FLOOR PANEL

Abstract

A floor panel with a substrate, including thermoplastic material, a decor provided thereon, and, on at least one pair of opposite edges, coupling parts realized at least partially from the substrate. The coupling parts allow a mechanical locking between two of such floor panels, where the substrate includes a rigid, non-foamed substrate layer of thermoplastic material.

Claims

1. A floor panel comprising a substrate and a decor, said substrate comprises a rigid substrate layer of thermoplastic material, wherein said rigid substrate layer of thermoplastic material is non-foamed, or wherein said rigid substrate layer of thermoplastic material is foamed and shows a density reduction of maximum 10% due to said foaming, and wherein said substrate comprises a substrate layer which is more flexible or compressible than the rigid substrate layer.

2. The floor panel of claim 1, wherein said substrate layer which is more flexible or compressible than the rigid substrate layer is situated between the rigid substrate layer and the decor.

3. The floor panel of claim 1, wherein said substrate layer which is more flexible or compressible than the rigid substrate layer comprises a thermoplastic material chosen from the group consisting of PVC, polyethylene, polypropylene, polyester, such as PET, polyurethane and/or elastomer.

4. The floor panel of claim 1, wherein said substrate layer which is more flexible or compressible than the rigid substrate layer comprises a plasticizer in an amount of at least 15 phr, preferably of at least 20 phr.

5. The floor panel of claim 1, wherein said thermoplastic material of the rigid substrate layer comprises a filler.

6. The floor panel of claim 5, wherein said filler is chosen from the group of an inorganic filler, an organic filler, a mineral filler, or combinations thereof.

7. The floor panel of claim 5, wherein said filler is present in said thermoplastic material in an amount of between 30 and 70 percent by weight, preferably of between 45 and 65 percent by weight.

8. The floor panel of claim 5, wherein the proportion of filler is at least 40 percent by weight, more preferably at least 50 percent by weight and still more preferably at least 60 or at least 70 percent by weight.

9. The floor panel of claim 1, wherein said thermoplastic material of the rigid substrate layer comprises an impact modifier, a stabilizer, such as a Ca/Zn stabilizer, and/or a color pigment, such as carbon black.

10. The floor panel of claim 1, wherein said thermoplastic material of the rigid substrate layer has a density of between 1300 and 2000 kg per cubic meter, preferably of between 1500 and 2000 kg per cubic meter.

11. The floor panel of claim 1, wherein the thermoplastic material of the rigid substrate layer comprises PVC.

12. The floor panel of claim 1, wherein said substrate comprises a second rigid substrate layer of thermoplastic material, and wherein said second rigid substrate layer of thermoplastic material is non-foamed, or wherein said second rigid substrate layer of thermoplastic material is foamed and shows a density reduction of maximum 10% due to said foaming.

13. The floor panel of claim 1, wherein the decor relates to an imprinted or printed decor.

14. The floor panel of claim 1, wherein the floor panel comprises a wear and/or lacquer layer provided above the decor.

15. The floor panel of claim 1, wherein the overall thickness of the floor panel is situated between 3.5 and 6 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0138] With the intention of better showing the characteristics of the invention, herein below, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0139] FIG. 1 represents a floor panel according to the invention;

[0140] FIG. 2 represents a cross-section according to line 11-11 in FIG. 1;

[0141] FIGS. 3 and 4 represent how the edges of FIG. 2 can be coupled;

[0142] FIG. 5, at a larger scale, represents what is indicated by F5 in FIG. 2;

[0143] FIGS. 6 to 13 represent variants of FIG. 2;

[0144] FIGS. 14 and 15 represent how floor panels can be coupled according to the fold-down technique;

[0145] FIG. 16 represents coupling parts which can be applied with such fold-down floor panels;

[0146] FIGS. 17 to 19 represent variants to FIG. 16;

[0147] FIG. 20 represents a method according to the invention; and

[0148] FIGS. 21 and 22 represent variants.

DETAILED DESCRIPTION OF THE INVENTION

[0149] FIG. 1 represents a floor panel 1 according to the invention. The represented floor panel 1 comprises a decor 2, which relates to printed wood decor. This relates to an oblong rectangular floor panel 1, which as a result has a pair of long edges 3-4 and a pair of short edges 5-6. Each pair of edges is provided with coupling parts, which are indicated by the reference numbers 7-8 and 9-10, respectively.

[0150] The shape of the coupling parts 7-8 is evident from FIG. 2. This relates to a tongue and groove connection comprising a tongue 11 and a groove 12, the groove being bordered by an upper lip 13 and a lower lip 14. The lower lip 14 protrudes to beyond the upper lip 13. Additionally, the connection comprises locking elements 15-16, in the form of a protrusion 15 on the lower side of the tongue 11 and an upward-directed locking element 16 in the portion of the lower lip 14 that protrudes beyond the upper lip 13, which, by cooperating locking surfaces 17-18, counteract the moving apart of the tongue 11 and the groove 12 in the horizontal direction H. The upper side 19 of the tongue 11 cooperates with the lower side 20 of the upper lip 13 in order to counteract the separation in the vertical direction V.

[0151] FIGS. 3 and 4 show how the coupling parts 7-8 can be coupled by means of a turning movement (FIG. 3) as well as a substantially horizontal snap movement (FIG. 4).

[0152] FIG. 2 also shows the construction of the floor panel 1. It is constructed of a substrate 21, a decor carrier 22 with decor 2, a wear layer 23 and a lacquer layer 24.

[0153] The substrate 21Consists of two substrate layers 21A and 21B realized on the basis of PVC.

[0154] The substrate layer 21A is rigid. For this purpose, no plasticizers are present in this layer 21A, or plasticizers are present in an amount of less than 15 phr only. Examples of plasticizers which can be used have already been mentioned. Also, the substrate layer 21A comprises a proportion of filler situated between 30 and 70 percent by weight. Preferably, chalk, talc and/or lime is used, possibly supplemented with wood, bamboo and/or cork particles. Further, the substrate layer 21A can comprise an impact modifier, a stabilizer, such as a Ca/Zn stabilizer, and/or a color pigment, such as carbon black. The thickness T1 of the substrate 21A is at least 2 mm. The result is that the substrate layer 21A has a high bending stiffness. This is advantageous, considering that the risk of warping of the floor panel 1 and of forming pushed-up edges under incident sunlight already is counteracted to a certain extent.

[0155] This risk is significantly reduced further due to the presence of the glass fiber fleece 25. Although it does not seem to be able to prevent the expansion/shrinkage of the substrate 21 with varying temperatures, it indeed counteracts the warping or pushing up. This actually is the most important, considering that the expansion/shrinkage as such can be counteracted by providing suitable expansion spaces, which also is known as such in the field of the wood laminate floors. The glass fiber fleece 25 is enclosed between the substrate layer 21A and 21B. In this manner, it can perform its function at its best. Possibly, the glass fiber fleece 25 is at least partially impregnated with thermoplastic material of the substrate layers 21A and/or 21B. This provides for a strong embedding in the substrate 21, such that it can perform its function even better. The position of the glass fiber layer 25 provides for that it extends uninterruptedly in both coupling parts 7-8. This is positive for the effectivity thereof, certainly at the respective edges 3-4 of the panel 1.

[0156] The rigid substrate layer 21A is obtained by means of a strewing process. By such process, a very good connection with the glass fleece 25 can be obtained. In such process, the glass fleece 25 can also have a support function. Possibly, the glass fleece 25 can also form a separation between the strewn layer 21A and the layer 21B in case the latter also would be strewn. This is certainly useful prior to consolidating, as this prevents a mutual mixing of the strewn material among the layers.

[0157] Also, the substrate layer 21A is not foamed. In comparison with foamed layers, hereby a better resistance against telegraphy and indentation effects is offered. The density of the layer 21A is situated between 1300 and 2000 kg per cubic meter.

[0158] The zone where the upper side 19 of the tongue and the lower side 20 of the upper lip cooperate, is situated entirely in the rigid substrate layer 21A, just like the zone where the locking elements 15-16 cooperate. This provides for that a strong mechanical coupling can be effected, wherein gap formation will arise less easily. The upper lip 13 is partially realized from the layer 17A, and the lower lip 14 even entirely. This provides for a reduced risk of breaking of one or both of the lips 13-14. Certainly, with the lower lip 14, this is advantageous as this lip 14 may not break as a result of the possible bending it is subjected to during the coupling of the edges 3-4. Otherwise, the coupling will be lost.

[0159] The substrate layer 21B is more flexible than the layer 21A. To this aim, in this layer 21B more plasticizers are present, namely at least 15 phr. This flexible layer 21B provides for that, regardless of the relatively stiff panel 1, no ticking sound is created when this panel 1 is walked upon. Thus, due to the soft character, it has sound absorbing properties. Moreover, such layer 21B is easier to deform in order to create a deep relief in the upper side of the panel 1. The proportion of filler in this layer 21B is situated between 30 and 70 percent by weight. Further, the substrate layer 21B can comprise an impact modifier, a stabilizer, such as a Ca/Zn stabilizer, and/or a color pigment, such as carbon black. The thickness T2 of the substrate layer 21B is situated between 0.5 and 1 mm.

[0160] The layers 17A and 17B are connected to each other by means of thermal lamination. In this manner, a reduced risk of delamination is obtained in comparison with the use of glue or the like.

[0161] The decor carrier 22 on which the decor is printed relates to a PVC film or foil.

[0162] The transparent wear layer 23 relates to a PVC layer with a thickness situated between 250 and 750 micrometers.

[0163] The overall thickness T of the floor panel 1 is situated between 3.5 and 6 mm.

[0164] FIG. 5 better shows the lacquer 24 which is provided on the wear layer 23. This relates to a lacquer realized on the basis of urethane acrylate. The relief 26 provided in the upper side of the panel 1 is visible, too.

[0165] FIG. 6 shows coupling parts 7-8 similar to those from FIG. 2, however, the substrate 21 is constructed differently. The layer 21A is constructed similar to the layer 21A of FIG. 2, however, thinner. Anyhow, a second rigid substrate layer 21C is present in the substrate 21As well, which also is made of PVC. The substrate layer 21C contains no plasticizers, or plasticizers in an amount of less than 15 phr only. The substrate layer 21C also comprises a proportion of filler situated between 30 and 70 percent by weight. Further, the substrate layer 21C can comprise an impact modifier, a stabilizer, such as a Ca/Zn stabilizer, and/or a color pigment, such as carbon black. The overall thickness T1 of the substrate layers 21A and 21C is at least 2 mm. The result is that the whole of both substrate layers 21A and 21C gives a high bending stiffness to the panel 1, which even is increased by the enclosed glass fleece 25. The position of the glass fleece 25 is such that it extends uninterruptedly through both coupling parts 7-8. And it is positioned at the height of the center line of the tongue 11 and goes through the most inwardly located point of the groove 12. Thus, at those locations additional support is given, which is beneficial for the strength of the tongue 11 and groove 12.

[0166] The rigid layers 21A and 21C are formed by means of a strewing process which is known as such from WO 213/179261. It offers the advantage that the glass fleece 25 can be embedded very well into the rigid whole, with a particularly stable sandwich as a result.

[0167] The rigid layer 21C also is not foamed.

[0168] FIG. 7 shows coupling parts 7-8 similar to those from FIG. 6, however, the substrate 21 is constructed differently. The substrate layers 21A and 21C are constructed similar to the layers 21A and 21C of FIG. 6. However, there is a third rigid substrate layer 21 D, which also is made of PVC. The substrate layer 21 D contains no plasticizers, or plasticizers in an amount of less than 15 phr only. Also, the substrate layer 21 D comprise a proportion of filler situated between 30 and 70 percent by weight. Further, the substrate layer 21 D can comprise an impact modifier, a stabilizer, such as a Ca/Zn stabilizer, and/or a color pigment, such as carbon black. The overall thickness T1 of the substrate layers 21A, 21C and 21 D is at least 2 mm. The result is that the whole of the substrate layers 21A, 21C and 21 D gives a high bending stiffness to the panel 1, which even is increased by the presence of two enclosed glass fleeces 25A and 25B. The two glass fleeces 25A and 25B are located off the center of the panel 1 at a distance D from each other of at least ⅕ the thickness T of the panel 1. The substrate layers 21C and 21 D are realized thinner than the center layer 21A, however, have a thickness of at least ⅕ the thickness of the center layer 21A. The result is a particularly balanced and stable sandwich construction. The substrate layers 21A, 21C and/or 21 Das such may comprise a plurality of substrate layers and thus be multi-layered. The substrate layer 21A, for example, may comprise a plurality of substrate layers which may or may not have a mutually differing composition, such as a mutually differing proportion of filler or plasticizer. The same is applicable to the layers 21C and 21 D and more generally to all substrate layers mentioned in this document.

[0169] The two glass fleeces 25A and 25B have a weight smaller than 65 gram per square meter. This has a positive influence on the process speed and practically no detrimental influence on the dimensional stability, at least not in the application with rigid substrate layers.

[0170] FIG. 8 shows a variant of FIG. 7, wherein the substrate 21At the lower side comprises a sound-absorbing substrate layer 21 E of XPE foam. The thickness of this layer 21E is situated between 1 and 2 mm.

[0171] FIG. 9 shows a variant of FIG. 7, wherein the glass fleeces 25A-25B are positioned somewhat differently. The glass fleece 25A goes centrally through the zone where the upper side 19 of the tongue 11 cooperates with the lower side 20 of the upper lip 13, whereas the glass fleece 25 goes centrally through the zone where the locking elements 15-16 cooperate. This provides for an excellent horizontal and vertical locking.

[0172] FIG. 10 shows a variant of FIG. 9. The glass fleece 25A is positioned similarly, however, the glass fleece 25B extends uninterruptedly in the coupling part 8. It extends continuously through the lower lip 14. This is beneficial for the strength of this lip 14.

[0173] FIG. 11 shows a similar construction of the substrate 21As in FIG. 10, however, the coupling parts 7-8 have another configuration. The lower side of the tongue 11 is convex, while the upper side of the lower lip 14 is concave.

[0174] FIGS. 12 and 13 show two more variants, where the lower side of the tongue 11 and the upper side of the lower lip 14 comprise a flat part.

[0175] FIGS. 14 and 15 represent how floor panels 1 can be coupled to each other by means of the fold-down technique.

[0176] To this aim, the short pair of edges 5-6 of the panel 1 is provided with the coupling parts 9-10 shown in FIG. 16. Those are realized in the form of a downward-directed hook 27 and an upward-directed hook 28. The downward hook 27 has a lip 29 with a downward-directed locking element 30, whereas the upward hook 28 has a lip 31 with an upward-directed locking element 32. The locking elements 30 and 32 cooperate, via locking surfaces 33-34, in order to counteract the moving apart of the hooks 27-28 in horizontal direction. The hooks 27-28 are also provided with vertically active locking elements 35-36. The vertically active locking element 35 is made as a separate insert, which is provided in a recess 37 in the downward hook 27. This recess is situated partially in the rigid layers 21A and 21C. it is also possible to provide the insert 35 in the upward hook 28.

[0177] The lip 29 is formed partially from the rigid layers 21A and 21C. The lip 31 is formed entirely from the rigid layers 21A and 21 D. The zone where the locking elements 30 and 32 cooperate is situated entirely in the rigid layer 21A. All these measures are advantageous for the strength of the locking. The zone where the insert 35 cooperates with the locking element 36 is situated in the more flexible layer 21B. However, it is not excluded that this last zone is situated at least partially or entirely in the rigid layers 21A and/or 21C.

[0178] The glass fiber layer 25A is situated at the height of the recess 37. This provides for additional stability there, where the floor panel, due to the recess 37, is somewhat weaker.

[0179] The glass fiber layer 25A extends continuously in the lip 31 of the upward-directed hook 28.

[0180] FIG. 17 shows a variant of FIG. 16. Here, the insert 36 is provided in a recess 37 in the upward hook 28. The zone where the insert 36 cooperates with the locking element 35, however, indeed is situated in a rigid substrate layer, namely in the rigid layer 21A. This provides for a very good vertical locking.

[0181] FIG. 18 shows a variant of FIGS. 16 and 17, wherein the vertically active locking elements are realized from the material of the panel 1. There, even two pairs of vertically active locking elements are present, namely the locking elements 35-36 as well as the locking surfaces 33-34, which provide for the horizontal as well as the vertical locking. All the vertical locking elements are made from the rigid layers 21A and 21C. Moreover, the glass fleece is situated at the height of the zone where the locking elements 35-36 cooperate. The glass fleece 25B extends continuously through the lip 31. This provides for that the lip 31 is realized very stable and the risk of damaging it, for example, during the elastic bending of the lip 31 during coupling, is very small, in spite of the recess provided in the lower side of the lip 31, which recess increases the bendability of the lip 31 and, thus, the ease of installation.

[0182] FIG. 19 shows a variant of FIG. 18, wherein the vertically active locking elements 35-36 are situated at the end of the lip 31. The glass fleece 25B goes therethrough.

[0183] FIG. 20 represents a method according to the fifth aspect of the invention. This method can be used in order to obtain the substrate construction of the panels 1 of, for example, FIG. 7. By means of strewing treatments successively the rigid substrate layers 21 D, 21A and 21C are provided. The rigid thermoplastic material thereof is strewn onto a transport belt 39 by means of strewing devices 38. On the strewn layers 21 D and 21A a glass fleece 25B and a glass fleece 25A, respectively, is provided. To this aim, the glass fleeces 25A and 25B are unrolled from rollers 40 and provided on the respective substrate layers 21 D and 21A. The formed complex subsequently is transported to a double-belt press 41, in which it is consolidated under the influence of pressure and/or heat. The press device 41 comprises, in transport direction, heating elements 42, an S-roller 43 and cooling elements 44. The heating elements 42 heat the complex brought into the press device 41, as a result of which the individual layers can be connected to each other more easily and better. The use of the S-roller 43 is advantageous as it provides for a calibration of the respective layers. The cooling elements 44 finally cool the consolidated complex, such that it can be processed more rapidly. Subsequently, the more flexible substrate layer 21B is provided on the consolidated whole, by means of calendering device 45 which consists of more than one calendering roller 46.

[0184] It is clear that in subsequent steps the decor carrier 22 with decor 2, the wear layer and the lacquer layer, 23 and 24, can be applied.

[0185] FIG. 21 shows a variant of FIG. 20. Here, the glass fleece 25 is brought into contact with a press element in the press device 43. This is different to FIG. 20, where each glass fleece is enclosed between rigid substrate layers.

[0186] FIG. 22 shows another alternative manner of providing a glass fleece 25 on a rigid substrate layer. Reference number 47 indicates an extrusion device with which the rigid substrate layer 21A is manufactured. This substrate layer 21 subsequently is transported between guide rollers 48. The glass fleece 25 is wound off a roll 49 and provided, between two of such guide rollers, on the substrate layer 21A. It is clear that this whole can be processed further and possibly can be supplemented with subsequent substrate layers and/or glass fleeces. It is also noted that this technique and be applied in an advantageous manner with any type of substrate layer of thermoplastic material, independently of whether this relates to a rigid, semi-rigid or flexible substrate layer.

[0187] The present invention further relates to several preferred embodiments as defined in the below numbered paragraphs:

[0188] 1.—Floor panel (1) with a substrate (17), comprising thermoplastic material, a decor (2) provided thereon, and, on at least one pair of opposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at least partially from the substrate (17), said coupling parts allowing to effect a mechanical locking between two of such floor panels (1), characterized in that the substrate (17) comprises a rigid substrate layer (17A) of thermoplastic material, and a glass fiber layer (25) is present in the floor panel (1).

[0189] 2.—Floor panel according to paragraph 1, wherein the rigid substrate layer (17A) comprises plasticizers in an amount of less than 15 phr, less than 10 phr or less than 5 phr, or does not comprise any plasticizers.

[0190] 3.—Floor panel according to paragraph 1 or 2, wherein the thermoplastic material of the rigid substrate layer (17A) comprises PVC.

[0191] 4.—Floor panel according to any of the preceding paragraphs, wherein the thermoplastic material of the rigid substrate layer (17A) comprises a proportion of filler, which proportion preferably is situated between 30 and 70 percent by weight or between 45 and 65 percent by weight.

[0192] 5.—Floor panel according to paragraph 4, wherein the proportion of filler comprises an inorganic filler, such as chalk, lime and/or talc, and/or an organic filler, such as wood, bamboo and/or cork.

[0193] 6.—Floor panel according to any of the preceding paragraphs, wherein the rigid 25 substrate layer (17A) is not foamed.

[0194] 7.—Floor panel according to paragraph 6, wherein the density of the rigid substrate layer (17A) is situated between 1300 and 2000 kg per cubic meter or between 1500 and 2000 kg per cubic meter.

[0195] 8.—Floor panel according to any of the preceding paragraphs, wherein the glass fiber layer (25) relates to a glass fiber fleece.

[0196] 9.—Floor panel according to any of the preceding paragraphs, wherein the glass fiber layer (25) adjoins to the rigid substrate layer (17A).

[0197] 10.—Floor panel according to any of the preceding paragraphs, wherein the substrate comprises a second rigid substrate layer (17B) of thermoplastic material, which preferably is not foamed.

[0198] 11.—Floor panel according to paragraph 10, wherein the glass fiber layer (25) is enclosed between the first and the second rigid substrate layer (17A-17B).

[0199] 12.—Floor panel according to any of the preceding paragraphs, wherein a second glass fiber layer (25B) is present in the floor panel (1).

[0200] 13.—Floor panel according to paragraph 12, wherein the first and the second glass fiber layer (25A-25B) each have a weight smaller than 65 or at most 50 gram per square meter.

[0201] 14.—Floor panel according to paragraph 12 or 13, wherein the first and the second glass fiber layer (25A-25B) are situated off the center of the floor panel (1).

[0202] 15.—Floor panel according to any of the paragraphs 12 to 14, wherein the first and the second glass fiber layer (25A-25B) are situated at a vertical distance (V) of at least ⅕ times or at least ¼ times the thickness of the floor panel (T) from each other.

[0203] 16.—Floor panel according to any of the paragraphs 12 to 15, wherein the first and the second glass fiber layer (25A-25B) enclose the rigid substrate layer (17A), which in this case preferably is situated in the center of the floor panel.

[0204] 17.—Floor panel according to any of the paragraphs 12 to 16, wherein the first glass fiber layer (25A) is enclosed between the rigid substrate layer (17A) and the possible second rigid substrate layer (17B), and the second glass fiber layer (25B) is enclosed between the rigid substrate layer (17A) and a third rigid substrate layer (17C) of thermoplastic material, which third rigid substrate layer (17C) preferably is not foamed.

[0205] 18.—Floor panel according to paragraph 17, wherein the second and the third substrate layer (17B-17C) are made thinner than the first rigid substrate layer (17A), however, preferably have at least ⅕ times or at least ¼ times its thickness.

[0206] 19.—Floor panel according to paragraph 16 or 17, wherein the third substrate layer (17C) is made thicker than the second substrate layer (17B), however, preferably maximum 2.5 or maximum 2 times as thick.

[0207] 20.—Floor panel according to any of the preceding paragraphs, wherein the one or more rigid substrate layers (17A-17B-17C) of thermoplastic material have an overall thickness of at least 2 mm.

[0208] 21.—Floor panel according to any of the preceding paragraphs, wherein the one or more rigid substrate layers (17A-17B-17C) of thermoplastic material have an overall thickness of at least half of the overall thickness (T) of the floor panel (1).

[0209] 22.—Floor panel according to any of the preceding paragraphs, wherein the substrate, between the decor and the rigid substrate layer (17A), comprises a substrate layer (17D) of thermoplastic material which is more flexible or more compressible than the rigid substrate layer (17A).

[0210] 23.—Floor panel according to paragraph 22, wherein the more flexible substrate layer (17D) is situated directly underneath the decor or the possible decor carrier on which the decor is provided.

[0211] 24.—Floor panel according to paragraph 21 or 22, wherein the more flexible substrate layer (17D) is connected to the underlying part of the substrate (17) by means of thermal lamination.

[0212] 25.—Floor panel according to any of the preceding paragraphs, wherein the decor (2) relates to an imprinted or printed decor.

[0213] 26.—Floor panel according to any of the preceding paragraphs, wherein the floor panel (1) comprises a wear and/or lacquer layer (21 and/or 29) provided above the decor (2).

[0214] 27.—Floor panel according to any of the preceding paragraphs, wherein the floor panel (1) will bend under its own weight less than 10 cm per meter or less than 5 cm per meter.

[0215] 28.—Floor panel according to any of the preceding paragraphs, wherein the floor 10 panel (1) has a modulus of elasticity of at least 2000 N per square millimeter.

[0216] 29.—Floor panel according to any of the preceding paragraphs, wherein the overall thickness (T) of the floor panel (1) is situated between 3.5 and 6 mm.

[0217] 30.—Floor panel according to any of the preceding paragraphs, wherein the coupling parts (5-6) are realized as a tongue and groove connection, the groove (12) being bordered by an upper (13) and a lower lip (14), and wherein this connection comprises locking elements (15-16).

[0218] 31.—Floor panel according to paragraph 30, wherein the tongue and groove connection shows one or more of the following features, as far as they are not contradictory: [0219] the upper lip (13) is at least partially realized from the first (17A) and/or the possible second rigid substrate layer (17B); [0220] the lower lip (14) is at least partially or entirely realized from the first (17A) or the possible third rigid substrate layer (17C); [0221] the center line through the tongue (11) is situated in the first rigid substrate layer (17A); [0222] the most inwardly located point of the groove (12) is situated in the first rigid substrate layer (17A); [0223] the zone where the upper side of the tongue (11) cooperates with the lower side of the upper lip (13) is situated at least partially or entirely in the first (17A) or the possible second rigid substrate layer (17B); [0224] the zone where the locking elements (15-16) cooperate is situated at least partially or entirely in the first (17A) and/or the possible third rigid substrate layer (17C); [0225] the glass fiber layer (25) is situated at the height of the zone where the upper side of the tongue (11) cooperates with the lower side of the upper lip (13); [0226] the glass fiber layer (25) is situated at the height of the zone where the locking elements (15-16) cooperate; [0227] the glass fiber layer (25) is situated on the center line through the tongue (11); [0228] the glass fiber layer (25) is situated at the height of the most inwardly located point of the groove (12);

[0229] in the case that the zone where the upper side of the tongue (11) cooperates with the lower side of the upper lip (13) is situated at another location than the zone where the locking elements (15-16) cooperate, preferably at least two glass fiber layers (25A-25B) are present, wherein it is preferably valid that the one glass fiber layer (25A) is situated at the height of the zone where the upper side of the tongue (11) cooperates with the lower side of the upper lip (13), and the other is situated at the height of the zone where the locking elements (15-16) cooperate; [0230] the glass fiber layer extends uninterruptedly or continuously in the lower lip or in the upper lip; and/or [0231] the glass fiber layer (25) extends uninterruptedly or continuously in at least one of the coupling parts (5-6).

[0232] 32.—Floor panel (1) with a substrate (17), comprising thermoplastic material, a decor (2) provided thereon, and, on at least one pair of opposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at least partially from the substrate (17), said coupling parts allowing to effect a mechanical locking between two of such floor panels (1), characterized in that the substrate (17) comprises a rigid, non-foamed substrate layer (17A) of thermoplastic material.

[0233] 33.—Floor panel (1) with a substrate (17), comprising thermoplastic material, a decor (2) provided thereon, and, on at least one pair of opposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at least partially from the substrate (17), said coupling parts allowing to effect a mechanical locking between two of such floor panels (1), characterized in that the substrate comprises a rigid substrate layer (17A) of thermoplastic material, which, via thermal lamination, is connected to a more flexible substrate layer (17D) which is situated between the decor (2) and the rigid substrate layer (17A).

[0234] 34.—Floor panel (1) with a substrate (17), comprising thermoplastic material, a decor (2) provided thereon, and, on at least one pair of opposite edges (3-4, 7-8), coupling parts (5-6, 9-10) realized at least partially from the substrate (17), said coupling parts allowing to effect a mechanical locking between two of such floor panels (1), characterized in that in the floor panel at least two glass fiber layers (25A-25B) are present, each having a weight of less than 65 g per square meter or even at most 50 g per square meter.

[0235] 35.—Method for manufacturing a floor panel (1) with a substrate (17), comprising thermoplastic material, and a decor (2) provided thereon, wherein the method comprises the following steps: [0236] providing a first rigid substrate layer (17A) of thermoplastic material by means of a first strewing treatment; [0237] providing a glass fiber layer (25) on the strewn substrate layer (17A); [0238] providing a second rigid substrate layer (17B) of thermoplastic material on the glass fiber layer (25), by means of a second strewing treatment; [0239] consolidating the strewn substrate layers (17A-17B) and the glass fiber layer (25) under the influence of pressure and/or heat; [0240] providing, on the consolidated second substrate layer (17B), a more flexible or more compressible substrate layer (17D) of thermoplastic material by applying this thermoplastic material in liquid condition.

[0241] 36.—Method according to paragraph 35, wherein the consolidation is performed in a press device (47).

[0242] 37.—Method according to paragraph 35 or 36, wherein the more flexible substrate layer (17D) is provided on the second substrate layer (17D) by means of a calendaring device.

[0243] 38.—Method according to any of the paragraphs 35 to 37, wherein the method also comprises providing the decor (2) and a possible wear and/or lacquer layer (21 And/or 29).

[0244] 39.—Method according to any of the paragraphs 35 to 38, wherein the aforementioned layers form a continuous material web, which finally is divided into individual pieces for forming the floor panels (1).

[0245] 40.—Method according to any of the paragraphs 35 to 39, wherein the method is employed for manufacturing a floor panel (1) according to any of the paragraphs 1 to 34.

[0246] The present invention is in no way limited to the herein above-described embodiments; on the contrary, such methods, floor panels and carrier material can be realized according to various variants without leaving the scope of the present invention.