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Title:
MULTILAYER FLOOR PANEL BASED ON A PVC PLASTISOL
Document Type and Number:
WIPO Patent Application WO/2021/094625
Kind Code:
A4
Abstract:
The present invention relates to floor panels comprising a substrate and a multi-layered top layer directly attached to the substrate, whereby the multi-layered top layer comprises a decor layer comprising a fused PVC plastisol, a print pattern deposited as single or stacked dots of a digitally printed material on top of the decor layer, a wear-resistant layer comprising a fused PVC plastisol provided above the print pattern, and optionally a lacquer layer provided directly on top of the wear-resistant layer. The invention furthermore relates to a method for producing such floor panels.

Inventors:
VAN ESSCHE SAM (BE)
EGGERMONT HANNA (BE)
LOMBAERT POL (BE)
FEYS JONAS GUIDO (BE)
VAN GIEL FRANS (BE)
Application Number:
PCT/EP2020/082307
Publication Date:
July 08, 2021
Filing Date:
November 16, 2020
Export Citation:
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Assignee:
BEAULIEU INT GROUP NV (BE)
International Classes:
C08J7/04; B32B5/18; B32B27/10; B32B27/30; B44C1/20; E04F15/02; E04F15/10
Attorney, Agent or Firm:
IPLODGE BV (BE)
Download PDF:
Claims:
39

AMENDED CLAIMS received by the International Bureau on 10 May 2021 (10.05.2021)

1. A floor panel comprising: a substrate; a multi-layered top layer directly attached to the substrate; whereby the multi-layered top layer comprises: a decor layer comprising a fused PVC plastisol, a print pattern deposited as single or stacked dots of a digitally printed material on top of the decor layer, a wear-resistant layer comprising a fused PVC plastisol provided above the print pattern, wherein the wear-resistant layer is obtained by gelling a PVC plastisol and by mechanically embossing the PVC plastisol during gelling and subsequently fusing the gelled PVC plastisol to obtain the fused wear-resistant layer.

2. A floor panel according to claim 1, further comprising a lacquer layer provided directly on top of the wear-resistant layer.

3. A floor panel according to claim 1 or 2, wherein the ratio between elastic moduli of the substrate and multi-layered top layer is at least 20 measured at 23 ± 2°C and 50 ± 10 % R.H. according to ISO 527.

4. A floor panel according to any of the claims 1 to 3, wherein the multi-layered top layer has an elastic modulus of less than 100 MPa at 23°C measured at 23 ± 2°C and 50 ± 10 % R.H., according to ISO 527.

5. A floor panel according to any of the claims 1 to 4, wherein the substrate has an elastic modulus of more than 2000 MPa measured at 23 ± 2°C and 50 ± 10 % R.H., according to ISO 527.

6. A floor panel according to any of the claims 1 to 5, wherein the multi-layered top layer does not comprise a reinforcement layer.

7. A floor panel according to any of claims 1 to 6, wherein the substrate does not comprise a reinforcement layer.

8. A floor panel according to any of the claims 1 to 7, wherein the floor panel is free of interlayer adhesive material.

9. A floor panel according to any of the claims 1 to 8, wherein the substrate is a foamed substrate. 40

10. A floor panel according to any of the claims 1 to9, wherein the substrate is a single layer substrate.

11. A floor panel according to claim 9 or 10, wherein a density of the foamed substrate is equal to or less than 1600 kg/m3, more preferably less than 1400 kg/m3, even more preferably less than 1300 kg/m3 and the density is equal to or more than 400 kg/m3, more preferably more than 600 kg/m3, even more preferably more than 800 kg/m3, and most preferably more than about 1000 kg/m3.

12. A floor panel according to claim 11, wherein the density is in the range 1050 kg/m3 to 1300 kg/m3, more preferably from 1100 kg/m3 to 1200 kg/m3.

13. A floor panel according to any of the previous claims, wherein the substrate has a thickness of 1 mm to 25 mm, preferably, the substrate has a thickness of 1.5 mm to 20 mm, and more preferably of 1.5 mm to 7 mm, and even more preferably between 2.4 mm to 5.8 mm.

14. A floor panel according to any of the previous claims, wherein the substrate has a glass transition temperature (Tg) of 80°C or higher and more preferable a glass transition temperature (Tg) of 85°C or higher.

15. A floor panel according to any of the claims 1 to 14, whereby the decor layer comprises a chemically embossed relief pattern formed by single or stacked dots of digitally printed material comprising a foam inhibiting agent.

16. A floor panel according to any of the previous claims, wherein a thickness of the decor layer is in the range 0.1 to 0.7 mm.

17. A floor panel according to any of the claims 1 to 16, wherein the wear- resistant layer has a mechanically embossed surface structure.

18. A floor panel according to any of the claims 15 to 17, when dependent on any of the claims 2 to 16, wherein the lacquer layer is a continuous or discontinuous, transparent layer that conforms to a mechanically and/or chemically embossed relief pattern.

19. A floor panel according to claim 18, wherein the lacquer layer is conformal with the wear- resistant layer.

20. A floor panel according to any previous claims comprising a surface with different gloss levels comprising first zones with high gloss, second zones with silk gloss, and third zones with matt.

21. A floor panel according to claim 20, wherein the surface has macro, micro, and nanoscale features.

22. A floor panel according to claim 20 or 21, wherein the one or more zones of a surface of the panel which has/have a gloss value or macro, micro, and nanoscale features are aligned with one or more parts of the print pattern.

23. A floor panel according to any of claims 1 to 22, whereby the resistance against separation of the substrate and the multi-layered top layer by peeling is at least 50 N/50mm as determined by a peel test as defined herein.

24. A method for producing a floor panel comprising the subsequent steps of:

S1 : providing a substrate,

S2: applying a first coating comprising a PVC plastisol directly onto the substrate to obtain a decor layer,

S3: gelling the decor layer,

S4: applying a print pattern of single or stacked dots of printing material directly onto the gelled decor layer by means of digital printing,

S5: applying a second coating comprising a PVC plastisol onto the printed decor layer to obtain a wear-resistant layer,

S6: gelling the wear-resistant layer and subsequently fusing the decor layer and wear- resistant layer, and further comprising the step of mechanically embossing the wear- resistant layer during gelling.

25. A method according to claim 24, further comprising a step of: S7: applying a lacquer layer directly on top of the fused wear- resistant layer.

26. A method according to claim 25, wherein the lacquer layer is conformal with the wear- resistant layer.

27. A method according to claim 25 or 26, wherein the lacquer layer is a continuous or discontinuous, transparent layer that conforms to a mechanically and/or chemically embossed relief pattern.

28. A method for producing a floor panel according to any of the claims 24 to 27, wherein the floor panel is free of interlayer adhesive material.

29. A method for producing a floor panel according to any of claims 24 to 28, wherein the substrate is a foamed substrate.

30. A method for producing a floor panel according to any of claims 24 to 29, wherein the substrate is a single layer substrate.

31. A method for producing a floor panel according to any of claims 24 to 30, further comprising the steps of:

- providing a blowing agent into the first coating to obtain a foamable decor layer in step S2,

- applying a pattern of single or stacked dots of printed material comprising foam inhibiting agent onto the gelled foamable decor layer by means of digital printing, and

- foaming the foamable decor layer in step S6.

32. A method for producing a floor panel according to any of the claims 24-31 , whereby an embossing mould is in contact with the wear-resistant layer during gelling without exerting additional pressure.

33. A method for producing a floor panel according to claim 32 , whereby the embossing mould is a release web.

34. A method for producing a floor panel according to claim 32, whereby the embossing mould is a polymer coated paper.

35. A method according to any of the claims 24 to 34, comprising generating multiple gloss levels in first zones with high gloss, second zones with silk gloss, and third zones which are matt on a surface of the floor panel.

36. A method according to claim 35, wherein the surface has macro, micro, and nanoscale features.

37. A method according to claim 35 or 36, wherein the one or more zones of a surface of the panel which has/have a gloss value or macro, micro, and nanoscale features are aligned with one or more parts of the print pattern.