FLOOR PANEL AND METHOD FOR MANUFACTURING A FLOOR PANEL

Abstract

Floor panel, which includes a substrate and a top layer provided above, and preferably directly above, the substrate, where the top layer includes a décor layer, a thermoplastic wear layer, and a lacquer layer provided above, and preferably directly above, the wear layer, and where the floor panel has an upper surface showing a relief, where the relief has a maximum relief depth which is larger than 100 microns, and where the wear layer and the lacquer layer are embossed in order to form the relief.

Claims

1. A floor panel, which comprises a substrate and a top layer provided above, and preferably directly above, the substrate, wherein the top layer comprises a decor layer, a thermoplastic wear layer, and a lacquer layer provided above, and preferably directly above, the wear layer, and wherein the floor panel has an upper surface showing a relief, wherein the relief has a maximum relief depth which is larger than 100 microns, wherein the wear layer and the lacquer layer are embossed in order to form the relief, and wherein the decor of the decor layer is imprinted or printed.

2. The floor panel of claim 1, wherein the decor is imprinted by means of any of the following printing techniques: offset printing, gravure printing or a digital printing technique.

3. The floor panel of claim 1, wherein the decor of the decor layer is imprinted or printed directly on the substrate.

4. The floor panel of claim 1, wherein the decor is printed on a primer present on the substrate.

5. The floor panel of claim 1, wherein the decor of the decor layer is printed or imprinted on the lower side of the wear layer.

6. The floor panel of claim 1, wherein the wear layer is a foil or film.

7. The floor panel of claim 1, wherein the wear layer is provided above, and preferably directly above, the decor layer, in the form of a liquid mass, and cured.

8. The floor panel of claim 1, wherein the wear layer is transparent or translucent.

9. The floor panel of claim 1, wherein the embossed lacquer layer is transparent or translucent.

10. The floor panel of claim 1, wherein the maximum relief depth is larger than 200 microns and preferably is larger than 250 microns.

11. The floor panel of claim 1, wherein the substrate, in order to form the relief, also is embossed.

12. The floor panel of claim 1, wherein the upper surface of the floor panel comprises a bevel on at least one edge.

13. The floor panel of claim 1, wherein the floor panel is suitable for forming a floating floor covering.

14. The floor panel of claim 13, wherein the floor panel, on at least one pair of opposite edges, is provided with integrated mechanical coupling parts and wherein these coupling parts allow effecting a locking between two of such floor panels in a direction (V) perpendicular to the plane of the coupled floor panels and in a direction (H) parallel to the plane of the coupled floor panels and perpendicular to the coupled edges.

15. The floor panel of claim 1, wherein the embossed lacquer layer is realized on the basis of a polyurethane dispersion.

16. The floor panel of claim 15, wherein the polyurethane dispersion is curable by means of radiation.

17. The floor panel of claim 1, wherein the relief is or is not realized in register with the decor of the decor layer, and wherein the relief simulates the texture of a natural product, such as wood, stone or ceramics.

18. The floor panel of claim 1, wherein the decor of the decor layer simulates a natural product, such as wood, stone or ceramics.

19. The floor panel of claim 1, wherein the substrate comprises a thermoplastic substrate layer.

20. The floor panel of claim 19, wherein the thermoplastic synthetic material is selected from the following group: polyvinylchloride, polyethylene, polypropylene, polyethylene terephthalate and polyurethane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0130] With the intention of better showing the characteristics of the invention, herein after, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0131] FIG. 1 represents a floor panel according to the invention;

[0132] FIG. 2 represents a cross-section according to line II-II in FIG. 1;

[0133] FIG. 3 represents in an enlarged manner that what is indicated by F3 in FIG. 2; and

[0134] FIG. 4 represents a method according to the invention which can be applied for manufacturing the floor panel of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0135] FIG. 1 represents a floor panel 1 according to the invention.

[0136] This relates to a rectangular floor panel which is oblong; however, the invention is not limited thereto. In a variant, for example, a square floor panel or a floor panel in another polygonal shape or geometrical shape.

[0137] The floor panel 1 is suitable for forming a floating floor covering. It comprises a pair of long edges 2-3 and a pair of short edges 4-5 and is provided, at least at the pair of long edges 2-3, with integrated coupling parts 6-7, which allow effecting a mechanical coupling between two of such floor panels. An example of such coupling parts 6-7 is described in greater detail in respect to FIG. 2.

[0138] Further, the floor panel 1 comprises an upper surface 8, which relates to the visible surface of the floor panel 1 when the latter is installed on an underlying surface or subfloor. The opposed surface, which is directed towards the underlying surface, is named the lower surface. The upper surface 8 shows a decor which, in the represented example, relates to a wood decor with wood nerves and pores.

[0139] FIG. 2 represents a cross-section according to line II-II in FIG. 1.

[0140] In this figure, the form of the coupling parts 6-7 can be seen. These coupling parts 6-7 allow effecting a locking between two of such floor panels in the vertical direction V and in the horizontal direction H perpendicular to the coupled edges.

[0141] The coupling parts 6-7 are of the type allowing to couple two of such floor panels 1 by means of a turning movement W. Here, this relates to a particular type of coupling parts, considering that they also allow coupling the floor panels by means of a substantially horizontal movement of the floor panels in respect to each other, with the performance of a snap action. This last-mentioned manner of coupling is not represented.

[0142] The coupling parts 6-7 are performed in the form of a tongue 9 and a groove 10, wherein the groove 10 is bordered by an upper lip 11 and a longer lower lip 12. Locking elements 13-14 are provided as well, which counteract or even prevent the moving apart of the tongue 9 and groove 10 in the horizontal direction H.

[0143] The coupling parts 6-7 are substantially and here even entirely manufactured in one piece with and from the material of the substrate 15.

[0144] It is noted that other types of coupling parts can be applied. In this manner, coupling parts can be applied of the type allowing to couple the floor panels by means of a turning movement, however, not by a substantially horizontal snap movement. Still another type is formed by the so-called “push-lock” coupling parts, which allows coupling the floor panels by means of a downward and substantially vertical movement.

[0145] It is not excluded that the short edges 4-5, too, are provided with integrated mechanical coupling parts. These can be of the same type as the coupling parts on the long edges, however, this is not necessarily the case. A particular embodiment is the one wherein on the long pair of edges turning coupling parts are applied, whereas on the short pair of edges push-lock coupling parts are applied.

[0146] In this embodiment, the floor panels can be coupled to adjacent floor panels in a single turning movement, the so-called “fold-down” movement, on the long edge as well as on the short edge. In a variant, the turning coupling parts are applied on the short edges and the push-lock coupling parts on the long edges.

[0147] From FIG. 2, also the general construction of the floor panel 1 becomes clear. The floor panel 1 comprises a substrate 15 and a top layer 16, wherein the top layer 16 comprises at least a decor layer 17 and a thermoplastic wear layer 18.

[0148] The upper surface 8 of the floor panel 1 shows a relief 19, which may or may not be performed in register with the decor of the decor layer 17.

[0149] In the represented example, the substrate 15 is multi-layered. In particular, it comprises three substrate layers 15A-15B-15C, which all are flexible thermoplastic layers. This concerns, for example, layers composed of supple or flexible PVC.

[0150] The substrate 15 comprises a reinforcement layer 20, which may comprise reinforcing fibers, such as glass fibers. In particular, this may relate to a glass fiber cloth.

[0151] The upper surface 8 comprises a bevel 21 on each of the long edges 2-3. These bevels 21 here relate to chamfers, which do not reach deeper than the wear layer 18. The upper surface thereof is formed in particular by the wear layer 18.

[0152] At the short edges 4-5, too, bevels may be applied.

[0153] The floor panel has a thickness T situated between 3 and 12 mm.

[0154] FIG. 3 in an enlarged view represents that which is indicated by F3 in FIG. 2.

[0155] From this figure, the precise construction of the top layer 16 becomes clear.

[0156] As already mentioned, the upper surface 8 of the floor panel 1 comprises a relief 19, which is formed by embossed zones 22. This relates to a relief which is used for simulating the texture of a natural product, in the example a wood texture. The bevels 21 thus do not form part of this relief, considering that they primarily are provided in order to simulate a plank effect rather than a natural texture. Thus, the depth of the bevels does not have to be considered when determining the maximum relief depth.

[0157] The relief 19 shows a maximum relief depth T1 which is larger than 100 microns and preferable is even larger than 200 or 250 microns. The relief depth is to be understood as the height difference between the deepest point of the relief 19 and the global level of the upper surface 8, as represented in the figure.

[0158] The top layer 16 comprises the embossed wear layer 18, as well as an embossed lacquer layer 23. As the lacquer layer 23 itself is embossed, the lacquer layer 23 is present over the entire wear layer 18 and even on the bottom of the embossed zones 22. Moreover, the lacquer layer 23 has a uniform or approximately uniform thickness, which can be somewhat thinner at the location of the embossed zones 22, due to which a good embossing resolution can be obtained.

[0159] In the represented example, the substrate 15 is not embossed in order to form the relief 19. However, in a variant this substrate 15 can be embossed in order to realize the deep relief. Herein, it is preferred that the substrate layer directly underneath the decor layer 17 is flexible or semi-rigid, which is the case here with the substrate layer 15A, considering that such substrate layer is easier to emboss or deform.

[0160] The wear layer 18 and the lacquer layer 23 preferably are transparent or translucent, such that the decor of the underlying decor layer 17 is visible. However, the lacquer layer 23 can be used for determining the gloss degree of the upper surface 8, as already described herein above.

[0161] The lacquer layer 23 may form the uppermost layer of the floor panel. However, in the example, above the lacquer layer 23 and in particular directly above the lacquer layer 23, an additional lacquer layer 24 is present as well. This lacquer layer 24 forms the uppermost layer of the floor panel 1. This preferably relates to a transparent or translucent lacquer layer 24. This lacquer layer 24 preferably is provided on the lacquer layer 23 only and thus best relates to a not embossed or not deformed lacquer layer. This makes this lacquer layer 24 extremely suitable for addressing the wear resistance, scratch resistance and/or stain resistance. As this lacquer layer 24 does not have to be embossed, there is of course a broader choice of lacquers which can be used. Thus, a lacquer can be chosen in function of the aforementioned features. The lacquer layer 24 is absent in one or more embossed zones 22 and especially on the bottom thereof.

[0162] FIG. 4 represents a method with which the floor panel 1 of FIG. 1 can be manufactured.

[0163] In the method, the substrate 15 is provided. It is not represented how this substrate 15 has been manufactured. Any suitable technique, such as a strewing, extrusion and/or calendering technique, may be used to this aim.

[0164] Above this substrate 15, the top layer 16 is provided, while the substrate 15 is moved along on a continuous conveyor 25. In the example, providing the top layer 16 is performed in a plurality of steps.

[0165] In a first step, the decor layer 17 is provided. By definition, the decor layer 17 comprises the decor, wherein the decor in the example is imprinted or printed on a thermoplastic foil or film, for example, a PVC film. This printed PVC film here is unwound from a roll 26 and provided above the substrate 15.

[0166] Subsequently, the wear layer 18 is provided above the decor layer 17. In the example, this wear layer 18 relates to a thermoplastic foil or film, such as a PVC film. Similar to the decor layer 17, this film is unwound from a roll 27 and provided above the decor layer 17.

[0167] In a following step, the lacquer layer 23 is provided above the wear layer 18, by means of a rubber roller 28. This takes place before the wear layer 18 is provided with any relief.

[0168] The lacquer which is used in order to form the lacquer layer 23 preferably comprises a water-based UV-curable PU dispersion with a solid matter content situated between 30% and 45%, limits included. This lacquer may also contain other components or ingredients, such as already explained above.

[0169] In the example, the lacquer, in a following step, is subjected to a pre-cure. To this aim, one or more UV lamps 29 can be employed.

[0170] In a next step, the whole consisting of the substrate 15, the decor layer 17, the wear layer 18 and the lacquer layer 23 is connected in a preferably heated press device 30.

[0171] It is noted that the lacquer layer 23 thus is provided prior to connecting the wear layer 18 with a remaining or underlying part of the floor panel 1. Moreover, the lacquer layer 23, as described earlier, is subjected to a pre-cure, which in this case is advantageous indeed.

[0172] After consolidation, the lacquer layer 23 is embossed together with the wear layer 18 by means of a mechanical embossing technique in order to form the relief 19. In the example, to this aim use is made of a structured roller 31. However, in a variant use may also be made of a structured press element, such as a press plate. In that case embossing may take place at the same time as connecting the wear layer in the preceding step, if such connecting is performed by means of a structured press element.

[0173] Possibly, the floor panel 1 subsequently can be immersed in a water bath. This step is not explicitly represented in the figure. Such water bath provides for a more accurate relief, considering that this, so to speak, freezes the relief and provides for that the relief is maintained throughout the further process.

[0174] In the example, an additional lacquer layer 24 is provided above the lacquer layer 23 by means of a rubber roller 32. This lacquer layer 24 does not have to be embossed, considering that the relief 19 has been formed already. Thus, a harder lacquer can be chosen, which is beneficial for the wear resistance and scratch resistance of the final floor panel. Preferably, the lacquer employed for the lacquer layer 24 has a solid matter content of 100% and is UV curable. This lacquer can also comprise PU.

[0175] Subsequently, both lacquer layers 23-24 are cured together by means of one or more UV lamps 33.

[0176] It is clear that in order to form the final floor panel, the continuous web still has to be divided into individual elements, which then form the floor panels. To this aim, for example, a cutting or sawing process can be employed.

[0177] Further, the method can also comprise the step of providing coupling parts on at least one pair of opposed edges of the floor panels. To this aim, cutting or milling tools can be applied.

[0178] It is noted that the term “horizontal” is applied for indicating a direction in the plane of the floor panel. The term “vertical” is applied for indicating the direction perpendicular to the plane of the floor panel.

[0179] The present invention is in no way limited to the herein above-described embodiments, on the contrary may such floor panels and methods be realized according to various variants, without leaving the scope of the present invention.