Method for manufacturing a single- or multi-layered substrate (9), which is suitable for a floor panel (1), wherein, for forming a substrate layer (9A-9B-9C), thermoplastic material (23A-23B-23C) is strewn, for example, onto a transport device (25), and this strewn thermoplastic material is consolidated under the influence of pressure and/or heat, preferably in a press device (27), characterized in that the thermoplastic material (23A-23B-23C) to be strewn comprises micronized material.

Method for manufacturing a single- or multi-layered substrate (9), which is suitable for a floor panel (1), wherein, for forming a substrate layer (9A-9B-9C), thermoplastic material (23A-23B-23C) is strewn, for example, onto a transport device (25), and this strewn thermoplastic material is consolidated under the influence of pressure and/or heat, preferably in a press device (27), characterized in that the thermoplastic material (23A-23B-23C) to be strewn comprises micronized material.

A method for producing a shaped profile section in a continuous line process provides providing an outer facing web, an inner facing web and laying down an liquid foam reactants in the outer facing web. The method pre-forms the outer facing web into a desired outer profile shape prior to laying down the liquid foam reactants. The inner facing web is shaped with the liquid foam reactants within the pre-formed outer facing web to provide a desired inner profile shape for the shaped profile section. Also provided is an apparatus for producing a shaped profile section and a shaped profile section of the method.

A method for producing a shaped profile section in a continuous line process provides providing an outer facing web, an inner facing web and laying down an liquid foam reactants in the outer facing web. The method pre-forms the outer facing web into a desired outer profile shape prior to laying down the liquid foam reactants. The inner facing web is shaped with the liquid foam reactants within the pre-formed outer facing web to provide a desired inner profile shape for the shaped profile section. Also provided is an apparatus for producing a shaped profile section and a shaped profile section of the method.

A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

A continuous process for preparing insulation panels having thick (0.2 mm to 1 mm) metal facing panels and a fiber-reinforced polymer foam core is disclosed. In the process, a bottom metal facing panel is continuously supplied. A mat of reinforcing fibers and a foamable resin composition are applied to the bottom facing panel. A flexible barrier layer is applied atop the foamable resin composition, and the assembly is passed through nip rolls to compress the assembly and force the resin composition into the fiber mat. An adhesive layer and top metallic facing layer are then applied on top of the flexible barrier layer, and the resulting assembly is gauged and cured by passing it through a double band laminator.

A method and device for manufacturing a sandwich structure comprising at least one foam layer of a first thermoplastic comprising a chemical blowing agent and two cover layers. The decomposition temperature of the chemical blowing agent is higher than the melting point or range of the first thermoplastic. The method comprises a series of steps performed on an advancing starting structure including heating under pressure in order to cause decomposition of the blowing agent, intermediate cooling, foaming at a constant volume and further cooling.

A method and device for manufacturing a sandwich structure comprising at least one foam layer of a first thermoplastic comprising a chemical blowing agent and two cover layers. The decomposition temperature of the chemical blowing agent is higher than the melting point or range of the first thermoplastic. The method comprises a series of steps performed on an advancing starting structure including heating under pressure in order to cause decomposition of the blowing agent, intermediate cooling, foaming at a constant volume and further cooling.

A method for making a floor or wall panel has a foamed polymer core. A foamable polymer powder is foamed between two conveyor belts in the forming zone of a steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press is less than or equal to the opening of the steel belt press at the entrance of the steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the substrate at the outlet of the steel belt press is equal to the opening of the steel belt press at the outlet of the steel belt press and greater than the sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press.

A method for making a floor or wall panel has a foamed polymer core. A foamable polymer powder is foamed between two conveyor belts in the forming zone of a steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press is less than or equal to the opening of the steel belt press at the entrance of the steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the substrate at the outlet of the steel belt press is equal to the opening of the steel belt press at the outlet of the steel belt press and greater than the sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press.