FLOOR ELEMENT AND METHOD FOR MANUFACTURING FLOOR ELEMENTS

Abstract

A floor element includes a decorative top layer on a polymer substrate. The sides of the floor element have a profile along a section with a surface at right angles to the decorative top layer. The floor panel is provided with a water-repellent coating on at least one side. For each side and along the entire length of the side, at least a part of the profile is coated with a water-repellent coating.

Claims

1.-24. (canceled)

25. A floor element comprising a decorative top layer on a polymer substrate, wherein the sides of the floor element have a profile along a section with a surface at right angles to the decorative top layer, wherein the floor panel is provided with a water-repellent coating on at least one side, and wherein for each side and along the entire length of the side, at least a part of the profile is coated with a water-repellent coating.

26. The floor element of claim 25, wherein the water-repellent coating comprises epoxy resin, fluoride-functionalized epoxy resin, fluoropolymers, fluorocopolymers, fluoride-functionalized acrylate and/or combinations thereof.

27. The floor element of claim 25, wherein the water-repellent coating comprises fluoropolymers and/or fluorocopolymers.

28. The floor element of claim 25, wherein the substrate comprises polyvinyl chloride.

29. The floor element of claim 25, wherein one or more of the sides has a straight profile.

30. The floor element of claim 25, wherein one or more of the sides has a non-straight profile.

31. The floor element of claim 30, wherein the floor element is substantially rectangular or square, and wherein at least a first pair of two opposite sides have a non-straight profile.

32. The floor element of claim 31, wherein the first pair of two profiles together form a set of coupling means to couple two adjacent floor elements to each other.

33. The floor element of claim 30, wherein the floor element is substantially rectangular or square, and wherein two pairs of two opposite sides have a non-straight profile.

34. The floor element of claim 33, wherein it is true for both pairs that the two profiles of mutually opposite sides together form a set of coupling means to couple two adjacent floor elements to each other.

35. The floor element of claim 32, wherein the interacting profiles of the coupling means each have at least a section which adjoin each other during coupling.

36. The floor element of claim 35, wherein at least one or more of the adjoining sections are provided with the water-repellent coating.

37. The floor element of claim 30, wherein at least one of the sides is provided with at least a beveled edge at the location of the transition from the top layer to the side.

38. The floor element in accordance with claim 37, wherein the coating is applied along the beveled edge.

39. The floor element of claim 37, wherein the coating is applied along a section of the profile adjoining the beveled edge.

40. The floor element of claim 25, wherein the coating is applied along a section of the profile, which section is oriented at right angles to or obliquely to the top surface of the floor element.

41. A method for manufacturing floor elements, comprising the following steps: providing a rectangular or square polymer substrate, wherein this substrate is provided with a decorative top layer; providing the profiles of the sides of the rectangular polymer substrate with a solvent-based cover layer, furthermore, comprising at least one water-repellent component; removing the solvent from the solvent-based cover layer until a water-repellent coating is obtained.

42. The method of claim 41, wherein the water-repellent components comprise epoxy resin and/or fluoride-functionalized epoxy resin and/or fluoropolymers and/or fluorocopolymers and/or fluoride-functionalized acrylate.

43. The method of claim 41, wherein at least two opposite sides have non-straight profiles, wherein the two profiles together form a set of coupling means to couple two adjacent floor elements to each other.

44. The method of claim 41, wherein the two pairs of opposite sides have a non-straight profile, wherein it is true for both pairs that the two profiles of mutually opposite sides together form coupling means to couple two adjacent floor elements to each other.

Description

[0076] FIG. 1 shows a diagrammatic representation of a top view of a floor element according to the invention;

[0077] FIGS. 2 and 4 show diagrammatic representations of cross sections along plane IV-IV shown in FIG. 1;

[0078] FIGS. 3 and 5 show diagrammatic representations of cross sections along plane V-V shown in FIG. 1.

[0079] The present invention is described below by means of specific embodiments.

[0080] It should be noted that the term “comprising”, as used, for example, in the claims, should not be interpreted in a limiting sense, limited to the elements, characterizing features and/or steps mentioned thereafter. The term “comprising” does not exclude the presence of other elements, characterizing features or steps.

[0081] Thus the scope of an expression “an object comprising the elements A and B” is not limited to an object which only contains the elements A and B. The scope of an expression “a method comprising the steps A and B” is not limited to a method which only contains the steps A and B.

[0082] In the light of the present invention, these expressions only mean that the relevant elements and steps, respectively, are the elements and steps A and B, respectively, for the invention.

[0083] In the following specification, reference is made to “an embodiment” or “the embodiment”. Such a reference means that a specific element or characterizing feature, described by means of this embodiment, is comprised in at least this one embodiment.

[0084] However, the use of the terms “in an embodiment” or “in the embodiment” at various points in this description does not necessarily refer to the same embodiment, although it may nevertheless refer to the same embodiment.

[0085] Furthermore, the properties or the characterizing features may be combined in one or more embodiments in any suitable manner, as will be clear to those skilled in the art.

[0086] A floor element according to the invention is diagrammatically shown in FIGS. 1 to 3.

[0087] In the cross sections shown in FIGS. 2 and 3, the decorative top layer 130 on the polymer substrate 140 is clearly visible.

[0088] The substrate 130 is a rigid PVC layer, i.e. a PVC layer made of hard PVC containing an amount of plasticizer of less than 10 phr. In addition to other additives, such as processing aids, this substrate comprises between 100 and 300 phr, for example 200 phr of fillers, preferably CaCO.sub.3. The polymer used is polyvinyl chloride with a K value of between 55 and 60, for example 57. The substrate 130 has a thickness of between 3 and 8 millimeters, for example 4 or 5 mm. One or two glass fiber nonwovens are embedded in this hard PVC, each having a weight per unit area of approximately 35 g/m.sup.2.

[0089] In an alternative form, this rigid PVC substrate is of the 3-layered ABA type, in which the A layers are formed as described above, where the intermediate B layer is made of similar PVC, but is foamed.

[0090] The top layer 140 itself is layered and comprises a PU coating on a wear layer which consists of transparent PVC. This wear layer has a thickness of between 0.1 and 1 mm, for example 0.3 mm. The PVC used does not comprise any fillers, but is semi-rigid PVC containing plasticizers between 25 and 40 phr, for example 30 phr.

[0091] Under the wear layer, there is a hard PVC film (containing less than 10 phr of plasticizer) which has a thickness of between 50 and 120 μm (for example 70 μm, 90 μm or 110 m) on which a decoration (for example a wood decoration) is printed. This decor layer is in turn bonded to a layer of soft or semi-soft, typically calendered, PVC. This soft PVC layer has a thickness of 0.6 mm. The PVC preferably comprises 38 phr of plasticizer and 200 phr of fillers, for example CaCO.sub.3. This PVC layer makes contact with the substrate 130.

[0092] The floor element 100 has four sides which are paired in pairs of two and situated one opposite the other and provided with a profile which offers the possibility of laterally coupling adjacent floor elements. The sides 101 and 102 are parallel to each other and opposite to each other. The tongue 112 of side 102 of a first board can be click-fitted into the groove 111 of side 101 of a second adjoining board by means of a downward movement (fold-down coupling system). The profile 121 of the groove 111 of side 101 cooperates with the profile 122 of the tongue 112 of side 102 in such a way that a horizontal displacement between themselves in the direction at right angles to the side 101 and 102, and a vertical displacement of two floor elements which have been coupled to each other is impossible. The profile sections 21 and 23 prevent the vertical movement, the profile sections 26 and 27 prevent the horizontal movement.

[0093] The sides 103 and 104 are parallel to each other and opposite to each other. The tongue 114 of side 104 of a first board can be rotated into the groove 113 of side 103 of a second adjoining board by means of a rotating movement. This is an example of coupling means comprising rotating profiles. The profile 123 of the groove 113 of side 103 cooperates with the profile 124 of the tongue 114 of side 104 in such a way that a horizontal displacement between themselves in the direction at right angles to the side 103 and 104, and a vertical displacement of two floor elements which have been coupled to each other is impossible. The profile sections 22 and 24 prevent the vertical movement, the profile sections 28 and 29 prevent the horizontal movement.

[0094] In an alternative embodiment, all sides are provided with a click-fit system.

[0095] When click-fitting profiles 121 and 122 to each other, the upright sections 31 and 32 will adjoin each other tightly, if not be pressed against each other by prestress or compressive stress, resulting from the coupling together of the sides. After profiles 123 and 124 have been connected to each other by rotation, the upright sections 33 and 34 will closely adjoin each other, if not be pressed against each other by prestress, resulting from the coupling together of the sides. Thus, prestress may be produced between the adjoining profiles, but this does not necessarily have to be the case. The sides may also be coupled together without prestress.

[0096] At least along a part or section of their profile, the sides 101 to 104 of the floor element 100 are coated, preferably at least along the profile sections 31 and 32, and 33 and 34, with a water-repellent coating. The latter is applied along the entire length of the side. Thus, an uninterrupted strip of side which is coated with a water-repellent coating is present between the first end 101a and second end 101b of the side 101. An uninterrupted strip of side which is coated with a water-repellent coating is present between the first end 102a and second end 102b of the side 102. An uninterrupted strip of side which is coated with a water-repellent coating is present between the first end 103a and second end 103b of the side 103. An uninterrupted strip of side which is coated with a water-repellent coating is also present between the first end 104a and second end 104b of the side 104. Possibly, the entire profiles 121, 122, 123 and 124 are coated with the water-repellent coating.

[0097] After a rectangular polymer substrate provided with a decorative top layer has been provided, the profiles 121, 122, 123 and 124 are milled into the sides. These profiles were subsequently provided with a solvent-based cover layer comprising a water-repellent component. The solvent is an organic solvent and the water-repellent component is a fluorocopolymer. The cover layer is applied at a rate of 0.5 to 5 g/m.sup.2 by means of spraying or applying with a brush or transfer roller. The cover layer comprises between 50 and 70 vol % of solvent, for example approximately 60 vol % of solvent. Alternatively, a water-based cover layer containing a water-repellent component may be used.

[0098] The water-repellent cover layer may optionally furthermore also comprise a pigment or colorant.

[0099] After the application, the solvent is removed by drying or evaporation, as a result of which a coating of fluorocopolymer remains behind on the profiles.

[0100] In an alternative embodiment, several layers of water-based or organic solvent-based cover layers are applied, optionally using evaporation or drying of the solvent in the interim.

[0101] In an alternative embodiment, the decorative top layer is a layer of wood veneer which is bonded to the substrate. The solvent-based cover layer comprising a water-repellent component is certainly applied to the upright edges of the layer of wood veneer in order to thus prevent the wood veneer against ingress of water.

[0102] FIGS. 4 and 5 show yet another embodiment.

[0103] In this case, the sides 101 to 104 are at least provided with a beveled edge 141, 142, 143 and 144 at the location of the transition of the top layer and the side. The beveled edge 141, 142, 143 and 144 adjoin the upright sections 31 and 32, and 33 and 34. These beveled edges 141 to 144 which thus form part of the profiles 101 to 104 may be but do not necessarily have to be provided with the water-repellent coating. In case the decorative top layer is a layer of wood veneer, these beveled edges are preferably provided with the water-repellent coating, optionally after having first been colored. The beveled edges 141 to 144 may be provided with a layer of paint before the water-repellent cover layer is applied. This layer of paint may be water-based or organic solvent-based. Optionally, the water-repellent cover layer may furthermore also comprise a pigment or colorant.

[0104] It will be clear that, although the embodiments and/or the materials for providing embodiments according to the present invention have been described, various modifications or changes may be made without deviating from the area of application and/or the spirit of this invention. The present invention is by no means limited to the above-described embodiments, but may be achieved by means of different variants without departing from the scope of the present invention.