Note: Descriptions are shown in the official language in which they were submitted.
1
FLOOR PANEL WITH A SUBSTRATE AND A TOP LAYER
This invention relates to floor panels.
More particularly, this invention relates to floor panels of the type which is
at least composed of a
substrate and a top layer provided on this substrate, wherein said top layer
comprises a print. As
known, above such motif a transparent or translucent synthetic material layer
may be provided,
which then forms part of said top layer.
In particular, the present invention relates to panels of the type which, at
two or more opposite
edges, comprises coupling means or coupling parts, with which two of such
floor panels can be
coupled at the respective edges, such that they are locked to each other in a
horizontal direction
perpendicular to the respective edge and as in the plane of the floor panels,
as well as in a vertical
direction perpendicular to the plane of the floor panels. Such floor panels
can be applied for
composing a so-called floating floor covering, wherein the floor panels are
connected to each other
at their edges, however, lie freely on the underlying surface.
From WO 97/47834, laminate floor panels are known for forming a floating floor
covering. However,
laminate floor panels have the disadvantage that they mostly are provided with
a moisture-sensitive
substrate, namely, MDF or HDF (Medium Density Fiberboard or High Density
Fiberboard), and that
the top layer provided on this substrate, when the floor covering is in use,
leads to the occurrence
of ticking noises. The top layer, to wit, is composed of thermo-hardening
resin and leads to the
development of a very hard surface layer. The substrate, too, is hard due to
the high density of
MDF or HDF. On average, laminate floor panels have a thickness situated
between 6 and 12
millimeters, wherein the thickness of the top layer mostly is less than 0.5
millimeters.
Date Recue/Date Received 2020-11-12
2
From EP 1 938 963 and WO 2010/023042, vinyl-based floor panels are known for
forming
such floating floor covering. Such vinyl-based floor panels mostly have a
thickness of 3 to 5
millimeters and have a high material density. Above the print, a transparent
thermoplastic
layer and possibly a superficial lacquer layer are provided. The thermoplastic
layer mostly
has a thickness of 1 millimeter or more. Such layer, on the one hand, provides
wear resistance
to the floor panel, and, on the other hand, allows forming a relief on the
surface. So, for
example, a chamfer can be realized in this transparent layer, such as in the
aforementioned
WO 2010/023042, or impressions for imitating wood pores can be provided.
Nevertheless,
the floor panels of the state of the art still do give a plastic-like
impression. The thick
thermoplastic layer may lead to a reduced view on the print, by a lack of
transparency.
Inherent to these floor panels is also their limited bending stiffness and
their high
deformability. These features lead to problems when the floor panels are
provided on an
uneven underlying surface. Namely, after a certain period of time, the
unevennesses of the
underlying surface may migrate towards the surface of the floor covering. With
a local load,
for example, underneath the legs of tables or chairs, permanent impressions
will be created,
which also are undesired.
From WO 2007/081267 and US 2004/146695, floor panels are known with a
substrate and a
top layer provided thereon, wherein the top layer is composed of a print and a
thick and soft
.. transparent layer situated above this print. At one edge, the floor panel
has a lowered edge
region in the form of a groove with a horizontal bottom. Possibly, the bottom
of this groove
can extend on a level situated below the global level of the print. Possibly,
the bottom of the
groove can be performed colored. This technique is suitable for imitating
cement joints or
other tile joints, however, leaves much to be desired when it should be
applied with floor
panels representing a print with a wood pattern.
Floor panels with a relatively thick soft top layer, for example, a
thermoplastic top layer, further
have the disadvantage that they can be pushed upward at the edge, for example,
in that the
floor panels are tensioned against each other or in that, when the floor
covering is being walked
on, a frictional contact is created between the shoe and the edge of the top
layer. This may
result in an accelerated wear on these edges and/or to possibly unsafe
situations. Up to now,
it was thought that a thick transparent top layer was necessary for
withstanding such wear.
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The present invention relates to an alternative panel, which in first instance
is intended as a
floor panel for forming a floating floor covering. According to various
preferred embodiments
of the invention, also a solution is offered for one or more problems with the
floor panels of
the state of the art.
To this aim, the invention, according to its first independent aspect, relates
to a floor panel
comprising:
a substrate defining a thickness of 2 to 10 millimeters, and a top layer
provided on the
substrate, the top layer including at least a print representing a wood
pattern and being
provided on a PVC-based film, an underlying layer situated between the
substrate and the
print, and a transparent thermoplastic layer based on PVC and situated above
the print, the
floor panel, at least on a long pair of two opposite edges, defining a
straight or curved chamfer,
such that when two of the floor panels are in an installed condition, the
chamfers form a V-
shaped groove;
wherein the transparent thermoplastic layer has a thickness of 0.15 to 0.4
millimeters
and is substantially free from solid additives;
wherein the chamfer extends below a global level of the print and through the
print
into the underlying layer;
wherein the chamfer is provided with a separate decorative layer comprising a
lacquer
layer or a transfer print layer;
wherein the floor panel has a rectangular and oblong shape;
wherein a material of the substrate is composed of glued together wood
particles or
MDF or HDF, the underlying layer includes a thermoplastic material extending
completely
above a centerline of a thickness of the floor panel; and
wherein the underlying layer includes a PVC layer.
In accordance with another aspect, the invention provides a floor panel having
a rectangular
and oblong shape with a pair of longitudinal opposite edges and a pair of
short opposite edges,
said floor panel comprising a substrate and a top layer provided on said
substrate;
wherein said top layer comprises from bottom to top a thermoplastic back layer
located on the
substrate, a print provided on a synthetic material film, and a transparent
thermoplastic layer
based on polyvinylchloride situated above said print; the synthetic material
film being located
between the back layer and the transparent thermoplastic layer, and the print
being provided
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between the transparent thermoplastic layer and the synthetic material film;
said top layer forming a
decorative side of said floor panel wherein said print shows a wood pattern
with a pore direction
extending in the direction of said pair of longitudinal opposite edges;
wherein said substrate is based on a thermoplastic material chosen from the
list consisting of
.. polyvinylchloride, polyethylene, polypropylene and polyurethane; said
substrate having an overall
thickness which is larger than half of the thickness of the entire panel;
wherein said floor panel at least at said pair of longitudinal opposite edges
is provided with coupling
parts allowing to couple two such floor panels to each other, such that, in a
coupled condition, said
two floor panels are locked to each other at the respective edge in a vertical
direction perpendicular
.. to the plane of the coupled panels, as well as in a horizontal direction
perpendicular to the coupled
edges and in the plane of the panels; wherein said coupling parts are formed
as a tongue and a
groove, wherein the contour of said tongue and groove is substantially
realized in said substrate with
said back layer extending above a horizontal level determined by a center line
of said tongue and
groove;
.. wherein said floor panel has a length of more than 118 centimeters, a width
between 8 and 22
centimeters and a thickness of more than 5 millimeters.
In accordance with a further aspect, the invention provides a floor panel,
wherein this floor panel is
made rectangular and oblong and comprises a substrate and a top layer provided
on this substrate,
.. wherein the substrate is single layered and has an overall thickness larger
than half of a thickness
of the floor panel, and wherein the top layer is at least composed of a print
and a transparent
thermoplastic layer situated above said print, characterized in that the floor
panel has a length of
more than 1.8 meters and that the floor panel comprises means for limiting the
bending by its own
weight. The means for limiting the bending consist in that the substrate
comprises hard PVC and
.. has a density of at least 750 kg/m3.
Date Recue/Date Received 2020-11-12
4a
The inventor has perceived that the thickness of the thermoplastic top layer
could be limited and
still an acceptable wear resistance could be obtained by means of a relatively
deep chamfer.
Possible upward-pushed portions of the top layer then are situated underneath
the floor covering,
such that no excessive signs of wear will occur. As a chamfer is applied, an
impact or friction of the
shoe on the edge of the upper surface largely will be avoided, such that also
on the new upper
edge of the floor panel the risk of accelerated wear is minimized. Moreover, a
solution is offered for
the plastic-like appearance of the floor panels from the state of the art. By
combining a print located
close to the surface, preferably less than 0.5 millimeters, with a deep
chamfer, preferably deeper
than 0.5 millimeters, an exceptional depth
Date Recue/Date Received 2020-11-12
5
effect is created. Problems with the transparency of the thermoplastic layer
are avoided to a
large extent by limiting its thickness.
According to the most preferred embodiment, said thermoplastic top layer has a
thickness of
0.3 millimeters or less.
Said substrate preferably is realized from a material which is harder than
said thermoplastic
transparent layer. By means of the thermoplastic synthetic material near to or
on the surface
of the floor panel, a solution is offered for the occurrence of excessive
ticking noises. As a
harder substrate is chosen, a good composition is obtained, wherein permanent
impressions
can be minimized. Moreover, said substrate avoids the lining out or migrating
of
unevennesses on the underlying surface towards said top layer.
Said chamfer can be realized in any manner. Below, some possibilities for the
realization
thereof are explained.
According to a first possibility, the chamfer is formed by removing a material
part of the top
layer on the respective edge. Preferably, the removed material part extends
through the
transparent thermoplastic top layer and the print into an underlying layer
and/or into the
substrate. According to this first possibility, the print is omitted on at
least a portion of the
obtained chamfer.
According to a second possibility, the chamfer is formed by locally pressing
down a material
part of the top layer at the respective edge. By facilitating such pressing
down, an underlying
layer and/or the substrate may or may not be pre-formed or provided with an
incision, which
at least partially offers room for the pressed-down material part. Preferably,
the print, in this
second possibility, extends uninterruptedly from on the actual surface of the
floor panel over
the entire or approximately entire surface of the chamfer.
Preferably, such chamfer is provided with a separate decorative layer. Such
embodiment is
particularly interesting in combination with said first possibility, but is
also not excluded in
combination with said second possibility. Preferably, said separate decorative
layer
comprises a lacquer layer or a transfer print layer or an otherwise obtained
print layer, such
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as a print layer obtained by means of a digital printing process, such as
inkjet printing. In the
case of a printing process, preferably UV-based inks are used. The inventor
has found that
these inks will adhere best to thermoplastic underlying layers. In the case of
transfer printing,
preferably heated transfer is applied, for example, in that the transfer
element, for example,
a transfer roller, is heated. In such manner, a good adherence to an
underlying thermoplastic
layer can be obtained.
As already mentioned, it is possible that in the floor panel of the invention,
the chamfer
extends through said print. This embodiment is particularly interesting with
said first possibility
for realizing chamfers.
Preferably, the top layer of the floor panel of the invention further also
comprises a back layer,
which is situated between said print and the substrate. Said back layer
preferably also
comprises thermoplastic material, and preferably a filler material, too. This
may relate, for
example, to a layer of PVC (Polyvinyl chloride), filled with chalk.
Preferably, so-called soft
PVC is applied, which is produced by means of plasticizers.
For the transparent thermoplastic layer, a PVC-based layer can be applied.
Alternatives are,
for example, PVdC (PolyVinyl diChloride)-based, PU
(PolyUrethane)-based or
PP (PolyPropylene)-based layers. As mentioned above, the thermoplastic layer
according to
the invention preferably has a limited thickness. Good values for the
thickness of the
transparent thermoplastic layer are situated, for example, between 0.15 and
0.4 millimeters.
Preferably, the transparent thermoplastic layer is free from solid additives,
such as ceramic
particles for promoting the wear resistance, although this kind of particles
as such is not
excluded. However, the inventor has found that they can be omitted, with the
intention of
obtaining good transparency, whereas still an acceptable wear resistance is
maintained,
namely, a wear resistance comparable to or better than that of a laminate
panel of the AC2-
or AC3-class, as measured according to EN 13329.
As already mentioned, a lacquer layer can be applied as the top layer of the
floor panel.
Herein, this may relate to a UV- or an electron beam-hardening lacquer layer
or to a PU
lacquer layer. Preferably, this lacquer layer extends uninterruptedly over the
chamfer. This
can be realized most simply in combination with the above-mentioned second
possibility and
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is not excluded in combination with the above-mentioned first possibility.
Preferably, said
lacquer layer is omitted on the surface of a chamfer realized by means of the
above-
mentioned first possibility.
Said print preferably is provided on a carrier sheet, wherein the carrier
sheet, together with
the print, forms a printed synthetic film. As synthetic film, preferably a PVC-
, PU- or PP-based
film is used. The print preferably is performed with solvent inks or with
water-based inks.
Preferably, in the final floor panel, the carrier sheet is located underneath
the print. However,
it is not excluded that the print could be situated on the underside of the
carrier sheet, wherein
then use is made of a transparent carrier sheet, which then effectively forms
part of the
transparent thermoplastic layer, which as a whole preferably meets the
preferred thickness
of the present invention.
The whole of the top layer, namely, the print including the possible carrier,
the transparent
top layer and the possible back layer, preferably consist of an annealed or
relaxed
thermoplastic layer. The common thickness of the composing layers of the top
layers
preferably is between 0.5 and 3 millimeters, or still better between 1 and 2
millimeters.
The top layer preferably is assembled prior to connecting it to the substrate.
The connection
to the substrate can be performed, for example, by means of a glue layer, for
example, by
means of dispersion glue based on polyurethane. It is not excluded that the
top layer is
assembled partially or entirely simultaneously with the connection to the
substrate. According
to another possibility thereof, for example, at least the top layer and/or the
backing layer
partially can be provided as a liquid or paste-like substance on the
substrate, where they are
hardened.
The substrate preferably comprises a board material having a density of more
than 450
kilograms per cubic meter, or even of more than 650 kilograms per cubic meter.
Preferably,
said substrate substantially consists of a wood-based material, such as MDF or
HDF (Medium
or High Density Fiberboard), or for the substrate use is made of another board
material on
the basis of glued-together wood particles or wood fibers. Such substrate
provides for that
relatively stiff or rigid panels are obtained, which can be gluelessly
installed in a smooth
manner.
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Preferably, the substrate has a thickness of 2 to 10 millimeters. The entire
floor panel
preferably has a thickness situated between 5 and 15 millimeters. Preferably,
the substrate
forms at least half of the thickness of the floor panel.
On the lower side of the substrate, a backing layer or sublayer, preferably a
vapor-tight layer,
can be provided. Such backing layer or sublayer preferably consists of a
thermoplastic
synthetic material layer and/or of a hot-melt glue. The backing layer
preferably has a
thickness corresponding to the thickness of the top layer, including a
possible back layer,
however, preferably is made thinner.
In the cases where a back layer or other intermediate layer is applied between
the print and
the substrate, two floor panels, in an installed condition of two of such
floor panels, preferably
have a contact surface formed on the respective back layers or intermediate
layers, wherein
this contact surface extends underneath the deepest point of the respective
chamfers. Such
contact can form a first barrier against moisture which would penetrate into
the seam or joint
between two floor panels. Said back layers or intermediate layers preferably
comprise a
compressed portion at the location of the contact surface.
Preferably, the invention is applied with floor panels which, at the
respective edges, are
provided with mechanical coupling means allowing that two of such floor panels
can be
coupled to each other, such that a locking is obtained in a vertical direction
perpendicular to
the plane of the coupled panels, as well as in a horizontal direction
perpendicular to the
coupled edge and in the plane of the panels. Preferably, the coupling means
also show one
or a combination of two or more of the following features:
- the feature that the mechanical coupling means or coupling parts
substantially are
realized as a tongue and a groove bordered by an upper lip and a lower lip,
wherein
this tongue and groove substantially are responsible for the locking in said
vertical
direction, and wherein the tongue and groove are provided with additional
locking
parts, substantially responsible for the locking in said horizontal direction.
Preferably,
the locking parts comprise a protrusion on the lower side of the tongue and a
recess
in the lower groove lip. Such coupling means and locking parts are known, for
example, from WO 97/47834;
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- the feature that the mechanical coupling means or coupling parts press the
coupled
floor panels against each other, for example, in that these mechanical
coupling means
are realized with a so-called pretension, as is known as such from EP 1 026
341. The
tensioning force with which the floor panels are pressed against each other or
towards
each other, can be obtained, for example, in combination with the above
feature, by
means of a lower lip, which is bent out in coupled position, which, in an
attempt of
springing back, presses against the lower side of the tongue. The invention is
particularly interesting for being applied with such floor panels, as there
the risk is
increased that the thermoplastic layer is pushed upward at the edges as an
effect of
the tensioning force. Preferably, here the aforementioned preferred embodiment
is
used, wherein underneath the chamfer a contact surface is formed on an
intermediate
layer or back layer. The tensioning force, together with a possible
compression at the
location of the contact surface, leads to a good resistance against moisture
penetration;
- the feature that the mechanical coupling means allow a coupling by means of
a
horizontal, or quasi-horizontal, shifting movement of the panels towards each
other.
With this type of panels, there is a risk of the thermoplastic layer being
pushed upward
near the panel edges, to wit at the end of the coupling movement, when the
edges
would bump against each other. By applying the invention, this risk is
reduced;
- the feature that the mechanical coupling means allow a coupling by means of
a turning
movement W along the respective edges. With this type of panels, there is a
risk of
the thermoplastic layer being pushed upward near the panel edges during the
coupling movement, when the edges should turn against each other. By applying
the
invention, this risk is reduced;
- the feature that the mechanical coupling means allow a coupling by means of
a
downward-directed movement of a male coupling part having, for example, a
tongue,
into a female coupling part having, for example, a groove. With this type of
panels,
there is a risk of pushing up the thermoplastic layer near the panel edges
during the
coupling movement, when the edges would chafe along each other. By applying
the
invention, this risk is reduced;
- the feature that the mechanical coupling means, or at least the
pertaining upper edge,
is realized by means of a milling treatment with rotating milling tools. The
use of milling
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,
tools can lead to the occurrence of pushed-up edges already during manufacture
of
the floor panels. By applying the invention, this risk is reduced.
Preferably, said coupling means substantially are realized in said substrate.
Preferably, said
5 coupling means are provided by means of a milling treatment with rotating
milling tools.
Preferably, the floor panel of the invention relates to a rectangular, either
oblong or square,
panel, which is provided with mechanical coupling means on both pairs of
opposite edges.
Preferably, the chamfers on both opposite edges are made identical or
approximately
10 identical.
The chamfer which is applied according to the invention, preferably, globally
seen, has an
angle of 35 to 55 with the panel surface, wherein an angle of approximately
45 is optimum.
Smaller angles than 35 lead to wide edges, whereas larger angles are
disadvantageous in
that they have a higher risk of being pushed up when the floor is being walked
on.
Preferably, the chamfers, in a coupled condition of two floor panels with the
characteristics of
the invention, form a V-groove, wherein the width of the possible bottom of
this V-groove is
less than one fifth and still better less than one seventh of the width of the
opening of the V-
groove at the upper surface of the coupled panels.
Preferably, the chamfers, in a coupled condition of two floor panels with the
characteristics of
the invention, form a V-groove, wherein the width of the possible bottom of
this V-groove is
smaller than the depth of the respective V-groove. Preferably, the width of
the possible bottom
is less than half of the depth of the respective V-groove.
The herein above-mentioned characteristic preferred embodiments of the
chamfers or V-
grooves of the invention, each individually, however, preferably in
combination, are ideal for
being applied with prints representing a wood pattern.
Preferably, the floor panel of the invention further is characterized in that
said floor panel is
made rectangular and oblong and that said chamfer is at least or exclusively
provided on the
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long pair of opposite edges. Of course, such chamfer can be provided also or
only on the
short pair of opposite edges.
According to a particular embodiment, said chamfer, seen in cross-sections
transverse to the
respective edge, has a geometry varying along the respective edge. Preferably,
this chamfer,
over the major part of the length of the respective edge, or over the entire
length thereof, has
the inventive feature that this chamfer extends to below the global level of
the print. The
varying geometry preferably comprises at least a variation of the global angle
over which the
chamfer extends.
According to another particular embodiment, said substrate is made waterproof
at least at the
respective edge, or at least measures have been taken at the respective edge
for obtaining
an increased resistance against moisture or moisture penetration in the
substrate. This can
be realized in different possible manners, for example, in that the substrate
as such is
waterproof, in that the substrate, at the respective edge, is provided with a
covering by means
of a water-repellent substance, or in that the substrate comprises a synthetic
edge portion at
the respective edge.
According to a second independent aspect, the present invention relates to a
floor panel
which can offer, amongst others, installation advantages. To this aim, the
invention, according
to its second independent aspect, also relates to a floor panel, wherein this
floor panel is
made rectangular and oblong and comprises a substrate and a top layer provided
on this
substrate, wherein the top layer is composed at least of a print and a
transparent
thermoplastic layer situated above this print, with the characteristic that
the floor panel has a
length of more than 180 centimeters and wherein the floor panel preferably
further comprises
means for limiting the bending by its own weight. As longer floor panels are
used, a surface
can be installed with less operations. The means which limit the bending allow
improving the
installation advantage even more. Namely, by the reduced bending, it is
simpler to market
and/or install the panels, certainly in the case when use is made of panels
which, at least at
one pair of opposite edges, are provided with mechanical coupling means,
which, for
installation, must be provided in each other. Preferably, finally a bending is
obtained of less
than 50 centimeters per meter, or even of less than 25 or less than 10
centimeters per meter.
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The means which limit the bending can comprise one or a combination of two or
more of the
following measures:
-
the measure wherein at least one layer of the floor panel has a density of
more than
650 kilograms per cubic meter, or even of more than 750 kilograms per cubic
meter;
- the measure wherein the floor panel has a thickness of 5 millimeters or
more;
- the measure wherein the floor panel comprises at least one embedded glass
fiber
layer, wherein this glass fiber layer is situated outside of the neutral
fiber;
- the measure wherein the floor panel comprises at least one embedded profile,
wherein this profile globally extends in the longitudinal direction of the
floor panel and
wherein this profile, in the case that coupling parts in the form of a tongue
and groove
are provided, preferably is situated closer to the tongue than to the groove.
Preferably, the print of the floor panel shows a wood pattern, which
preferably extends with
the pore direction in the longitudinal direction of the floor panel.
Preferably, the wood pattern,
at least in the longitudinal direction and preferably also in the width
direction of the floor panel,
is free from repetitions.
Preferably, here this relates to a print provided on a carrier sheet, for
example, a printed
synthetic material film. Such synthetic material film can consist
substantially of PVC (Polyvinyl
chloride), PU (Polyurethane) or PP (Polypropylene).
The print preferably is applied by means of an offset printing process on said
carrier sheet or
possibly direct on the underlying substrate or the possible back layer.
However, it is not
excluded that a digital print might be applied, for example, by means of an
inkjet printing
device. As inks, preferably UV-based or solvent-based inks are applied. It is
not excluded that
water-based inks might be applied. Preferably, an ink on the basis of pigments
is applied.
Preferably, printing is performed on a web or roll of such synthetic film,
back layer or on a
larger board of the underlying substrate material, wherein said pore direction
preferably
extends transverse to this web. So, with offset printing or other printing
processes in which
printing cylinders are applied, a motif can be obtained without repetitions in
the longitudinal
direction of the floor panel, even with floor panels having a length of 1.8
meters or more.
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The use of fast-drying inks, such as inks on the basis of pigment, enable such
technique, also
in offset printing, for printing on an underlying synthetic material layer,
such as on the
synthetic material film, the back layer, or an underlying substrate on the
basis of synthetic
material. In particular, UV- or solvent-based inks are suited for this
purpose. At least with the
use of water-based inks, preferably after each printing cylinder or print
head, in the case of
digital techniques, an appropriate drying technique is applied. With such
transversely printed
wood patterns on an underlying synthetic material layer, fast drying is of
importance for
obtaining a good resolution, for example, a resolution of more than 250 dots
per inch, or still
better of more than 500 dots per inch.
It is clear that such printed web of synthetic film, back layer or printed
larger board of substrate
material can be applied for manufacturing a plurality of floor panels, by
subdividing the
respective layers or boards.
.. Preferably, the floor panel has a relief on its surface, which is made
corresponding to said
print, such that a so-called embossed-in-register structure is obtained.
It is evident that in the floor panel of the second aspect, the materials and
composition of the
first aspect can be applied for the substrate, the top layer, the print, the
back layer and/or the
.. underlying layer, without herein necessarily applying a chamfer. Also, the
coupling means
and locking parts mentioned there can be applied. Of course, it is not
excluded to combine a
chamfer according to the first aspect with a floor panel showing the
characteristics of the
second aspect.
.. According to all aspects, it is possible that the substrate substantially
consists of a
thermoplastic material. So, for example, a vinyl-based substrate, such as PVC,
a
polyethylene-based substrate, a polypropylene-based substrate or a
polyurethane-based
substrate can be applied. These materials have a good resistance against water
or moisture
and are readily available. Preferably, the substrate substantially consists of
a foamed
synthetic material board. Preferably, in that case synthetic material of the
closed-cell type is
concerned. By foaming, by means of an amount of synthetic material comparable
to that of
the floor panels of EP 1 938 963, a thicker and stiffer substrate is obtained,
such that the risk
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of the occurrence of migration effects from the underlying layer to the
surface of the floor
covering can be minimized.
It is not excluded that soft PVC could be applied for the substrate 6. To
those skilled in the
art, soft PVC is known as a material which is obtained on the basis of PVC and
plasticizers
and which has a density of less than 1.35 grams per cubic meter.
Preferably, the transparent thermoplastic layer mentioned in the various
aspects substantially
consists of PVC and/or plasticizer. Preferably, for the manufacture of this
layer, use is made
of a paste containing a percentage of plasticizer situated between 5 and 75
percent by weight.
Preferably, said transparent or translucent layer has a Shore A hardness
situated between
50 and 100.
It is clear that, where "hardness" is mentioned, the hardness is intended of
the surface of the
respective layer, substrate, or other material, measured on a flat side
thereof, namely, the
side thereof which is directed upward in the final floor panel, or the side
which is relevant for
the occurrence or non-occurrence of permanent impressions.
According to all aspects, the present invention preferably relates to floor
panels or other
panels which as such are rigid and thus can not be wound up. Preferably, the
final panel
shows a thickness of more than 5 millimeters, however, preferably of less than
15 millimeters.
A good value for the thickness is 7 to 10 millimeters. Such panels are very
suitable for
providing mechanical coupling means thereon, which allow to connect two or
more such
panels to each other at their edges. It is clear that also the possible larger
boards, from which
a plurality of such floor panels are formed, and the substrates as such are
rigid. Preferably,
the floor panels, boards and substrates are so rigid that they will bend less
than 10
centimeters per meter under their own weight.
According to all aspects, the floor panels preferably have a width of 8
centimeters or more.
Particularly preferred dimensions are a width situated between 14 and 22
centimeters and a
length situated between 118 and 220 centimeters.
CA 2989174 2017-12-15
15
It is clear that according to the invention, by "substrate" an internal layer
of the floor panel
itself is meant, which as such can be made single- or multi-layered, however,
wherein the
respective layer or layers preferably have an overall thickness which is
larger than half of the
thickness of the entire respective panel and/or wherein the respective layer
or layers have an
overall weight which preferably is higher than half of the weight of the
entire respective panel.
Preferably, the contour of the respective coupling parts is substantially or
entirely realized in
the substrate.
Preferably, the possible intermediate layer or back layer extends above the
horizontal level
determined by a center line of the floor panel, and still better above the
center line of the
possible coupling parts, such as above the center line determined by the
tongue-in-groove
coupling. Preferably, the possible intermediate layer or back layer extends
above the coupling
parts which for the major part are responsible for the vertical locking. These
coupling parts
namely are preferably realized in the substrate.
In accordance with another aspect, the invention provides a floor panel
comprising:
a substrate defining a thickness of 2 to 10 millimeters, and a top layer
provided on the
substrate, the top layer being composed of at least a print representing a
wood pattern and
being provided on a PVC-based film, and a transparent thermoplastic layer
based on PVC
and situated above the print, the floor panel, at least on a long pair of two
opposite edges,
defining a straight or curved chamfer, such that when two of the floor panels
are in an installed
condition, the chamfers form a V-shaped groove;
wherein the chamfer extends below a global level of the print and through the
print
into an underlying layer or into the substrate;
wherein the chamfer is provided with a separate decorative layer comprising a
lacquer
layer or a transfer print layer;
wherein the floor panel has a rectangular and oblong shape;
wherein the substrate is substantially made from a soft PVC including PVC with
a
plasticizer content, the panel including a glass fiber containing layer at a
position under the
print and embedded in the substrate material.
According to a further aspect, the invention provides a floor panel
comprising:
CA 2989174 2017-12-15
=
16
a substrate defining a thickness of 2 to 10 millimeters, and a top layer
provided on the
substrate, the top layer including at least a print representing a wood
pattern and being
provided on a film, an underlying layer situated between the substrate and the
print, and a
transparent thermoplastic layer and situated above the print, the floor panel,
at least on a long
pair of two opposite edges, defining a straight or curved chamfer, such that
when two of the
floor panels are in an installed condition, the chamfers form a V-shaped
groove;
wherein the transparent thermoplastic layer has a thickness of 0.15 to 0.4
millimeters
and is substantially free from solid additives;
wherein the chamfer extends below a global level of the print and through the
print
into the underlying layer or into the substrate;
wherein the chamfer is provided with a separate decorative layer comprising a
lacquer
layer or a transfer print layer;
wherein the floor panel has a rectangular and oblong shape;
wherein the substrate is substantially made from thermoplastic material
selected from
the list consisting of hard polyvinylchloride, polyethylene, and
polypropylene; and
wherein the underlying layer includes a PVC layer.
In accordance with another independent aspect, the invention provides a floor
panel having
a rectangular shape with two pairs of opposite edges, the floor panel
comprising a waterproof
substrate comprised of a single layer and defining a thickness of 2 to 10
millimeters, said
thickness being more than half of the entire thickness of the floor panel, the
substrate material
being chosen from the list consisting of a polyvinyl chloride-based substrate,
polyethylene-
based substrate, a polypropylene-based substrate and a polyurethane-based
substrate, a top
layer provided on the substrate, the top layer including a print provided on a
carrier sheet with
said carrier sheet being provided underneath said print, a transparent
thermoplastic layer of
less than 1 millimeter thickness situated above said print, the floor panel
either being free
from intermediate layers between said substrate and said carrier sheet, or
including a glue
layer between said substrate and said carrier sheet; the floor panel, at least
on one pair of
two opposite edges, including mechanical coupling parts for coupling two of
such floor panels
to each other, such that a locking is created in a vertical direction
perpendicular to the plane
of coupled panels, as well as in a horizontal direction perpendicular to the
coupled edges and
CA 2989174 2017-12-15
17
in the plane of the panels, said coupling parts being substantially realized
in said substrate
material.
In accordance with another independent aspect, the invention provides a floor
panel, being
rectangular and oblong, and thus comprising a pair of long edges and a pair of
short edges,
and comprising a rigid substrate being realized from a closed-cell foamed
thermoplastic
material, having a thickness of 2 to 10 millimeters and forming at least half
of the thickness
of the floor panel; the panel further comprises a top layer provided onto the
substrate, the top
layer comprising a back layer comprising PVC with plasticizers and a filler
material, having a
thickness of more than 45 percent of the thickness of the top layer, a printed
synthetic film
being situated above the back layer and a transparent or translucent
thermoplastic layer being
situated above the printed synthetic film and being a PVC-based layer, the PVC
material of
the substrate being harder than the material of the transparent or translucent
thermoplastic
layer; the panel also comprises first mechanical coupling means at the pair of
long edges
being substantially realized in the substrate, being configured so as to allow
a coupling of two
of such floor panels to each other, thereby obtaining a locking in the
direction perpendicular
to the plane of the coupled floor panels as well as in the direction
perpendicular to the coupled
edges and in the plane of the coupled floor panels, being configured so as to
allow a coupling
of two of such floor panels to each other by means of a turning movement along
the respective
edges, being realized as a tongue and a groove, the groove being bordered by
an upper lip
and a lower lip, the tongue and the groove being responsible for the locking
in the direction
perpendicular to the plane of the coupled floor panels, the tongue and the
groove being
provided with locking parts, the locking parts being responsible for the
locking in the direction
perpendicular to the coupled edges and in the plane of the coupled floor
panels, the back
layer extending above the center line determined by the tongue-in-groove
coupling. The panel
also comprises second mechanical coupling means at the pair of short edges
being realized
as a male coupling part and a female coupling part and being configured so as
to allow a
coupling between two of such floor panels by means of a downward movement, in
which the
male coupling part is provided in the female coupling part, automatically
created by the turning
movement.
In accordance with another aspect, the invention provides a floor panel, being
rectangular
and oblong, and thus comprising a pair of long edges and a pair of short
edges, and
CA 2989174 2017-12-15
18
comprising a single-layered rigid substrate being PVC-based, having a
thickness of 2 to 10
millimeters and forming at least half of the thickness of the floor panel, and
a top layer
provided onto the substrate, the top layer comprising a printed synthetic film
and a transparent
or translucent thermoplastic layer being situated above the printed synthetic
film and being a
PVC-based layer, the PVC material of the substrate being harder than the
material of the
transparent or translucent thermoplastic layer; the panel further comprises
first mechanical
coupling means at the pair of long edges being substantially realized in the
substrate, being
configured so as to allow a coupling of two of such floor panels to each
other, thereby
obtaining a locking in the direction perpendicular to the plane of the coupled
floor panels as
well as in the direction perpendicular to the coupled edges and in the plane
of the coupled
floor panels, being configured so as to allow a coupling of two of such floor
panels to each
other by means of a turning movement along the respective edges, being
realized as a tongue
and a groove, the groove being bordered by an upper lip and a lower lip, the
tongue and the
groove being responsible for the locking in the direction perpendicular to the
plane of the
coupled floor panels, the tongue and the groove being provided with locking
parts, the locking
parts being responsible for the locking in the direction perpendicular to the
coupled edges
and in the plane of the coupled floor panels, and second mechanical coupling
means at the
pair of short edges being realized as a male coupling part and a female
coupling part and
being configured so as to allow a coupling between two of such floor panels by
means of a
downward movement, in which the male coupling part is provided in the female
coupling part,
automatically created by the turning movement.
In accordance with another aspect, the invention provides a floor panel, being
rectangular
and oblong, and thus comprising a pair of long edges and a pair of short
edges, and
comprising a rigid substrate being PVC-based, having a thickness of 2 to 10
millimeters, and
forming at least half of the thickness of the floor panel and a top layer
provided onto the
substrate, the top layer comprising a back layer comprising PVC with
plasticizers and a filler
material and having a thickness of more than 45 percent of the thickness of
the top layer; a
printed PVC-based film being situated above the back layer and a transparent
or translucent
thermoplastic layer being situated above the printed synthetic film; being a
PVC-based layer,
the PVC material of the substrate being harder than the material of the
transparent or
translucent thermoplastic layer and having a thickness of 1 millimeter or
less; and a lacquer
layer as uppermost layer, the lacquer layer being a UV-hardening lacquer layer
or a PU
CA 2989174 2017-12-15
19
(polyurethane) lacquer layer; the panel further comprises first mechanical
coupling means at the
pair of long edges being substantially realized in the substrate, being
configured so as to allow a
coupling of two of such floor panels to each other, thereby obtaining a
locking in the direction
perpendicular to the plane of the coupled floor panels as well as in the
direction perpendicular to
the coupled edges and in the plane of the coupled floor panels, being
configured so as to allow a
coupling of two of such floor panels to each other by means of a turning
movement along the
respective edges and being realized as a tongue and a groove, the groove being
bordered by an
upper lip and a lower lip; the tongue and the groove being responsible for the
locking in the direction
perpendicular to the plane of the coupled floor panels; the tongue and the
groove being provided
with locking parts, the locking parts being responsible for the locking in the
direction perpendicular
to the coupled edges and in the plane of the coupled floor panels; and second
mechanical coupling
means at the pair of short edges being realized as a male coupling part and a
female coupling part
and being configured so as to allow a coupling between two of such floor
panels by means of a
downward movement, in which the male coupling part is provided in the female
coupling part,
automatically created by the turning movement.
In accordance with another aspect, the invention provides a floor panel
defining a longitudinal
direction and having a rectangular and oblong shape with a pair of
longitudinal opposite edges and
a pair of short opposite edges, said floor panel comprising a substrate and a
top layer provided on
said substrate; wherein said top layer comprises a print and a thermoplastic
layer situated above
said print; said top layer forming a decorative side of said floor panel;
wherein said substrate
comprises thermoplastic material and fillers; wherein said floor panel at
least at said pair of
longitudinal opposite edges is provided with coupling parts allowing to couple
two of such floor
panels to each other, such that, in a coupled condition, said two coupled
floor panels are locked to
each other at the respective edge in a vertical direction perpendicular to a
plane of the coupled
panels, as well as in a horizontal direction perpendicular to the coupled
edges and in the plane of
the panels; wherein said coupling parts include a tongue and a groove, and
wherein, in the coupled
condition, a contact surface active in the horizontal direction is formed
above the tongue with a
closed chamber available between an upper surface of the tongue and the
contact surface, the
contact surface and the coupling parts being at least partially formed in the
substrate; wherein said
floor panel has a length of more than 110 centimeters and comprises means for
limiting the bending
by its own weight; wherein said means for limiting the bending comprise at
least one glass fiber
Date Recue/Date Received 2020-11-12
20
layer underneath said print; wherein said floor panel comprises at least one
synthetic material layer
other than a wood-based material and having a density of at least 1,000
kilograms per cubic meter.
In accordance with another aspect, the invention provides a floor panel,
wherein this floor panel is
made rectangular and oblong and comprises a substrate and a top layer provided
on this substrate
and forming a decorative side of the floor panel, wherein the top layer is at
least composed of a
print provided on a carrier sheet and a transparent thermoplastic layer
situated above said print,
wherein said substrate is a single-layered substrate having a thickness from 2
to 10 millimeter and
forms at least half of a thickness of the floor panel, wherein said substrate
is a polyurethane-based
.. substrate and said transparent thermoplastic layer is polyurethane-based,
and wherein the floor
panel has a length of more than 1.1 meters and comprises a plurality of
reinforcing layers situated
outside a center line of said substrate and embedded in said substrate,
wherein a thickness of the
transparent thermoplastic layer is 1 mm or less.
According to a still further aspect, the invention provides a floor panel,
wherein this floor panel
comprises a substrate and a top layer provided on this substrate, wherein the
top layer is at least
composed of a print and a transparent thermoplastic layer situated above the
print, characterized
in that the print globally extends in a horizontal level, however, comprises
parts which extend below
the horizontal level.
Other possible aspect(s), object(s), embodiment(s), variant(s) and/or
advantage(s) of the present
invention, all being preferred and/or optional, are briefly summarized
hereinbelow.
With the intention of better showing the characteristics of the invention,
hereafter, as an example
without any !imitative character, some preferred embodiments are described,
with reference to the
accompanying drawings, wherein:
Figure 1 represents a panel, more particularly a floor panel, with the
characteristics of,
amongst others, the first aspect of the invention;
Figure 2 in cross-section represents a view according to the line II-II
represented in figure
1;
Figure 3, at a larger scale, represents a view on the area indicated by F3 in
figure 2;
Date Recue/Date Received 2020-11-12
20a
Figure 4 in cross-section represents a view according to the line IV-IV
represented in
figure 1;
Figure 5, in a view similar to that of figure 3, represents a variant;
Date Recue/Date Received 2020-04-09
21
Figure 6 in perspective represents a possible manner of coupling floor panels
having
the characteristics of the invention;
Figures 7 to 10 represent various possibilities for realizing a chamfer in a
view on the
area indicated by F7 in figure 2;
Figures 11 and 12, in a view similar to that of figures 3 and 5, represent
still more
variants;
Figures 13 and 14, in a view similar to that of the right-hand part of figure
4, represent
another possibility for realizing a floor panel having the characteristics of
the invention;
Figure 15 illustrates a method having the characteristics of a third aspect of
the
invention, which will be described in more detail below;
Figure 16 represents a floor panel having the characteristics of the second
aspect of
the invention mentioned in the introduction;
Figure 17 represents a cross-section according to the line XVII-XVII
represented in
figure 16;
Figure 18 represents a cross-section according to the line XVIII-XVIII
represented in
figure 17;
Figures 19 and 20, in a view similar to that of the left-hand part of figure
17, represent
variants.
Figure 1 represents a floor panel 1 with the characteristics of, amongst
others, the first aspect
of the invention. In this case, this relates to a rectangular and oblong floor
panel 1 with a pair
of long sides or edges 2-3 and a pair of short sides or edges 4-5.
Figure 2 represents that the floor panel 1 is of the type which comprises at
least a substrate
6 and a top layer 7 provided thereon. In the example, the top layer 7 has a
thickness T of at
least 0.5 millimeters. Here, specifically an annealed thermoplastic top layer
is concerned,
which substantially consists of PVC.
Figure 3 shows that the thermoplastic top layer 7 preferably as such is
composed of a back
layer 8, a provided thereon motif 9 and a transparent thermoplastic layer or
wear layer 10.
Herein, the back layer 8 preferably covers a thickness T1 of more than 45
percent of the
CA 2989174 2017-12-15
22
overall thickness T of the top layer 7. In this case, the back layer 8
consists of a layer of soft
recycled PVC, which is filled with chalk. In this case, the back layer 8 as
such has a higher
density than said transparent or translucent layer 10. In this case, the motif
9 is provided on
a carrier 11. In this case, this relates to a printed PVC film. For the
transparent thermoplastic
layer or wear layer 10, preferably a PVC layer with a thickness T2 of minimum
0.2 millimeters
is applied. Preferably, the PVC layer is not thicker than 0.5 millimeters. The
inventors have
found that a thickness 12 of 0.15 to 0.4 millimeters effects a good war
resistance, even when
it should be substantially free from solid additives, such as ceramic
particles, for example,
aluminum oxide particles, which as such would effect an increase of the wear
resistance. The
overall thickness T of said top layer 7 preferably is between 0.5 and 3
millimeters, wherein a
thickness T of 1 to 2 millimeters is desirable. In the cases where no use is
made of a back
layer 8, the overall thickness of the top layer 7 of course may be thinner,
for example, a
thickness situated between 0.2 and 1 millimeter, for example, a thickness of
approximately
0.5 millimeters.
For the substrate 6 of the floor panel 1 of figure 1, use is made of a
substrate 6, which
comprises wood particles, in this case, wood fibers, bonded with a binding
agent, such as
MDF or HDF. Preferably, the applied substrate material has a residual moisture
content of
less than 10 percent by weight. Instead of MDF or HDF, also a substrate having
a low density
can be chosen, for example, of less than 600 kilograms per cubic meter. This
may relate, for
example, to a wood-based material which comprises wood fibers, which are
obtained from
recycled wood and which also are bonded with a binding agent. Also, a wood
particle board
may be opted for.
.. At the lower side of the substrate 6, there is an underlying layer 12 or
backing layer. In this
case, the backing layer comprises thermoplastic synthetic material.
Preferably, for the
backing layer or underlying layer 12, PVC, preferably recycled PVC, is
applied, filled with
chalk or hot-melt glue. In principle, for the backing layer or underlying
layer 12, a similar
composition can be applied as for the back layer 8 situated in the top layer
7. Of course, also
.. another, preferably vapor-tight layer can be chosen, certainly in the cases
in which no back
layer 8 is present, or in the cases where use is made of an annealed or
relaxed thermoplastic
top layer. Such vapor-tight backing layer or underlying layer can consist, for
example, of a
substance applied in liquid condition, which hardens on the lower side of the
substrate, for
CA 2989174 2017-12-15
23
example, a vinyl-based substance or a hot-melt glue, which then preferably is
based on
polyurethane.
The substrate 6 preferably is made pigmented in a color corresponding to the
color of said
back layer 8, for example, both the substrate 6 and the back layer 8 in black,
or both in white.
The floor panel 1 from figures 1 to 4 shows an edge portion 13 of synthetic
material on at
least one edge 4, in this case on both opposite edges of the short pair of
sides 4-5, wherein
said synthetic material is different from the substrate material 6. This
synthetic material
concerns a measure for obtaining an increased resistance against moisture or
moisture
penetration in the substrate material 6. In this case, the synthetic material
extends at least
over 80 percent of the thickness T3 of the substrate. The attachment of the
edge portion 13
to the substrate material 6 is obtained by hardening said synthetic material
on the respective
portion of the substrate material 6. In this case, by the hardening of the
synthetic material,
also an adherence is obtained to the lower side of the top layer 7 and to the
lateral edges 14
of the backing layer 12. This latter is not necessarily the case. So, for
example, either the top
layer 7 or the backing layer 12 can be glued against the upper side or lower
side, respectively,
of the edge portion 13.
Figure 2 represents that the connection between the edge portion 13 and the
substrate
material 6 extends over a boundary surface 15, which comprises partial
surfaces 16
extending transverse to the normal of the surface 17 of the panel 1. In this
case, the respective
partial surfaces 16 respectively extend approximately horizontal. However,
this is not
necessarily so, and inclined partial surfaces and/or curved boundary surfaces
can be used.
The example also illustrates that the respective edges 4-5 of the substrate
material 6 can be
formed exclusively from said edge portion 13. In those cases, an appropriate
complete
protection of the substrate material 6 is obtained on the respective edges 4-
5.
For the synthetic material of the edge portions 13, use is made of a material
obtained on the
basis of a two-component system. Preferably, a polyurethane is applied,
obtained on the
basis of the components polyol and isocyanate. By means of this material, a
chemical bond
CA 2989174 2017-12-15
24
to the wood particles of the substrate 6 can be obtained. Moreover, the
polyurethane
preferably has the features of a thermo-hardening polymer.
Figure 2 represents that the respective edges 4-5 are made with a profile and
that this profile
comprises coupling means 18, with which this panel 1 can be coupled to other
similar panels
1, as represented in dashed line 19. In the coupled condition, not represented
here, a locking
is effected in a horizontal direction H1 perpendicular to the edge and in the
plane of the panel
1, as well as in a vertical direction V1 perpendicular to the plane. The
coupling means 18
represented here substantially are made as a tongue 20 and a groove 21,
bordered by a
lower lip 22 and an upper lip 23. For obtaining the locking in horizontal
direction H1, the
tongue 20 and groove 21 are provided with cooperating locking parts 24-25, in
this case in
the form of a protrusion 24 on the lower side of the tongue 20 and a recess 25
in the lower
groove lip 23. In this case, the tongue profile can be introduced into the
groove 21 at least by
means of a turning movement W along the respective edge for obtaining the
coupled
condition. Preferably, the coupling means 18 also allow other coupling
movements, such as
a coupling by means of a substantially horizontal shifting movement of the
panels 1 towards
each other.
It is clear that also on the long sides 2-3 of the floor panel 1, use can be
made of edge portions
13, as illustrated by means of figure 2.
Figure 4 represents that on the other pair of opposite edges 2-3, in this case
on the long sides
2-3 of the floor panel 1, other measures are performed for obtaining an
increased resistance
against moisture or moisture penetration in the substrate thereof. The
substrate has a profile
26 on the respective edges 2-3, and on this profile 26, a moisture-repellent
or sealing covering
layer 27 is applied, in this case a hot-melt glue, which can be based, for
example, on
polyurethane.
In the example, this covering 27 extends along the long sides 2-3 of the floor
panel 1 at least
over the entire distance between the edge portions 13 of the short pair of
edges 2-3. Herein,
this relates to a covering 27, which has been applied calibrated at least on a
portion of the
profiled edge region or profile 26, such that the present thereon coupling
means 18 and
locking parts 24-25 are not or almost not hindered when performing the
coupling movement.
CA 2989174 2017-12-15
25
A particularity of the covering layer 27 represented here is that it extends
over the profile 26
up to a lateral surface 28 of said top layer 7. This is illustrated lucidly by
means of figure 5.
Moreover, the covering layer, at least on one of the long edges, in this case
on both long
edges 2-3, is provided in an undercut 29 performed in said lateral surface 28.
By means of
this measure, it is effected that in coupled condition a gap of less than 0.2
millimeters is
obtained between the upper edges 30 of the panels 1, and in this case even no
gap.
The covering 27 maximally extends to a point 31 at a distance from the upper
edge 30 or
decorative side 17 of the respective panel I. At this point 31, the covering
27 is countersunk
at least partially, in this case even completely, in said recess 29.
Generally, the point 31 preferably is situated in said recess 29 provided in
the lateral surface
28 of the top layer 7. Preferably, said recess extends substantially or even
entirely underneath
the motif 9 of the top layer 7, such as it is the case here.
In the example of figure 4, the covering 27 is applied at least calibrated on
a portion of the
profiled edge region or the profile 26, which, in a coupled condition of two
such panels 1,
forms a contact surface 32-33-34-35. In the present case, this is provided at
least calibrated
on the contact surfaces 32-33 responsible for the vertical locking V1 and on
the contact
surfaces 34-35 responsible for the horizontal locking H1.
According to the example of figure 4, on the long pair of opposite edges 2-3
similar coupling
means 18 are applied as on the short pair of opposite edges 4-5, in that they
also allow a
coupling at least by means of a turning movement W along the respective edges.
However,
this is not necessarily so, and it is possible that coupling by turning is
only possible on the
long pair of edges 2-3, whereas the short pair of edges 4-5, for example,
allows at least a
coupling by means of a substantially horizontal or downward coupling movement
N of the
respective edges 4-5 towards each other. Such embodiment is represented on
figure 6.
The floor panel 1 of figure 6 is provided, on the short pair of edges 4-5,
with coupling means
18, which allow a coupling by means of a downward movement N of the coupling
means on
the one edge 4 in the coupling means on the other edge 5. Herein, the coupling
means 18
CA 2989174 2017-12-15
26
are realized as a male coupling part 36 and a female coupling part 37, wherein
the male
coupling part 36 can be provided in the female coupling part 37 by means of
said downward
movement N.
Figure 6 illustrates how these panels 1 can be coupled, wherein these panels
1, on the long
sides 2-3, are provided with coupling means 18, which allow at least a
coupling by means of
a turning movement W, and, on the short sides 4-5, are provided with coupling
means 18,
which allow at least a coupling by means of a downward movement N. As
represented, they
can be engaged into each other by means of a single fold-down movement N,
wherein the
long sides 2-3 are turned into each other and automatically a downward
coupling movement
N is created on the short sides 4-5. With the turning on the long sides 2-3,
as well as with the
automatic downward movement N on the short pair of edges, there may be a
contact between
the upper edges 30 of the floor panels, by which a bulging of the
thermoplastic material of the
wear layer 10 can occur at the location of these upper edges 30. The present
invention can
minimize the risk of the occurrence of such bulging edges.
The particularity of the present invention according to its first aspect is
that, as clearly
illustrated by means of figures 1 to 5, the floor panel 1, at feast at two
opposite edges 2-3, is
provided with a chamfer 38, in this case a straight chamfer. In the examples,
this chamfer 38
is combined with a relatively thin transparent thermoplastic layer or wear
layer 10, which, for
example, has a thickness T2 of approximately 0.3 millimeters. Herein, the
chamfer 38 extends
to below the global level N1 of the print 9 and preferably to below the global
level N2 of the
printed film or the carrier 11. In the represented cases, this each time
relates to a chamfer 38
realized by means of the first possibility therefor mentioned in the
introduction. Hereby, the
print 9 is omitted on a portion of the surface of the chamfer 38. The
represented chamfers
38-38A form an angle A of approximately 45 with the panel surface or the
decorative side
17. In a coupled condition of two of such floor panels 1, as represented here,
a V-groove is
created. In this case, the bottom 39 of the V-groove is formed by a line, or,
seen in this cross-
section, by a point, and thereby clearly is less wide than one fifth of the
width B1 of the
opening of the V-groove at the upper surface or the decorative side 17 of the
coupled panels,
and also is less wide than the depth D1 of the V-groove.
CA 2989174 2017-12-15
27
In the example of the figures 1 to 5, such chamfer 38 is provided on all edges
2-3-4-5 of the
rectangular and oblong floor panel I. According to variants, such chamfer 38,
for example,
can be omitted on the short pair of edges 4-5. It is also noted that in figure
3 in dashed line a
chamfer 38A is represented, which extends to below the global level N2 of the
carrier 11,
whereas the chamfer 38 represented in solid line indeed extends to below the
global level Ni
of the print 9, however, not to below the global level N2 of the carrier.
Figure 5 represents that such chamfer 38 can be provided with a separate
decorative layer
40, for example, with a lacquer layer or transfer print layer. Underneath the
deepest point or
the bottom 39 of the respective chamfers 38 of the coupled panels 1, a contact
surface 41 is
created on the back layers 8. Preferably, herein at the location of the
contact surface 41 a
compression of the material of the back layer 8 will take place. The contact
surface 41 is
active in the locking in said horizontal direction H1. In the examples, a,
seen in cross-section,
closed chamber or cavity 42 is situated underneath this contact surface.
The examples of chamfers 38-38A listed up herein above are realized by means
of the first
possibility thereof mentioned in the introduction.
Figure 7 represents a possibility for realizing a chamfer 38, wherein in this
case the second
possibility mentioned introduction is applied. The respective chamfer is
formed by locally
pressing down the top layer 7 at the respective edge 5. Herein, a pressing
element 43, in this
case a rolling element 43, is applied, which possibly can be heated. It is
also possible to heat
up the transparent thermoplastic layer 10 prior to pressing down, for example,
by means of
an infrared beam device, wherein then possibly use can be made of a press
element 43 which
is only slightly heated, for example, to maximum 40 C or 35 C, with an
unheated one, thus,
on room temperature, or with one which is cooled down below room temperature,
for
example, maximum to 15 C. In connection with figure 7, it is also noted that
the pressing
down in this case also results in a local compression of the substrate 6.
Instead of the
substrate 6 or in combination therewith, also the possible back layer 8, which
is not
represented here, can be compressed locally.
Figures 8 and 9 also represent an example of said second possibility for
realizing a chamfer
38. In order to facilitate the pressing down, in this case the substrate 6 is
provided with an
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incision 44, which at least partially offers room for the pressed-down
material part. Of course,
glue 45 can be provided in the incision in order to minimize or prevent the
springing back of
the pressed-down upper edges 30. It is possible that the lateral edge 46 of
the chamfer 38
has to be post-treated in order to obtain a good adjoining of the floor panels
1, for example,
by providing a lateral edge 46A extending perpendicular to the global
decorative side 17, such
as represented by the dashed line, for example, by means of a cutting
treatment.
Figure 10 represents another example of the aforementioned second possibility
for realizing
a chamfer 38. What is represented is a larger board of substrate material
comprising at least
the substrates 6 of two floor panels 1. These floor panels 1 are obtained,
amongst others, by
subdividing from the larger board. Herein, an amount 47 of material will be
lost, situated
between the finally realized profiled edges 4-5 of the respective floor panels
1. In order to
facilitate the pressing down, the substrate 6 is pre-formed. To this aim, at
the height of the
chamfers 38 to be provided, a recess 48 or impression is provided in the final
decorative side
17, here represented in dashed line. The composing layers 9-10-11 of the top
layer 7 are
connected with the pre-formed substrate 6 via an adhesive layer 49, for
example, a
polyurethane dispersion glue. Prior to gluing, the composing layers 9-1 0-1 1
mutually already
can be adhered to each other, for example, melded or otherwise laminated. Of
course, it is
also possible that the composing layers comprise a back layer 8, however, this
is not
.. represented here. For obtaining a good pressing-on of the composing layers
9-10-11 on the
substrate 6, it is possible to work, such as here, with a press element 50,
which comprises
protrusions 51 corresponding to the recesses 48. Such press element 50 can
also be applied
without pre-deforming the substrate 6, wherein then during pressing possibly a
compression
of the substrate material can be obtained.
In the examples of figures 7 to 10, it is respectively obtained that the print
9 extends
uninterruptedly from on the surface or the decorative side 17 of the floor
panel 1 over the
entire or approximately the entire surface of the chamfer 38.
The possible superficial lacquer layer, for example, a UV-hardening lacquer
layer, can be
provided and/or hardened on the floor panel before or after realizing the
chamfer 38,
according to which possibility this chamfer 38 then also is realized. For
example, in the case
of the second possibility, it can be advantageous to provide and/or harden the
lacquer layer
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only after realizing the chamfer 38. Namely, a hardened lacquer layer might
burst when being
pressed down together with the transparent thermoplastic layer 10.
Figure 11 represents other floor panels with a chamfer 38 similar to that of
figure 5, but which
is made curved and globally extends according to an angle A of approximately
40 with the
panel surface or the decorative side 17.
Figure 12 represents other floor panels with a chamfer 38, wherein these floor
panels 1 in
coupled condition show a V-groove formed by the chamfers 38, and wherein the
bottom 39
of this V-groove shows a width B2 which is smaller than one third of the width
B1 of the
opening of the V-groove at the decorative side 17 of the coupled floor panels
1.
Figure 13 represents an example, wherein also measures have been taken for
obtaining an
increased resistance against moisture or moisture penetration in the substrate
6. In this case,
use is made of a covering layer 27 on the basis of a water-repellent
substance. The covering
27 initially can be formed on an incompletely performed profile 26 of the edge
portion. In this
case, the final upper edge 30 of the respective edge region still is to be
formed by cutting the
final lateral surface 28 of the top layer 7 according to the dashed line 52
and by forming the
surface of the chamfer 38 in order to remove in this manner an excess material
portion 53
from this top layer 7. Figure 14 shows the obtained result, wherein the floor
panel 1 is provided
with a chamfer 38 on the respective edge.
Figure 13 clearly shows that the covering layer 27 in this case initially,
thus, prior to performing
the cutting treatment which forms the chamfer, extends at least from on the
substrate 6 onto
the lateral surface 29 of the top layer 7. By the cutting treatment, which has
to be performed
subsequently, for forming the chamfer, an excess portion of this covering
layer 27 is removed.
It is noted that the edge of the top layer 7 extends distally over the surface
of the chamfer.
Thereby, the top layer 7 forms a barrier against possible soiling of the
surface or decorative
side 17, and it is possible to achieve a smoother production of such floor
panels 1.
It is evident that at the opposite edge 4 of the edge 3 represented in figures
13 and 14,
preferably a similar treatment is performed, however, with this difference
that this opposite
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edge 4 preferably comprises the complementary coupling means 18, in this case,
a coupling
means in the form of a tongue.
Further, it is clear that in figures 13 and 14 the first possibility for
forming the chamfer 38 is
applied.
Figures 7 to 10 and 15 further illustrate a third independent aspect of the
invention. According
to this third aspect, the invention also relates to a floor panel 1 with a
thermoplastic top layer
7, wherein this floor panel 1 comprises a substrate 6 and a top layer 7
provided on this
substrate 6, wherein the top layer 7 is at least composed of a print 9 and a
transparent
thermoplastic layer 10 situated above said print 9, with the characteristic
that said print 9
globally extends in a horizontal level Ni, however, comprises parts which
extend below said
level Ni. In the case of the figures 7 to 10, this relates at least to parts
of the print 9 on the
surface of the chamfer 38, which extend below the level N1. In the case of
figure 15, the floor
panel 1 also comprises portions extending below the level Ni in the internal
part of the
decorative side 17. These portions may relate to imitations of removed
material parts, such
as it may be the case when imitating scraping traces in wooden floor panels,
or imitations of
joints, cracks or gaps, or imitations of wood knots or other strongly
pronounced relief of wood
and/or stone. It is clear that such floor panel 1 offers new possibilities for
imitating strongly
structured floors. The third aspect, for example, allows still forming deep
structures with
panels of which the transparent thermoplastic layer 10 has a limited thickness
T2, for
example, a thickness of less than 1 millimeter, or even of less than 0.5 or
less than 0.3
millimeters. As already mentioned, it is advantageous to limit the thickness
T2 of the
transparent thermoplastic layer 10.
According to preferred embodiments of the third aspect, the motif or the print
9 can also
extend to below the global level N2 of the lower side of the possible carrier
11 of the print 9
and/or into the substrate 6 and/or an underlying back layer. To this aim, the
back layer 8
and/or the substrate 6 may or may not be pre-formed. Possibly, a compression
of the material
of this back layer 8 and/or substrate 6 takes place there, where the print
extends at least to
below the global level N1 and/or N2.
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There, where a global level is mentioned, respectively the horizontal level is
meant, wherein
the sum of the square deviations of the actual level of the respective layer
in the floor panel
is minimal in respect to this horizontal level. In other words, this relates
to the smallest square
horizontal area best approaching the respective layer.
In figure 15, the top layer 7 is represented schematically as a single layer.
However, it is clear
that the top layer 7 preferably is composed of several layers, such as at
least of a carrier
sheet 11, a print 9 and a transparent thermoplastic layer 10.
It is clear that the third aspect can be combined with the first aspect and/or
the second aspect
of the invention or the preferred embodiments thereof. According to the second
and third
aspect, it is not necessary, however, also not excluded to apply a chamfer 38,
whether or not
according to the first aspect. However, this second and third aspect in fact
can adopt one or
more of the other characteristics mentioned within the scope of the first
aspect, such as, for
example, the characteristics of the coupling means, locking parts, top layers
or the like
mentioned there.
Figure 16 represents an example of a floor panel 1 having the characteristics
of the second
aspect of the present invention mentioned in the introduction. Herein, this
relates to a
rectangular and oblong floor panel 1. Figure 17 represents that this floor
panel 1 comprises
a substrate 6 and a top layer 7 provided on this substrate 6. As a top layer
7, the top layers 7
mentioned in connection with the first aspect can be applied, namely top
layers 7 having at
least a print 9 and a transparent thermoplastic layer 10 situated above said
print 9. For
simplicity's sake, in figures 16 through 20 the top layer 7 is represented as
a single layer. The
particularity of the floor panel of figure 16 is that it has a length L of
more than 180 centimeters.
The print 9 represents a wood pattern, the pores of which extend globally in
the longitudinal
direction of the floor panel 1.
Figure 17 represents that the floor panel 1 further comprises means for
restricting the
bending-through by its own weight. To this aim, the floor panel 1 comprises an
embedded
profile 53, for example, a profile which is based on synthetic material or
metal and preferably
is extruded. In the case of synthetic material, glass fibers or other filler
materials can be
applied in the material in order to obtain a higher bending strength. In this
case, the embedded
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profile 53 relates to an I-profile. Of course, other profiles can also be
applied. Preferably,
profiles are striven for which have a largest-possible moment of inertia when
bending. The
embedded profile 53 globally extends in the longitudinal direction of the
floor panel 1 and in
this case is located closer to the long edge 2 with the profile of the tongue
20 than to the
opposite long edge 3 with the profile of the groove 21. It is not excluded
that the embedded
profile 53 globally might extend according to the diagonal of the floor panel
1.
Figure 18 represents that the embedded profile 53 in that case is situated
integrally internally
within the substrate 6. However, it is not excluded that the profile 53, on
one or more long or
short edges, might extend into the profile 26, where it then preferably also
has the same
profile 26 as the remaining parts of the respective edge.
Figure 19 represents a variant, wherein instead of an embedded profile 53, at
least one glass
fiber mat or glass fabric layer 54 embedded in the substrate 6 is used, which
is situated
outside of the center line of the substrate 6, or outside of the neutral
fiber, when bending the
floor panel 1. In this case, the glass fabric layer 54 is situated closer to
the decorative side 17
than to the lower side of the substrate 6. Of course, a plurality of such
glass fiber-containing
layers can be applied, and possibly they may be situated on both sides of the
center line of
the substrate. According to the invention, such reinforcing layer does not
necessarily have to
be embedded in the substrate 6 but may also be located in the top layer, for
example,
underneath the print 9, or in the underlying layer 12.
Figure 20 represents a variant, wherein at least one layer 55 of the floor
panel 1 has a density
of more than 650 kilograms per cubic meter. In this case, between the top
layer 7 and the
substrate 6, in this case of soft PVC, a HDF board having a thickness of 3
millimeters or more
and a density of at least 1000 kilograms per cubic meter is applied. Instead
of using a wood-
based board material, also hard PVC or other hard synthetic material can be
used.
In figures 16 to 20, also the measure is applied that the floor panels have a
thickness of 5
millimeters or more. Preferably, the thickness is limited to a maximum of 7, 8
or 9 millimeters.
It is clear that the means restricting the bending can also be applied in
floor panels having a
length of less than 180 centimeters, however, preferably of more than 110
centimeters.
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According to a deviating variant, the invention thus also relates to such
floor panels. It is clear
that such floor panel further also can show the preferred characteristics of
the floor panels of
the first, second and/or third aspect, with the difference that they have a
length of less than
180 centimeters.
The present invention is in no way limited to the herein above-described
embodiments; on
the contrary, such panels may be realized according to various variants
without leaving the
scope of the present invention. Moreover, the panels, instead of as floor
panels, also can be
realized as wall panels or ceiling panels or even as furniture panels.
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