Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
  • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
  • B32B2264/10—Inorganic particles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/514—Oriented
  • B32B2307/516—Oriented mono-axially
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/704—Crystalline
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
  • B32B2307/734—Dimensional stability
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2471/00—Floor coverings
• • 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

Definitions

• the present invention relates to decorative panels and a method for manufacturing decorative panels.
• the decorative panels of the invention are in the first place destined for application as floating floor panels, but may also be applied otherwise. For example as glued down floor panels, or as wall or ceiling panels.
• WO 97/47834 describes a laminate floor panel for assembling a floating floor covering.
• the floor panel as described herein, has as a disadvantage that the applied substrate, more in particular the MDF or HDF substrate (Medium Density Fiberboard of High Density Fiberboard) is prone to damaging by moisture.
• the laminate top layer gives raise to walking and/or ticking sounds.
• EP 1 938 963 discloses a floor panel based on synthetic material, more particularly soft polyvinyl chloride (PVC).
• the floor panels may be obtained at least by lamination of several synthetic foils.
• EP 3 405 346 discloses a floor panel of a high density filled polyvinyl chloride material.
• the floor panels may be obtained at least by extrusion.
• the EP ’963 and the EP ’346 the floor panels are provided with a decorative top layer comprising PVC.
• the floor panels of EP’ 963 and EP‘346 may be more water resistant than the panels of WO’834, and/or provide for a more pleasant walking and/or ticking sound.
• the use of PVC, plasticizers and/or other additives may, however, at least in some cases, be harmful to the environment.
• a PET (polyethylene terephthalate) composition as a substrate in a flooring panel, wherein the substrate may be formed at least by means of extrusion.
• a thermoplastic composition comprising PP (polypropylene) as a substrate in a decorative panel. Panels comprising a substrate with PET or PP may be particularly prone to deformation in changing ambient conditions, due to their crystallinity.
• the present invention in the first place seeks to provide an alternative decorative panel, wherein, in accordance with preferred embodiments, a solution is provided for one or more of the problems with the decorative panels of the state of the art.
• the present invention in accordance with its first independent aspect is a decorative panel comprising a substrate and a provided thereon top layer, wherein said substrate at least comprises a semi-crystalline or crystalline polymer and/or a polymer chosen from the list consisting of polyacetal (POM), polyphenylene sulfide (PPS), polyamides (such as PA 6 and PA 66), polyethylene terephthalate (PET), glycol modified PET (PETG), polycyclohexylenedimethylene terephthalate (PCT), glycol modified polycyclohexylenedimethylene terephthalate (PCTG), polycyclohexylenedimethylene terephthalate acid (PCTA), polyethylene (PE), low-density polyethylene (LDPE), for example linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), polybutylene terephthalate (PBT), poly lactic acid (PLA), polyether ether ketone (PEEK) and poly
• the crystallinity of said polymer is below 95% or below 85%, as preferably measured using differential scanning calorimetry (DSC) in accordance with ISO 11357-3:2018.
• DSC differential scanning calorimetry
• the crystallinity of said polymer is above 35%, preferably above 50%, as preferably measured using differential scanning calorimetry (DSC) in accordance with ISO 11357-3:2018. Allowing for a minimum crystallinity may be beneficial for the toughness, the tensile strength of the substrate material, and chemical resistance of the substrate material.
• the first and second possible property are preferably combined, such that an optimized crystallinity is obtained in view of the desired properties of the decorative panel, for example a floor panel, while maintaining a good dimensional stability.
• said polymer is mono-axially oriented, or at least oriented in one direction.
• the orientation of the polymer chains predominantly in at least one direction may lead to an increased tensile strength, in the respective direction.
• the direction of orientation coincides, or about coincides, with the largest dimension of the decorative panel.
• the direction of orientation preferably coincides, or about coincides with the longitudinal direction of the decorative panels. In such case, stresses due to dimensional instability may be best coped with, since it may be expected that shrinkage or expansion will be largest in the longitudinal direction.
• this third property is practiced at least in combination with said first possible property, and potentially said second possible property, the remaining, to be expected dimensional instability, may be managed.
• the dimensional instability may be further limited by using filler materials, for example by using wollastonite, mica, alumina silicate and/or glass, preferably in fiber form, and/or by using thermomechanical pulp fibers.
• said filler materials are anisotropic from the point of view of their mechanical properties, in particular their tensile strength.
• the filler material is generally directed, such that its direction of largest tensile strength coincides or generally coincides with the direction of orientation of said semicrystalline or crystalline polymer and/or with the longitudinal direction of rectangular and oblong decorative panels.
• the ratio of the tensile strength values in orthogonal directions of said filler materials is at least 125%, or at least 200%.
• said top layer comprises a crystalline or semicrystalline polymer, wherein the crystallinity of said polymer comprised in said substrate is lower than the crystallinity of said polymer comprised in said decorative top layer, or vice-versa.
• a difference in crystallinity between the polymer in said decorative top layer and the polymer in said substrate of at least 5% or at least 10% is present.
• This property limits possible dimensional changes, especially when the layer with the largest crystallinity, and thus the highest expected dimensional instability, e.g. the decorative top layer, may be, and preferably is, thinner than the substrate.
• the substrate may thus stabilize the decorative top layer to a certain extent, or vice-versa.
• said decorative panel further comprises a layer at the bottom of said substrate, wherein said layer also comprises a semicrystalline or crystalline polymer, and preferably has a higher crystallinity than said substrate, or vice- versa.
• this layer may to a certain extent counterbalance any warping effects created by the different, e.g. higher, dimensional instability of the decorative top layer as compared to said substrate.
• the crystallinity of said layer applied to the bottom of the substrate is the same, or within 10% or within 5% of the crystallinity of the decorative top layer and/or the thickness of said layer applied to the bottom of the substrate is the same, or within 10% or within 5% of the thickness of the decorative top layer. In such case, an optimal counterbalancing effect may be obtained.
• the present fourth possible property is preferably combined with the first, second and/or third property.
• the crystalline or semicrystalline polymer contained in said decorative top layer and/or layer applied to the bottom of said substrate is at least mono- axially oriented, and is preferably biaxially oriented.
• the decorative top layer and/or layer applied to the bottom of said substrate may for example comprise an oriented polypropylene or polyethylene foil.
• the polymer of the decorative top layer and/or the bottom layer may be oriented at least in one direction that is transverse to the orientation of the semi-crystalline polymer contained in said substrate, wherein the orientation of the semicrystalline polymer contained in said substrate is preferably mono-axially, or predominantly in a single direction.
• the substrate polymer material may be at least oriented, or predominantly oriented, in the longitudinal direction, in the case of rectangular and oblong panels, while the decorative layer and/or bottom layer may comprise a foil being bi-axially oriented, both in the longitudinal direction and the transverse direction of the panel.
• the combination of the third and fourth possibility yields desirable synergistic effects in relation to an enhanced dimensional stability of the decorative panel as a whole.
• Said decorative top layer preferably comprises a foil provided with a printed ink pattern.
• at least said foil comprises the crystalline or semi-crystalline polymer in accordance with said fourth possible property.
• Said decorative top layer preferably further comprises a wear layer applied on top of said printed ink pattern.
• Said wear layer preferably comprises an amorphous polymer or a polymer with a crystallinity below 35% or below 10%.
• the polymer of the wear layer is of the same type as the polymer of said foil.
• said wear layer may comprise amorphous or atactic polypropylene
• said foil comprises semi-crystalline, crystalline or syndiotactic or isotactic polypropylene, for example with an isotactic index between 85 and 95%.
• Said isotactic index can be measured in accordance with DIN 16774, for example by determining the fraction of the polymer insoluble in boiling heptane.
• said decorative top layer comprises a printed foil, for example of polypropylene, and a casted thereon transparent wear layer comprising polypropylene, which is preferably embossed.
• the decorative panel comprises a top layer and/or a layer applied to the bottom of the substrate, wherein said top layer and/or bottom layer comprise amorphous polypropylene or polypropylene having a crystallinity of 35% or below, and/or wherein said top layer and/or bottom layer are obtained through casting polypropylene.
• said top layer may comprise casted PP, for example a casted PP foil, with a provided thereon decorative print and/or a wear layer comprising casted PP, for example a casted PP foil.
• Such casted PP is mainly un-oriented and minimizes the occurrence of directional stability effects caused by the top layer.
• said bottom layer also comprises casted PP, for example a casted PP foil.
• a wear layer comprising PP in accordance with the present special property further comprises an amorphous polymer or copolymer, for example a cyclo olefine polymer or copolymer (COP or COC).
• COP or COC cyclo olefine polymer or copolymer
• said substrate comprises a plurality of substrate layers, wherein at least two of said plurality of substrate layers comprise a semicrystalline polymer and/or a polymer chosen from the list consisting of polyacetal (POM), polyphenylene sulfide (PPS), polyamides (such as PA 6 and PA 66), polyethylene terephthalate (PET), glycol modified PET (PETG), polycyclohexylenedimethylene terephthalate (PCT), glycol modified polycyclohexylenedimethylene terephthalate (PCTG), polycyclohexylenedimethylene terephthalate acid (PCTA), polyethylene (PE), low-density polyethylene (LDPE), high- density polyethylene (HDPE), polybutylene terephthalate (PBT), polyether ether ketone (PEEK) and polypropylene (PP).
• POM polyacetal
• PPS polyphenylene sulfide
• PCS polyamides
• PET polyethylene terephthalate
• the semi-crystalline polymer in said at least two substrate layers is the same or is at least build from the same monomer.
• the other constituents of the respective two substrate layers are similar, or the same, and are present in a similar amount, or in the same amount.
• both substrate layers may comprise filler materials, preferably at a same rate or about the same rate.
• said at least two substrate layers are distanced from one another by an additional layer comprising polymer, either a semi-crystalline or crystalline polymer or another polymer, such as PVC.
• said at least two substrate layers may be comprised in a substrate having basically an A-B or an A- B-A configuration, wherein A stands for a layer having a first composition, and B for a layer having a second composition.
• said two substrate layers may either have a same or similar composition, or a mutually different composition, and as such may each form an A layer, or, one of said two substrate layers forms an A layer, while the other forms a B layer.
• said two substrate layers may have a mutually different composition, for example where the difference in the composition at least or mainly relates to a different filler content.
• said substrate layer may comprise a first substrate layer having a first composition comprising a semi-crystalline or crystalline material and/or a polymer chosen from the list consisting of polyacetal (POM), polyphenylene sulfide (PPS), polyamides (such as PA 6 and PA 66), polyethylene terephthalate (PET), glycol modified PET (PETG), polycyclohexylenedimethylene terephthalate (PCT), glycol modified polycyclohexylenedimethylene terephthalate (PCTG), polycyclohexylenedimethylene terephthalate acid (PCTA), polyethylene (PE), low-density polyethylene (LDPE), high- density polyethylene (HDPE), polybutylene terephthalate (PBT), polyether ether ketone (PEEK) and polypropylene (PP) and a first content of filler material, e.g.
• POM polyacetal
• PPS polyphenylene sulfide
• polyamides such as PA
• a filler to polymer weight ratio of more than 1,5: 1, or even of 2:1, 2,5: 1 or more and a second substrate layer having a second composition comprising a semi-crystalline or crystalline material and/or a polymer chosen from the list consisting of polyacetal (POM), polyphenylene sulfide (PPS), polyamides (such as PA 6 and PA 66), polyethylene terephthalate (PET), glycol modified PET (PETG), polycyclohexylenedimethylene terephthalate (PCT), glycol modified polycyclohexylenedimethylene terephthalate (PCTG), polycyclohexylenedimethylene terephthalate acid (PCTA), polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polybutylene terephthalate (PBT), polyether ether ketone (PEEK) and polypropylene (PP) and a first content of filler material, e.g.
• POM
• the substrate is substantially made up of, or consists of, said two sublayers such that a substrate with an A-B configuration is obtained, wherein the A layer, or the first layer formed by said first composition, is preferably nearer the top layer than the B layer, or the second layer formed by said second composition, and/or wherein said A-layer forms more than half of the thickness of said substrate.
• the inventors note that this particular combination of a highly filled substrate layer with a lesser filled substrate material is particularly advantageous for minimizing warping effects due to the crystallinity of the polymer.
• these layers may be glued to each other, thermally laminated, coextruded or hardened on top of each other, potentially with the intermediate of a primer layer or tie layer, as further described herein. Any combination of these techniques is possible with a substrate layer.
• said semi-crystalline or crystalline polymer is a thermoplastic polymer.
• polypropylene for example semi-crystalline or crystalline polypropylene
• polypropylene having an isotactic index between 85 and 95% is applied.
• Said isotactic index can be measured in accordance with DIN 16774, for example by determining the fraction of the polymer insoluble in boiling heptane.
• the substrate or the respective substrate layer or layers that comprise said semicrystalline polymer are preferably consisting of, or essentially comprising, a filled synthetic material, for example for more than 85 wt% formed from such filled synthetic material.
• the synthetic material is preferably mainly or exclusively formed from said semi-crystalline or crystalline polymer, for example for more than 85%, wherein said semi-crystalline or crystalline polymer is preferably thermoplastic, or formed from a polymer chosen from the list consisting of polyacetal (POM), polyamides (PA 6 and PA 66), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), glycol modified polyethylene terephthalate (PETG), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyphenylene sulfide (PPS), and polypropylene (PP).
• POM polyacetal
• PA 6 and PA 66 polyamides
• PBT polybutylene terephthalate
• PET polyethylene terephthal
• said substrate or the respective layer or layers may at least comprise a thermoplastic elastomer, such as a polymer or a copolymer, for example a styrene block copolymer, wherein the polymer or copolymer comprises or consists of ethylene-propylene-diene-monomer (EPDM), styrene-ethylene-butadiene-styrene (SEBS), poly(styrene-butadiene-styrene) (SBS), polyether block amide (PEBA), thermoplastic polyurethane (TPU), styrene-ethylene- propylene-styrene (SEPS), styrene ethylene ethylene propylene styrene (SEEPS), acrylonitrile ethylene styrene (AES) or polybutadiene (PB), preferably in a semicrystalline or crystalline version and/or in accordance with any of the first till fifth
• said semi-crystalline polymer is chosen from the list consisting of polyacetal (POM), polyamides (PA 6 and PA 66), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), glycol modified PET (PETG), polycyclohexylenedimethylene terephthalate (PCT), glycol modified polycyclohexylenedimethylene terephthalate (PCTG), polycyclohexylenedimethylene terephthalate acid (PCTA), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyphenylene sulfide (PPS), and polypropylene (PP).
• POM polyacetal
• PA 6 and PA 66 polyamides
• PBT polybutylene terephthalate
• PET polyethylene terephthalate
• PET glycol modified PET
• PCT polycyclohexylenedimethylene terephthalate
• PCTG glycol modified polycyclohexylenedimethylene ter
• Said semi-crystalline polymer may be a homopolymer or a heteropolymer, preferably having a main component of one of polyacetal (POM), polyamides (PA 6 and PA 66), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polyphenylene sulfide (PPS), and polypropylene (PP).
• POM polyacetal
• PA 6 and PA 66 polyamides
• PBT polybutylene terephthalate
• PET polyethylene terephthalate
• LDPE low-density polyethylene
• HDPE high-density polyethylene
• PPS polyphenylene sulfide
• PP polypropylene
• PETG, PCT, PCTG or PCTA may be preferred because of an increased indentation resistance, as well as an optimal delamination resistance.
• the polymer, semi-crystalline polymer or crystalline polymer applied in the first aspect is a polypropylene polymer.
• the polypropylene may herein be a homopolymer or a heteropolymer with the main constituent being polypropylene.
• the semi-crystalline polymer may be polypropylene copolymerized with ethylene, for example with 15 wt% or less ethylene.
• the polypropylene is copolymerized with 3w% or about 3wt% ethylene.
• a copolymerization with ethylene may yield a more fluent working of the material, such as a more fluent extrusion.
• a copolymer, for example with ethylene may influence the amount or speed of crystallization.
• the required heating capacity in production can be reduced for obtaining a desired crystallization.
• the PP may be blended with a co[poly(butylene terephthalate-p-oxybenzoate)] copolyesters, for example with the copolyester level between 5 and 15 wt.%, to yield an interesting ethyl ene-propylene copolymer.
• the PP may be blended with an amorphous polymer or copolymer, such as with a cyclo-olefine polymer or copolymer (COP or COC).
• amorphous polymer or copolymer such as with a cyclo-olefine polymer or copolymer (COP or COC).
• COP or COC cyclo-olefine polymer or copolymer
• the use of an amorphous polymer or copolymer in a blend with PP can lead to a better meltflow, e.g. in an extruder, and/or to an enhanced thermal stability of the substrate.
• the polymer, semi-crystalline polymer or crystalline polymer applied in the first aspect is a heteropolymer, preferably comprising ethylene and propylene.
• the polymer may for example be polyethylene copolymerized with polypropylene, for example with 15wt% or less propylene.
• the semicrystalline or crystalline polymer is a propyl ene-ethylene random copolymers (PP-R).
• said substrate comprises a filled synthetic material, wherein said filled synthetic material is formed at least by said semi-crystalline or crystalline polymer and filler material.
• said filler material mainly three variants are envisaged.
• said filler material has a density of 300 kg/m 3 or lower, for example of 120-180 kg/m 3 and/or comprises materials chosen from the list consisting of rice husk, cork, bamboo, sugar cane, foamed synthetic material, porous inorganic material, perlite (preferably expanded perlite), vermiculite (preferably expanded or exfoliated vermiculite), cenolite and pumicite.
• Such filler materials may limit the density of the obtained substrate material.
• the filler material is present in particle form.
• the filler material, bamboo and sugar cane for example, may be present in fiber form. In such case the fibers may mechanically reinforce the semi-crystalline or crystalline material.
• a weight reduction is obtained of at least 10%, or even of at least 35%. It is not excluded that a reduction 50% or more in weight is obtained.
• an amount of filler material is available in said filled synthetic material as expressed by a weight ratio filler to synthetic material of 5 to 25%.
• a weight ratio filler to synthetic material of 5 to 25%.
• a ratio of 15% of a 150 kg/m 3 filler may be applied, for example 15% of exfoliated vermiculite. Making abstraction from possible minority additives, and with a density of 920 kg/m 3 of the polypropylene, this means that about 48% of the volume of the filled synthetic material is formed by said filler and a total density of 550 kg/m 3 is obtained.
• a weight reduction of 370/920 or about 40% is obtained.
• the use of light filler materials is also of interest to other decorative panels than those of the first independent aspect, and therefore forms per se a particular independent aspect of the present invention, which is a decorative panel comprising a substrate and a provided thereon top layer, wherein said substrate at least comprises a filled synthetic material, wherein said filled synthetic material is formed at least by a, preferably thermoplastic, polymer and filler material characterized in that said filler material comprises filler material having a density of 300 kg/m 3 or lower, for example of 120-180 kg/m 3 , and/or materials chosen from the list consisting of rice husk, cork, bamboo, sugar cane, foamed synthetic material, porous inorganic material, perlite, vermiculite, cenolite and pumicite.
• the polymer may also be polyvinyl chloride (PVC).
• PVC polyvinyl chloride
• the entirety, or at least 75 vol% or at least 85 vol%, of the filler material in the filled synthetic material of the particular independent aspect is the light weight filler material.
• said filler material has a density higher than said polymer, or a density of 1200 kg/m 3 or higher, for example a density of 1800-3000 kg/m 3 and/or said filler material comprises materials chosen from the list consisting of chalk, talcum, limestone, CaCO3, sand and SiO2. It is noted that high weight filler materials, as the above, have a further stabilizing effect on possible dimensional instability, and may keep the decorative panel in its installed position more easily. In said second variant, preferably an amount of filler material is available in said filled synthetic material as expressed by a weight ratio filler to synthetic material of 100 to 450%.
• a ratio of 400% of a 2500 kg/m 3 filler may be applied, for example 400% of chalk.
• highly filled polypropylene material shows a lower weight than a similarly filled polyvinylchloride material, and may therefore be interesting to limit transportation costs and enhance the ergonomics for the installer. This may also be the case with highly filled polyethylene, such as highly filled LDPE or HOPE.
• a high volume for example more than 20 vol %, or more than 40 vol % of the semi-crystalline or crystalline polymer, for example PP, possibly a copolymer thereof, in the synthetic material by a low or high weight filler, for example respectively a filler with a density lower than 250 kg/m 3 or above 2000 kg/m 3 , is possible and does not necessarily create strength problems. This is especially the case where the previously mentioned second and/or third possible property of the invention is practiced.
• a relatively high degree of crystallinity and/or an orientation of the polymer in at least one direction is herein advantageous.
• the high volume content of filler may limit the dimensional instability.
• the entirety, or at least 75 vol% or at least 85 vol%, of the filler material in the filled synthetic material is the light weight filler material, respectively the high weight filler material.
• said filler material comprises a portion of low weight filler materials as described in the first variant, and a portion of high weight filler materials as described in the second variant.
• the density of such filler material is within 25% of the density of the semi -crystalline or crystalline polymer, and preferably within 20% of the density of the semi-crystalline or crystalline polymer.
• a polypropylene with a density of 920 kg/m 3 may comprise a filler material mix having a density between 690 kg/m 3 and 1150 kg/m 3 , preferably between 736 kg/m 3 and 1104 kg/m 3 .
• such filler material may for 33.3 vol%, or one third, be a filler material having a density of 2500 kg/m 3 , for example chalk, and for 66.6 vol%, or two thirds, be a filler material having a density of 150 kg/m 3 , for example exfoliated vermiculite.
• Such filler material has a total density of 933 kg/m 3 , where 89,3 wt% is made up by the high weight filler, in this example, chalk.
• an amount of filler material is available in said filled synthetic material as expressed by a weight ratio filler to synthetic material of 50 to 250%, or preferably of 80 to 200%.
• the density of the filled semi-crystalline or crystalline polymer is within 30%, or within 20%, of the density of the polymer concerned.
• the density of the filled polypropylene material is preferably between 644 kg/m 3 and 1196 kg/m 3 , or between 736 kg/m 3 and 1104 kg/m 3 .
• a ratio of 150% of the above 933 kg/m 3 filler material may be applied.
• a highly filled polypropylene material has about the same weight as an unfilled polypropylene material, while still acceptable mechanical strength is obtained. The material savings on the polymer material, in such case, does not negatively influence the ergonomics and the transportation costs.
• a highly filled synthetic material of about the same density as the polymer contained in the filled synthetic material e.g. within 30%, or within 20%, of the density of the polymer concerned, may also be obtained in the case of filled polyethylene, such as filled LDPE or HDPE.
• This preferred embodiment is a decorative panel comprising a substrate and a provided thereon top layer, wherein said substrate at least comprises a filled synthetic material, wherein said filled synthetic material is formed at least by a, preferably thermoplastic, polymer and filler material characterized in that said filler material comprises at least, and preferably consists of, a first portion and a second portion of filler material, wherein said first portion is a filler material having a density of 300 kg/m 3 or lower, for example of 120-180 kg/m 3 , and/or comprises materials chosen from the list consisting of rice husk, cork, bamboo, sugar cane, foamed synthetic material, porous inorganic material, perlite, vermiculite, cenolite and pumicite, and wherein said second portion is a filler material having a density of 1200 kg/m 3 or
• the density of such filler material is within 25% of the density of the polymer, and preferably within 20% of the density of the polymer.
• said first portion and said second portion preferably make up for the entirety of the filler material available in said filled synthetic material.
• an amount of filler material is available in said filled synthetic material as expressed by a weight ratio filler to synthetic material of 50 to 250%, or preferably of 80 to 200%.
• an amount of filler material is available in said filled synthetic material as expressed by a weight ratio filler to synthetic material of 50 to 250%, or preferably of 80 to 200%.
• the density of the filled synthetic material is within 30%, or within 20%, of the density of the polymer concerned.
• the second portion of the filler material i.e. the high density portion
• the second portion of the filler material is present in the filled synthetic material in a higher percentage by weight than the first portion, while, preferably the second portion of the filler material is present in the filled synthetic material in a lower percentage by volume than the first portion.
• the difference in weight percentage between the second portion and the first portion is at least 20wt% or at least 25wt%.
• the difference in volume percentage between the second portion and the first portion is at least 5 vol%, or at least 10 vol%.
• said polymer and/or said filler material are provided with a coupling agent and/or with maleic anhydride and/or a silane, for example an amino-silane.
• a coupling agent and/or with maleic anhydride and/or a silane, for example an amino-silane.
• maleic anhydride, silane or a coupling agent enhances the incorporation of the filler material in the polymer.
• the substrate, or the filled synthetic material as the case may be may comprise additives, such as one or more elastomers.
• one or more elastomers Preferably 15 to 200 phr (parts per hundred by weight of the resin, i.e. the semi-crystalline or crystalline polymer) of the elastomer is used.
• the use of elastomers allows to set the desired flexibility of the panel.
• the flexural modulus of the substrate is 550MPa or less, and even better 275 MPa or less.
• SEBS styrene-ethylene/butylene-styrene triblock-copolymers
• SEBS propyl ene-ethylene random copolymer
• the semi-crystalline or crystalline polymer is a mixture of a semi-crystalline or crystalline homopolymer, such as polypropylene or polyethylene, and a semi-crystalline or crystalline heteropolymer.
• a semi-crystalline or crystalline homopolymer such as polypropylene or polyethylene
• a semi-crystalline or crystalline heteropolymer is at least built from monomers of said homopolymer.
• said heteropolymer is built for at least 30 wt% or at least 50 wt% from the monomer of said homopolymer.
• the heteropolymer may be built at least from propylene, respectively ethylene, for example as is the case with a heteropolymer comprising ethylene and propylene, for example being a propyleneethylene random copolymer (PP-R).
• the semi-crystalline or crystalline polymer is a mixture of polypropylene homopolymer and an ethylene propylene heteropolymer containing at least 50% ethylene, for example ethylenepropylene diene copolymer.
• the homopolymer preferably forms 25 to 45 mole percent, and even better 30 to 40 mole percent.
• said semi-crystalline polymer is foamed.
• the foaming leads to a weight reduction of 10% or more.
• the foam is a closed cell foam, i.e. a foam where the cells are predominantly closed chambers.
• a blowing agent for example citric acid and/or sodium bicarbonate may be used.
• An ideal semicrystalline polymer for foaming is polypropylene-/polypropylene-grafted glycidyl methacrylate/thermoplastic polyester elastomer (PP/PP-g-GMA/TPEE).
• said substrate is a filled synthetic material comprising
• the method comprises the step of dividing the extruded semi-crystalline polymer into panels having a dimension corresponding, or about corresponding, to the dimension of the finally to be obtained panels.
• said panels may be rectangular and oblong.
• the longitudinal direction of said panels is formed transversely to the extrusion direction. In such case, potential shrinkage or other dimensional instabilities resulting from an orientation of the semi-crystalline polymer in the extrusion direction are in the transverse direction of the panel, and can thus be limited in absolute size.
• the method comprises the step of drying the polymer to be extruded and/or drying the filler material to be incorporated in said polymer before mixing the polymer and said filler material.
• drying steps are especially important when said polymer is PET, PETG, PCT, PCTG or PCTA. These polymers are prone to hydrolysis.
• a deep vacuum is applied in the extruder used in said extrusion operation, e.g. a pressure below 5 mbars, or even below 2 mbars, in order to remove any remaining water or other contaminants in an extruder section.
• the low vacuum is especially important when said polymer is PET, PETG, PCT, PCTG or PCTA.
• a corotating twin screw extruder is applied in said extrusion operation. It is not excluded to use a single screw extruder or a multiple rotating screw extruder.
• the method comprises:
• the step of forming an outermost layer of said substrate wherein said outermost layer comprises an elastomer, preferably said outermost layer is coextruded with said polymer, e.g. through the same die; the step of applying a tie layer, a heat seal additive, ethylene vinyl acetate or ethylene methyl acrylate to an outermost surface of said substrate; and/or the step of corona or plasma treating an outermost surface of said substrate.
• the crystallinity is preferably measured using differential scanning calorimetry (DSC) in accordance with ISO 11357-3:2018 and/or at a heating rate of 20°C/minute.
• DSC differential scanning calorimetry
• the remaining enthalpy of crystallization in a specimen can be measured for reaching 100% crystallinity.
• the remaining enthalpy is compared to the enthalpy of full crystallization when starting from an amorphous sample of the same polymer, to thus calculate the percentage of additional crystallization that takes place during the DSC. It is clear that the semi-crystallinity present in the specimen before the start of the DSC can then be expressed as 100% minus the obtained percentage of additional crystallization.
• this polymer may be, or instead be, a polymer chosen from the list consisting of polyacetal (POM), polyphenylene sulfide (PPS), polyamides (such as PA 6 and PA 66), polyethylene terephthalate (PET), polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), polybutylene terephthalate (PBT) and polypropylene (PP).
• POM polyacetal
• PPS polyphenylene sulfide
• PA 6 and PA 66 polyethylene terephthalate
• PET polyethylene
• PE polyethylene
• PE low-density polyethylene
• HDPE high-density polyethylene
• PBT polybutylene terephthalate
• PP polypropylene
• said polymer, or semi-crystalline polymer is a mixture of polypropylene and, ethylene-propylene copolymer or ethyl ene-propylene diene copolymer, or a mixture of polypropylene and an amorphous polymer or copolymer, such as COC or COP.
• the substrate may be single-layered or comprising a plurality of substrate layers, preferably an uneven number of substrate layers.
• the substrate, whether single-layered or multi-layered preferably forms at least half the thickness and/or half the weight of said decorative panel and/or is at least available at a central location within the thickness of said decorative panel.
• the decorative panel of the invention preferably has a total thickness between 2 and 8 mm, and even better between 3.2 and 5.5 mm.
• the substrate whether multi-layered or single layered, preferably has a thickness between 2 mm and 5 mm.
• any panel portion indicated as a layer for example a substrate layer, has a clearly distinct property form the layers adjacent to it.
• the distinct property may for example comprise a different material composition, a different color, a different geometry.
• the wear layer may be formed as a liquidly applied and UV and/or excimer cured lacquer layer, for example an acrylic lacquer layer.
• said top layer comprises one or more casted layers, for example of polypropylene.
• Such casted layer may form a priming and/or background layer for a print formed on the substrate and/or may form part of or be a transparent or translucent wear layer on top of a printed decoration.
• the decoration of the top layer preferably comprises a wood pattern.
• the wood pattern preferably has a grain direction corresponding with the direction of one of the edges of said panel and/or corresponding to the one of the potential orientation directions of the polymer of the substrate. In the case of a rectangular and oblong panel, it preferably corresponds to the direction of a longitudinal edge.
• the decorative panel of any of the aspects mentioned above may be provided on at least two opposite edges with coupling parts, allowing that two such panels at the respective edges can be coupled to each other, wherein, in the coupled condition, a locking is obtained in a vertical direction perpendicular to the plane of coupled panels, and in a horizontal direction in the plane of coupled panels and perpendicular to said edges.
• the coupling parts are basically formed as a tongue and groove with locking means.
• the coupling parts and locking means preferably show one or more of the following properties:
• the respective edge is formed for at least 70% of its contour, as seen in a cross-section in a plane perpendicular to said edge, out of said substrate comprising said semi-crystalline polymer material and/or said filled synthetic material;
• said groove has a lower and an upper groove lip, wherein the lower groove lip preferably extends beyond said upper groove lip.
• said locking means comprise a protrusion formed on the upper side of said lower groove lip, and an excavation at the bottom of said tongue;
• said substrate is an extruded semi-crystalline polymer, wherein said horizontal direction coincides with the extrusion direction, wherein said panel is rectangular and oblong
• said coupling parts are preferably available at the pair of longitudinal edges.
• said coupling parts are available at the pair of short edges, and/or at both pairs of edges.
• Differential tension may in particular arise with such decorative panels in accordance with the second possible property, namely where the crystallinity of said polymer is above 35%, preferably above 50%, as preferably measured using differential scanning calorimetry (DSC) in accordance with ISO 11357-3:2018.
• the crystallinity may for example by around 60%.
• the cooling of a polymer having such a high crystallinity leads to higher tension differences between respective layers, for example between the substrate and the decorative top layer, such that the adhesion may become partly undone.
• the surface energy of the polymer for example of polypropylene (PP) may play an important role.
• the surface energy of polypropylene is for example so low, such that good bonding is difficult to achieve.
• an elastomer is used as an additive in the polymer, for example at 0.1 to 7.5 phr.
• a thermoplastic polyolefin (TPO) as elastomer.
• thermoplastic polyolefins e.g. homopolymeric or heteropolymeric polypropylene, that are obtained through the Cataloy process, or through any multi-stage gass phase polymerization process;
• EPDM ethyl ene-propylene-diene- monomer
• SEBS styrene-ethylene-butadiene-styrene
• SBS
• one or both outermost layers of said substrate, or of an extruded sheet material comprised in said substrate comprises, or consists of a tie layer or a heat seal additive, such as a maleic anhydride grafted polypropylene or polyethylene based adhesive, a polyethylene based adhesive.
• Heat seal additives are known per se from the food packaging industry to improve the sealing of bags. The inventors have found that these seal additives can be used to improve the adhesion between the top layer and the substrate of the decorative panels of the invention.
• one or both outermost layers of said substrate, or of an extruded sheet material comprised in said substrate may comprise or consist of ethylene vinyl acetate or ethylene methyl acrylate.
• Ethylene vinyl acetate and/or ethylene methyl acrylate are particularly effective for raising the lamination strength on substrates that comprise polypropylene as said polymer, for example polypropylene having a crystallinity of 50% or more.
• Figure 9 in a view similar to that of figure 2 represents a variant
• Figure 4 clearly shows that at least one, and in this case even a plurality of reinforcement layers 29-30 may be applied in the substrate 2.
• a first reinforcement layer 29-30 may be applied in the substrate 2.
• the reinforcement layers 29-30 extends uninterruptedly in the aforementioned lower lip 13; a second reinforcement layer 29 extends uninterruptedly in the aforementioned upper lip 12.
• the first and second reinforcement layers 29-30 thus are situated off center with respect to the thickness T1 of the substrate 2.
• the reinforcement layers are, in the example, each time flanked by an additional substrate layer 31 of filled semi-crystalline polymer.
• these additional substrate layers 31 show another composition than the central substrate layer 32 of substrate 2, for example, in that they contain no or less fillers than the central substrate layer 32.
• the example of figure 4 shows the fifth possible property mentioned in the introduction, wherein said additional substrate layers
• the substrate 31 have an equal thickness and are positioned with one of their main surfaces at equal distance from the center line C of the substrate 2. Said additional substrate layers 31 are distanced at least by said central substrate layer 32. It is clear that the substrate 2, or at least the central substrate layer 32 thereof, preferably is positioned such that it is at least centrally present in the substrate 2, namely, on the central line C. In this case, the thickness T2 of the central substrate layer 32, i.e. the layer between the two reinforcement layers 29-30, amounts to more than 40 percent of the thickness T1 of the substrate.
• a floor panel 1 according to the invention may show an additional layer on the lower side of the substrate 2.
• this preferably relates to a foam layer, for example, of cross-linked or crosslinked polyethylene (XPE), which is fixed to the lower side of the substrate 2 by means of glue, for example in particular is fixed to the substrate layer 31 which flanks the reinforcement layer 30.
• XPE cross-linked or crosslinked polyethylene
• this relates to a soft foam.
• a tension force can be obtained between the respective floor panels 1, more particularly at the location of the second pair of horizontally active locking surfaces 20-21, namely between the respective decorative top layers 3 on the upper edges of the coupled floor panels 1.
• dashed line 36 in figure 3 is represented that such tension force can be obtained, for example, in that the lower lip 13 in the coupled condition is spring-deflected and in the coupled condition pushes against the tongue 10.
• Such pretension is known as such, for example, from WO 97/47834.
• a so-called play may be present in the coupled condition.
• some space may be available between the first pair of horizontally active locking surfaces 16- 17, while a second pair of horizontally active locking surfaces is in contact at a position above the vertically active contact surfaces 22-23 between the upper side of the tongue 10 and the lower side of the upper lip 12 of the groove 11.
• Such space preferably extends over a horizontal distance smaller of 0,2 mm or smaller.
• a turnable profile on the long edges 5-6 for example, according to figures 2 and 3, and a downwardly coupleable profile at the short edges 7-8, for example, according to any of the figures 4 to 6, leads to the creation of a floor panel 1 which can be coupled by means of a so-called fold-down movement.
• the long edges 5-6 are provided in each other by means of a turning movement W, wherein by this turning movement W at the short edges 7-8 a downward movement M is created, which provides the male part 37 present there in the female part 38.
• the example of such downwardly coupleable profile is made in one piece with the substrate 2 of the floor panel 1 and comprises, for effecting the locking, a cooperating snap hook 39 and undercut 40, as well as a hook-shaped part 41 on the lower lip 13, which in this case also shows an undercut 42.
• the undercut 42 on the hook-shaped part 41 is made such that it forms an angle Al with the vertical of 1° to 10° and preferably approximately 5°.
• the locking groove 19, which cooperates with the aforementioned hook-shaped part 41, is positioned entirely underneath the reinforcement layer 29 at the upper surface.
• the aforementioned cooperating snap hook 39 and undercut 40 in this case comprise vertically active contact surfaces 22-23, cooperating in the coupled condition, which are realized in the filled semi-crystalline polymer 4 of the substrate 2.
• the horizontally as well as vertically active contact surfaces 16-17 of the hook-shaped part 41 are also realized entirely in the filled semi-crystalline polymer 4 of the substrate 2.
• the upper surface of the lower lip 13 consists entirely of the filled semi-crystalline polymer 4 of the substrate 2.
• the edge profiles also show vertically active contact surfaces 25-26 formed on this upper surface. Between these vertically active contact surfaces 25-26 and horizontally active contact surfaces 16-17, a space 43 is present.
• the uppermost reinforcement layer 29 extends in one piece over the aforementioned locking groove 19 at the lower side of the male coupling part 37.
• a recess 44 is realized, which extends at least partially underneath the aforementioned space 43. It provides for a smoother coupling, even with the represented overlap 45 in the contours of the male coupling part 37 and the female coupling part 18 at the location of the horizontally active locking surfaces 16-17.
• the lowermost reinforcement layer 30 is removed at the location of the aforementioned recess 44. This does not necessarily have to be so. According to a not represented embodiment, the lowermost reinforcement layer 30 can extend in one piece above said recess 44.
• Figure 5 represents a variant of profiles which can be coupled into each other by a downward movement M, wherein the snap hook 39 is situated at the distal end 46 of the lower lip 13 of the female part 38, whereas the undercut 40 is provided in the male part 38.
• the upper surface of the lower lip 13 is formed entirely from the filled semi-crystalline polymer 4 of the substrate 2, and in coupled condition the edge profiles show vertically active contact surfaces 25-26 formed on this upper surface. Between these vertically active contact surfaces and horizontally active contact surfaces 16-17, a space 43 is present.
• the lowermost reinforcement layer 30 extends in one piece in the lower lip 13, and the uppermost reinforcement layer 29 extends in one piece over the aforementioned locking groove 19 at the lower side of the male coupling part 37.
• the hook-shaped part 41 is realized with an undercut 42, wherein this undercut 42 is realized such that it forms an angle Al with the vertical of 1° to 10°, and preferably approximately 5°. It is evident that, in figure 4 as well as in figure 5, such undercut 42 at the location of the horizontally active contact surfaces 16-17 on the hook-shaped part 41 is not necessary and that as well contact surfaces can be used which are vertical or which are less steeply inclined than the vertical, for example, with an inclination wherein the respective contact surfaces enclose an angle with the horizontal of 45° to 90°.
• Figure 6 represents a variant of downwardly coupleable profiles, wherein the snap hook 39 is formed by a separate insert 46, which in this case is provided in the male part 37.
• a separate insert 46 preferably is formed of thermoplastic material, for example, at least from PP, PVC or ABS (Acrylonitrile-butadiene-styrene), and in coupled condition preferably shows, such as here, a vertically active contact surface 22 with the filled semicrystalline polymer 4 of the female part 38. In this manner, a precise vertical positioning of the male part 37 in the female part 38 can be obtained.
• the aforementioned separate insert 46 is situated, in this example, in a seat 47 with walls, which are entirely formed from the filled semi-crystalline polymer 4 of the substrate 2.
• a space 49 is situated between the lower side of the tongue 10 and the upper side of the lower lip 13, wherein this space 49, such as here, extends horizontally underneath the tongue 10 at least from on the tip 50 of the tongue 10 up to beyond the distal end of the upper lip 12.
• the projection in the horizontal plane of the vertically active contact surfaces 25- 26 between the lower side of the tongue 10 and the upper side of the lower lip 13 shows a length LI which is at least 15%, and still better at least 20% or 25%, of the length L2 of the protruding part 48 of the lower lip 13;
• the length L2 of the protruding part 48 of the lower lip 13 is at least 80% of the thickness T1 of the substrate layers comprising filled semi-crystalline polymer 4 and preferably is smaller than 130% of the thickness T1 thereof;
• the smallest width Bl of the standing portion 18 of the lower lip 13 at the location of the horizontally active locking surfaces 16-17 is at least 15% of the thickness T1 of the substrate layers comprising filled semi-crystalline polymer 4 and still better at least 20% of the thickness T1 of the substrate layers comprising filled semi-crystalline polymer 4.
• Figure 8 represents another variant, wherein the coupling means 9, for example, the coupling means of the long opposite edges 5-6, show some preferred characteristics, which each separately or in any combination result in an edge profile which is ideally suited for being applied in a floor panel 1 with a substrate 2 of, whether or not filled, semi-crystalline polymer 4, such as a filled ethylene-propylene copolymer.
• semi-crystalline polymer 4 such as a filled ethylene-propylene copolymer.
• the lower lip 13 shows a point 51 or area where the remaining thickness DI of the lower lip 13 is smallest
• the floor panel 1 comprises a reinforcement layer 30 which extends in the respective lower lip 13, and wherein said reinforcement layer 30, at the location of said point 51 or area, is situated off center from the remaining thickness DI, preferably, such as shown here with the arrows El, closer to the upper side of the lower lip 13 than to the lower side.
• the upper lip 12 shows a point or area 52, at the location of the vertically active locking surfaces 22-23, where the remaining thickness D2 of the upper lip 12 is smallest, wherein the floor panel 1 comprises a reinforcement layer 29 which extends in the respective upper lip 12, and wherein said reinforcement layer 29, at the location of said point or area 52, is situated off center from the remaining thickness D2, preferably, such as shown here with the arrows E2, closer to the lower side of the upper lip 12 than to the upper side. In this manner, a very significant effect on the possible bending of the upper lip 12 is obtained.
• example coupling means 9 illustrated by means of the figures may be used on any pair of opposite edges5-6-7-8, in any decorative panel 1 having the characteristics of the first aspect of the invention and/or the particular independent aspect mentioned in the introduction, and/or being obtained through a method in accordance with the second aspect of the present invention, and/or the preferred embodiments of these aspects.
• Figure 9 shows an example floor panel 1 having a substrate 2 with an integrated reinforcement layer 29A.
• a woven glass fiber reinforcement layer 29A In this case a woven glass fiber reinforcement layer 29A.
• the woven glass fiber reinforcement layer 29A has a net structure of glass fibers 53 extending in at least two crossing directions. In the plane of figure 9 the cross-section of the glass fibers 53 that run in the longitudinal direction of the floor panel 1 are shown, while in dashed line 54 a glass fiber running in the transversal direction of the floor panel 1 is illustrated.
• the semi-crystalline or crystalline polymer of the substrate 2 is continuous through the openings 55 of the reinforcement layer 29. In this case, the semi-crystalline polymer 4 is continuous through the openings 55 or mazes of said net structure.
• Figure 12 illustrates a variant where in the step S3 the extruded semi-crystalline polymer 4 is cooled in a water bath 61, wherein the water is maintained at a temperature above the glass transition temperature of the semi-crystalline polymer 4.

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• 2023
  • 2023-06-23 EP EP23734756.2A patent/EP4577405A1/de active Pending
  • 2023-06-23 CN CN202380060612.7A patent/CN119731018A/zh active Pending
  • 2023-06-23 CA CA3264341A patent/CA3264341A1/en active Pending
  • 2023-06-23 WO PCT/IB2023/056510 patent/WO2024042380A1/en not_active Ceased

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