PANEL AND METHODS FOR MANUFACTURING A PANEL

Abstract

A panel including a primary and a secondary substrate layer, an intermediate layer, and a top layer. The intermediate layer is located between the primary and secondary substrate layers. The top layer is applied on the secondary substrate layer. The intermediate layer has at least one of the following properties: the intermediate layer has a Shore A hardness that is 10 units lower than the Shore A hardness of the primary and/or secondary substrate layer; the intermediate layer has an elastic modulus that is at least 10.0% lower than the elastic modulus of the primary and/or secondary substrate layer; the intermediate layer includes a material with a substantially open cell structure; or the intermediate layer includes a foamed thermoplastic material or a foamed thermosetting material. Methods are provided for manufacturing the panel.

Claims

1.-45. (canceled)

46. A panel comprising a primary and a secondary substrate layer, an intermediate layer, and a top layer, wherein said intermediate layer is located between said primary and secondary substrate layer, and wherein said top layer is applied on the secondary substrate layer, wherein the intermediate layer has at least one of the following properties: the intermediate layer has a Shore A hardness that is 10 units lower than the Shore A hardness of the primary and/or secondary substrate layer; the intermediate layer has an elastic modulus that is at least 10.0% lower than the elastic modulus of the primary and/or secondary substrate layer; the intermediate layer comprises a material with a substantially open cell structure; or the intermediate layer comprises a foamed thermoplastic material or a foamed thermosetting material, wherein the shore A hardness is determined in accordance with ASTM standard D2240, in particular ASTM standard D2240-15R21, wherein the elastic modulus is determined in accordance with ASTM standard E111-17.

47. The panel in accordance with claim 46, wherein the intermediate layer has a Shore A hardness that is 10 units lower than the Shore A hardness of the secondary substrate layer and/or in that the intermediate layer has an elastic modulus that is at least 10.0% lower than the elastic modulus of the secondary substrate layer.

48. The panel in accordance with claim 46, wherein the intermediate layer comprises a foamed thermoplastic material or a foamed thermosetting material, wherein the foamed thermoplastic material or the foamed thermosetting material has an empty cell volume between 10.0 and 80.0 vol %.

49. The panel in accordance with claim 46, wherein the intermediate layer comprises a foamed thermoplastic material or a foamed thermosetting material, wherein the foamed material is selected from the group of ethylene vinyl acetate (EVA), irradiation-crosslinked polyethylene (IXPE), irradiation-crosslinked polypropylene (IXPP), expanded polyethylene (EPE), expanded polyethylene copolymer (EPC), polypropylene (PP), polyvinyl chloride (PVC), PVC-plastisol, polyurethane, or combinations thereof.

50. The panel in accordance with claim 46, wherein said primary substrate layer comprises polyvinyl chloride (PVC) and calcium carbonate (CaCO3) as filler, wherein the calcium carbonate (CaCO3) has a concentration between 60.0 and 80.0 wt % and the polyvinyl chloride (PVC) has a concentration between 20.0 and 40.0 wt %.

51. The panel in accordance with claim 46, wherein said secondary substrate layer comprises polyvinyl chloride (PVC).

52. The panel in accordance with claim 51, wherein said secondary substrate layer comprises plasticizers in an amount of less than 15 phr.

53. The panel in accordance with claim 46, wherein said secondary substrate layer is configured to increase the stiffness of the panel, wherein the secondary substrate layer has at least one of the following properties: the secondary substrate layer comprises a reinforcing layer; the secondary substrate layer comprises calcium carbonate (CaCO3) as filler; or the secondary substrate layer has a thickness of at least 2.0 mm.

54. The panel in accordance with claim 53, wherein said secondary substrate layer comprises calcium carbonate (CaCO3) as filler, wherein the calcium carbonate (CaCO3) has a concentration between 60.0 and 80.0 wt % and the polyvinyl chloride (PVC) has a concentration between 20.0 and 40.0 wt %.

55. The panel in accordance with claim 46, wherein the aforementioned panel is provided with coupling means on at least two opposite edges, wherein on the respective edges, locking is brought about at least in a vertical direction perpendicular to the plane of the panels and/or at least in a horizontal direction in the plane of the panels and perpendicular to the edges.

56. The panel in accordance with claim 55, wherein at least one of the aforementioned edges is provided with a groove, wherein this groove is flanked by an upper lip and a lower lip, wherein said intermediate layer extends substantially through the upper lip.

57. The panel in accordance with claim 56, wherein the lower surface of the upper lip is formed at least partially in said primary substrate layer.

58. The panel in accordance with claim 56, wherein the aforementioned upper lip is formed substantially in the primary substrate layer, the intermediate layer and the secondary substrate layer.

59. The panel in accordance with claim 55, wherein, in a coupled state between two adjacent panels, the intermediate layers of said adjacent panels press against each other, wherein a seal forms along the edges of said panels.

60. The panel in accordance with claim 55, wherein, in a coupled state between two adjacent panels, the intermediate layers of said adjacent panels do not touch each other, wherein a space forms between said intermediate layers along the edges of said panels.

61. A method for manufacturing a panel, comprising the steps: extruding a primary substrate layer, extruding an intermediate layer, extruding and/or laminating a secondary substrate layer, and laminating a top layer, wherein at least the primary substrate layer and the intermediate layer are formed by coextrusion.

62. The method in accordance with claim 61, wherein the primary substrate layer, the intermediate layer and the secondary substrate layer are formed by coextrusion.

63. The method in accordance with claim 61, wherein the secondary substrate layer is laminated.

64. The method in accordance with claim 61, wherein said layers that are formed by coextrusion are formed by a single die.

65. The method in accordance with claim 61, wherein said layers which that are formed by coextrusion are formed by two or more separate dies.

Description

[0109] With a view to better illustration of the features of the invention, a preferred embodiment is described hereunder, as an example without any limiting character, referring to the appended drawing, in which:

[0110] FIGS. 1 and 2 show panels with the features of the invention, comprising a first and a second edge;

[0111] FIG. 3 shows two panels as in FIG. 2 in the coupled state;

[0112] FIG. 4 shows a panel with the features of the invention, comprising a third and a fourth edge;

[0113] FIGS. 5 and 6 show specific configurations of edges of panels according to the invention;

[0114] FIGS. 7, 8 and 9 illustrate methods for manufacturing a panel, with the features of the invention in its second aspect;

[0115] FIG. 10 illustrates a method for manufacturing a panel, with the features of the invention in its third aspect; and

[0116] FIG. 11 shows a variant of a panel according to the invention.

[0117] FIG. 1 shows a panel 1 according to the invention, and comprises a primary 1 and a secondary substrate layer 2, an intermediate layer 3, and a top layer 4, wherein said intermediate layer 3 is located between said primary 1 and secondary substrate layer 2, and wherein said top layer 4 is applied on the secondary substrate layer 2, characterized in that the intermediate layer 3 has at least one of the following properties: [0118] the intermediate layer 3 has a Shore A hardness that is 10 units lower than the Shore A hardness of the primary 1 and/or secondary substrate layer 2; [0119] the intermediate layer 3 has an elastic modulus that is at least 10.0% lower than the elastic modulus of the primary 1 and/or secondary substrate layer 2; [0120] the intermediate layer 3 comprises a material with a substantially open cell structure; or [0121] the intermediate layer 3 comprises a foamed thermoplastic material.

[0122] The intermediate layer 3 of the panel as shown herein possibly comprises a foamed thermoplastic material or a foamed thermosetting material, wherein the foamed thermoplastic material or the foamed thermosetting material has an empty cell volume between 10.0 and 80.0 vol %. Suitable foamed thermoplastic or foamed thermosetting materials are possibly selected from the group of ethylene vinyl acetate (EVA), irradiation-crosslinked polyethylene (IXPE), irradiation-crosslinked polypropylene (IXPP), expanded polyethylene (EPE), expanded polyethylene copolymer (EPC), polypropylene (PP), polyvinyl chloride (PVC), PVC-plastisol, polyurethane, or combinations thereof.

[0123] It is clear from FIGS. 1 and 2 that said panel is provided with coupling means on at least two opposite edges, wherein on the respective edges, locking is brought about at least in a vertical direction perpendicular to the plane of the panels and/or at least in a horizontal direction in the plane of the panels and perpendicular to the edges. Herein, at least one of the aforementioned edges is provided with a groove 5, wherein this groove 5 is flanked by an upper lip 6 and a lower lip 7, wherein said intermediate layer 3 extends substantially through the upper lip 6, in particular wherein the lower surface of the upper lip 6 is formed at least partially in said primary substrate layer 1, more particularly wherein the aforementioned upper lip 6 is formed substantially in the primary substrate layer 1, the intermediate layer 3 and the secondary substrate layer 2. As shown, the coupling means then comprise mutually interacting coupling parts, namely the groove 5 as described herein, and a tongue-shaped element, the tongue 8. In particular, further reference is made to the edges constituting the first edge 9, comprising the tongue 8, and to the second edge 10, comprising the groove 5, said groove 5 being flanked by the upper lip 6 and the lower lip 7. The lower lip 7 extends farther than the upper lip 6. The tongue 8 and the groove 5 provide, in the coupled state, locking in the direction perpendicular to the plane of the coupled panels.

[0124] FIGS. 2 and 3 further show that the top layer 4 comprises a decorative layer 11 and a wear-resistant layer 12. The panel further comprises a damping layer 13 applied to the underside. The coupling means as shown in FIGS. 2 and 3 relate to the lower lip 6, which comprises a vertical locking part 14 which, together with a recess 15 on the underside of the tongue 8, provides, in the coupled state, locking perpendicular to the coupled edges and in the plane of the coupled panels.

[0125] The intermediate layer 3 is located over its entire thickness in the upper lip 6. The minimum thickness DI of the primary substrate 1 in the upper lip 6 and under the intermediate layer 3 in the section where in the coupled state of a panel with its first edge 9 on the second edge 10 of another such panel, the tongue 8 of the first panel comes into contact with the upper lip 6 of the second panel, is preferably at least 0.4 mm, and more preferably at least 0.5 mm and even more preferably at least 1.0 mm.

[0126] On the decorative side, i.e. the upper side, the panel comprises a first sealing face 16 on the first edge 9. The distal end of the upper lip 6 comprises a second sealing face 17. The first sealing face 16 and second sealing face 17 are configured so that in the coupled state of such a panel with its first edge 9 on the second edge 10 of another such panel, the first sealing face 16 of said panel comes into contact with or is tightly against the second sealing face 17 of the other such panel.

[0127] The coupling parts on the first edge 9 and the second edge 10 of the panel in FIG. 2 are configured so that the panel can be coupled with its first edge 9 on the second edge 10 of another such panel by means of a rolling movement and/or by means of a sliding movement substantially parallel to the plane of the panels, so that snapping occurs. The panel shown in FIGS. 2 and 3 further comprises a chamfer 18 on the first edge 9 and on the second edge 10. Such chamfers are optional in the context of the invention.

[0128] FIG. 4 shows an example of the third edge 19 and the opposite fourth edge 20 of a panel according to the invention. This relates to the same panel whose first edge 9 and second edge 10 are shown in FIG. 2. The same reference numbers thus have the same meaning.

[0129] The panel comprises, on its third edge 19, a coupling part formed by a downward directed upper hook-shaped portion. This upper hook-shaped portion comprises a lip 21 with a downward directed locking element 22 that forms a male part. The panel comprises, on the fourth edge 20, a coupling part formed by an upward directed lower hook-shaped portion. This lower hook-shaped portion consists of a lip 23 with an upward directed locking element 24 that defines, proximally thereto, a female part in the form of a recess 25. These coupling parts are configured for coupling together the third edge 19 of such a panel to the fourth edge 20 of another such panel, wherein during coupling of the third edge 19 of such a panel to the fourth edge 20 of another such panel, the male part engages in the female part, wherein locking is produced in the direction in the plane of the panels and perpendicular to the coupled edges 19, 20.

[0130] The coupling parts 34, 35 on the third edge 19 and on the fourth edge 20 comprise a first pair of locking parts 26, 27 which, together in the coupled state, provide locking of the coupled panels in the direction perpendicular to the coupled edges. The coupling parts 34, 35 on the third edge 19 and on the fourth edge 20 comprise a second pair of locking parts 28, 29 which, together in the coupled state, provide locking of the coupled panels in the direction perpendicular to the coupled edges.

[0131] The distal end of the lip 21 of the upper hook-shaped portion comprises a third sealing face 30. The proximal end of the fourth edge 20 comprises a fourth sealing face 31. The third sealing face 30 and the fourth sealing face 31 are configured so that in the coupled state of such a panel with its third edge 19 on the fourth edge 20 of another such panel, the third sealing face 30 of said panel comes into contact with or is tightly against the fourth sealing face 31 of the other such panel.

[0132] It can also be seen in FIGS. 1 to 4 that the intermediate layer 3 is thicker than the secondary substrate layer 2. In particular the thickness of the secondary substrate layer 2 and the intermediate layer 3 are in proportion to one another according to a ratio between 8:10 and 4:10. Thus, the thickness of the intermediate layer 3 is for example 1.0 or 1.5 mm and the thickness of the secondary substrate layer 2 is about 0.7 mm. The intermediate substrate layer consists ideally of ethylene vinyl acetate, preferably with a density between 120 and 140 kg/m.sup.3, for example such as 130 kg/m.sup.3.

[0133] FIGS. 5 and 6 show in detail according to F5A and F5B of the respective FIGS. 2 and 4, specific configurations of the edges of panels according to the invention. In the embodiment in FIGS. 2 and 4, the intermediate layer 3 on both opposite edges 9, 10 or 19, 20 ends in the same vertical plane as the top layer 4.

[0134] FIG. 5 shows an embodiment wherein the intermediate layer 3 comprises a bulge 32 on the edge of the panel. This may be made on both opposite edges, or only on one of the pair of opposite edges. This may be produced by suitable milling operations during milling of the coupling parts on the respective edges of the panel. This embodiment has the advantage that in the coupled state between two adjacent panels, the intermediate layers of the adjacent panels press against each other, this forms a seal along the coupled edges of the adjacent panels.

[0135] This may be carried out on one of the two pairs of opposite edges (either on the first pair of opposite edges or on the second pair of opposite edges) or on both pairs of opposite edges.

[0136] FIG. 6 shows an embodiment wherein, on the edge of the panel, the edge of the intermediate layer 3 is located in a recess 33. This may be carried out on both opposite edges, or only on one of the pair of opposite edges. This may be produced by suitable milling operations during milling of the coupling parts on the respective edges of the panel. In such embodiments, in the coupled state between two adjacent panels, the intermediate layers of the adjacent panels do not touch each other, and a space forms between the intermediate layers on the coupled edges of the coupled panels.

[0137] This may be carried out on one of the two pairs of opposite edges (either on the first pair of opposite edges or on the second pair of opposite edges) or on both pairs of opposite edges.

[0138] It is also possible that on one edge of the panel, the intermediate layer has a bulge, and on the opposite edge, the edge of the intermediate layer is located in a recess on this edge.

[0139] FIG. 7 illustrates a method for manufacturing a panel according to the second aspect of the present invention. In particular, FIG. 7 shows extrusion of a primary substrate layer 1, extrusion of an intermediate layer 3 and laminating of a secondary substrate layer 2. The method illustrated is characterized in that the primary substrate layer 1 and the intermediate layer 3 are formed by coextrusion. For this purpose, it is shown in FIG. 7 that the primary substrate layer 1 is extruded by means of a first extruder 34 and the intermediate layer 3 is extruded by means of a second extruder 35. The first extruder 34 and the second extruder 35 give combined supply to a die 36, wherein the primary substrate layer 1 and the intermediate layer are coextruded. In a next step, the secondary substrate layer 2 is laminated on the coextruded assembly of the primary substrate layer 1 and the intermediate layer 3. The laminating of the secondary substrate layer 2 on the assembly of the primary substrate layer 1 and the intermediate layer 3, as shown in FIG. 7, is possibly carried out by means of a roller 39. The secondary substrate layer 2 is possibly formed offline as a film in order to allow efficient lamination on the assembly of the primary substrate layer 1 and the intermediate layer 3.

[0140] FIG. 8 illustrates a variant of the method for manufacturing a panel according to the second aspect of the present invention, in which the primary substrate layer 1 and the intermediate layer 3 are coextruded, by means of two separate dies 36, 37. Immediately after extrusion, the primary substrate layer 1 and the intermediate layer 3 are possibly fastened to one another by means of a roller 41.

[0141] FIG. 9 shows yet another variant of the method according to the second aspect of the present invention, wherein both the primary substrate layer 1, the intermediate layer 3 and the secondary substrate layer 2 are formed by coextrusion. In this case the primary 1 and the secondary substrate layer 2 are formed by means of the first extruder 34 and the intermediate layer 3 is formed by means of the second extruder 35, said material streams being formed by a single die 36.

[0142] FIG. 10 shows a method for manufacturing a panel according to the third aspect of the present invention, comprising the following steps: extruding a first substrate layer 1, laminating an intermediate layer 3, and laminating a secondary substrate layer 2, wherein the intermediate layer 3 and the secondary substrate layer 2 together are laminated on the primary substrate layer 1 in the form of a laminated complex 38. According to some embodiments of the method shown here, this laminated complex 38 is formed prior to laminating, by means of the steps (not shown): providing the secondary substrate layer 2, coating said secondary substrate layer 2 with a foamable composition, and foaming said foamable composition with formation of the intermediate layer 3. The intermediate layer 3 and the secondary substrate layer 2 together form the laminated complex 38. Alternatively the laminated complex 38 is formed by means of the steps (not shown): providing the secondary substrate layer 2, providing the intermediate layer 3, and gluing the intermediate layer 3 and the secondary substrate layer 2, with formation of the laminated complex 38. Laminating of the laminated complex 38 on the primary substrate layer 1 is possibly carried out by means of a roller 42.

[0143] Each of these methods further comprises the step of laminating a top layer, said top layer possibly consisting of a decorative and/or wear-resistant layer. This step is not shown explicitly in FIGS. 7, 8, 9 and 10. Possibly the primary substrate layer 1, the intermediate layer 3 and the secondary substrate layer 2 making up the assembled material are pressed against each by means of one or more rolls 40.

[0144] The methods as shown in each of FIGS. 7-10 are further characterized in that the intermediate layer 3 has at least one of the following properties: [0145] the intermediate layer has a Shore A hardness that is 10 units lower than the Shore A hardness of the primary and/or secondary substrate layer; [0146] the intermediate layer has an elastic modulus that is at least 10.0% lower than the elastic modulus of the primary and/or secondary substrate layer; [0147] the intermediate layer comprises a material with a substantially open cell structure; or [0148] the intermediate layer comprises a foamed thermoplastic material or a foamed thermosetting material.

[0149] The intermediate layer of the panel as shown herein possibly comprises a foamed thermoplastic material or a foamed thermosetting material, wherein the foamed thermoplastic material or the foamed thermosetting material has an empty cell volume between 10.0 and 80.0 vol %. Suitable foamed thermoplastic or foamed thermosetting materials are possibly selected from the group of ethylene vinyl acetate (EVA), irradiation-crosslinked polyethylene (IXPE), irradiation-crosslinked polypropylene (IXPP), expanded polyethylene (EPE), expanded polyethylene copolymer (EPC), polypropylene (PP), polyvinyl chloride (PVC), PVC-plastisol, polyurethane, or combinations thereof. According to a practical embodiment, the intermediate layer consists of ethylene vinyl acetate (EVA), preferably with a density between 120 and 140 kg/m.sup.3, for example such as 130 kg/m.sup.3.

[0150] FIG. 11 shows a variant of a panel according to the invention in one and the same view as in FIG. 4. It can be seen from FIG. 11 that the intermediate layer 3 may also be thinner than the secondary substrate layer 2. Thus, the intermediate layer 3 may for example be only half as thick as the secondary substrate layer 2, or more explicitly, the intermediate layer 3 may be only 25%, or even only 10%, as thick as the secondary substrate layer 2.

[0151] The present invention is by no means limited to the embodiments described above, but such panels and methods for the manufacture thereof may be realized according to different variants while remaining within the scope of the present invention.