Multilayer floor panel based on a PVC plastisol
AssigneeBeaulieu International Group NV
InventorsSam Van Essche, Hanna Eggermont, Pol Lombaert, Jonas Guido Feys, Frans Van Giel
Life of this patent
Estimating the term…
Abstract
Floor panels that includes a substrate and a multi-layered top layer directed attached to the substrate. The multi-layered top layer includes a décor layer that includes a fused PVC plastisol, a print pattern deposited as single or stacked dots of a digitally printed material on top of the décor layer, a wear-resistant layer including a fused PVC plastisol provided above the print pattern. Optionally, a lacquer layer is provided directly on top of the wear-resistant layer.
Claims23
A floor panel comprising:
- a substrate;
- a multi-layered top layer directly attached to the substrate;
- wherein the multi-layered top layer comprises:
- a decor layer comprising a fused PVC plastisol,
- a print pattern deposited as single or stacked dots of a digitally printed material on top of the decor layer,
- a wear-resistant layer comprising a fused PVC plastisol provided above the print pattern, wherein the wear-resistant layer is obtained by gelling a PVC plastisol and by mechanically embossing the PVC plastisol during gelling and subsequently fusing the gelled PVC plastisol to obtain the fused wear-resistant layer, wherein the ratio between elastic moduli of the substrate and multi-layered top layer is at least 20 measured at 23±2° C. and 50±10% R.H. according to ISO 527.
A method for producing a floor panel comprising the subsequent steps of:
- S1:
- providing a substrate,
- S2:
- applying a first coating comprising a PVC plastisol directly onto the substrate to obtain a decor layer,
- S3:
- gelling the decor layer,
- S4:
- applying a print pattern of single or stacked dots of printing material directly onto the gelled decor layer by means of digital printing,
- S5:
- applying a second coating comprising a PVC plastisol onto the printed decor layer to obtain a wear-resistant layer, and
- S6:
- gelling the wear-resistant layer and subsequently fusing the decor layer and wear-resistant layer, and further comprising the step of mechanically embossing the wear-resistant layer with an embossing mould during gelling, wherein the embossing mould is a release web, or wherein the embossing mould is a polymer coated paper.
A floor panel comprising:
- a substrate;
- a multi-layered top layer directly attached to the substrate, wherein the multi-layered top layer comprises:
- a decor layer comprising a fused PVC plastisol,
- a print pattern deposited as single or stacked dots of a digitally printed material on top of the decor layer,
- a wear-resistant layer comprising a fused PVC plastisol provided above the print pattern, wherein the wear-resistant layer is obtained by gelling a PVC plastisol and by mechanically embossing the PVC plastisol during gelling and subsequently fusing the gelled PVC plastisol to obtain the fused wear-resistant layer, wherein resistance against separation of the substrate and the multi-layered top layer to peeling is at least 50 N/50 mm.
Dependencies are inferred from the claim text.