FLOOR PANEL

Abstract

A floor may include a substrate having a top side and a bottom side. A top layer may be provided on the substrate. The top layer may consist of a printed thermoplastic film and a thermoplastic transparent or translucent layer provided on the printed thermoplastic film. The top layer may be directly adhered to the substrate by heat welding the printed thermoplastic film and the top side of the substrate, in the absence of a glue layer. The substrate may be a synthetic material board including a filler. The substrate at least at two opposite edges may include coupling means provided in the synthetic material board. The thermoplastic transparent or translucent layer may be provided with a structure.

Claims

1. A method for manufacturing a plurality of floor, wall or ceiling panels, said panels being rectangular, having at least a pair of longitudinal opposite edges and a pair of short opposite edges; the method comprising: forming a board larger than a single one of said panels; said board comprising at least a synthetic material substrate, a printed film located on top of said synthetic material substrate, and a transparent or translucent wear layer located on top of said printed film; said synthetic material substrate having a density of more than 450 kilograms per cubic meter and comprising fillers; said transparent or translucent wear layer having a thickness of 0.2 mm to 1 mm; wherein forming said board includes a first step of extruding said synthetic material substrate; a second step of providing a top layer on said synthetic material substrate by at least adhering the printed film to said synthetic material substrate by at least one of heating or pressing and providing said transparent or translucent wear layer on said printed film by at least adhering the transparent or translucent wear layer to said film by at least one of heating or pressing; and a third step of mechanically embossing said top layer in such a way that impressions formed from said mechanically embossing are limited in depth to said transparent or translucent wear layer; wherein said first step and said second step are performed in a continuous manner on a same production line; obtaining said plurality of panels from said board; wherein said obtaining said plurality of panels from said board comprises a dividing operation; wherein said obtaining said plurality of panels from said board comprises a milling treatment with rotating milling tools at least for providing mechanical coupling parts to at least the pair of longitudinal opposite edges of said plurality of panels; wherein said mechanical coupling parts are configured to allow two of said plurality of panels to couple to each other at the corresponding pair of longitudinal opposite edges; wherein said mechanical coupling parts include vertically active locking surfaces configured to provide locking in a vertical direction between the two of said plurality of panels perpendicular to a plane of the coupled panels; wherein the vertically active locking surfaces are realized in said synthetic material substrate; and wherein said milling treatment occurs after said dividing operation.

2. The method of claim 1, wherein said milling treatment comprises forming a recessed edge at least on one or both edges of said pair of longitudinal opposite edges by removing a portion on the respective edges.

3. The method of claim 1, wherein said mechanical coupling parts include horizontally active locking surfaces configured to provide locking in a horizontal direction between the two of said plurality of panels in the plane of the coupled panels; wherein said horizontally active locking surfaces are realized in said synthetic material substrate.

4. The method of claim 2, wherein said recessed edge has a shape of a chamfer.

5. The method of claim 4, wherein said chamfer is limited in depth to the thickness of said transparent or translucent wear layer.

6. The method of claim 2, wherein a surface of said recessed edge is formed by said synthetic material substrate.

7. The method of claim 6, wherein the surface of said recessed edge comprises a separate decorative covering.

8. The method of claim 5, wherein said top layer further comprises a UV surface coating; wherein forming said board includes applying said UV surface coating subsequently to said adhering the transparent or translucent wear layer to the printed polyvinyl chloride film.

9. The method of claim 8, wherein said dividing operation is a sawing operation.

10. The method of claim 9, wherein said board is rigid and cannot be wound up.

11. The method of claim 10, wherein said board has a thickness of 5 millimeter or more.

12. A method for manufacturing a plurality of floor, wall or ceiling panels, said panels being rectangular, having at least a pair of longitudinal opposite edges and a pair of short opposite edges; the method comprising: forming a board larger than a single one of said panels; said board comprising at least a synthetic material substrate, a printed film located on top of said synthetic material substrate, and a transparent or translucent wear layer located on top of said film; having a density of more than 450 kilograms per cubic meter and comprising fillers; said transparent or translucent wear layer having a thickness of 0.2 mm to 1 mm; wherein at least the pair of longitudinal opposite edges of said plurality of panels comprises mechanical coupling parts configured to allow two of said plurality of panels to couple to each other at the corresponding pair of longitudinal opposite edges; wherein said mechanical coupling parts comprise a tongue and a groove; wherein said groove is defined by an upper lip and a lower lip extending in a horizontal direction beyond said upper lip in a plane of the coupled floor panels; wherein said mechanical coupling parts include a first pair of vertically active locking surfaces formed between an upper surface of the tongue and a lower side of the upper lip configured to provide locking in a vertical direction between the two of said plurality of panels perpendicular to the plane of the coupled panels; wherein the first pair of vertically active locking surfaces are realized in said synthetic material substrate; wherein forming said board includes a first step of extruding said synthetic material substrate; a second step of providing a top layer on said synthetic material substrate by at least adhering the printed film to said synthetic material substrate by at least one of heating or pressing and providing said transparent or translucent wear layer on said printed film by at least adhering the transparent or translucent wear layer to said film by at least one of heating or pressing; and a third step of mechanically embossing said top layer in such a way that impressions formed from said mechanically embossing are limited in depth to said transparent or translucent wear layer; wherein said first step and said second step are performed in a continuous manner on a same production line; and obtaining said plurality of panels from said board, wherein said obtaining said plurality of panels from said board comprises a dividing operation; wherein said obtaining said plurality of panels from said board comprises a milling treatment with rotating milling tools at least for providing said mechanical coupling means.

13. The method of claim 12, wherein said mechanical coupling parts include a first pair of horizontally active locking surfaces formed between an upstanding part on the lower lip and a recess on a lower side of the tongue configured to provide locking in a horizontal direction between the two of said plurality of floor panels in the plane of the coupled floor panels; wherein said first pair of horizontally active locking surfaces are realized from said synthetic material substrate and are oriented at an angle with said plane of the coupled panels; said angle being more than 30 degrees.

14. The method of claim 13, wherein said angle is more than 45 degrees.

15. The method of claim 13, wherein a second pair of horizontally active locking surfaces is formed adjacent to the respective top layers of coupled panels; said second pair of horizontally active locking surfaces being substantially vertical.

16. The method of claim 15, wherein said obtaining said plurality of panels from said board comprises forming a recessed edge at least on one or both edges of said pair of longitudinal opposite edges by removing a portion on the respective edges; wherein said recessed edge has a shape of a chamfer limited in depth to the thickness of said transparent or translucent wear layer.

17. The method of claim 16, wherein said top layer further comprises a UV surface coating; wherein forming said board includes applying said surface coating subsequently to said adhering the transparent or translucent wear layer to the printed film.

18. The method of claim 17, wherein said plurality of panels are rigid and cannot be wound up.

19. The method of claim 18, wherein said dividing operation is a sawing operation.

20. The method of claim 19, wherein said board has a thickness of 5 millimeter or more.

21. The method of claim 1, wherein said transparent or translucent wear layer is free from filler materials and hard particles.

22. The method of claim 12, wherein said transparent or translucent wear layer is free from filler materials and hard particles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings.

[0055] FIG. 1 in perspective represents a floor panel according to a non-limiting embodiment of the invention.

[0056] FIG. 2, at a larger scale, represents a cross-section according to the line II-II represented in FIG. 1.

[0057] FIG. 3 schematically represents a method for manufacturing floor panels.

[0058] FIG. 4, at a larger scale, represents a cross-section according to the line IV-IV represented in FIG. 3.

[0059] FIGS. 5 to 7, in a view similar to that of FIG. 3, represent variants of a method for manufacturing floor panels.

DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0060] FIG. 1 represents a floor panel 1 for forming a floating floor covering.

[0061] FIG. 2 clearly shows that the floor panel 1 is of the type which comprises at least a substrate 2 and a top layer 3 provided on this substrate 2, wherein the top layer 3 comprises a motif 4, in this case a wood motif.

[0062] In the example of FIGS. 1 and 2, this relates to a rectangular floor panel 1, which, at the first pair 5-6 as well as at the second pair 7-8 of opposite edges, is provided with mechanical coupling means 9.

[0063] FIG. 2 represents that the coupling means 9 at the first pair 5-6 of opposite edges, namely, the long edges of the floor panel 1, substantially are performed as a tongue 10, a groove 11, respectively. Herein, the groove 11 is flanked by an upper lip 12 and a lower lip 13. When two of such floor panels 1 are coupled to each other at these edges 5-6, the cooperation of the tongue 10 and the groove 11 as such leads to a locking in a vertical direction V1 perpendicular to the plane of the floor panels 1. The cooperation between the tongue 10 and the groove 11 preferably comprises forming one or more pairs 14-15-16-17 of vertically active locking surfaces. In this case, a pair of locking surfaces 14-15 is formed between the upper surface of the tongue 10 and the lower side of the upper lip 12 and a pair 16-17 between the lower side of the tongue 10 and the upper side of the lower lip 13. At least one of said pairs 14-15, and in this case both pairs 14-15-16-17 of vertically active locking surfaces are formed in the example of the particular substrate 2 of the invention. In this manner, a strong locking in vertical direction V1 is obtained.

[0064] The coupling means 9 represented here also comprise locking means or locking parts 18-19, which result in a locking in a horizontal direction H1 perpendicular to the coupled edges 5-6 and in the plane of the coupled floor panels 1. In the example, the locking parts 18-19 are formed as an upstanding part 19 on the lower lip 13 and a recess 18 on the lower side of the tongue 10. These locking parts 18-19 are provided in each other when coupling two or more of such floor panels 1. Herein, one or more, preferably two, pairs 20-21-22-23 of horizontally active locking surfaces are created. In the example, one pair of horizontally active locking surfaces 20-21 is situated on said upstanding part 19 and cooperating therewith surface 20 of said recess 18. This pair of horizontal locking surfaces 20-21 is formed from the material of the particular substrate 2 of the invention. The respective locking surfaces 20-21 are oriented at an angle A with the surface of the floor panels 1. This angle A preferably is more than 30 degrees, and still better more than 45 degrees. Angles A of 90 degrees or more are not excluded. The second pair of horizontal locking surfaces 22-23 of the example is situated next to the floor surface, at the height of the location where the top layers 3 of two floor panels, which are coupled to each other, are flanking each other. In this case, this second pair of locking surfaces 22-23 is made substantially vertical. Moreover, this pair of horizontally active locking surfaces 22-23 is substantially and here even exclusively formed of the material of the top layer 3.

[0065] Many of the characteristics listed up above and represented in FIGS. 1 and 2 can be applied, within the scope of the invention, broader than in combination with the other characteristics of the example. The following characteristics, each individually or in any combination, can offer interesting advantages: [0066] the characteristic that the coupling means 9 offer a locking in horizontal direction H1 as well as in vertical direction V1, independently from the fact whether the coupling means 9 are mechanical and/or are performed, whether or not substantially, in the form of a tongue 10 and groove 11; [0067] the characteristic that at least one pair of horizontally active locking surfaces 20-21 of the coupling means 9 is realized in the substrate 2 of the invention and/or the characteristic that at least one pair of horizontally active locking surfaces 22-23 of the coupling means 9 is at least partially and preferably entirely realized in the top layer 3; [0068] the characteristic that one or more pairs 14-15-16-17 of the vertically active locking surfaces are formed at least partially and preferably entirely from the substrate 2; [0069] the characteristic that the mechanical coupling means 9 consist of milled profiles, which, for at least 70 percent of their circumference, are provided in the substrate 2 of the invention; [0070] the characteristic that the first pair of opposite edges 5-6 as well as the second pair of opposite edges 7-8 is provided with coupling means; [0071] the characteristic that the mechanical coupling means 9 allow a coupling by means of a turning movement W along the respective edges 5-6 and/or a horizontal shifting movement S of the edges towards each other and/or a downwardly directed movement of a male coupling part having for example, a tongue 10, into a female coupling part having, for example, a groove 11; [0072] the characteristic that the lower lip 13 extends in horizontal direction beyond the upper lip 12; [0073] the characteristic that in a coupled condition of two of such floor panels 1 a tension force is obtained between the top layers 3 of the respective floor panels 1;
herein, the lower lip 13 preferably is in a bent condition; [0074] the characteristic that the lower lip 13, in a coupled condition, is bent.

[0075] The particularity of the present invention, at least according to its first aspect, consists in that said substrate 2 substantially consists of a foamed synthetic material board. In the example, the substrate 2 relates to a foamed PVC board of the closed cell type. The board 2 concerned has an average density of 450 kilograms per cubic meter, however, also has a local density on both flat sides 24-25, namely, a density of 500 kilograms per cubic meter or more, which is higher than the density of a central layer 26 of the synthetic material board 2. Moreover, the substrate 2 comprises separate layers 27, in this case layers of glass fiber, which increase the bending stiffness thereof. In the example, these separate layers 27 are situated on both flat sides 24-25 of the substrate 2.

[0076] The top layer 3 of the floor panel 1 of the example is a top layer 3 which substantially consists of synthetic material, namely, of a vinyl compound such as PVC (polyvinyl chloride). This top layer 3 has a higher density than the average density of the substrate 2. The represented top layer 3 as such consists of a back layer 28, a provided thereon motif 4 and a transparent wear layer 29. The back layer 28 is the thickest and densest layer of the top layer 3. It consists of recycled synthetic material, here PVC, which comprises filler material, preferably chalk. For said motif 4, use is made of a printed synthetic material film 30. For example, use can be made of a synthetic material film 30 which is printed by means of solvent inks. Such inks may result in a high-resolution print quality. The synthetic material film 30 as such can consist of PVC or another vinyl compound. For the transparent layer or wear layer 29, use is made of vinyl, such as PVC.

[0077] Preferably, said transparent layer 29 is free from filler materials or hard particles, such as aluminum oxide. The inventors have found that a transparent or translucent layer 29 of 0.2 millimeters of vinyl as such is sufficient for obtaining an acceptable wear resistance. Of course, it is not excluded that use should be made of a wear layer 29 which comprises hard particles. However, these have a negative influence on the transparency of such wear layer and lead to accelerated wear of machines which are applied when manufacturing such floor panels 1. When hard particles are applied, preferably a wear layer 29 is used having a thickness of less than 0.3 millimeters, or even less than 0.2 millimeters. Preferably, in such case use is made of hard particles in a concentration of 5 to 20 grams per square meter, wherein 10 grams per square meter represent a good value. Preferably, the applied hard particles have an average grain size between 30 and 120 micrometers, and still better between 50 and 90 micrometers.

[0078] As is mentioned in the introduction, however, not represented here, the floor panel 1 can be provided with a surface layer at its surface, for example, on the basis of a UV-hardened substance. Such layer preferably has a thickness of less than 0.1 millimeter, or still better of less than 50 micrometers. It is not excluded that such surface layer includes hard particles, such as aluminum oxide particles, wherein these hard particles preferably have an average grain size of less than 50 micrometers. Possibly, flat particles may be used here.

[0079] In dashed line 31, it is represented on FIG. 2 that a backing layer 32 can be provided on the lower side of the floor panel 1. Such backing layer 32 preferably consists of a similar material as the top layer 3, for example, of vinyl, which possibly is provided with filler material. Preferably, the density of said backing layer 32 is lower than the density of said top layer 3, or anyhow at least lower than the back layer 28, which in the example is included in said top layer 3. Preferably, the backing layer 32 consists of open cell foamed PVC or so-called cushion vinyl (cushion vinyl). Such backing layer 32 can be connected to the substrate by similar methods as the top layer 3, namely, either by gluing, by foaming it against the substrate or vice versa, by melting or by extruding or otherwise forming this backing layer 32 together with said synthetic material board 2.

[0080] FIG. 3 represents a method for manufacturing floor panels 1 in accordance with the embodiment of FIGS. 1 and 2. Herein, larger boards are formed, which show the composition of such floor panel 1 and which, in a step not represented here, are divided into panels showing approximately the final dimensions of such floor panel 1. After this step of dividing, still further operations can be performed on these panels 1, such as forming coupling means or coupling parts 9 at the edges thereof.

[0081] The method comprises a step S1 where in the top layer 3 is provided on the substrate 2, and a step S2 wherein a thermoplastic translucent or transparent layer 29, which forms part of the top layer 3, is structured by means of a mechanical press element 33. In the example of FIG. 3, these two steps S1-S2 are performed simultaneously in a press device 34, for example, as represented here, in a press device 34 of the short-cycle type. As press element 33, a press platen is applied.

[0082] FIG. 4 clearly shows that this press platen 33 is provided with a structure 35 which is copied by means of the press treatment at least into thermoplastic transparent or translucent layer 29. In this case, the underlying motif 4 and the back layer 28 are deformed as well. However, it is also possible that the motif 4 and/or the back layer 28 are left undisturbed during the press treatment, or that, in other words, the impressions 36 which are formed in the thermoplastic layer 29 are limited in depth, such that at least the motif 4, or the printed synthetic material film 30, is free from local deformations.

[0083] Preferably, by means of the step S2 of structuring, impressions 36 are obtained which in location and/or size correspond to the motif 4.

[0084] Prior to the press treatment, a step S0 is performed, wherein two thermoplastic layers 29-30 are adhered to each other. Namely, the synthetic material film 30 and the transparent thermoplastic layer 29 are welded or melted to each other by means of a calender device 37. To this aim, use is made of infrared heating 38 and one or more rollers 39. The obtained whole is cut to sheets 41 by means of the cutting tool 40 and, together with the back layer 28, the substrate 2 and a backing layer 32, is brought into the press device 34.

[0085] During said press treatment, a third step S3 is performed, too. Herein, the thermoplastic translucent or transparent layer 29 is heated again, by which providing a structure by means of the press element 33 becomes possible. Moreover, by means of this heat an adherence of the thermoplastic layer 29, the synthetic material film 30, the back layer 28, the substrate 2 and the backing layer 32 is obtained. Preferably, the hot press cycle is followed by a cold or cooled press cycle, whether or not taking place in the same press device 34. Such cool cycle prevents an excessive springing back of the realized structure of impressions 36.

[0086] According to a not represented variant of FIG. 3, the thermoplastic layer 29 can be sufficiently heated prior to the press treatment, for example, by means of the represented infrared heating 38, such that it can be fed into the press device 37 in warm condition. In such case, a cold press cycle may suffice for structuring the thermoplastic layer 29. The adherence between this thermoplastic layer 29, the back layer 28, the substrate 2 and the possible backing layer 32 then preferably is obtained in another manner than by means of the cold press treatment.

[0087] FIG. 5 represents a variant, wherein the thermoplastic layer 29 is provided on the substrate 2 prior to the step S2 of providing a structure. Schematically, a calender device 37 is represented by which the thermoplastic layer 29 and the possible backing layer 32 are adhered to the substrate 2. It is clear that also a possible printed synthetic material film 30 and/or back layer 28, for example, also by means of such device 37, can be provided on the substrate 2 prior to the step S2 of providing a structure. In this case, the complete layer composition Feb. 3, 1932 of the floor panel 1 is obtained prior to the step S2 of providing a structure.

[0088] In accordance with the second aspect of the invention, in FIG. 5 the thermoplastic layer 29 is heated, in this case prior to the step S2 of providing a structure, by means of one or more infrared heating units 38. The thermoplastic layer 29, while it already forms part of the connected whole of substrate 2, top layer 3 and possible backing layer 32, is fed in its hot condition into the press device 34, where it is provided with impressions 36 by means of a press element 33. Preferably, here a cold press cycle is used. A similar result can be achieved as represented in FIG. 4.

[0089] FIG. 6 represents another variant, wherein the thermoplastic transparent or translucent layer 29 is formed in line with the step S1 of providing at least this thermoplastic layer 29 on the substrate 2. To this aim, an extruding machine 42 is installed above a pair of heated rollers 43. By means of the extruding machine 42, amounts of vinyl are provided between said heated rollers 43 and applied in paste-like form on a web-shaped carrier material 44, where it hardens. The carrier material 44 as such can be heated, for example, by means of one or more infrared heating units 38. The carrier material 44 preferably comprises a printed synthetic material film 30, which shows the motif 4 of the final floor panel 1. The extruded vinyl forms a thermoplastic transparent or translucent layer 29 above the motif 4. It is clear that in a similar manner also the back layer 28 and/or the backing layer 32 can be formed against the substrate 2. The step S1 of applying the thermoplastic layer 29 on the substrate 2, the step S3 of heating the thermoplastic layer and the step S2 of providing a structure in this example are performed in a similar manner as in the embodiment of FIG. 5.

[0090] It is possible that the thermoplastic layer 29 is provided with a structure at least partially prior to the step S1 of applying this layer 29 on the substrate 2. To this aim, for example, a structured roller 45 can be applied.

[0091] In the example of FIG. 6, use is made of a method having the characteristics of the third aspect of the invention. To this aim, the step of manufacturing the synthetic material board 2 and the step S1 of providing the top layer 3 on this synthetic material board 2, or at least providing at least a portion or a partial layer 28-29-30 thereof, for example, the transparent or translucent synthetic material layer 29, are performed continuously and on the same production line. In this case, the synthetic material board 2 is manufactured by means of an extrusion process, which makes use of an extruding machine 46.

[0092] FIG. 7, too, represents an embodiment having, amongst others, the characteristics of the second and the third aspect of the invention. In this case, the vinyl originating from the extruding machine 42 is provided in past-like form directly on the substrate 2, namely, without the intermediary of a carrier material. Of course, in such example already one or more other partial layers 28-29-30 of the top layer 3 can be provided on the substrate 2, such as, for example, a back layer 28 and/or a motif 4, for example, in the form of a printed synthetic material film 30. For the rest, the process represented here is similar to that represented in FIGS. 6, 7 and 8.

[0093] According to an alternative, which is not represented here, the substrate 2 and one or more partial layers 28-29-30 of the top layer 3 and/or the backing layer 32 are extruded together via so-called coextrusion. Preferably, in such case at least the back layer 28 and/or the backing layer 32 are extruded together with a synthetic material board 2, preferably a foamed synthetic material layer, such as described by means of the first aspect of the invention.

[0094] It is clear that the method illustrated in FIGS. 3 to 7 shows examples of a method having the characteristics of the second aspect of the invention. FIGS. 6 and 7 also are examples of the third aspect of the invention.

[0095] According to the embodiments of FIGS. 5, 6 and 7, the substrate 2 is supplied as an endless board material, which is divided prior to the step S2 of providing a structure. However, it is not excluded that in these embodiments, too, boards of limited length are applied, for example, a length approximately corresponding to the length of an integer of the final floor panels, for example, corresponding to one to four times this length. It is also possible that the board material from FIGS. 3, 5, 6 and 7, in endless form, is at least subjected to step S2 of providing a structure. In such embodiment, preferably a press device is applied of the continuous type. Of course, in such case the cutting device 40 preferably is arranged after the press device.

[0096] It is clear that the infrared heating units 38, as mentioned and/or represented in connection with the figures, can be replaced by any other heating apparatus. According to a particular variant, the press element 33 is provided on the thermoplastic layer 29 prior to the step S2 of providing a structure and this press element 33 is heated, wherein the heating of the thermoplastic layer 29 then occurs at least partially by the contact with the press element 33. In the case of a metallic press element 33, the warming up of the press element 33 can be performed by means of magnetic induction.

[0097] The present invention is in no way limited to the embodiments described herein above, on the contrary, such methods and floor panels can be realized according to various variants, without leaving the scope of the present invention. Moreover, the panels, instead as floor panels 1, may also be realized as wall panels or ceiling panels or even as furniture panels. Of course, the methods of the invention, mutatis mutandis, can be applied for manufacturing wall panels, ceiling panels, furniture panels or the like.