RU2774351C2 - Floor panel for formation of flooring and substrate for panel - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to the field of construction, namely to a floor panel. The floor panel contains layered substrate, as well as a decorative upper layer located above substrate. Substrate contains at least a layer, which is obtained based on a composition containing at least thermoplastic synthetic material. The composition also contains at least one or more elastomers. Thermoplastic synthetic material relates to thermoplastic composite polyester.

EFFECT: increase in the strength of a panel.

31 cl, 2 dwg

Description

The present invention relates to a floor panel for forming a floor covering, as well as to a substrate for the panel.

More specifically, the invention relates to a floor panel for forming a floor covering of the type in which the floor panel comprises a layered substrate as well as a decorative top layer located on top of the substrate; and while the substrate contains at least a layer, which is obtained on the basis of a composition containing at least a thermoplastic synthetic material.

The term "layered substrate" indicates that the substrate consists of one or more layers, more specifically layers of material.

It is also noted that the decorative top layer need not be in direct contact with the substrate.

This type of floor panel is known inter alia from WO 01/44669, WO 2011/085306, WO 2013/179260, WO 2013/179261, WO 2014/117887 and WO 2015/011049.

Various synthetic materials are known from the above documents, on the basis of which the substrate of the floor panel can be produced. However, many of these synthetic materials, such as polyvinyl chloride (PVC), have come under fire. In fact, they arguably create a problem observed from an environmental point of view. For example, for the production of PVC plasticizers, it is necessary to use, for example, plasticizers from the phthalates group. However, such plasticizers are critically evaluated in recent legal regulations.

WO 2014/111192 discloses a floor panel underlay that provides an alternative to PVC-based underlays. The substrate is made on the basis of a thermoplastic matrix material and a spatially cross-linked polymer in the form of a powder, which is embedded in the matrix material. The thermoplastic matrix material refers to a polyolefin such as polypropylene (PP) or polyethylene (PE) or an olefin copolymer such as ethylene propylene tertiary rubber (EPDM).

A disadvantage of such PP or PE-based substrates is that under the influence of, for example, sunlight or floor heating, they can deform to such an extent that cracks or gaps can occur between these bonded floor panels. In addition, the risk of cracks or gaps is higher than on PVC substrates.

Another disadvantage is that with such PP or PE based substrates it is relatively difficult to obtain a hard and at the same time mechanically strong floor panel in relation to, for example, PVC based substrates.

The mentioned publication WO'049 refers in particular to polyethylene terephthalate, abbreviated as PET, as a synthetic material that can be used to make a floor panel substrate.

A disadvantage of such a PET-based substrate is that load fatigue in the substrate can be significant. This is particularly disadvantageous when the connecting parts, such as clip-on profiles, are made from the substrate material. In fact, fatigue can lead to damage or destruction of these connecting parts.

Another disadvantage is that such a PET-based backing can be quite brittle.

Another disadvantage is that with such a PET-based substrate, there is a relatively high risk of cracks or gaps forming between the connected floor panels due to deformation from, for example, sunlight or floor heating.

The present invention is generally directed to an alternative floor panel of the aforementioned type, in which, according to various preferred embodiments, solutions are provided for the problems with floor panels of the prior art.

To this end, the invention relates to a floor panel for forming a floor covering of the type mentioned above, with the characteristic that the composition, in addition to the thermoplastic synthetic material, also contains at least one or more elastomers; and that said thermoplastic synthetic material is a thermoplastic polyester.

The advantage of such a composition is that the respective substrate layer can be made very strong. Thus, it is possible to provide a solid floor panel from which connecting parts, such as clip-on profiles, can be made, which allow a strong and stable connection between the floor panels.

In addition, the inventor has found that the composition not only makes it possible to realize a corresponding very strong substrate layer, but also makes it possible to reduce load fatigue. This is because the composition can provide an appropriate backing layer with the elasticity needed for this purpose. Of course, in the case where connecting parts, such as snap-on profiles, are provided in the substrate layer, this is preferable in view of the fact that the risk of breaking or damaging them can be minimized.

It has also been found that the composition makes it possible to realize a particularly strong and rigid substrate layer. In fact, the composition appears to be able to compensate for the sensitivity of the thermoplastic polymer to hydrolysis, and is also able to reduce the associated reduction in viscosity, resulting in a less brittle substrate layer.

One or more of the above advantages in this case are particularly noticeable when the amount of thermoplastic polyester in the composition is from 5 wt.% to 50 wt.%. More preferably, this amount is from 10 wt.% to 40 wt.%, and even more preferably, from 15 wt.% to 35 wt.%.

The thermoplastic polyester may be selected from the group consisting of the following materials: polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), also known as polypropylene terephthalate (PTT), polyethylene naphthalate (PEN), and combinations thereof.

Preferably, the thermoplastic polyester is PET, given that the aforementioned advantages here can be shown particularly well when PET is used. In addition, PET also offers environmental benefits given that it allows the use of recycled PET in the above composition. This recycled PET can then come from, for example, PET bottles or from PET-containing floor coverings, such as PET-containing carpets or PET-containing floor panels in accordance with the present invention.

In particular, the thermoplastic polymer may be present in the composition in the form of PET flakes, such as colored PET flakes.

One or more of the above advantages are especially noticeable when the amount of elastomer in the composition is between 1 wt.% and 35 wt.%. Preferably, this amount is between 1 wt.% and 30 wt.%, more preferably between 5 wt.% and 30 wt.%, and even more preferably between 5 wt.% and 25 wt.%.

The at least one elastomer may be selected from the group of elastomers having a hardness greater than 20 Shore A and less than 90 Shore A, or even better from the group of elastomers having a hardness greater than 40 Shore A and less than 85 Shore A. D. In this case, Shore hardness is measured in accordance with ISO 868. In particular, one or more elastomers are all selected from the above groups.

Preferably, at least one elastomer is a thermoplastic elastomer. When the composition contains a plurality of elastomers, they are preferably thermoplastic.

The thermoplastic elastomer can be made according to any of the following possibilities.

According to the first possibility, the thermoplastic elastomer is based on propylene. In a first preferred embodiment according to this first possibility, it refers to an ethylene-propylene copolymer, where propylene specifically refers to isotactic propylene. Thus, the elastomer, for example, may consist essentially of repeating units of isotactic propylene with a random distribution of ethylene. Examples of such ethylene/propylene copolymers are the commercially available Vistamaxx propylene elastomers from ExxonMobil, with Vistamaxx 3020 FL and Vistamaxx 6202FL being preferred. In a second preferred embodiment according to the above first possibility, the propylene-based elastomer refers to a thermoplastic polyolefin (TPE-O or TPO) or a composition of PP and EPDM-based non-crosslinked rubber. An example of such a thermoplastic polyolefin is Q 100 F from LyondellBasell.

In a second possibility, the thermoplastic elastomer is based on a styrene block copolymer such as styrene-butylene-styrene (SBS) or styrene-ethylene-butylene-styrene (SEBS). In a first preferred embodiment according to this second possibility, this refers to a block copolymer based on styrene and ethylene/butylene or styrene and ethylene/propylene. Examples of this are the commercially available Kraton G elastomers. In particular, this concerns a linear triblock copolymer based on styrene and ethylene/butylene or linear SEBS, with Kraton G1645 M elastomer being preferred. based on a styrene block copolymer obtained from a composition of, on the one hand, SEBS or SBS, and, on the other hand, polyolefins such as PP or PE. Examples of this document are commercially available Ensoft-S elastomers, with Ensoft-S SM-300-40A and Ensoft SX-241-50A-T2-000 being preferred. Kraton G synthetic materials can also be used in this second preferred embodiment, with Kraton G1645 M being preferred.

According to a third possibility, the thermoplastic elastomer refers to the so-called polyolefin elastomer (POE). Such an elastomer is based on an ethylene-α-olefin copolymer such as ethylene-octene or ethylene-butene copolymer. Examples of such elastomers are the commercially available Engage elastomers from The Dow Chemical Company, with Engage 8180 and Engage 8402 being preferred. Another example is Queo 0203 from Borealis.

Each of the above described thermoplastic elastomer embodiments is particularly preferred in that the types of elastomers described can be easily worked together with a thermoplastic polyester such as PET to a suitable floor panel backing layer.

In the event that the composition contains a plurality of elastomers, each of these elastomers is preferably prepared according to any of the possibilities described above, and the plurality of embodiments may be combined.

There are other thermoplastic elastomer embodiments that can be used. Thus, an elastomer may refer to, for example, a thermoplastic vulcanized elastomer (TPV or TPE-V) such as TPV based on PP and EPDM. According to another possibility, the elastomer is a thermoplastic polyester blockamide (PEBA). Examples of such a PEBA elastomer are the commercially available Pebax elastomers. In yet another alternative, the elastomer is a thermoplastic copolyester (COPE), of which Eastman's commercially available Ecdel elastomers are examples. Another alternative for an elastomer is a thermoplastic urethane (TPU) such as the commercially available Estollan from BASF.

Alternatively, at least one of the elastomers may be polychloroprene or neoprene.

Although the invention does not exclude that at least one of the elastomers is of the heat-strengthening type, this option is not preferred due to the difficult processability of such elastomers and their negative effect on processability.

Preferably, at least one of the elastomers does not contain maleic anhydride or is not grafted with maleic anhydride. In the event that the composition contains a plurality of elastomers, preferably all of them do not contain maleic anhydride or are not grafted with maleic anhydride.

Additionally, the composition can also be at least provided with mineral fiber structures such as glass fibers, talc and/or wollastonite. These mineral fiber structures ensure that the degree of deformation caused by changing temperatures, such as sunlight or underfloor heating, can be limited. Thus, the associated risk of cracks or gaps between the connected floor panels can be reduced. In other words, the mineral fiber structures increase the dimensional stability of the respective substrate layer and reduce thermal shrinkage or expansion with temperature. Moreover, one or more elastomers appear to enhance the positive effect of mineral fiber structures on dimensional stability. Together with the thermoplastic polyester they form a flexible matrix in which the fiber structures appear to be well embedded. It has also been found that the composition of fiber structures can be provided without an appropriate backing layer, thus becoming too stiff or too hard. This is remarkable in view of the already relatively high stiffness or hardness of thermoplastic polyester such as PET.

The amount of mineral fibrous structures in the composition is preferably between 5 wt.% and 40 wt.%, more preferably between 10 wt.% and 30 wt.%, and even more preferably between 15 wt.% and 25 wt.% .

At least a filler may be added to the composition such as chalk, limestone and/or talc. Such a filler, on the one hand, makes it possible to modify the mechanical properties of the substrate, and on the other hand, this can mean economic advantages. It has also been found that a filler can be added to a composition without an appropriate backing layer, thus becoming too stiff or too hard. This is remarkable in view of the already relatively high stiffness or hardness of thermoplastic polyester such as PET.

The amount of filler in the composition is preferably between 10 wt.% and 80 wt.%, more preferably between 20 wt.% and 70 wt.%, and even more preferably between 20 wt.% and 60 wt.%. In an embodiment, the amount of filler in the composition may be between 55 wt.% and 70 wt.%.

Although the composition preferably does not contain plasticizers, the present invention does not preclude their use. In any case, the present invention makes it possible to reduce the content of the plasticizer to a minimum. Examples of plasticizers that may possibly be used are DOP, DINCH, DINP, DOTP or polyisobutenes such as Oppanol B.

The composition preferably also contains at least a compatibilizer or coupling agent. The compatibilizer or coupling agent provides the advantage that the stability of the composition can be increased. This is particularly the case when the thermoplastic polyester exhibits no or little resemblance to one of the one or more elastomers. In this context, it should be noted that the elastomers made according to the first preferred embodiment of the second embodiment described herein above, namely, block copolymers based on styrene and ethylene/butylene or styrene and ethylene/propylene, such as linear triblock copolymers based on styrene and ethylene/butylene may show this similarity. For example, here the aforementioned Kraton elastomers can already show similarities with thermoplastic polyester, which is particularly the case for PET. In this case, it is not required to use a compatibilizer, but this is not excluded.

It should also be noted that in the case where the composition contains a plurality of elastomers, a plurality of compatibilizers or coupling agents may be used. The amount of compatibilizers used here may depend on the amount of elastomers that already exhibit similarity to the thermoplastic polyester.

A suitable compatibilizer or coupling agent may be based on glycidyl methacrylate. An example of this is an ethylene-glycidyl methacrylate copolymer such as the commercially available Lotader AX 8840. Another example of this is an ethylene acrylic ester glycidyl methacrylate terpolymer such as the commercially available Lotader AX 8900.

Another example of a suitable compatibilizer or coupling agent is an ethylene terpolymer, whether combined with glycidyl methacrylate or not, such as the commercially available Elvaloy PTW from Dupont.

Another suitable compatibilizer may be formed by PP, which is made from maleic anhydride. Of these, for example, Orevac CA100, Polybond 3200, Polyram Bondyram 1001 and 1101 are commercially available.

The amount of compatibilizer or coupling agent in the composition is preferably less than 10% by weight, more preferably less than 5% by weight, and even more preferably less than 2.5% by weight.

The composition may also contain at least so-called melt enhancers, the amount of which in the composition is preferably less than 5 wt.%, more preferably less than 2.5 wt.%, and even more preferably less than 1 wt.%. Melt enhancers contribute to the strength and toughness of the respective substrate layer. In fact, they reduce the decrease in viscosity of the thermoplastic polyester, which can be carried out by its hydrolysis.

In addition to the components or constituents already mentioned above, the composition may also contain at least a thermoplastic synthetic material other than a thermoplastic polyester. The fact that the composition contains an additional thermoplastic synthetic material other than a thermoplastic polyester, referred to herein as "additional thermoplastic synthetic material", has the advantage that additional freedom is created to change the properties of the substrate layer.

The additional thermoplastic synthetic material is preferably PP. This has the advantage that the stiffness of the respective substrate layer can still be reduced, whereby the degree of load fatigue can be limited. Of course, in the case where connecting parts, such as snap-on profiles, are provided in the substrate layer, this is preferable, given that the risk of their destruction or damage can be minimized. Moreover, by using PP as an additional thermoplastic synthetic material, the strength and toughness of the respective substrate layer can be increased even further.

While it is preferred to use isotactic polypropylene as the additional thermoplastic synthetic material, the invention does not preclude the use of atactic polypropylene. In fact, the use of atactic polypropylene may contribute to the fact that more filler can be achieved.

In yet another possibility, the additional thermoplastic synthetic material refers to polystyrene or a combination of PP and polystyrene.

It should also be noted that the most advantageous values for at least the amount of polyester, elastomer and possibly present filler in the composition depend on the type of elastomer that is used, as described below.

In the first embodiment of the elastomer capability described above, the composition preferably has one or more of the following characteristics:

- the amount of thermoplastic polyester in the composition is between 20 wt.% and 30 wt.%;

- the amount of elastomer in the composition is between 5 wt.% and 15 wt.%; and/or

- the amount of filler in the composition is between 40 wt.% and 50 wt.%.

In the second embodiment of the elastomer capability described herein, the composition preferably has one or more of the following characteristics:

- the amount of thermoplastic polyester in the composition is between 15 wt.% and 25 wt.%;

- the amount of elastomer in the composition is between 5 wt.% and 15 wt.%; and/or

- the amount of filler in the composition is between 45 wt.% and 55 wt.%.

In the third embodiment of the elastomer capability described herein, the composition preferably has one or more of the following characteristics:

- the amount of thermoplastic polyester in the composition is between 25 wt.% and 35 wt.%;

- the amount of elastomer in the composition is between 15 wt.% and 25 wt.%; and/or

- the amount of filler in the composition is between 25 wt.% and 35 wt.%.

The corresponding backing layer can also be foamed. This has the advantage that the density of the substrate layer can be reduced. In this way, it is possible to realize savings on raw materials and energy. In addition, the backing layer can provide new properties, for example in the area of comfort and dimensional stability.

To this end, the composition may contain a blowing agent. In a first possibility, the blowing agent may refer to a chemical blowing agent such as azoisobutyronitrile or azodicarbonamide. In a second possibility, the blowing agent is an expandable microsphere. Examples of such expandable microspheres are commercially available Expancel expandable microspheres. According to a third possibility, the blowing agent refers to a physical blowing agent.

It should also be noted that many of the blowing agents described above can be combined.

To reduce the density of the substrate layer or based on economic advantages, the composition may also contain at least a density reducing filler such as perlite, vermiculite and/or silicate. The filler refers in particular to a foamed, porous or hollow filler. In the case of such an expanded filler, this refers to a filler that has already been expanded before being added to the composition. In particular, the expanded filler relates to an already expanded microsphere, such as commercially available Expancel already expanded microspheres.

The laminated substrate may be provided with a reinforcing layer such as glass fiber cloth or glass fleece, whether or not it is in the corresponding substrate layer. The reinforcement layer can increase the dimensional stability of the floor panel and thus reduce thermal shrinkage or expansion with temperature, which limits the risk of cracks and gaps in the connected floor panels.

The thickness of the floor panel is preferably thus substantially formed by half or more of the layered substrate. More specifically, the layered substrate forms a carrier for the decorative top layer located above it.

The thickness of the layered substrate is preferably between 1 mm and 6 mm, and more preferably between 2 mm and 5 mm. This makes it possible to realize the floor panel sufficiently thin, although it has sufficient strength and stability.

It should also be noted that the corresponding substrate layer can be made according to various possibilities. Therefore, the substrate layer can be made by dusting, extrusion, injection molding, calendering and/or coating techniques.

The layered substrate may be composed of a plurality of layers. In this case, at least one of the layers is based on the composition described above. One or more remaining layers can be obtained on the basis of the composition described above, which, however, does not have to be identical to the composition of at least one layer. However, it is possible that one or more of the remaining layers are implemented differently, and not on the basis of the composition described here above.

The top layer contains at least decor, as well as a transparent or translucent wear layer located above the decor.

The top layer décor preferably comprises a design or pattern which is provided in the form of a print on the carrier sheet. The decor may show, for example, a wooden pattern or pattern, a stone pattern, a ceramic pattern, or the like. The carrier sheet may refer to a paper sheet impregnated with a resin or synthetic film. An example of a resin impregnated paper sheet is a melamine impregnated paper sheet. Examples of synthetic material films are polyvinyl chloride films, polyurethane films, polypropylene films, polyethylene terephthalate films and polyethylene films. Such a printed carrier sheet is preferably bonded to the substrate or the rest of the top layer by a thermal lamination process. The printed carrier sheet may or may not be bonded to the substrate along with one or more remaining layers of the top layer.

According to an alternative, however, also a preferred embodiment of the decor refers to the so-called "direct printing". In this document, the decor is provided directly on the bottom layer of the floor panel or on the base layer or primer provided on this underlying layer. The underlying layer may refer to the substrate, but also to another layer of the top layer. Such direct printing may use a printer which is preferably a digital printer, such as a digital inkjet printer.

According to another alternative, the décor refers to a print applied on the underside of the wear layer.

According to the first possibility, the wear layer refers to a resin impregnated paper sheet. An example of such a paper sheet is a sheet of paper impregnated with melamine. The paper sheet is preferably provided with solid particles such as corundum particles. Such particles increase the wear resistance of the floor panel. The resin-impregnated paper sheet, whether or not together with the aforementioned printed paper sheet, may be provided on a substrate or other layer of the top layer, for example, by a thermal lamination process.

According to the second possibility, the wear layer refers to a wear layer based on synthetic material, which is either applied in the form of a film, or together with the aforementioned printed film, for example, through a thermal lamination process, or applied in liquid form and then cured on a substrate or other layer of the top layer. layer. In case the wear layer comprises a film, this preferably refers to a thermoplastic film, in particular a PVC film, a polyurethane film, a polypropylene film, a polyethylene terephthalate film or a polyethylene film.

The top layer may include a back layer that contains at least a thermoplastic synthetic material. The back layer, whether or not it contains the aforementioned printed carrier sheet and/or wear layer, may be bonded to the substrate under pressure and temperature, or applied in liquid or paste form by calendering or otherwise provided to the substrate.

The back layer is preferably based on a flexible thermoplastic. Such a flexible backsheet has the advantage that the flexibility of the floor panels can be increased. Such flexibility can contribute to the ease of installation of the floor panels, as well as, for example, the reduction of noise, for example, when walking on the floor panels.

The top layer can be finally completed with a lacquer layer which is applied as a liquid layer on said wear layer and/or the above decor and subsequently cured. Preferably, this refers to a lacquer layer that can be cured with ultraviolet light or excimer radiation, or a layer that can be cured by heating. This last mentioned layer can use, for example, blocked isocyanates as a crosslinking agent. Preferably, the lacquer layer is applied on top of the possible wear layer, however, alternatively, the lacquer layer can function as a wear layer.

The top layer can also be provided with an embossing, whether or not it is obtained in combination with a decor. For this purpose, a roller can be used, for example, as described in PCT/IB2015/055826. The embossings provide the floor panels with a relief so that they can even better imitate a natural structure such as a wood structure. Embossments can be obtained, for example, in accordance with the pattern of wood fibers.

In addition to the underlay and the top layer, the floor panel may also comprise a counter-layer which is located under the underlay, but need not be in contact with it. The counter layer can be, for example, based on cork or based on a thermoplastic synthetic material, which is preferably flexible. Such a rather flexible counter-layer can give new properties to the floor panel, for example in the areas of comfort and sound absorption. In particular, such a counter-layer forms a layer with acoustic properties. The counter layer can help, for example, to reduce the noise generated by the floor panel, for example when walking on the floor panel.

At at least two opposite edges, the floor panel is preferably provided with mechanical connecting means or connecting parts which allow two of such floor panels to be connected to each other. Here, the connecting means or connecting parts may close in a direction perpendicular to the plane of the connected floor panels, or in a direction perpendicular to the connected edges and in the plane of the connected floor panels. Preferably, the connecting means or connecting parts provide a closing in both of the aforementioned directions.

Preferably, the connecting means or connecting parts have one or a combination of the following characteristics:

- the characteristic that the mechanical connecting means or connecting parts are essentially implemented as a tongue and a groove defined by a top edge and a bottom edge, this ledge and groove being essentially responsible for closing in said direction perpendicular to the plane of the connected floor panel and wherein the tongue and groove are provided with additional closing portions substantially responsible for closing in said direction perpendicular to the joined edges and in the plane of the joined floor panels. Preferably, the closures comprise a protrusion on the underside of the tongue and a recess in the bottom edge of the groove. Such connecting means and locking parts are known, for example, from WO 97/47834;

- the characteristic that the mechanical connecting means or connecting parts press the connected floor panels against each other, for example in the sense that these mechanical connecting means are implemented with a so-called pretension, as is known from EP 1 026 341. Tension force with which the floor panels are pressed against each other or against each other, can be obtained, for example, in combination with the above feature by means of a lower edge that bends outward in the connected position, which, trying to return back elastically, is pressed against the underside of the tongue;

- the characteristic that the mechanical connecting means or connecting parts provide a connection by horizontal or quasi-horizontal slight movement of the panels towards each other;

- the characteristic that the mechanical connecting means or connecting parts provide the connection by means of a rotary movement along the respective edges;

- the characteristic that mechanical connecting means or connecting parts provide a connection by means of a downward movement of a male connecting part, for example a tongue, into a female connecting part, for example a groove, preferably for the installation of such floor panels according to the so-called "folding" principle, as this is known from WO 01/75247;

- the characteristic that the mechanical connecting means or connecting parts, or at least the corresponding upper edge, is obtained by milling with rotary milling tools; and/or

- the characteristic that the mechanical connecting means or connecting parts use a separate locking element or insert, as described, for example, in documents WO 2006/043893 A1, WO 2008/068245 A1 and WO 2009/066153 A2.

Preferably, said connecting means or connecting parts, or at least a portion of these connecting means or connecting parts, are provided in a substrate material, more specifically, in a substrate layer material obtained from the composition described herein above. The substrate layer has excellent properties for this purpose, for example in the area of mechanical strength and flexibility. The connecting means or connecting parts can be applied by milling with rotary milling tools.

A floor panel preferably refers to an elongated rectangular or square floor panel which is provided at both of its opposite edges with connecting means or connecting parts such as those described herein above.

However, it is not excluded that the floor panel is free of connecting means or connecting parts at the edges, while the floor panel is then intended to be glued with its bottom side to the underlying surface or to be installed freely.

It should also be noted that the present invention also relates to a substrate for a panel, more specifically, to a floor panel, in which the substrate is laminated and contains at least a layer that is based on a composition containing at least a thermoplastic synthetic material. , characterized in that the composition, in addition to thermoplastic synthetic material, also contains at least one or more elastomers; and in that said thermoplastic synthetic material is a thermoplastic polyester. The substrate and composition can additionally be obtained as already described here above.

Additionally, it should also be noted that each of the above ranges of values contains the mentioned boundaries, unless otherwise indicated.

For the purpose of better depicting the characteristics of the invention, some preferred embodiments are described herein, by way of example without any limitation, with reference to the accompanying drawings, in which:

Fig. 1 is a plan view of a floor panel according to the invention; and

Fig. 2 is a section along the line II-II in Fig. 1.

Fig. 1 is a plan view of a floor panel 1 according to the present invention. The floor panel 1 here is oblong and rectangular. It contains a pair of long sides 2-3 and a pair of short sides 4-5.

Fig. 2 is a section along the line II-II in Fig. 1. From the section, it is clear that the floor panel 1 consists of a layered substrate 6 and a decorative top layer 7 located above the substrate 6.

In this example, the substrate 6 contains a single layer 8, which is based on the composition described above. Here, the composition specifically contains PET, a thermoplastic elastomer, a compatibilizer or binder, glass fibers, calcium carbonate, and melt enhancers. Three practical examples of such a composition will be described below.

Example 1

PET is present in the form of PET flakes, the amount of which in the composition is 25 wt.%. The elastomer is obtained according to the above possibility of the first embodiment. Thus, it is a thermoplastic elastomer made from propylene, and more specifically refers to an ethylene-propylene copolymer, namely Vistamaxx 6202FL. This elastomer is present in an amount of 8% by weight. The compatibilizer or coupling agent refers to a terpolymer of ethylene, acrylic ester and glycidyl methacrylate, namely Lotader AX8900, which is present in the composition in an amount of 1.8 wt.%. Additionally, glass fiber, calcium carbonate and melt enhancers are present at 20 wt.%, 45 wt.% and 0.2 wt.%, respectively.

Example 2

PET is present in the composition in an amount of 20% by weight. The elastomer is obtained according to the possibility of the second embodiment described above. Thus, it relates to a thermoplastic elastomer based on a styrenic block copolymer, and more specifically, obtained from a composition of a block copolymer of SEBS and a polyolefin such as PP, namely Ensoft SX-241-50A-T2-000. This elastomer is present in an amount of 8% by weight. The compatibilizer refers to a copolymer of ethylene and glycidyl methacrylate, namely Lotader AX8840, which is present in the composition in an amount of 1.8 wt.%. Additionally, glass fiber, calcium carbonate and melt enhancers are present at 20 wt.%, 50 wt.% and 0.2 wt.%, respectively.

Example 3

PET is present in the composition in an amount of 30% by weight. The elastomer is obtained according to the possibility of the third embodiment described here above, and thus refers to a polyolefin elastomer. More specifically, it is an ethylene-octene copolymer, namely Engage 8180. This elastomer is present in an amount of 18% by weight. The compatibilizer refers to Sukano TA52-10 MB02, which is present in the composition in an amount of 1.8 wt.%. Additionally, glass fiber, calcium carbonate and melt enhancers are present at 20 wt.%, 30 wt.% and 0.2 wt.%, respectively.

Here, the substrate 6 has a thickness T forming more than half of the total thickness T1 of the floor panel 1.

In this example, the decorative top layer 7 comprises a decor 9 as well as a transparent or translucent wear layer 10 located above the decor 9. Here, the decor 9 and the wear layer 10 can be obtained as described herein above. As schematically shown in figure 1, the decor contains a wooden repeating pattern 11.

It should also be noted that here, for clarity, the decorative top layer 7 is shown larger than it actually is.

Here the floor panel 1 is provided with mechanical connecting parts 12 at least on sides 2-3. The connecting parts 12 make it possible that two such floor panels 1 can be connected to each other in such a way that a locking is created in the direction V, perpendicular to the plane of the connected floor panels 1, as well as in the direction H, perpendicular to the connected sides 2-3 and in the plane connected panels of 1 floor.

The connecting portions 12 shown are essentially in the form of a tongue 13 and a groove 14 which are responsible for closing in the V direction. Here, the groove 14 is provided with an upper edge 15 and a lower edge 16 which extends beyond the distal end of the upper edge 15.

The tongue 13 and the groove 14 are also provided with locking parts 17-18, which are responsible for closing in the H direction. bottom edge 16 of groove 14.

In the example shown, the connecting parts 11-12 are essentially obtained in the layer 8 of the substrate. This can take place by means of milling operations, for example with rotary milling tools.

The outline represented by the dashed line of the side 2 shows that the connecting parts 12 in the example allow at least connection by means of a pivotal movement W along the respective sides 2-3.

The present invention is in no way limited to the embodiments described above, on the contrary, such floor panels and substrates are implemented in accordance with various embodiments without departing from the scope of the present invention.

Claims (45)

1. Floor panel for forming a floor covering, while the floor panel (1) contains a layered substrate (6), as well as a decorative top layer (7) located above the substrate (6), while the substrate (6) contains at least a layer (8), which is obtained on the basis of a composition containing at least a thermoplastic synthetic material, and the composition also contains at least one or more elastomers, and the thermoplastic synthetic material refers to a thermoplastic complex polyester, characterized in that the floor panel (1) according to at least on two opposite edges (2-3) provided with mechanical connecting means or connecting parts (12), said connecting means or connecting parts (12) being essentially obtained in the layer (8) of the substrate; moreover, these connecting means or connecting parts (12) allow two of such floor panels (1) to be connected to each other in such a way that the closure is created in the direction (V) perpendicular to the plane of the connected floor panels (1), and also in the direction (H) perpendicular to the connected edges (2-3) and in the plane of the connected floor panels (1). 2. The floor panel according to claim 1, wherein the mechanical connecting means or connecting parts comprise a snap profile. 3. The floor panel of claim 1 or 2, wherein the thermoplastic polyester is selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), and combinations thereof. 4. The floor panel according to any one of the preceding claims, wherein the amount of thermoplastic polyester in the composition is between 5 wt.% and 50 wt.%, preferably between 10 wt.% and 40 wt.%, and even more preferably between 15 wt.% and 35 wt.%. 5. Floor panel according to any one of the preceding claims, wherein the thermoplastic polyester refers to polyethylene terephthalate (PET). 6. The floor panel of claim 5 wherein the thermoplastic polyester is present in the composition as PET flakes. 7. Floor panel according to any one of the preceding claims, wherein the amount of elastomer in the composition is between 1 wt.% and 35 wt.%, preferably between 1 wt.% and 30 wt.%, even more preferably between 5 wt.% and 30 wt.% and most preferably between 5 wt.% and 25 wt.%. 8. The floor panel according to any of the preceding claims, wherein at least one elastomer has a shore hardness that is greater than 20 Shore A and less than 90 Shore A, and preferably greater than 40 Shore A and less than 85 Shore D, wherein the Shore hardness measured according to ISO 868. 9. The floor panel according to any one of the preceding claims, wherein at least one of the elastomers is a thermoplastic elastomer. 10. Floor panel according to claim 9, wherein at least one elastomer derived from propylene, wherein the propylene derived elastomer preferably has any of the following characteristics: - it refers to an ethylene-propylene copolymer or - it refers to a thermoplastic olefin (TPO) or a composition of polypropylene and non-crosslinked rubber based on a copolymer of ethylene, propylene and diene monomer (EPDM); or derived from a styrenic block copolymer such as styrene-butylene-styrene (SBS) or styrene-ethylene-butylene-styrene (SEBS), wherein the elastomer derived from the styrene block copolymer preferably has any of the following characteristics: - it refers to a block copolymer based on styrene and ethylene/butylene or styrene and ethylene/propylene, more specifically a linear triblock copolymer based on styrene and ethylene/propylene or linear SEBS; or it is based on a composition of, on the one hand, SEBS or SBS and, on the other hand, a polyolefin such as polypropylene or polyethylene; refers to a polyolefin elastomer (POE) and preferably refers to an ethylene-octene copolymer. 11. Floor panel according to any of the preceding claims, wherein the composition also comprises at least mineral fiber structures such as glass fibers, the amount in the composition being preferably between 5 wt.% and 40 wt.%, more preferably between 10 wt. .% and 30 wt.% and even more preferably between 15 wt.% and 25 wt.%. 12. Floor panel according to any one of the preceding claims, wherein the composition also contains at least a filler such as chalk, limestone and/or talc, the amount of which in the composition is preferably between 10 wt% and 80 wt%, more preferably between 20 wt.% and 70 wt.% and even more preferably between 20 wt.% and 60 wt.%. 13. Floor panel according to any one of the preceding claims, wherein the decorative top layer (7) comprises a decor (9) as well as a transparent or translucent wear layer (10) located above the decor (9). 14. Floor panel according to any one of the preceding claims, wherein the floor panel (1) also comprises an opposite layer located under the substrate (6). 15. Floor panel for forming a floor covering, while the floor panel (1) contains a layered substrate (6), as well as a decorative top layer (7) located above the substrate (6), while the substrate (6) contains at least a layer (8), which is obtained on the basis of a composition containing at least a thermoplastic synthetic material, characterized in that the composition also contains at least one or more elastomers, and the thermoplastic synthetic material refers to a thermoplastic polyester, and at least one elastomer - derived from propylene; or - obtained on the basis of a styrene block copolymer; or - refers to polyolefin elastomer (POE). 16. The floor panel of claim 15, wherein the thermoplastic polyester may be selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), and combinations thereof. 17. Floor panel according to claim 15 or 16, in which the amount of thermoplastic polyester in the composition is between 5 wt.% and 50 wt.%, preferably between 10 wt.% and 40 wt.%, and even more preferably between 15 wt. % and 35 wt.%. 18. Floor panel according to any one of claims 15 to 17, wherein the thermoplastic polyester refers to polyethylene terephthalate (PET). 19. The floor panel of claim 18, wherein the thermoplastic polyester is present in the composition as PET flakes. 20. Floor panel according to any one of claims 15 to 19, wherein the amount of elastomer in the composition is between 1 wt.% and 35 wt.%, preferably between 1 wt.% and 30 wt.%, even more preferably between 5 wt. % and 30 wt.% and most preferably between 5 wt.% and 25 wt.%. 21. A floor panel according to any one of claims 15 to 20, wherein at least one elastomer has a shore hardness that is greater than 20 Shore A and less than 90 Shore A, and preferably greater than 40 Shore A and less than 85 Shore D, wherein Shore hardness is measured according to ISO 868. 22. A floor panel according to any one of claims 15 to 21, wherein at least one of the elastomers is a thermoplastic elastomer. 23. The floor panel according to any one of claims 15-22, wherein at least one elastomer is derived from propylene, wherein the elastomer derived from propylene has any of the following characteristics: - it refers to an ethylene-propylene copolymer or - it refers to a thermoplastic olefin (TPO) or a composition of polypropylene and non-crosslinked rubber based on a copolymer of ethylene, propylene and diene monomer (EPDM). 24. Floor panel according to any one of claims 15-23, wherein at least one elastomer is based on a styrenic block copolymer such as styrene-butylene-styrene (SBS) or styrene-ethylene-butylene-styrene (SEBS), wherein the styrene block copolymer based elastomer has any of the following characteristics: - it refers to a block copolymer based on styrene and ethylene/butylene or styrene and ethylene/propylene, more specifically a linear triblock copolymer based on styrene and ethylene/propylene or linear SEBS; or it is based on a composition of, on the one hand, SEBS or SBS and, on the other hand, a polyolefin such as polypropylene or polyethylene. 25. A floor panel according to any one of claims 15 to 24, wherein at least one elastomer is an ethylene-octene copolymer. 26. A floor panel according to any one of claims 15 to 25, wherein the composition also comprises at least mineral fiber structures such as glass fibers, the amount in the composition being preferably between 5 wt% and 40 wt%, more preferably between 10 wt.% and 30 wt.% and even more preferably between 15 wt.% and 25% wt. 27. Floor panel according to any one of claims 15-26, in which the composition also contains at least a filler such as chalk, limestone and/or talc, and its amount in the composition is preferably between 10 wt.% and 80 wt.% , more preferably between 20 wt.% and 70 wt.% and even more preferably between 20 wt.% and 60 wt.%. 28. Floor panel according to any one of claims 15 to 27, wherein the decorative top layer (7) comprises a decor (9) as well as a transparent or translucent wear layer (10) located above the decor (9). 29. Floor panel according to any one of claims 15 to 28, wherein the floor panel (1) also comprises an opposite layer located under the substrate (6). 30. The floor panel according to any one of claims 15-29, wherein the floor panel (1) is provided on at least two opposite edges (2-3) with mechanical connecting means or connecting parts (12), these connecting means or connecting parts (12) allow two of such floor panels (1) to be connected to each other in such a way that a closure is created in a direction (V) perpendicular to the plane of the connected floor panels (1) and also in a direction (H) perpendicular to connected edges (2-3), and in the plane of the connected floor panels (1). 31. The floor panel according to claim 30, wherein the mechanical connecting means or connecting parts comprise a snap profile.

Images