising:
a substantially planar top side, a substantially planar bottom side, and at least four substantially linear side edges comprising at least one pair of opposite side edges;
wherein the panel has a layered structure which comprises:
at least one extruded and at least partially foamed core layer; and
at least one decorative top layer;
wherein the at least one extruded and at least partially foamed core layer comprises at least one composite material, said composite material comprising:
at least one filler, wherein the at least one filler is a mineral filler; and
at least one binder, wherein the at least one binder is a thermoplastic material;
wherein the composite material comprises the at least one filler in an amount greater than or equal to 30 wt. % and the at least one binder in an amount less than or equal to 40 wt. %, and the ratio of mineral filler to thermoplastic material in the composite material is at least 3:1; and
wherein the at least one extruded and at least partially foamed core layer has an average density variation, said average density variation across a lateral width of the at least one extruded and at least partially foamed core layer is within 10%.

### Claim 2 (depends on 1)

The panel according to claim 1, wherein the at least one extruded and at least partially foamed core layer comprises an upper core surface; and wherein the at least one decorative top layer is directly attached to said upper core surface.

### Claim 3 (depends on 1)

The panel according to claim 1, wherein the at least one extruded and partially foamed core layer has a density in the range of 1500 to 1900 kg/m3.

### Claim 4 (depends on 1)

The panel according to claim 1, wherein the at least one extruded and partially foamed core layer has a density gradient.

### Claim 5 (depends on 1)

The panel according to claim 1, wherein the at least one extruded and partially foamed core layer has an average density, an upper core surface, and a bottom core surface; and wherein the density near the upper core surface and/or the bottom core surface is at least 5% higher than the average density of the at least one extruded and partially foamed core layer.

### Claim 6 (depends on 1)

The panel according to claim 1, wherein the at least one extruded and partially foamed core layer has a density in the range of 70 to 90% of the gravimetric density of the composite material in a non-foamed state.

### Claim 7 (depends on 1)

The panel according to claim 1, wherein at least one mineral filler of the composite material comprises calcium carbonate, chalk, clay, calcium silicate, dolomite, talc, magnesium oxide, magnesium chloride, magnesium oxysulfate and/or limestone.

### Claim 8 (depends on 1)

The panel according to claim 1, wherein at least one thermoplastic material of the composite material comprises polyvinyl chloride, polystyrene, polyethylene, polyurethane, acrylonitrile butadiene styrene, polypropylene, polyethylene terephthalate, phenolic and/or melamine or formaldehyde resins.

### Claim 9 (depends on 1)

The panel according to claim 1, wherein the at least one extruded and at least partially foamed core layer has an expansion percentage of at least 10%.

### Claim 10 (depends on 1)

The panel according to claim 1, comprising multiple extruded and partially foamed core layers.

### Claim 11 (depends on 1)

The panel according to claim 1, wherein the at least one ore layer at least one pair of opposite side edges has complementary coupling parts.