EA041189B1 - FLOOR PANEL AND METHOD FOR MANUFACTURING A FLOOR PANEL - Google Patents

Description

The present invention relates to a floor panel and to a method for manufacturing a floor panel.

More specifically, the present invention relates to a floor panel of this type, which comprises a substrate containing a thermoplastic material and a finish provided thereon, as well as at least one pair of opposite edges of the connecting parts, realized at least partially from the substrate and allowing mechanical fixation, i.e. without the use of glue or the like, between two such floor panels. This type of floor panel allows you to form a waterproof floor covering in a simple and convenient way. This flooring can also be used without any problems in wet rooms such as bathrooms, unlike wood based laminate flooring using for example medium density fibreboard or high pressure fibreboard underlay, which are less suitable. for such applications.

Patent document WO 2013/026559 describes such a floor panel in which the substrate comprises one or more layers of soft or flexible polyvinyl chloride (PVC). However, such a floor panel has a number of problems. For example, she has a significant risk of telegraphy effects. At the same time, after a certain period of time, the imperfections of the underlying surface or the subfloor on which the panels are installed become visible on the surface of the panels. When installing the panels in a room with a lot of incident sunlight, such as a porch, etc., there is also a high risk of curled up edges and/or gaps between the connected panels. This is a result of the expansion/shrinkage that the substrate undergoes as the temperature changes. While the use of a fiberglass layer can increase the dimensional stability of the floor panel, this is often still not enough to avoid the problems mentioned. In addition, these panels are relatively flexible and may not always install smoothly. In addition, the lacquer layer present on the top side of the panel generally does not score well enough in terms of wear resistance, scratch resistance, stain resistance, and the like.

The floor panel, which is known from patent document WO 2014/006593, attempts to solve a number of the problems mentioned. It has a rigid support layer, formed by extrusion, which contains, on the one hand, high density polyethylene (HDPE) or PVC, and on the other hand, bamboo, wood and/or cork powder. This backing layer is bonded to a veneer layer, such as a decorative vinyl layer. This floor panel already offers a significantly higher resistance to telegraphic effects. Due to its rigidity, it is also easier to install. However, it also has disadvantages. Thus, the flatness of this floor panel cannot be guaranteed. There is a significant risk of warping. In addition, this floor panel appears to be sensitive to the formation of indentations in its upper surface, for example from the legs of a table or chair. In addition, delamination problems are possible when the veneer layer separates from the backing layer.

The object of the present invention is to provide a solution to one or more of the above and/or other problems.

To this end, the present invention, according to its first independent aspect, relates to a floor panel of the type mentioned above, characterized in that the substrate comprises a layer of rigid thermoplastic material and a glass fiber layer is present in this floor panel. The present inventor has found that the use of a glass fiber layer with a rigid backing layer is extremely advantageous. It provides a reduced risk of panel warping. In addition, the risk of upward folded edges and/or gaps when installing panels on a porch or the like is reduced. The expansion/shrinkage still remains, but it appears that the disadvantageous effects mentioned are reduced. It should be noted that expansion is not inherently a problem, since it can be countered with the necessary spaces for expansion.

It should be noted that the term "substrate" means that part of the floor panel which is located under the trim or possible trim carrier.

The rigidity of the substrate layer is preferably derived from the rigidity of its thermoplastic material. This is possible by using the right amount of plasticizer or not using any plasticizer at all. If plasticizers are used, their amount is preferably less than 15 ppm. per 100 m.h. resin, less than 10 m.h. per 100 m.h. resin or less than 5 m.h. per 100 m.h. resins. It should be noted that the amount of plasticizers is less than 15 m.h. per 100 m.h. resin means that less than 15 parts of plasticizers are present per 100 parts of thermoplastic synthetic material. Examples of plasticizers that can be used are phthalate-based plasticizers such as di-isononyl phthalate (DINP) or dioctyl phthalate (DOP or DnOP), or alternatively for phthalate-based plasticizers, dioctyl terephthalate (DOTP) or di-isononyl- 1,2-cyclohexanedicarboxylate (DINCH).

The thermoplastic material of the rigid backing layer preferably comprises one or more of the following thermoplastic synthetic materials: PVC, polyethylene, HDPE, polypropylene, polyester, polyethylene terephthalate (PET), polyurethane and/or elastomer. The most preferred synthetic material is PVC.

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The thermoplastic material of the rigid backing layer preferably contains some filler. Fillers contribute to the rigidity of the panels. Various types of fillers may be used, singly or in combination: an inorganic filler such as chalk, lime and/or talc; organic filler such as wood, bamboo and/or cork; and/or mineral filler.

It should also be noted that talc filler is particularly advantageous. Namely, this filler has been shown to have a positive effect on the dimensional stability of the panel.

The filler concentration is preferably 30-70% by weight or 45-65% by weight. It should be noted here that the weight percent is determined by the total weight of the thermoplastic material in the substrate layer.

The proportion of filler is preferably at least 40 wt.%, more preferably at least 50 wt.%, and even more preferably at least 60 or at least 70 wt.%. This rather high percentage of filler has been shown to increase the dimensional stability of the substrate layer.

The thermoplastic hard backing layer material may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black.

It should also be noted that the thermoplastic material of the substrate layer may be a recycled material.

Preferably, the rigid backing layer is non-foamed or nearly non-foamed. The inventor of the present invention has found that such a backing layer not only provides better resistance against telegraphy effects than foam layers, but also provides dent resistance. It should also be noted that almost no foam means that the density of the non-foamed thermoplastic material is reduced by foaming by a maximum of 10% and preferably a maximum of 5% or a maximum of 2%. The density of the non-foamed or almost non-foamed substrate layer is preferably 1300-2000 kg/m ³ or 1500-2000 kg/m ³ .

However, it is also possible that the rigid support layer may be foamed. In fact, the present inventor has found that foaming has a positive effect on dimensional stability. Preferably, the decrease in density is greater than 10%. This means that the density of the non-foamed thermoplastic material decreases by more than 10% during foaming.

The rigid support layer can be formed by various techniques such as dusting, extrusion or calendering processes. The sprinkling process, which is known per se from patent documents WO 2013/179261 and BE 2015/5572, is preferred. In fact, the flatness of the substrate layer can be better guaranteed by such a process.

The fiberglass layer may refer to, for example, a fiberglass fleece, a fiberglass cloth or a fiberglass mesh.

The glass fiber layer is preferably adjacent to the rigid substrate layer. In this position, the glass fiber layer can best resist possible warping or dimensional deformation of the substrate layer.

The glass fiber layer is preferably at least partially impregnated with the thermoplastic material of the rigid substrate layer. This provides a good filling of the fiberglass layer, thanks to which its work becomes more efficient. The risk of delamination is also reduced.

It should also be noted that the glass fiber layer preferably refers to a glass fiber fleece. This type of fiberglass layer bonds better to the substrate layer. Better impregnation is also possible.

The substrate may comprise a second rigid substrate layer of thermoplastic material. This substrate layer may have one or more of the characteristics of the first mentioned substrate layer.

Preferably the glass fiber layer is adjacent to the first mentioned as well as to the second substrate layer. Thus, the glass fiber layer is sandwiched between the two substrate layers. This can be achieved in various ways.

Preferably, these two rigid backing layers are provided by shedding. In this case, one substrate layer may be deposited, a glass fiber layer may be provided on it, and another substrate layer may be deposited on this complex. Then this complex can be consolidated. Such a process is known per se from patent document WO 2013/179261. It has the advantage that the glass fiber layer can be very well cast between two substrate layers.

Another possibility is one in which one substrate layer is provided by sprinkling, a glass fiber layer is provided on it, this complex is consolidated, and only then another substrate layer is provided on this consolidated complex. Such a process is known from patent document WO 2016/079225. It has the advantage that the risk of deformation and/or damage to the glass fiber layer can be minimized, since the press element of a possibly used pressing device can be in direct contact with the glass fiber layer. The other support layer may be provided, for example, by means of a calendering technique.

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Another possibility is to produce two rigid substrate layers by extrusion. In this case, the extruded substrate layers and the glass fiber layer can be stacked on top of each other and then can be bonded to each other. The interconnection can be carried out in a pressing device, for example in a single platen or multi-platen press.

Another possibility is to form one substrate layer by extrusion, transport this extruded substrate layer and provide a glass fiber layer during said transport on said extruded substrate layer. The advantage of this process over the previous one is that it can be performed continuously. For example, one layer of substrate may be transported along guide rollers and the glass fiber layer may be fed along with the substrate layer between these guide rollers. Another substrate layer may be provided subsequently on the glass fiber layer. Alternatively, it is possible to provide this substrate layer together with the glass fiber layer on one substrate layer during its transportation.

The glass fiber layer may be untreated. However, it is also possible for the glass fiber layer to be pre-treated. This may provide better bonding to the substrate layer or layers adjacent to the glass fiber layer.

The pre-treatment may include providing a coating on the glass fiber layer or impregnation of the glass fiber layer. The coating or impregnation material may refer to a plastisol, preferably a PVC plastisol. Pre-processing can be performed separately.

The density of the glass fiber layer may be 30-100 g/m ² . However, it is preferably less than 65 g/m ² . This has the advantage that the glass fiber layer can be cast into the substrate more easily and quickly. In addition, this lighter fiberglass leads to only a small (or no) decrease in dimensional stability, at least not to the same extent as in the case of rigid substrate layers, which was rather surprisingly found by the present inventor.

Preferably, a second glass fiber layer is present in the floor panel. It has been proven that the use of more than one glass fiber layer is more effective than the use of a single glass fiber layer. The second glass fiber layer may have one or more of the characteristics of said first glass fiber layer.

In particular, the first and second glass fiber layers have a density of less than 65 or at most 50 g/m ² . This has a positive effect on the processing speed and practically no negative effect on dimensional stability, at least not in the case of applications with rigid substrate layers.

The two layers of fiberglass are preferably located on the sides of the center of the floor panel. Thus, their effect is better distributed over the floor panel. Preferably, one glass fiber layer is located in the lower half of the floor panel, while the other glass fiber layer is located in its upper half.

The two glass fiber layers are preferably spaced vertically apart, at least 1/5 or at least 1/4 of the thickness of the floor panels. This ensures good distribution of the effect of the fiberglass panels over the entire thickness of the floor panel. Most preferably they are located at a vertical distance from each other, which is approximately 1/3 of the thickness of the floor panel.

Preferably, these two glass fiber layers surround the first substrate layer. In the present invention, the top side of this substrate layer is defined by one glass fiber layer and its bottom side by another glass fiber layer. The thickness of the first substrate layer in this case is preferably at least 1/5, at least 1/4 or approximately 1/3 of the total thickness of the floor panel. The two layers of fiberglass are preferably arranged to the sides of the center of the floor panel, so that the center line of the floor panel in this case passes through the first substrate layer.

One glass fiber layer is preferably positioned between the first substrate layer and the second rigid thermoplastic substrate layer, while the other substrate layer is preferably positioned between the first substrate layer and the third rigid thermoplastic substrate layer. This results in a particularly balanced and stable multilayer structure. The second and third substrate layers may have one or more of the characteristics of the first substrate layer. The first backing layer is preferably centrally located, i.e. the center line of the floorboard extends through it, while the second and third backing layers are preferably centrally located such that the second backing layer is in the top half and the third backing layer is in the bottom half of the floorboard. . The second and third substrate layers are preferably made thinner than the first substrate layer, but preferably they are at least 1/5 or at least 1/4 of the thickness of the first substrate layer. The third substrate layer is preferably made thicker than the second substrate layer, but preferably no more than 2.5 or 2 times thicker.

One or more rigid layers of thermoplastic substrate form the rigid part of the floor panel. This rigid part preferably has a total thickness of at least

- 3 041189 mm. Namely, the inventor of the present invention has found that with such a thickness, the telegraphy resistance and bending rigidity are very good. Even better, the total thickness of the rigid part is at least 2.5 or at least 3 mm. The total thickness of the rigid part is preferably at most 8 mm, at most 6 mm or at most 4 mm. Thus, the weight of the panels can remain limited. The total thickness of the rigid part is preferably 2-8 mm, 2-6 mm or 2-4 mm. The total thickness of the rigid part is preferably at least 50%, at least 60% or at least 65% of the total thickness of the floor panel.

The substrate preferably comprises a substrate layer that is more flexible or compressible than the first rigid substrate layer. This more flexible backing layer has the advantage that the sound generated when walking on the installed floor panels can be muted. Preferably, this flexible backing layer is positioned between the first backing layer and the finish. Preferably, this more flexible backing layer is positioned directly below the trim or possible trim carrier on which the trim is provided. In this case, it also contributes to the efficient production of deep relief structures on the upper side of the floor panel. To this end, it is indeed desirable to deform the material under the finish, which is easier to do when the material is relatively flexible.

This more flexible backing layer is preferably made from a thermoplastic material, preferably PVC, but other synthetic materials such as polyethylene, polypropylene, polyester such as PET, polyurethane and/or elastomer are not excluded. The flexibility of this substrate layer is preferably obtained by realizing its thermoplastic material as soft or semi-rigid. This is possible with the use of a suitable amount of plasticizers, in particular when PVC is used as the thermoplastic synthetic material. The amount of plasticizers in the more flexible backing layer is preferably at least 15 ppm. per 100 m.h. resin and even better at least 20 m.h. per 100 m.h. resin

Examples of plasticizers that can be used, in particular in the case of PVC, are phthalate-based plasticizers such as DINP or DOP, or alternatively DOTP or DINCH.

When implementing a more flexible substrate layer, extrusion, calendering, or sprinkling techniques can be used.

Preferably, the more flexible backing layer is bonded to the first or optionally second rigid backing layer by thermal lamination, which, compared to using an adhesive or the like, limits the risk of delamination. Preferably this is done by a calendering process, for example by means of a calendering device consisting of more than two calendering rollers.

However, it is not ruled out that the more flexible substrate layer may consist of a material other than the thermoplastic material. For example, it is possible for this backing layer to refer to a carpet layer or a textile layer in general, or to be made of rubber or cork. In these cases, it is preferable that the corresponding substrate layer is connected to the first or possible second rigid substrate layer by means of an adhesive or the like, preferably a waterproof adhesive such as hot melt adhesive. It should also be noted here that in the case of, for example, carpeting, the finish is actually contained in this layer of carpeting.

The thickness of the more flexible substrate layer is preferably 0.5-3 mm, even more preferably 0.5-2 mm, and most preferably 0.5-1 mm inclusive, since at these thicknesses the above-described advantages are particularly pronounced.

The substrate may comprise on its underside a substrate layer which is preferably more flexible or more compressible than the first rigid substrate layer. With such an underlay layer located on the underside of the underlay, the advantage is obtained that the noise generated when walking on the installed floor panels can be dampened. This substrate layer may consist of a thermoplastic material, in which synthetic materials such as PVC, polyethylene, polypropylene, polyester such as PET, polyurethane and/or elastomer may be used. The corresponding backing layer is preferably foamed as this can improve its sound absorbing properties. A preferred embodiment of such a backing layer is one containing XPE or cross-linked polyethylene foam.

When implementing said substrate layer located on the underside of the substrate, extrusion, calendering or sprinkling techniques can be used.

It is also possible to bond this backing layer to the first or possible third rigid backing layer by means of thermal lamination which, compared with the use of an adhesive or the like, limits the risk of delamination. However, it is not excluded that the corresponding substrate layer is connected to the first or possible third substrate layer in another way, for example by means of an adhesive or the like, in which case a waterproof adhesive such as a hot melt adhesive is preferably used.

It is also not excluded that the bottom layer consists of a different material than the thermoplastic material. It is possible, for example, that this lower layer be a textile layer or consist of cork or rubber. In these cases, it is preferable that this lower layer is connected to the core by means of an adhesive or the like, preferably a waterproof adhesive such as hot melt adhesive.

The thickness of said substrate layer located on the underside of the substrate is preferably 1-4 mm, even better 1-3 mm and most preferably 1-2 mm inclusive, with a thickness of approximately 1.5 mm being ideal.

The finish preferably refers to an embossed or printed finish that preferably depicts a natural product such as wood or stone. In the case of wood, the finish may represent, for example, the layers and/or pores of the wood. Any of the following techniques may be used for embossing or printing: offset printing, gravure printing, and digital printing, which, for example, uses a digital printer or an inkjet printer.

The trim may be embossed or printed on the trim carrier. Alternatively, the finish may be embossed or printed directly onto the substrate, in which case it is referred to as so-called direct printing. It is also possible for the substrate to be provided with primer or primer, possibly multiple layers of primer or primer, prior to embossing or printing.

When a finish is embossed or printed on a finish carrier, it preferably refers to a foil or film, which may be thermoplastic. This may apply, for example, to foils or films made of PVC, polyethylene, polypropylene, polyurethane or polyester such as PET.

It is also possible for the wearing layer to be a cellulose-based layer, preferably impregnated with resin. For example, the cellulose-based layer refers to paper such as standard paper or kraft paper. The resin preferably contains melamine resin and/or phenolic resin.

It should also be noted that when the finish carrier is a cellulose-based layer, one or more cellulose-based layers, such as paper, may also be present underneath, which improves the rigidity of the floor panel. These one or more additional cellulose-based layers are preferably impregnated with a resin such as melamine and/or phenolic resin.

As an alternative for an embossed or printed finish, for example a wood or stone veneer can be provided on the substrate, which then forms the finish. Preferably, this possible wood veneer is treated to be waterproof or substantially waterproof.

Preferably, the floor panel comprises a wear and/or lacquer layer provided on the finish to protect it and prevent wear. Preferably these layers are transparent or translucent so that the finish is visible.

The wear layer preferably refers to a foil or film, which is preferably thermoplastic. This may apply, for example, to foils or films made of PVC, polyethylene, polypropylene, polyurethane or polyester such as PET. The thickness of such a foil or film is preferably 250-750 µm inclusive. This type of wear layer is preferably applied when the finish is embossed or printed on foil or film.

It is also possible that the wear layer refers to a cellulose-based layer, preferably impregnated with resin. For example, a cellulose-based wear layer refers to paper such as standard paper or kraft paper. The resin preferably contains melamine resin and/or phenolic resin. Preferably, the cellulose-based wear layer contains wear-resistant particles such as ceramic particles or corundum. This type of wear layer is preferably applied when the finish is embossed or printed on the cellulose based layer.

The lacquer layer is preferably based on urethane acrylates, polyester acrylates and/or epoxy acrylates. Preferably, this refers to a lacquer layer which can be cured with UV radiation or excimer radiation. The lacquer layer may contain ceramic particles such as alumina and/or silica. The lacquer layer may be provided before or after the possible relief is formed on the upper side of the floor panel. Of course, with rather deep relief, for example, with a depth of more than 100 or 250 µm, it is advantageous to provide a layer of lacquer before embossing, as described in patent document BE 2016/5732, since this helps to prevent tears in the lacquer layer. This is of course useful when applying high gloss wear layers, such as PVC wear layers, since the shimmering spots resulting from such wear layers as described in BE 2016/5732 can thus be avoided.

It should also be noted that multiple layers of lacquer may be present over the finish. This is particularly advantageous when the relief is provided on the upper side of the floor panel. In this case, the first layer of lacquer may be provided before the embossing, so that the lacquer layer does not have breaks and prevent the formation of flickering spots, and the second after the embossing, and for this second layer of lacquer, a harder varnish can be used, which in principle is known per se from patent document BE 2016/5732.

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It should also be noted that the present invention allows the application of more rigid varnishes. The reason for this is the presence of a rigid substrate layer. In fact, this backing layer can counteract the shrinkage to which the lacquer is subjected, and thus warping or warping of the panel. The application of harder varnishes has the advantage that they are more efficient and provide better mechanical and chemical resistance.

The top side of the floor panel may be embossed to simulate the texture of a natural product such as wood, stone or ceramic. In the case of wood, the relief may model inter alia the layers and/or pores of the wood. Possible bevels on one or more edges of the upper side of the floor panel do not belong to such a pattern and are not considered to form part of the pattern, given the fact that they are not intended to simulate a natural texture, but rather to achieve a plank effect. The relief can be provided by mechanical and/or chemical embossing.

The relief preferably has a maximum depth of more than 100 µm, and even better more than 200 or 250 µm. Such a deep relief contributes to the fact that the floor panel looks natural. With such deep relief, it is particularly advantageous to use a more flexible backing layer, as described above herein. In fact, such a substrate layer can be easily warped or embossed to form a deep relief.

In the case where the relief is formed on the upper side of the floor panel, it is best that there is a wear layer in which the relief is created. It is possible for the deep relief to extend into the wear layer, however, it is desirable that it extends into the substrate, preferably into the more flexible substrate layer possible.

The relief can be created simultaneously with the creation of the finish. Simultaneous creation has the advantage that a more natural-looking and tactile floor panel is obtained. Various techniques for implementing such a simultaneous embodiment are known in particular from the following patent documents: EP 2636524, EP 2447063 and EP 2447064.

It should be noted that when a wood or stone veneer is provided above the substrate, the top side of the floor panel is automatically embossed with the texture of the wood or stone, respectively.

The top side of the floor panel may include a bevel at one or more of its edges. This may refer to a bevel that has a depth no greater than the thickness of a possible wear layer. However, it is possible for this bevel to have a depth greater than the thickness of the wear layer, for example to extend into the substrate, in which case this bevel is preferably finished off. This can be provided by a separate bevel finish, i.e. a finish separate from the base finish, such as varnish, paint or foil. Alternatively, the main finish may run continuously along this bevel. In this case, it may refer to the so-called pressed bevel, where the bevel is formed by pressing the upper side of the floor panel, including trim, close to its edge.

The floor panel preferably has one or more of the following characteristics: the floor panel flexes under its own weight by less than 10 cm/m, and even better by less than 5 cm/m; and/or the floor panel has an elastic modulus or Young's modulus of at least 2000 N/mm ² , at least 3000 N/mm ² or at least 3500 N/mm ² .

The camber can be measured by clamping the floorboard fixed at one end and measuring the camber of the remaining free portion. In the case of an elongated rectangular panel, for example, one of its short sides can act as the clamped end.

The modulus of elasticity should be measured at room temperature of 25°C.

The overall thickness of the floor panel is preferably 3-10 mm, or 3-8 mm, or 3.5-8 mm, or 3.5-6 mm, or 4-6 mm inclusive, with an ideal thickness of approximately 4.5 mm.

The mechanical fixation carried out by the connecting parts in the connected state of two such floor panels can be carried out at least or exclusively in the horizontal direction, that is, in the plane of the connected floor panels, which is perpendicular to the connected edges. This horizontal fixation can be realized by the interaction of the fixing surfaces. The zone in which these locking surfaces interact is preferably located at least partially or completely in the first, optionally second or optionally third rigid substrate layer, which has the advantage of providing a strong fixation and minimizing the formation of gaps. It is also possible to position the glass fiber layer at the height of this zone, which improves the fixation strength.

The mechanical fixation carried out by the connecting parts in the connected state of two such floor panels can be carried out at least or exclusively in the vertical direction, that is, perpendicular to the plane of the connected floor panels. This vertical fixation can be realized by the interaction of the locking surfaces, and the zone in which these locking surfaces interact is preferably located at least partially or completely in the first, optional second or optional third rigid substrate layer, which has the advantage of providing strong fixation and minimizing the formation gaps. Also

- 6 041189 it is possible to position the glass fiber layer at the height of this zone, which improves the fixation strength.

Preferably, both horizontal and vertical fixing are present, preferably implemented by interaction of the fixing surfaces, wherein the zone or zones in which the fixing surfaces interact are preferably located at least partially in the first, optionally second, or optionally third rigid substrate layer. The glass fiber layer may be located at the height of the zone in which the locking surfaces interact. In the case where there are a plurality of zones in which the fixing surfaces interact, these glass fiber layers, when a plurality of glass fiber layers are used, or at least a portion of these glass fiber layers, can be located at the height of the aforementioned zones.

The connecting parts can be implemented as a connection with a ledge and a groove, limited by the upper and lower collars. This connection preferably comprises locking elements, for example in the form of a protrusion on the underside of the protrusion of the connection and a recess in the upper side of the lower shoulder, which, in the connected state, resist movement of the protrusion and groove in the horizontal direction. Preferably, this tongue-and-groove connection has one or more of the following characteristics, provided that they do not conflict with each other, all of which increase the stability and strength of the fixation: the top bead is at least partially realized from the first or optionally second rigid substrate layers; the lower bead is at least partially realized from the first or optional third rigid substrate layers; the center line through the protrusion is located in the first rigid layer of the substrate; the innermost point of the groove is located in the first rigid substrate layer; the zone in which the upper side of the protrusion interacts with the lower side of the upper bead is located at least partially or completely in the first or optionally second rigid substrate layers; the zone in which the possible locking elements interact is located at least partially or completely in the first or possible third rigid substrate layer; the glass fiber layer is located at the height of the zone in which the upper side of the protrusion interacts with the lower side of the upper shoulder; the glass fiber layer is located at the height of the zone in which the possible fixing elements interact; the glass fiber layer is located on the center line through the ledge; the glass fiber layer is located at the height of the innermost point of the groove; in the case where the zone in which the upper side of the protrusion interacts with the lower side of the upper shoulder is located in a different position than the zone in which the possible locking elements interact, preferably at least two layers of glass fiber are present, and preferably one layer of glass fiber is located on the height of the zone in which the upper side of the protrusion interacts with the lower side of the upper shoulder, and the other fiberglass layer is located at the height of the zone in which the possible locking elements interact; the glass fiber layer extends continuously through the bottom bead or the top bead; and/or the glass fiber layer extends continuously in at least one of the connecting parts.

The connecting parts implemented as a tongue and groove connection are preferably selected from the following types: a type in which the connecting parts are configured in such a way that they allow the connection of two such floor panels at respective edges by means of a pivoting movement, in which the tongue and groove floor panel is a position in which the protrusion is already partially located in the groove, rotates down to fully insert the protrusion into the groove and connect the respective edges to each other; the type in which the connecting parts are configured in such a way that they allow the connection of two such floor panels at the respective edges by essentially linear movement in the plane of the floor panels and essentially perpendicular to the respective edges, preferably with a snap-in action; the type in which the connecting parts are configured in such a way that they allow the connection of two such floor panels at the respective edges, both by means of the pivotal movement described above in this document, and by essentially linear movement in the plane of the floor panels and substantially perpendicular to the respective edges, preferably with a latching action.

It should also be noted that a tongue and groove connection, when the floor panel is square or rectangular, can be applied on each pair of opposite edges of that floor panel.

Alternatively, the connection parts can be realized as hook-shaped parts consisting, on the one hand, of an upwardly directed hook-shaped fixing part with a shoulder and an upwardly directed locking element, and on the other hand of a downwardly directed hook-shaped part with a shoulder and directed downwards. hook-shaped parts, wherein these locking elements, in the connected state of two such floor panels, resist movement of the hook-shaped parts in a horizontal direction. The mechanical locking effected by these hook-shaped parts preferably also works in the vertical direction, and for this purpose they can be provided with vertically active locking elements. Preferably, the hook-shaped portion has one or more of the following characteristics, all of which enhance the stability and strength of the fixation:

- 7 041189 or a possible second rigid substrate layers; the bead of the upward hook-shaped part is at least partially realized from the first or optionally third rigid substrate layers; the zone in which the upwardly directed locking element interacts with the downwardly directed locking element to effect horizontal fixation is located at least partially or completely in the first or optionally third rigid substrate layer; the zone or zones in which the possible vertically active locking elements interact are located at least partially or completely in the first, optional second or optional third rigid substrate layer; the glass fiber layer is located at the height of the zone in which the upwardly directed locking element interacts with the downwardly directed locking element to effect horizontal fixation; the glass fiber layer is located at the height of the zone or zones in which the possible vertical fixing elements interact; in the event that the zone in which the upwardly directed locking element interacts with the downwardly directed locking element to effect horizontal fixation is located in a different position than the zone in which possible vertically active locking elements interact, preferably at least two glass fiber layers are present, wherein preferably one layer of glass fiber is located at the height of the zone in which the upwardly directed locking element interacts with the downwardly directed locking element to effect horizontal locking, and the other glass fiber layer is located at the height of the zone in which possible vertically active locking elements interact; the glass fiber layer extends continuously in the collar of the downward hook-shaped portion or in the collar of the upward hook-shaped portion; and/or the glass fiber layer extends continuously in at least one of the hook-shaped parts.

The vertically active locking elements may comprise a separate insert, preferably a resiliently deformable and/or movable insert, which is per se known, for example, from patent documents WO 2006/043893, WO 2008/068245 and WO 2009/066153. This insert has the advantage that the strength of the vertical fixation becomes largely independent of the floor panel material itself, and that a stronger vertical fixation can be provided compared to elements that are realized from the floor panel material itself. Thus, such an insert is useful in reducing the risk of gaps between floor panels being joined.

This insert is preferably provided in a recess in the upward or downward hook-shaped part. This recess is preferably located at least partially in the first rigid substrate layer.

When such an insert is not used, the vertically active locking elements are preferably made from the material of the floor panel itself, and even better from the material of the first, optionally second, or optionally third rigid substrate layer. The rigid nature of these backing layers ensures that these locking elements will also provide a strong vertical hold.

The hook-shaped parts can preferably be engaged with each other by a substantially linear movement perpendicular to the plane of the connected floor panels or to the plane of the floor covering.

It should also be noted that hook-shaped pieces, when the floorboard is square or rectangular, can be applied on each pair of edges of that floorboard.

Preferably the floor panel is square or rectangular and can be connected to adjacent floor panels by a fold-down technique. To this end, this floor panel contains, on the one hand, on one pair of opposite edges, connecting parts, which are realized in the form of a connection with a ledge and a groove, and which are of a type that allows this floor panel to be connected to an already installed similar floor panel, which is located in the previous row, by means of a pivoting movement, and on the other hand, on the other pair of edges, connecting parts, which are realized in the form of hook-shaped parts and which allow the corresponding floor panel to be connected by the same pivoting movement with an already installed similar floor panel located in that same row. This fold-down laying technique has been shown to be excellent for installing a floor panel in accordance with the present invention.

It should also be noted that any reinforcing layer can be used instead of the glass fiber layer. Preferably, this is a reinforcing layer which contains reinforcing fibers such as carbon fibers.

According to an independent second aspect, the present invention relates to a floor panel of the type mentioned above, characterized in that the substrate comprises a rigid, non-foamed thermoplastic material substrate layer. As a result, this floor panel is less sensitive to indentation effects, for example by chair and/or table legs, compared to floor panels with foam backing layers.

It should be noted that this advantage also appears when the rigid substrate is lightly foamed, i.e. when foaming reduces the density of the rigid substrate layer by up to 10%.

According to an independent third aspect, the present invention relates to a floor panel of the aforementioned type, characterized in that the substrate comprises a substrate layer of thermoplastic material, which is thermally laminated to a more flexible substrate layer which is located between the trim and this rigid substrate layer. Thus, the risk of delamination is reduced.

According to an independent fourth aspect, the present invention relates to a floor panel of the aforementioned type, characterized in that it contains at least two layers of glass fibers, each of which has a density of less than 65 g/m ² or even at most 50 g/m ² .

It should also be noted that each of the second to fourth aspects may be combined with one or more of the characteristics of the first aspect without requiring the floor panel to exhibit the characteristic of that first aspect.

According to an independent fifth aspect, the present invention relates to a method for manufacturing a floor panel with a substrate containing a thermoplastic material and a finish provided thereon, which includes the following steps: providing a first rigid layer of a substrate of thermoplastic material through a first heap treatment; providing a glass fiber layer on the poured substrate layer; providing a second rigid substrate layer of thermoplastic material on the glass fiber layer by means of a second bulking treatment; consolidation of the poured layers of the substrate and the glass fiber layer under the influence of pressure and/or heat; providing on the consolidated second substrate layer a more flexible or more compressible substrate layer of thermoplastic material by applying the thermoplastic material in a liquid state.

A feature of this method is that the rigid substrate layers are consolidated, and only then a more flexible substrate layer is provided on them. This allows the consolidation parameters such as pressure and/or temperature to be optimally adjusted depending on the characteristics of the thermoplastic material of the rigid backing layers, which differ from those of the material of the more flexible backing layer, taking into account the difference in stiffness/flexibility.

The thermoplastic material of the first and/or second substrate layer may be deposited in the form of grains or powder. Preferably, this material, or at least part of it, is poured in the form of a granulate, however, it may be advantageous to pour it as a dry mix, for example, when this material or part of it is to be foamed. Such a dry mix actually guarantees the characteristics of the blowing agents added to the material, as described in patent document BE 2015/5572, in the best possible way.

Consolidation may be carried out in a pressing device, preferably in a double belt pressing device. This pressing device may include a tension roller, which may provide calibration of the poured material.

Preferably, a more flexible backing layer is provided on the second backing layer by means of a calendering device. The calendering device preferably comprises more than two calendering rollers.

Obviously, this method may also include providing a finish and possible wear and/or lacquer layers.

The aforementioned layers preferably form a continuous web of material, which is finally divided into separate parts, for example by cutting, to form floor panels.

After being divided into separate parts, the floor panels can be provided along one or more edges with connecting parts, which provide a mechanical connection between two such floor panels. These connecting parts are preferably made by means of cutting tools such as milling tools.

The floor panel obtained in accordance with the present invention may further have one or more characteristics of the floor panel in accordance with the first, second, third and/or fourth aspects mentioned.

It should be noted that the present invention is applicable not only to floor panels. It can be applied advantageously to any type of panel such as wall panels, ceiling panels or door panels.

The present invention can also be applied more broadly than just panels. It can advantageously be applied to any type of floor, wall, ceiling or door element. Examples of this are rolled floor elements or full floor floor elements such as full floor vinyl.

It should also be noted that each of the mentioned ranges of values includes the specified limits, unless explicitly stated otherwise.

To better illustrate the characteristics of the present invention, hereinafter, as non-limiting examples, some preferred embodiments are described with reference to the accompanying drawings, in which:

- 9 041189 fig. 1 represents a floor panel in accordance with the present invention;

fig. 2 is a cross section along the line II-II of FIG. 1;

fig. 3 and 4 show how the edges shown in FIG. 2;

fig. 5 is an enlarged view of the area F5 shown in FIG. 2;

fig. 6 and 7 are variants of FIG. 2;

fig. 14 and 15 show how the floor panels can be connected according to the fold-down laying technique;

fig. 16 shows fittings that can be used with such floor panels;

fig. 17-19 represent variants of FIGS. 16;

fig. 20 represents a method in accordance with the present invention; and fig. 21 and 22 represent options.

Fig. 1 shows a floor panel 1 in accordance with the present invention. The floor panel 1 shown contains a finish 2 which refers to a printed wood finish. This refers to an elongated rectangular floor panel 1 which has a pair of long edges 3-4 and a pair of short edges 5-6. Each pair of edges is provided with connecting parts 7-8 and 9-10, respectively.

The shape of the connecting parts 7-8 is shown in FIG. 2. This refers to a tongue and groove joint comprising a tongue 11 and a groove 12 defined by an upper collar 13 and a lower collar 14. The lower collar 14 protrudes further than the upper collar 13. In addition, this joint comprises locking elements 15-16 in the form projection 15 on the lower side of the projection 11 and an upward locking element 16 in the part of the lower shoulder 14, which protrudes beyond the upper shoulder 13, which, through the interaction of the locking surfaces 17-18, counteract the movement of the projection 11 and the groove 12 in the horizontal direction H. Upper side 19 of the projection 11 cooperates with the underside 20 of the upper bead 13 in order to resist separation in the vertical direction V.

Fig. 3 and 4 show how the connecting parts 7-8 can be connected by means of a pivoting movement (FIG. 3) as well as a substantially horizontal snap-in movement (FIG. 4).

Fig. 2 also shows the construction of the floor panel 1. It consists of a substrate 21, a finish carrier 22 with a finish 2, a wearing layer 23 and a lacquer layer 24.

The substrate 21 consists of two substrate layers 21A and 21B realized on the basis of PVC.

The substrate layer 21A is rigid. To this end, no plasticizers are present in this layer 21A, or plasticizers are present in an amount of less than 15 ppm. per 100 m.h. resins. Examples of plasticizers that can be used have already been mentioned. In addition, the substrate layer 21A contains a filler in an amount of 30 to 70% by weight. Preferably, chalk, talc and/or lime are used, optionally supplemented with particles of wood, bamboo and/or cork. In addition, the substrate layer 21A may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The thickness T1 of the substrate 21A is at least 2 mm. As a result, the substrate layer 21A has high bending rigidity. This is advantageous because it reduces to some extent the risk of floor panel 1 warping and curling edges under the action of sunlight.

This risk is further reduced to a large extent by the presence of the fiberglass fleece 25 . While this does not appear to be able to prevent the substrate 21 from expanding/contracting with temperature changes, it does in fact counteract warpage or extrusion. This is in fact the most important given that expansion/contraction can inherently be counteracted by providing suitable spaces for expansion, which is also known per se in the field of wood laminate flooring. The fiberglass fleece 25 is sandwiched between the backing layers 21A and 21B. Thus, it can perform its function in the best possible way. The fiberglass fleece 25 may be at least partially impregnated with the thermoplastic material of the backing layers 21A and/or 21B. This provides a strong potting in the substrate 21 so that it can perform its function even better. This position of the glass fiber layer 25 ensures that it runs continuously in both connecting parts 7-8. This is advantageous for its efficiency, in particular at the respective edges 3-4 of panel 1.

The rigid backing layer 21A is obtained through a sprinkling process. With such a process, a very good bond with the glass fleece 25 can be obtained. In such a process, the glass fleece 25 can also have a supporting function. The glass fleece 25 can also form a separation between the poured layer 21A and the layer 21B if the latter is also poured. This is definitely useful prior to consolidation as it prevents intermixing of the poured material of different layers.

In addition, the substrate layer 21A is non-foamed. This provides a better resistance against telegraphy effects and indentation compared to foam layers. The density of layer 21A is 1300-2000 kg/m ³ .

The zone in which the upper side 19 of the ledge and the lower side 20 of the upper collar interact

- 10 041189 ka, is located completely in the rigid layer of the substrate 21A, just like the zone in which the locking elements 15-16 interact. This provides a strong mechanical connection, in which the formation of a gap is difficult. The upper collar 13 is partly realized from the layer 17A, and the lower collar 14 even completely. This reduces the risk of breakage of one or both of the collars 13-14. In particular, this is advantageous for the lower bead 14, since this bead 14 may not break as a result of the possible bending it undergoes during the joining of the edges 3-4. Otherwise, the connection will be lost.

The substrate layer 21B is more flexible than the layer 21A. To this end, more plasticizers are present in this layer 21B, namely at least 15 m.h. per 100 m.h. resins. This flexible layer 21B ensures that, regardless of the relatively rigid panel 1, there will be no clattering sounds when walking on this panel 1. Thus, due to its soft nature, it has sound-absorbing properties. In addition, such a layer 21B is easier to deform in order to create a deep relief on the upper side of the panel 1. The filler concentration in this layer 21B is 30-70% by weight. In addition, the substrate layer 21B may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The thickness T2 of the substrate layer 21B is 0.5-1 mm.

Layers 17A and 17B are bonded to each other by thermal lamination. Thus, a reduced risk of delamination is obtained compared with the use of glue and the like.

The finish carrier 22 on which the finish is printed is a PVC film or foil.

The transparent wear layer 23 refers to a PVC layer with a thickness of 250750 µm.

The overall thickness T of the floor panel 1 is between 3.5 and 6 mm.

Fig. 5 shows in more detail the lacquer 24 which is provided on the wear layer 23. It refers to a lacquer based on urethane acrylate. Also visible is the relief 26 provided on the upper side of the panel 1.

Fig. 6 shows connecting parts 7-8 similar to those shown in FIG. 2, however, the substrate 21 has a different design. Layer 21A is similar to layer 21A in FIG. 2, but is thinner. The second rigid backing layer 21C is also present in the backing 21 and is also made of PVC. The substrate layer 21C does not contain plasticizers, or contains plasticizers in an amount of less than 15 ppm. per 100 m.h. resins. The substrate layer 21C also contains a filler in an amount of 30 to 70% by weight. In addition, the substrate layer 21C may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The total thickness T1 of the substrate layers 21A and 21C is at least 2 mm. The result is that the combination of the substrate layers 21A and 21C gives a high bending rigidity of the panel 1, which is even increased by the presence of the glass fleece 25 inside them. The position of the glass fleece 25 is such that it passes continuously through both connecting parts 7-8 . In addition, it is located at the height of the center line of the protrusion 11 and passes through the innermost point of the groove 12. Thus, additional support is provided at these positions, which is beneficial for the strength of the protrusion 11 and groove 12.

The rigid layers 21A and 21C are formed by a shedding process which is known per se from WO 213/179261. This has the advantage that the glass fleece 25 can be molded very well into a rigid whole, resulting in a particularly stable sandwich.

The rigid layer 21C is also non-foamed.

Fig. 7 shows connecting parts 7-8 similar to those shown in FIG. 6, however, the substrate 21 has a different structure. The substrate layers 21A and 21C have a construction similar to the layers 21A and 21C in FIG. 6. However, there is a third hard backing layer 21D which is also made of PVC. The substrate layer 21D does not contain plasticizers, or contains plasticizers in an amount of less than 15 ppm. per 100 m.h. resins. In addition, the layer 2ID of the substrate contains a filler in an amount of from 30 to 70 wt.%. In addition, the substrate layer 21D may contain an impact modifier, a stabilizer such as a Ca/Zn stabilizer, and/or a color pigment such as carbon black. The total thickness T1 of the substrate layers 21A, 21C and 21D is at least 2 mm. The result is that the combination of substrate layers 21A, 21C and 21D gives the panel 1 a high flexural rigidity, which is even increased by the presence of two glass fleece layers 25A and 25B inside them. These two glass fleece layers 25A and 25B are located outside the center of the panel 1 at a distance D from each other that is at least 1/5 of the thickness T of the panel 1. The substrate layers 21C and 21D are thinner than the center layer 21A, but have a thickness component of at least 1/5 of the thickness of the Central layer 21A. The result is a particularly balanced and stable sandwich construction. The substrate layers 21A, 21C and/or 21D may in fact comprise a plurality of substrate layers and thus be multi-layered. The backing layer 21A, for example, may comprise a plurality of backing layers, which can have mutually different compositions, such as mutually different filler or plasticizer concentrations. The same applies to layers 21C and 21D, and more generally to all substrate layers mentioned in this document.

- 11 041189

The two glass fleece layers 25A and 25B have a density of less than 65 g/m ² . This has a positive effect on the speed of the process and has practically no negative effect on dimensional stability, at least not in the case of applications with rigid substrate layers.

Fig. 8 shows the variant shown in FIG. 7, in which the substrate 21 on its underside includes a sound-absorbing XPE foam substrate layer 21E. The thickness of this layer 21E is 1-2 mm.

Fig. 9 shows the variant shown in FIG. 7, in which the glass fleece layers 25A-25B are arranged somewhat differently. The glass fleece 25A passes centrally through the area in which the top side 19 of the projection 11 engages with the underside 20 of the top bead 13, while the glass fleece 25 passes centrally through the area in which the locking elements 1516 interact. This provides excellent horizontal and vertical locking. .

Fig. 10 shows a variant of FIG. 9. The glass fleece 25A is arranged in a similar manner, however the glass fleece 25B extends continuously in the connecting part 8. It passes continuously through the lower bead 14. This is advantageous for the strength of this bead 14.

Fig. 11 shows the construction of the substrate 21 similar to that shown in FIG. 10, however, here the connecting parts 7-8 have a different configuration. The lower side of the protrusion 11 is convex, while the upper side of the lower bead 14 is concave.

Fig. 12 and 13 show two more variants, in which the lower side of the projection 11 and the upper side of the lower shoulder 14 comprise a flat part.

Fig. 14 and 15 show how the floor panels 1 can be connected to each other by means of a fold-down laying technique.

To this end, the short pair of edges 5-6 of the panel 1 is provided with fittings 9-10 shown in FIG. 16. They are implemented in the form of a downward hook 27 and an upward hook 28. The downward hook 27 has a collar 29 with a downwardly directed locking element 30, while the upwardly directed hook 28 has a collar 31 with an upwardly directed locking element 32. The locking elements 30 and 32 cooperate by fixing the surfaces 33-34 in order to counteract the movement of the hooks 27-28 in the horizontal direction. Hooks 27-28 are also provided with vertically active locking elements 35-36. The vertically active locking element 35 is designed as a separate insert which is provided in a recess 37 in the downwardly directed hook 27. This recess is located partly in the rigid layers 21A and 21C. It is also possible to provide the insert 35 in the upward hook 28.

The bead 29 is formed in part from the rigid layers 21A and 21C. The bead 31 is formed entirely from the rigid layers 21A and 21D. the zone in which the locking elements 30 and 32 interact lies entirely within the rigid layer 21A. All of these measures are advantageous for fixation strength. The area in which the insert 35 interacts with the locking element 36 is located in the more flexible layer 21B. However, it is possible that this zone is located at least partially or completely in the hard layers 21A and/or 21C.

The fiberglass layer 25A is positioned at the height of recess 37. This provides additional stability where the floorboard is weakened by recess 37.

The glass fiber layer 25A extends continuously in the shoulder 31 of the upward hook 28.

Fig. 17 shows a variant of FIG. 16. Here, the insert 36 is provided in a recess 37 in the upwardly directed hook 28. However, the zone in which the insert 36 interacts with the locking element 35 is actually located in the rigid layer of the substrate, namely the rigid layer 21A. This provides a very good vertical hold.

Fig. 18 shows one embodiment of FIG. 16 and 17, in which the vertically active locking elements are implemented from the material of the panel 1. There are even two pairs of vertically active locking elements, namely the locking elements 35-36, as well as the locking surfaces 3334, which provide both horizontal and vertical fixation. All vertical locking elements are made of rigid layers 21A and 21C. In addition, the glass fleece is located at the height of the zone in which the locking elements 35-36 interact. The glass fleece 25B passes continuously through the bead 31. This ensures that the bead 31 is realized very stably and the risk of damage, for example during elastic bending of the bead 31 during connection, is very small, despite the recess provided on the underside of the bead. 31 which increases the flexibility of the bead 31 and thus ease of installation.

Fig. 19 shows one embodiment of FIG. 18, in which the vertically active locking elements 35-36 are located at the end of the bead 31. The glass fleece 25B extends through this bead.

Fig. 20 represents a method according to the fifth aspect of the present invention. This method can be used to obtain the construction of the substrate of the panels 1 shown, for example, in FIG. 7. By sprinkling, rigid substrate layers 21D, 21A and 21C are successively provided. Their rigid thermoplastic material is deposited onto the conveying belt 39 by means of the depositing devices 38. On these deposited layers 21D and 21A, glass fleece 25B and glass fleece 25A are provided, respectively. For this purpose, glass fleece 25A and 25B is unwound from the rollers

- 12 041189 and is provided on the respective substrate layers 21D and 21A. The formed complex is then transported to the press 41 with two belts, where it is consolidated under the influence of pressure and/or heat. The pressing device 41 comprises, in the direction of travel, thermocouples 42, a tension roller 43 and cooling elements 44. The heating elements 42 heat the complex entering the pressing device 41, thereby facilitating and improving the bonding of the individual layers to each other. The use of the tension roller 43 is advantageous as it ensures the calibration of the respective layers. Cooling elements 44 finally cool the consolidated complex so that it can be processed more quickly. Thereafter, a more flexible substrate layer 21B is provided on this consolidated complex by means of a calendering device 45 which consists of more than one calendering roller 46.

Obviously, in subsequent steps, the finish 2 finish carrier 22, the wear layer 23 and the lacquer layer 24 can be applied.

Fig. 21 shows a variant of FIG. 20. Here the glass fleece 25 is brought into contact with the press element in the press device 43. This differs from FIG. 20, where each glass fleece is sandwiched between rigid backing layers.

Fig. 22 shows another alternative way of providing a glass fleece 25 on a rigid backing layer. Reference numeral 47 indicates an extrusion apparatus with which a rigid substrate layer 21A is produced. This substrate layer 21 is then transported between guide rollers 48. The glass fleece 25 is unwound from a roll 49 and, after passing between two guide rollers, is placed on the substrate layer 21A. It is obvious that the resulting complex can be further processed, and possibly supplemented with subsequent layers of substrate and/or glass fleece. It should also be noted that this technique can be applied advantageously with any type of thermoplastic backing layer, whether it is a rigid, semi-rigid or flexible backing layer.

The present invention is in no way limited to the embodiments described herein above; on the contrary, such methods, floor panels and carrier material can be implemented in accordance with various options without departing from the scope of the present invention.

Claims (13)

CLAIM 1. Floor panel (1) with substrate (17) containing thermoplastic material, trim (2) provided on it, and connecting parts (5-6, 9-10) on at least one pair of opposite edges (3-4 , 7-8), made at least partially from a substrate (17) and allowing mechanical fixation between two such floor panels (1), characterized in that the substrate (17) contains a rigid, non-foamed layer (17A) of a substrate made of thermoplastic material, and the rigid substrate layer is free from plasticizers or contains plasticizers in an amount of less than 5 m.h. per 100 m.h. resin, wherein the thickness of the rigid layer (17A) is at least 65% of the total thickness of the floor panel, while the total thickness of the floor panel is between 3 and 10 mm. 2. The floor panel according to claim 1, wherein the thickness of the rigid layer (17A) is between 2 and 6 mm. 3. The floor panel according to any one of the preceding claims, wherein the finish (2) is printed directly on one or a plurality of ground layers provided on the substrate (17). 4. The floor panel according to any one of claims 1 to 3, wherein the finish (2) is printed on the finish carrier, the finish carrier being a thermoplastic film or paper layer impregnated with melamine resin. 5. A floor panel according to any one of the preceding claims, wherein the finish is wood or stone veneer. 6. The floor panel according to any one of the preceding claims, which comprises a transparent or translucent wear and/or varnish layer provided on the finish (2). 7. The floor panel according to claim 6, wherein the wearing layer is a thermoplastic foil with a thickness of 350 to 750 µm or a layer of paper impregnated with melamine resin. 8. The floor panel according to any one of the preceding claims, wherein the relief is provided on the upper side of the floor panel, the relief having a depth of more than 100 µm, the relief being mechanically and/or chemically embossed. 9. The floor panel of claim 8, wherein the pattern extends into the substrate. 10. Floor panel according to any one of the preceding claims, which has an elastic modulus of at least 2000 N/mm ² . 11. The floor panel according to any one of the preceding claims, wherein the mechanical fixation is carried out in the horizontal and vertical directions, wherein the fixation is realized by the interaction of the locking surfaces, and the zones in which the locking surfaces interact are located, at least partially, in the rigid layer of the substrate . - 13 041189 12. The floor panel according to any one of the preceding claims, wherein the rigid backing layer contains an inorganic filler content of at least 60% by weight. 13. The floor panel according to any one of the preceding claims, wherein the thermoplastic material of the rigid backing layer comprises polyvinyl chloride.