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US 2025/0059775 A1Published application
Floor panel for forming a floor covering
AssigneeUnilin BV
InventorsKristof VAN VLASSENRODE, Filip BOSSUYT
Life of this patent
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Abstract
Floor panel for forming a floor covering, where the floor panel includes a carrier on the basis of a thermoplastic material and a top layer provided on the carrier. The thermoplastic material is free from plasticizers or includes a plasticizer in an amount up to maximum 20 phr, where the thermoplastic material is foamed or expanded, and where the carrier is provided with a reinforcement layer.
Claims20
A floor or wall panel, wherein the panel comprises:
- a carrier consisting of a first layer and a counter layer, wherein said carrier forms at least 40 percent of a thickness of said floor panel;
- wherein said first layer comprises a first thermoplastic material;
- wherein said first thermoplastic material is a thermoplastic polyester, polypropylene or a combination of polyethylene and polypropylene;
- said first layer having a top surface and a bottom surface, wherein said bottom surface is directly adjacent to said counter layer, wherein said counter layer forms the underside of said panel and wherein said counter layer is softer than said first layer;
- a top layer provided on the carrier, the top layer including at least a print and at least a wear layer;
- wherein said print is applied on a synthetic material film, wherein said synthetic material film is directly fused to said top surface of said first layer or is bonded to said top surface of said first layer with an adhesive agent;
- wherein said panel is provided on at least two opposite edges with coupling means which allow that two of such panels can be coupled to each other in such a manner that a locking is obtained in a vertical direction perpendicular to a plane of coupled panels as well as in a horizontal direction perpendicular to coupled edges and in the plane of the panel;
- wherein the coupling means are provided substantially in said carrier.
5 more elements
A floor or wall panel, wherein the panel comprises:
- a carrier consisting of a first layer and a counter layer, wherein said carrier forms at least 40 percent of a thickness of said floor panel;
- wherein said first layer comprises a first thermoplastic material;
- wherein said first thermoplastic material is a thermoplastic polyester, polypropylene or a combination of polyethylene and polypropylene;
- said first layer having a top surface and a bottom surface, wherein said bottom surface is directly adjacent to said counter layer, wherein said counter layer forms the underside of said panel and wherein said counter layer is softer than said first layer;
- a top layer provided on the carrier, the top layer including at least a print and at least a wear layer;
- wherein said print is applied by means of a digital printer on a basic layer or primer provided on said top surface and wherein said wear layer comprises a lacquer layer solidified at least by UV light or excimer radiation;
- wherein said panel is provided on at least two opposite edges with coupling means which allow that two of such panels can be coupled to each other in such a manner that a locking is obtained in a vertical direction perpendicular to a plane of coupled panels as well as in a horizontal direction perpendicular to coupled edges and in the plane of the panel;
- wherein the coupling means are provided substantially in said carrier.
5 more elements
A method for manufacturing a floor or wall panel, wherein said method at least comprises:
- the step of providing a carrier, wherein said carrier consists of a first layer and a counter layer, wherein said carrier forms at least 40 percent of a thickness of said floor panel;
- wherein said first layer comprises a first thermoplastic material;
- wherein said first thermoplastic material is a thermoplastic polyester, polypropylene or a combination of polyethylene and polypropylene;
- said first layer having a top surface and a bottom surface, wherein said bottom surface is directly adjacent to said counter layer, wherein said counter layer forms the underside of said panel and wherein said counter layer is softer than said first layer;
- the step of providing a top layer to said first layer, at least by providing a basic layer or primer on said top surface and digitally printing on said basic layer or primer;
- and providing a wear layer on said print;
- wherein said wear layer comprises a lacquer layer, wherein said lacquer layer is solidified at least by means of UV light or at least by means of excimer radiation;
- the step of providing said panel by means of a milling operation on at least two opposite edges with coupling means which allow that two of such panels can be coupled to each other in such a manner that a locking is obtained in a vertical direction perpendicular to a plane of coupled panels as well as in a horizontal direction perpendicular to coupled edges and in the plane of the panel;
- wherein the coupling means are provided substantially in said carrier;
- wherein said carrier forms at least 40 percent of a thickness of said panel.
7 more elements
Dependencies are inferred from the claim text.