EP4248033B1 - Revêtement de sol assemblé à partir de panneaux de sol - Google Patents

Revêtement de sol assemblé à partir de panneaux de sol

Info

Publication number
EP4248033B1
EP4248033B1 EP21806403.8A EP21806403A EP4248033B1 EP 4248033 B1 EP4248033 B1 EP 4248033B1 EP 21806403 A EP21806403 A EP 21806403A EP 4248033 B1 EP4248033 B1 EP 4248033B1
Authority
EP
European Patent Office
Prior art keywords
layer
floor
substrate
floor covering
covering according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP21806403.8A
Other languages
German (de)
English (en)
Other versions
EP4248033A1 (fr
Inventor
Kristof van Vlassenrode
Quinten CHRISTIAENS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Unilin BV
Original Assignee
Unilin BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Unilin BV filed Critical Unilin BV
Publication of EP4248033A1 publication Critical patent/EP4248033A1/fr
Application granted granted Critical
Publication of EP4248033B1 publication Critical patent/EP4248033B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02005—Construction of joints, e.g. dividing strips
    • E04F15/02033—Joints with beveled or recessed upper edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
    • E04F2201/0107—Joining sheets, plates or panels with edges in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
    • E04F2290/043—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise with a bottom layer for sound insulation

Definitions

  • the present invention relates to a floor covering assembled from floor panels, the floor panels comprising a substrate, a decorative layer and a wear layer.
  • the invention is particularly interesting for being applied with floor coverings wherein at least one of the substrate, decorative layer and said transparent wear layer comprises thermoplastic synthetic material.
  • the thermoplastic material relates to so-called soft PVC (PolyVinyl Chloride), or PVC comprising a percentage of plasticizers, for example, of 5 to 20 percent by weight or even to 35 percent by weight or more.
  • the decorative layer relates to a print, the decor of which may form a representation of a wood or stone pattern or any other pattern, such as a fancy pattern.
  • a relief or structure may be provided, such as a wood or stone structure, respectively.
  • floor panels incorporating rigid PVC may have poor sound absorption properties.
  • a floor covering assembled from floor panels wherein the floor panels comprise a substrate, a decorative layer and a wear layer, the decorative layer being positioned between the substrate and the wear layer. At least one of the substrate, the decorative layer and the wear layer comprises a thermoplastic synthetic material.
  • the floor panel further comprises a foamed backing layer attached to a side of the panel opposite to the wear layer.
  • the foamed backing layer has a density of at least 120 kg/m 3 and preferably a compressive strength value as determined in accordance with ASTM D 3575-91 (25 %) of at least 210 kPa.
  • ASTM D 3575-91 25 a compressive strength value
  • the inventors have found that utilizing a foamed backing layer of at least 120 kg/m 3 and a compressive strength value of at least 210 kPa implies that the backing layer is sufficiently lofty to attenuate sound but sufficiently firm to prevent excessive vertical movement when walked upon.
  • the foamed backing layer has a thickness of between 0.50 mm and 1.0 mm.
  • a preferred thickness interval is between 0.60 mm and 0.90 mm, more preferably between 0.70 mm and 0.80 mm.
  • the foamed backing layer has a thickness of about 0.75 mm.
  • the foamed backing layer may have a compressive strength value within the range of 250 kPa to 750 kPa, preferably 400 kPa to 700 kPa, more preferably 550 kPa to 650 kPa. Its density may be within the range of 130 kg/m 3 to 350 kg/m 3 , preferably 160 kg/m 3 to 300 kg/m 3 , more preferably 190 kg/m 3 to 270 kg/m 3 . Although, for a particular material, there is a correlation between the density and compressive strength, the actual correlation will vary between materials.
  • an advantageous foamed backing layer may have a compressive strength value within the range of 400 to 700 kPa and a density within the range of 130 kg/m 3 to 350 kg/m 3 or within the range of 160 kg/m 3 to 300 kg/m 3 . More specifically, a foamed backing layer having a compressive strength value within the range of 400 to 700 kPa may have a density within the range of 190 kg/m 3 to 270 kg/m 3 . Similarly, other advantageous foamed backing layers may have a compressive strength value within the range of 550 to 650 kPa and a density within the range of 130 kg/m 3 to 350 kg/m 3 or within the range of 160 kg/m 3 to 300 kg/m 3 . The same holds true for foamed backing layers with a compressive strength value within the range of 550 to 650 kPa and a density within the range of 190 kg/m 3 to 270 kg/m 3 .
  • floor panels having advantageous properties may be attained even if the backing layer does not exhibit the recited compressive strength values.
  • the floor panel may still offer favourable sound insulation properties, stability and ease of installation.
  • a suitable material for the foamed backing layer is a cross-linked polyethylene, for example a polyethylene which is cross-linked by irradiation, commonly referred to as IXPE (Irradiated Crosslinked PolyEthylene).
  • IXPE Irradiated Crosslinked PolyEthylene
  • an open or closed cell foamed polyvinyl chloride may be opted for.
  • a polyurethane or polyisocyanurate foam may be opted for.
  • thermoplastic synthetic material used in the floor panel of the present invention is selected from the following group: polyvinyl chloride (PVC), polyethylene, polypropylene, polyethylene terephthalate and polyurethane.
  • PVC polyvinyl chloride
  • polyethylene polyethylene
  • polypropylene polypropylene
  • polyethylene terephthalate polyethylene terephthalate
  • polyurethane polyurethane
  • the substrate comprises polyvinyl chloride (PVC), preferably of the rigid type.
  • PVC polyvinyl chloride
  • a rigid PVC offers the advantage that irregularities of the underlying subfloor are less likely to be transmitted through the panel, it is conceivable that soft PVC or semi-rigid PVC be used for at least some regions of the substrate.
  • soft PVC or semi-rigid PVC be used for at least some regions of the substrate.
  • the terms "rigid”, “semi-rigid” and “flexible” i.e. soft
  • plasticizers from the following group may be used: DOP, DINCH, DINP,DOTP and/or epoxidized soybean oil.
  • the substrate comprises filler materials, for example chalk, limestone, talc or sand.
  • the content of filler materials may range between 5 and 80 percent by weight.
  • an amount of filler materials is present in the substrate material at a rate of 40 to 65 percent by weight.
  • Such highly filled materials may lead to a higher weight and a better sound absorption, as well as to a more stable installation and a reduced thermal expansion.
  • the substrate is a solid material, i.e. free of internal voids or foam.
  • Such substrate can have an increased indentation resistance as compared to a foamed substrate. This is of importance considering the presence of a backing layer that may support the substrate to a lesser extent as compared to a similar floor panel without such backing.
  • a reinforcement layer may be incorporated in the substrate.
  • its presence may lead to improved indentation resistance, thereby allowing the use of softer substrate material and/or softer material in the backing layer.
  • the reinforcement layer has an open structure. Consequently, substrate material may pass through openings in the structure to thereby fixedly incorporate the reinforcement layer in the substrate.
  • a suitable material for the reinforcement layer is glass-fibre, preferably in the form of a fleece, a nonwoven cloth or a net.
  • the reinforcement layer will improve the thermal dimensional stability of the substrate of the floor panel. A consequence of this is that, even though the material of the substrate and that of the foamed backing layer may have significantly different coefficients of thermal expansion, the relative size change between the two components will not be so great as to affect the reliability of the, often glued, connection between the substrate and the foamed backing layer.
  • the positioning of the reinforcement layer within the substrate may influence the stability imparted to the floor panel.
  • the reinforcement layer within the substrate is closer to the foamed backing layer than to the decorative layer.
  • the decorative layer is in the form of a printed thermoplastic synthetic film.
  • a printed thermoplastic synthetic film This may relate, for example, to a hard or soft PVC film having a thickness of 0.03 mm to 0.15 mm, preferably between 0.07 and 0.11 mm or between 0.08 mm and 0.10 mm.
  • the decorative layer may be a printed decor provided on an upper surface of the substrate by forming this decor, by means of any printing technique, directly on the substrate.
  • such decor is printed by means of UV-based inks.
  • the decorative layer may be in the form of a decor which is provided on the wear layer, more particularly on the side thereof which is intended for being directed towards the substrate.
  • this relates to a so-called "reverse" print, wherein the usual colour sequence of the inks is reversed.
  • such decor is preferably printed by means of UV-based inks. It is not excluded that instead of UV-based inks, water-based inks are used to print the decor in either of the alternatives mentioned here above.
  • a hard PVC film as a decorative layer, namely a PVC film without plasticizers, or of a PVC film having a percentage of plasticizers which is lower than 5 percent by weight, may be advantageous for obtaining a good registering between the printed decor and the structure of the wear layer. Due to the low percentage of plasticizer, such PVC films are less subject to dimensional alteration.
  • the wear layer is a thermoplastic synthetic material and is preferably transparent to thereby allow the decor of the decorative layer to be visible therethrough.
  • a preferred material is transparent PVC, for example a soft PVC.
  • the wear layer preferably shows a relief comprising a plurality of recesses.
  • the relief may correspond to a printed decor, such that a so-called structure in register with the printed decor is obtained.
  • a printed decor which represents a wood pattern with wood nerves, this may relate to a structure of a plurality of impressions or recesses in the form of wood pores which follow the course of the wood nerves, and/or a line structure corresponding to the course of the wood nerves.
  • this may relate to a structure which imitates joints or chamfers between a plurality of panels and corresponds to a joint or border between panels represented in the printed decor.
  • the recesses forming the relief may vary in size and shape.
  • the depth of the recesses may vary. This also applies to the area of the opening to the recesses.
  • the wear layer has a thickness of at least 0.15 mm and still better at least 0.30 mm, however preferably less than 1.0 mm.
  • An advantageous range is between 0.40 and 0.70 mm.
  • a floor panel having a wear layer of between 0.40 mm and 0.70 mm has the advantage that an effective wear resistance can be obtained for residential applications without resorting to solid wear-enhancement additives such as aluminium oxide. For example, it is possible to achieve an IP value (Initial wear point) of 2000 or more in the Taber tests, as described in EN 13329, Annex E.
  • the floor panels of the invention preferably have a total thickness of 2.0 mm to 5.0 mm, preferably between 3.0 mm and 4.0 mm.
  • the substrate which comprises one or more substrate layers, has a thickness of 1.3 mm to 5.0 mm.
  • the substrate forms at least half of the thickness of the floor panel.
  • the panels of the invention preferably have a width of 8 cm or more. Particularly preferred dimensions relate to a width situated between 15 and 22 cm and a length situated between 118 and 220 cm. It is clear that this relates to panel-shaped elements. However, it is not excluded that the invention may be applied to floor panels in the form of rectangular tiles. In particular, the invention relates to so-called LVT (Luxury Vinyl Tile) in plank format or in tile format.
  • LVT Luxury Vinyl Tile
  • the floor panel of the invention may comprise an upper surface with a lowered edge region at one or both edges of a pair of opposite sides.
  • a lowered edge region may be in the form of a chamfer, i.e. bevelled, or may comprise a flat bottom. In the latter case, an imitation of a cement joint may be sought.
  • the lowered edge region mitigates the risk that a possible temporary difference in height between adjacent floor panels in a floor covering would lead to excessive wear.
  • the backing layer applied in connection to the present invention delivers an ideal compromise between compressive strength and sound attenuation. This compromise does not necessarily lead to the absence of vertical motion of the floor panels. On the contrary, the slightly resiliently moving floor covering may deliver comfort when being walked upon.
  • Temporary height differences may thus still occur when the floor is being walked upon, or when heavy objects are on the floor covering.
  • the provision of a lowered edge region may alleviate the consequences of such height differences.
  • the lowered edge regions may hide such temporary imperfections from the average person walking on the floor.
  • the floor panel of the invention may comprise vertical edges at one or more of its sides.
  • the floor panel of the invention may comprise profiled edges at one or more pairs of opposite sides.
  • such profile may be such that only the upper edges of adjacent floor panels touch each other.
  • such profile at opposite sides may consist of inwardly inclined flanks converging at said upper edge.
  • the profile at one or more pairs of opposite sides may be such that the profiles of adjacent floor panels at least partially overlap each other, for example forming a shiplap j oint, or a tongue-in-groove joint. According to this second possibility an increased vertical stability of the floor panels in the floor covering is obtained.
  • the floor covering is assembled from floor panels as described, wherein such floor panels are loosely installed over the subfloor, or are glued to the subfloor. In either case an additional layer is available between the subfloor and the panel, for example a vapor blocking layer.
  • reference number 10 generally denotes a floor panel of the floor covering in accordance with the present invention.
  • the floor panel 10 is generally rectangular and has a first pair of opposite sides 12, 14 and a second pair of opposite sides 16,18.
  • the first pair of opposite sides is longer than the second pair of opposite sides, though it is to be understood that the principles of the present invention are applicable to panels and tiles of any shape, including tiles having sides of the same length, i.e. square tiles.
  • the floor panel 10 of the invention comprises a plurality of layers, including a substrate 20, a decorative layer 22 and a wear layer 24.
  • the decorative layer 22 is positioned between the substrate 20 and the wear layer 24.
  • At least one, preferably two, though most preferably all three of the substrate 20, decorative layer 22 and wear layer 24 comprises a thermoplastic synthetic material such as PVC.
  • the floor panel 10 further comprises a foamed backing layer 26 attached to a side of the floor panel opposite to the wear layer 24.
  • the foamed backing layer has a density of at least 120 kg/m 3 and may optionally have a compressive strength value as determined in accordance with ASTM D 3575-91 (25 %) of at least 210 kPa.
  • the floor panel illustrated in Fig. 2 includes additional optional layers.
  • One such layer is a reinforcement layer 28 which is incorporated into the substrate 20.
  • a suitable material for the reinforcement layer is a glass-fibre fleece or a nonwoven cloth.
  • the fleece or cloth may have a basis weight of between about 20 g/m 2 and 40 g/m 2 , for example about 30 g/m 2 .
  • the reinforcement may be in the form of a net.
  • the reinforcement layer may have an open structure.
  • the reinforcement layer 28 is illustrated as being within the substrate 20 closer to the foamed backing layer 26 than to the decorative layer 22. However, it is conceivable that the reinforcement layer 28 be located closer to the decorative layer 22 than to the foamed backing layer 26, depending on the relative rigidity of the materials making up the constituent layers of the floor panel.
  • the topcoat 30 may be a transparent or translucent lacquer layer.
  • the lacquer layer may comprise a solvent- or water-based UV-curable PU dispersion.
  • the lacquer layer may comprise ceramic particles. These particles enhance properties such as scratch resistance and wear resistance.
  • the ceramic particles may include aluminium oxide particles. Preferably, these particles have a diameter of from 2 to 20 microns.
  • the particles can be coated with silanes in order to better embed them in the PU dispersion.
  • the solid matter content of the PU dispersion may be from 30 wt.% to 40 wt.%.
  • an additional lacquer layer may form the uppermost layer of the floor panel.
  • the additional layer is transparent or translucent and can be used to determine the gloss degree of the floor panel.
  • the additional lacquer layer may be a UV-curable lacquer, such as polyurethane, with a solid matter content of 100 %.
  • Such a layer has enhanced mechanical and chemical resistance, something which is of course beneficial for properties such as wear resistance, scratch resistance and stain resistance.
  • the foamed backing layer 26 may have a thickness of between 0.50 mm and 1.0 mm.
  • a preferred thickness interval is between 0.60 mm and 0.90 mm, more preferably between 0.70 mm and 0.80 mm.
  • the foamed backing layer has a thickness of about 0.75 mm.
  • a suitable material for the foamed backing layer is a polyethylene which is cross-linked by irradiation, commonly referred to as IXPE.
  • Other possible materials include an open or closed cell foamed polyvinyl chloride, a polyurethane foam or a polyisocyanurate foam.
  • the foamed backing layer 26 may have a compressive strength value within the range of 250 kPa to 750 kPa, preferably 400 kPa to 700 kPa, more preferably 550 kPa to 650 kPa. Its density may be within the range of 130 kg/m 3 to 350 kg/m 3 , preferably 160 kg/m 3 to 300 kg/m 3 , more preferably 190 kg/m 3 to 270 kg/m 3 .
  • the substrate 20 may comprise polyvinyl chloride (PVC), preferably of the rigid type.
  • PVC polyvinyl chloride
  • a rigid PVC offers the advantage that irregularities of the underlying subfloor are less likely to be transmitted through the panel, it is conceivable that soft PVC or semi-rigid PVC be used for at least some regions of the substrate. Indeed, if a reinforcement layer 28 is present, the substrate material need not be as rigid as for a panel without a reinforcement layer.
  • the substrate 20 itself may consist of a plurality of layers 32, 34, 36, 38. In this manner, compatibility between the substrate 20 and further layers of the floor panel can be optimized.
  • the substrate may comprise a top layer 32, the material of which is selected to be compatible with the material of the decorative layer 22.
  • the substrate may have a backing layer 34 made of a material which advantageously allows the foamed backing layer 26 to be adhered thereto.
  • the substrate 20 may also include an upper core layer 36 and a lower core layer 38, with the reinforcement layer 28 being positioned therebetween.
  • the materials of the upper core layer and the lower core layer may be the same.
  • the material making up the substrate is a solid material, i.e. it is free from internal voids or foam.
  • the foamed backing layer 26 may be adhered to the substrate 20, more particularly to the backing layer 34 of the substrate, using any suitable adhesive.
  • Preferred adhesives are polyurethane reactive adhesive, also known as reactive hot melts. This type of adhesive is a one-part formulation with the bond forming in two stages. In a first stage, the adhesive cools back down and solidifies to reach its holding strength. In a second stage, a moisture-curing reaction takes place, typically over 24 to 48 hours, to reach final structural strength.
  • the decorative layer 22 may be in the form of a thermoplastic synthetic foil or film having a printed or imprinted decor thereon.
  • the foil or film may relate, for example, to a hard or soft PVC film having a thickness of 0.03 mm to 0.15 mm, preferably between 0.07 and 0.11 mm or between 0.08 mm and 0.10 mm.
  • the decor may represent a wood pattern with wood nerves, a stone pattern or a fancy pattern. Although it is preterred that the decor is printed by means of UV-based inks, it is not excluded that water-based inks may be used.
  • a hard PVC film as a decorative layer, namely a PVC film without plasticizers, or of a PVC film having a percentage of plasticizers which is lower than 5 percent by weight, may be advantageous for obtaining a good registering between the printed decor and the structure of the wear layer. Due to the low percentage of plasticizer, such PVC films are less subject to dimensional alteration.
  • the wear layer 24 may be a thermoplastic synthetic material and is preferably transparent to thereby allow the decor of the decorative layer 22 to be visible therethrough.
  • a preferred material is transparent PVC, for example a soft PVC.
  • the wear layer preferably shows a relief comprising a plurality of recesses 40 (see Fig. 1 ).
  • the relief may correspond to a printed decor, such that a so-called structure in register with the printed decor is obtained. In the case of a printed decor which represents a wood pattern with wood nerves, this may relate to a structure of a plurality of impressions or recesses 40 in the form of wood pores which follow the course of the wood nerves, and/or a line structure corresponding to the course of the wood nerves.
  • this may relate to a structure which imitates joints or chamfers between a plurality of panels and corresponds to a joint or border between panels represented in the printed decor.
  • the recesses forming the relief may vary in size and shape.
  • the depth of the recesses may vary. This also applies to the area of the opening to the recesses.
  • the wear layer 24 has a thickness of at least 0.15 mm and still better at least 0.30 mm, however preferably less than 1.0 mm. An advantageous range is between 0.40 and 0.70 mm.
  • the wear layer 24, the decorative layer 22 and the top layer 32 may be flexible PVC layers and may include a relatively high amount of plasticizer.
  • the backing layer 34, the upper core layer 36 and the lower core layer 38 of the substrate 20 may be more rigid than the top layer 32 of the substrate.
  • Fig. 3 depicts a cross-section through a second embodiment of a floor panel of the floor covering in accordance with the invention.
  • This floor panel differs from that illustrated in Fig. 2 only in that the substrate 20 consists of a single layer of material, preferably a single layer of rigid PVC. Consequently, the floor panel of Fig. 3 does not have a reinforcement layer incorporated in the substrate. Nevertheless, it is to be understood that a floor panel in accordance with the invention may have a single layer substrate and a reinforcement layer on either or both sides of the substrate. However, since it is advantageous if the decorative layer 22 overlies a smooth surface, it is preferred that any reinforcement layer be located between the foamed backing layer 26 and the single layer substrate 20.
  • Figs. 4, 5 and 6 illustrate possible lowered edge regions 42, 44, 46, respectively, which may be incorporated into the upper surface of floor panels 10 of the present invention.
  • the lowered edge regions may be applied along a single side 12, 14, 16, 18 of the floor panel, along a pair of opposed sides or along all four sides.
  • the lowered edge regions 42, 44, 46 may be in the form of a bevel or chamfer 48, 50, 52, respectively.
  • the lowered edge region may comprise a flat bottom, possibly mimicking the appearance of a cement- or grouted joint.
  • the lowered edge regions 42, 44, 46 are shown as being applied to the upper surface of panels having a multi-layered substrate 20, but it is to be understood that floor panels having a single layer substrate may also have corresponding lowered edge regions.
  • the chamfer or bevel 48 forming the lowered edge region 42 passes through a depth d of the wear layer 24, the depth d being less than the total thickness t of the wear layer. In this manner, the underlying decorative layer 22 is still covered by wear layer material.
  • the chamfer or bevel has a depth d of at least 50 %, preferably at least 60 %, more preferably at least 70 %, of the entire wear layer thickness t.
  • the chamfer or bevel may subtend an angle of from 6° to 25°, preferably 8° to 20°, more preferably 10° to 15° and most preferably about 11° to the upper surface of the floor panel.
  • the chamfer or bevel 50 forming the lowered edge region 44 subtends an angle of about 45° to the upper surface of the floor panel 10, though the skilled person will appreciate that this angle may have a value of from 30° to 60°, preferably from 40° to 60°.
  • the chamfer or bevel 50 passes through the entire thickness of the wear layer 24, and may, as illustrated, also pass through the decorative layer 22 and into an upper region of the substrate 20. In the case of a multi-layered substrate, the chamfer or bevel may extend though at least a part of the top layer 32.
  • the chamfer or bevel 50 may be covered by a cover layer 54.
  • the cover layer 54 may be a lacquer layer, for example of the same type as that used for the optional topcoat 30. Alternatively, or in combination, the cover layer may be coloured to enhance the impression of a v-shaped groove between two adjacent panels.
  • the chamfer or bevel 52 forming the lowered edge region 46 is in the form of a pressed-down bevel.
  • the edge region is subjected to pressure and, optionally, heat, to create a plastic deformation of the floor panel 10 in the edge region. In this manner, no material has to be removed from the floor panel 10 to create the lowered edge region 46.
  • the uppermost surface of the floor panels 10 is constituted by the optional topcoat 30, as described above with respect to Fig. 2 . It is to be understood that forming the chamfer or bevels 48 and 50 in the Figs. 4 and 5 embodiments, respectively, will then involve removal of the topcoat material covering the portion of the wear layer 24 that is removed when forming the lowered edge regions 42, 44, respectively.
  • the floor panels 10 comprise vertical edges at least at one or more of their sides 12, 14, 16, 18.
  • the floor panel 10 of the invention may comprise profiled edges at one or more pairs of opposite sides.
  • a first side 12 of one panel is provided with a tongue 56 and a second side 14 of an adjacent panel is provided with a groove 58.
  • the tongue 56 and the groove 58 are shown as being formed in the substrate 20 of the floor panels since this is generally the most rigid section of the panels.
  • profiled edges may be incorporated in floor panels with a single layer substrate as well as in floor panels having a multilayer substrate. As a result of the tongue 56 engaging in the groove 58 of an adjacent panel, vertical stability of a thus laid floor covering is increased.
  • the floor panels may have profiled edges such that upper edges 60 of adjacent panels touch each other when laid. This may be attained by at least one side 12 of a panel having an inwardly inclined flank 62. In this manner, a gap 64 may be created between lower regions of adjacent panels, thereby allowing any dirt or debris on the subfloor to gather in the gap while still allowing the upper edges 60 to touch each other.
  • the provision of one or more inwardly inclined flanks 62 is not necessarily dependent on the presence of tongue-and-groove profiled edges.
  • any material overlap between adjacent panels will contribute to improved vertical stability.
  • a tongue 56 and a groove 58 are illustrated in Fig. 7
  • this aspect of the invention may be attained by, for example a bulge and corresponding recess or a heel and corresponding recess. Indeed, any form of partial overlap is contemplated, for example the overlap provided by a shiplap joint.
  • both the first pair of opposite sides 12, 14 and the second pair 16, 18 are provided with profiled edges.
  • the floor panels of the invention preferably have a total thickness of 2.0 mm to 5.0 mm, preferably between 3.0 mm and 4.0 mm.
  • the substrate has a thickness of 1.3 mm to 5.0 mm.
  • the substrate forms at least half of the thickness of the floor panel.
  • the floor covering is assembled from floor panels 10 described above, wherein the floor panels are loosely installed over a subfloor or adhered thereto.
  • an additional layer is provided between the subfloor and the floor panels, for example a vapour-blocking layer.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Floor Finish (AREA)
  • Laminated Bodies (AREA)

Claims (15)

  1. Revêtement de sol assemblé à partir de panneaux de sol, dans lequel les panneaux de sol comprennent un substrat (20), une couche décorative (22) et une couche d'usure (24), dans lequel ladite couche décorative (22) est disposée entre le substrat (20) et la couche d'usure (24) ; dans lequel au moins un élément choisi parmi le substrat, la couche décorative et la couche d'usure comprend une matière synthétique thermoplastique, dans lequel le panneau de sol (10) comprend en outre une couche (26) transformée en mousse faisant office de dessous qui est fixée à un côté du panneau de sol, qui est opposé à la couche d'usure (24), caractérisé en ce que la couche transformée en mousse faisant office de dessous possède une masse volumique qui s'élève à au moins 120 kg/m3 et, de préférence, une valeur de résistance à la compression, telle qu'on la détermine en conformité avec la norme ASTM D3575-91 (25 %), qui s'élève à au moins 210 kPa ; et dans lequel les panneaux de sol sont montés sans être fixés sur ou sont collés à un sous-plancher, dans lequel une couche supplémentaire est prévue entre le sous-plancher et le panneau.
  2. Revêtement de sol selon la revendication 1, dans lequel la couche (26) transformée en mousse faisant office de dessous possède une valeur de résistance à la compression qui se situe dans la plage allant de 250 à 750 kPa, de préférence de 400 à 700 kPa, de manière plus préférée de 550 à 650 kPa.
  3. Revêtement de sol selon la revendication 1 ou 2, dans lequel la masse volumique de la couche (26) transformée en mousse faisant office de dessous possède une valeur qui se situe dans la plage allant de 130 kg/m3 à 350 kg/m3, de préférence de 160 kg/m3 à 300 kg/m3, de manière plus préférée de 190 kg/m3 à 270 kg/m3.
  4. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel la couche (26) transformée en mousse faisant office de dessous possède une épaisseur qui se situe entre 0,50 mm et 1,0 mm, de préférence entre 0,60 mm et 0,90 mm, de manière de loin préférée entre 0,70 mm et 0,80 mm.
  5. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel la couche (26) transformée en mousse faisant office de dessous comprend du polyéthylène réticulé.
  6. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel le substrat (20) comprend du chlorure de polyvinyle, de préférence un chlorure de polyvinyle rigide.
  7. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel une couche de renforcement (28) est incorporée dans le substrat (20).
  8. Revêtement de sol selon la revendication 7, dans lequel la couche de renforcement (28) possède une structure ouverte.
  9. Revêtement de sol selon la revendication 7 ou 8, dans lequel la couche de renforcement (28) comprend des fibres de verre, de préférence sous la forme d'une nappe, d'une étoffe non tissée ou d'un filet.
  10. Revêtement de sol selon l'une quelconque des revendications 7 à 9, dans lequel la couche de renforcement (28) au sein du substrat (20) est plus proche de la couche (26) transformée en mousse faisant office de dessous que de la couche décorative (22).
  11. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel le panneau possède une épaisseur totale qui se situe entre 2,5 mm et 5,0 mm, de préférence entre 3,0 mm et 4,0 mm.
  12. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel la couche décorative (22) est une couche de PVC qui a été imprimée.
  13. Revêtement de sol selon la revendication 12, dans lequel la couche de PVC qui a été imprimée possède une épaisseur qui se situe entre 0,08 mm et 0,10 mm.
  14. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel la couche d'usure (24) est une couche transparente à base de PVC ; et dans lequel le panneau est de préférence muni d'un revêtement supérieur (30), dans lequel le revêtement supérieur est de préférence obtenu à partir d'une couche de laque durcissable par exposition au rayonnement ultraviolet, de préférence de polyuréthane.
  15. Revêtement de sol selon l'une quelconque des revendications précédentes, dans lequel la couche d'usure (24) comprend une surface supérieure dans laquelle est réalisé un relief, dans lequel ledit relief comprend un certain nombre d'évidements (40).
EP21806403.8A 2020-11-18 2021-11-09 Revêtement de sol assemblé à partir de panneaux de sol Active EP4248033B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP20208368.9A EP4001546B1 (fr) 2020-11-18 2020-11-18 Panneau de revêtement de sol
PCT/IB2021/060341 WO2022106957A1 (fr) 2020-11-18 2021-11-09 Panneau de plancher

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EP4248033A1 EP4248033A1 (fr) 2023-09-27
EP4248033B1 true EP4248033B1 (fr) 2025-12-31

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EP20208368.9A Active EP4001546B1 (fr) 2020-11-18 2020-11-18 Panneau de revêtement de sol
EP21806403.8A Active EP4248033B1 (fr) 2020-11-18 2021-11-09 Revêtement de sol assemblé à partir de panneaux de sol

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EP20208368.9A Active EP4001546B1 (fr) 2020-11-18 2020-11-18 Panneau de revêtement de sol

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EP (2) EP4001546B1 (fr)
KR (1) KR102851515B1 (fr)
CN (1) CN116601365A (fr)
CA (1) CA3196687A1 (fr)
ES (2) ES2993871T3 (fr)
PL (2) PL4001546T3 (fr)
PT (2) PT4001546T (fr)
WO (1) WO2022106957A1 (fr)

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EP4337474B1 (fr) * 2021-05-12 2025-08-06 Unilin, BV Procédé pour fabriquer un panneau décoratif
CN119816649A (zh) * 2022-09-07 2025-04-11 瓦林格创新股份有限公司 用于制造建筑镶板上的斜面的方法及这种建筑镶板
EP4364961A1 (fr) * 2022-11-03 2024-05-08 Unilin, BV Panneau décoratif et procédé de fabrication des panneaux décoratifs
NL2037569B1 (en) * 2024-04-29 2025-11-17 Northann Building Solutions LLC Decorative panel, decorative covering, and method for producing such a panel

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NL2013486B1 (en) * 2014-09-18 2016-09-28 Champion Link Int Corp Panel suitable for assembling a waterproof floor or wall covering, method of producing a panel.
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PT4001546T (pt) 2024-09-24
ES2993871T3 (en) 2025-01-10
PT4248033T (pt) 2026-02-26
PL4248033T3 (pl) 2026-03-23
WO2022106957A1 (fr) 2022-05-27
CN116601365A (zh) 2023-08-15
KR20230107623A (ko) 2023-07-17
US20240011306A1 (en) 2024-01-11
EP4001546B1 (fr) 2024-08-07
EP4248033A1 (fr) 2023-09-27
ES3064124T3 (en) 2026-04-22
PL4001546T3 (pl) 2024-12-16
CA3196687A1 (fr) 2022-05-27
KR102851515B1 (ko) 2025-08-27
EP4001546A1 (fr) 2022-05-25

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