Patent Application
20250223815
The present application claims the benefit of Swedish Application No. 2450022-5, filed on Jan. 10, 2024. The entire contents of Swedish Application No. 2450022-5 are hereby incorporated herein by reference in their entirety.
Examples of the present disclosure relates to a method to produce a board element, which may form a panel or may be divided into panels, such as building panels. The disclosure also relates to a panel, such as a building panel. The building panel may be a floor panel, a wall panel, a furniture component, a building component, a worktop, etc.
Digital printing technologies offer advantages when designing décors for panels. For example, repetition can be avoided, and the possibilities for designing décors are endless. No expensive gravure cylinders have to be engraved for each décor.
In order to reduce cost and material consumption, examples of floor panels are printed directly on the substrate by a digital printer, such that the substrate is provided with a digitally printed décor. However, when such floor panels are provided with a mechanical locking system, the mechanical locking system may not withstand forces applied to the surface of the floor panel. Such forces may be represented by the Castor chair testing process. When testing a directly printed floor panel in a Castor chair test, it has been discovered that the floor panel tends to crack over certain portions of the mechanical locking system. As a result, the mechanical locking system breaks and the floor panels disengage from each other, such that the joint between adjacent panels breaks.
One such portion of the mechanical locking system which tends to crack is the portion of the substrate located above the insertion groove, as indicated by dashed line in
WO2023126442A1 discloses a method for manufacturing customized decorative laminated panels, wherein a user selects and/or designs a digital image and digital embossing structure, which are digitally printed by a printing device on a substrate.
An object of at least examples of the present disclosure is to provide an improved method to produce a board element.
An object of at least examples of the present disclosure is to provide an improved panel configured to be joined to an adjacent panel.
According to a first aspect, a method to produce a board element is provided. The method comprises:
The digital printing device is configured to digitally print the décor.
By the method above is a board element formed, which may be divided into panels, in one or several steps, or may itself form a panel. The panel may be a building panel such as a floor panel, a wall panel, a furniture component, a building component, a worktop, etc.
Advantages of at least examples of the first aspect are that the thermoplastic film can be laminated to the substrate at least partly by heat remaining in the substrate from the extrusion process. The thermoplastic film can be laminated to the substrate directly after, or in close proximity to, the time at which the substrate leaves the die.
Advantages of at least examples of the first aspect are that the thermoplastic film may reinforce and/or strengthen parts of the substrate, for example, parts of the substrate which may be provided with a mechanical locking system in subsequent process. When forming the mechanical locking system, parts of the substrate may be removed such that the thickness of the substrate is reduced, thereby weakening the substrate.
Bending strength and maximum applied force, and/or strain at maximum load, or strain at 80% of maximum load of the board element may be improved. Thereby, the board element may be stronger and/or less brittle. A mechanical locking system later provided in the board element may be less prone to damage and breaking.
Further, the thermoplastic film simultaneously forms a print layer by being printed with a décor after being laminated to the substrate.
The substrate may comprise one or more extruded substrate layers.
The thermoplastic film may be laminated to the substrate by heat and pressure.
The thermoplastic film may be laminated to the substrate at least partly by heat from the extruded substrate.
The thermoplastic film may be laminated to the substrate in proximity of the die.
The thermoplastic film may be laminated to the substrate in proximity in time and/or in distance to the die.
The thermoplastic film may be laminated to the substrate when the substrate remains heated from the extrusion process.
By being heated from the extrusion process, the substrate may have a temperature above room temperature, i.e. above 22° C., such as having a temperature exceeding 50° C. at its surface, such as exceeding 100° C.
The thermoplastic film may be laminated to the substrate, e.g., advantageously no later than 30 minutes after the substrate has left the die, such as no later than 15 minutes or no later than 5 minutes after the substrate has left the die.
The thermoplastic film may be pigmented.
The pigment may be or comprise titanium dioxide, and/or other inorganic pigments such as calcium carbonate, talc, zinc sulphide, or barium sulphate.
The method may further comprise applying a primer to the thermoplastic film prior to printing the décor.
The thermoplastic film may be laminated to the substrate as a continuous web.
The substrate may be in continuous form when the thermoplastic film is laminated to the substrate.
A temperature on the first surface of the substrate may be 120-240° C., such as 130-230° C., such as 140-220° C., when the thermoplastic film is laminated to the first surface of the substrate.
The thermoplastic film may have a temperature of 18-170° C. when being laminated to the substrate.
A thickness of the thermoplastic film may be or exceed 0.05 mm. The thickness of the thermoplastic film may be 0.05-1 mm. The thickness of the thermoplastic film may be 0.05-0.55 mm. The thickness of the thermoplastic film may be 0.07-0.3 mm.
The method may further comprise laminating at least one substrate layer to the substrate after the substrate has passed the die, prior to laminating the thermoplastic film to the substrate.
The substrate may comprise at least one substrate layer being laminated to the substrate after extrusion, such that the substrate comprises one or more extruded substrate layers and at least one laminated substrate layer.
The at least one laminated substrate layer may be a plasticized layer.
The thermoplastic film may comprise one or more plasticizers.
The thermoplastic film may comprise, e.g., advantageously no more than 50 phr plasticizer, such as less than 35 phr plasticizer, for example less than 10 phr plasticizer.
The thermoplastic film may comprise one or more plasticizer in an amount of 1-50 phr, such as 5-35 phr.
The thermoplastic film may comprise, e.g., advantageously no more than 40 wt % plasticizer, such as less than 25 wt % plasticizer, for example, less than 10 wt % plasticizer. The thermoplastic film may comprise one or more plasticizer in an amount of 0.5-40 wt %, such as 3-25 wt %.
The thermoplastic film may comprise at least one filler. The filler or fillers may be present in the thermoplastic film in an amount of less than 50 phr, such as 5-40 phr, for example 10-30 phr.
The thermoplastic film may comprise at least one filler in an amount of 1-55 phr.
The thermoplastic film may comprise at least one filler in an amount of 0.5-50 wt %, such as 0.5-25 wt %.
The filler or fillers of the thermoplastic film may be CaCO3, talc, fly ash, or a stone material, such as stone powder. Pigments may have a similar function as a filler, and may therefore be included in the term “filler” if present.
The filler may be inorganic and/or organic fillers. The inorganic filler may be a mineral material, for example CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk. The organic filler may be a wood material, a bamboo material, cork, or rice husks. For example, the wood material may be wood fibres, wood flour and/or wood dust, and the bamboo material may be bamboo dust.
The fillers, including pigments and non-pigments, may be included in the thermoplastic film in an amount of 1-55 phr.
The thermoplastic film may further include a reinforcement, such as a fibre reinforcement, such as glass fibre reinforcement, carbon fibre reinforcement, aramid fibre reinforcement, and/or basalt fibre reinforcement.
The thermoplastic film may further comprise stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents.
The thermoplastic film may consist of the thermoplastic material, plasticizer, filler, stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents.
The thermoplastic film may consist of the thermoplastic material, plasticizer/s, filler/s, and/or additives chosen from the group consisting of lubricants, process aids, modifiers, stabilizers, UV absorbents, blowing agents.
The thermoplastic film may be free from any paper layer.
The thermoplastic material of thermoplastic film may be PVC, PE, PP, TPU, PET, PETG, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a copolymer thereof, or a combination thereof.
The thermoplastic material of thermoplastic film may be a copolymer such as PP/PE copolymer, PVC/PVAc copolymer, PET-G (polyethylene-terephthalate-glycol), ABS (acrylonitrile butadiene styrene), different polyamide grades, and different polyester grades.
The coating may be a UV curable coating.
The coating may be an EB curable coating.
The method may further comprise curing the coating, for example by UV or EB curing.
The digital printing device may be an inkjet printer, preferably a piezo-electric DOD (Drop on Demand) inkjet printer.
Printing may further comprise digitally printing an embossed structure on the thermoplastic film when the thermoplastic film has been laminated to the substrate.
The method may further comprise conveying the substrate between at least two rollers after the substrate has passed the die.
The thermoplastic film may be laminated to the substrate by at least one of said rollers.
A temperature on the first surface of the substrate may be 130-220° C., such as 160-210° C., such as 170-190° C., when the thermoplastic film is laminated to the substrate.
The substrate may comprise a thermoplastic material and calcium carbonate. At least one layer of the substrate layer, such as at least one extruded substrate layer, may comprise a thermoplastic material and calcium carbonate.
A density of the substrate may be 1000-2500 kg/m3.
A density of at least one of the substrate layers, such as at least one of the extruded substrate layers, may be 1000-2500 kg/m3.
The method may further comprise conveying the substrate through at least one cooling zone.
The thermoplastic film may be laminated to the substrate by at least one roller, prior or after the cooling zone.
A temperature on the first surface of the substrate may be 120-180° C., such as 130-170° C. such as 140-160° C., when the thermoplastic film is laminated to the substrate.
The substrate may comprise at least one foamed substrate layer, such as at least one foamed extruded substrate layer.
The method may further comprise applying a backing layer and/or a reinforcement layer to a second surface of the substrate, opposite the first surface.
The method may further comprise, after the thermoplastic film has been laminated to the substrate, dividing the board element into board element members or panels.
The step of printing may be performed prior to dividing the board element into board element members or panels.
The step of printing may be is performed after dividing the board element into board element members or panels.
The board element members may be divided into panels.
The thermoplastic film coated by the coating layer may form surface layer of the panel, which is intended to be the visible surface of the panel when installed as, for example, a floor panel.
The method may further comprise providing the panels with a mechanical locking system, configured to join a first panel to a second, adjacent panel.
The method may further comprise providing the panels with a locking strip and an insertion groove along at least a first edge of the panels, the locking strip and the insertion groove being configured for joining the panel to an adjacent panel along the first edge,
The thickness of the thermoplastic film may be 2-200% of the minimum insertion groove distance, such as 4-150% of the minimum insertion groove distance, such as 5-75% of the minimum insertion groove distance.
The thickness of the thermoplastic film may be 2-110% of the minimum insertion groove distance, such as 4-100% of the minimum insertion groove distance, for example 5-75% of the minimum insertion groove distance.
In one example, the thickness of the thermoplastic film may be 7-45% of the minimum insertion groove distance.
The insertion groove may be configured to receive a tongue of the adjacent panel for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
The locking strip may be configured to be received in a locking groove for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
The locking strip may comprise a locking element configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
The method may further comprise providing the panels with a locking groove along at least a second edge of the panels, the locking groove being configured for joining the panel to an adjacent panel along the second edge,
The thickness of the thermoplastic film may be 1-100% of the minimum locking groove distance, such as 1.5-80% of the minimum locking groove distance, such as 2-50% of the minimum locking groove distance.
In one example, the thickness of the thermoplastic film may be 5-25% of the minimum locking groove distance.
The thickness of the thermoplastic film may be 1-50% of the minimum locking groove distance, such as 1.5-45% of the minimum locking groove distance.
In one example, the thickness of the thermoplastic film may be 2-20% of the minimum locking groove distance.
The locking groove may be configured to receive the locking strip of the adjacent panel for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
According to a second aspect, a panel is provided. The panel comprises:
The thickness of the thermoplastic film may be 2-200% of the minimum insertion groove distance, such as 4-150% of the minimum insertion groove distance, for example 5-75% of the minimum insertion groove distance.
The thickness of the thermoplastic film may be 2-110% of the minimum insertion groove distance, such as 4-100% of the minimum insertion groove distance, for example 5-75% of the minimum insertion groove distance.
In one example, the thickness of the thermoplastic film may be 7-45% of the minimum insertion groove distance.
In one example wherein the thermoplastic film has a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film may be 2-110% of the minimum insertion groove distance, such as 4-75% of the minimum insertion groove distance.
In another example wherein the thermoplastic film has a thickness of 0.55-1 mm, the thickness of the thermoplastic film may be 20-200% of the minimum insertion groove distance, such as 40-200% of the minimum insertion groove distance.
The insertion groove being configured to receive the tongue may be configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
According to a third aspect, a panel is provided. The panel comprises:
The thickness of the thermoplastic film may be 1-100% of the minimum locking groove distance, such as 1.5-80% of the minimum locking groove distance, such as 2-50% of the minimum locking groove distance.
In one example, the thickness of the thermoplastic film may be 5-25% of the minimum locking groove distance.
The thickness of the thermoplastic film may be 1-50% of the minimum locking groove distance, such as 1.5-45% of the minimum locking groove distance.
In one example, the thickness of the thermoplastic film may be 2-20% of the minimum locking groove distance.
The locking groove being configured to receive locking strip may be configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
The locking strip may comprise a locking element configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
Advantages of at least examples of the second and third aspects are that the thermoplastic film may reinforce and/or strengthen parts of the substrate, for example, parts of the substrate provided with a mechanical locking system. When forming the mechanical locking system, parts of the substrate may be removed such that the thickness of the substrate is reduced, thereby weakening the substrate.
Bending strength and maximum applied force, and/or strain at maximum load, or strain at 80% of maximum load of the panel may be improved. Thereby, the panel may be stronger and/or less brittle. The mechanical locking system of the panel may be less prone to damage and breaking.
Further, the thermoplastic film simultaneously forms a print layer by being provided with a décor.
In one example wherein the thermoplastic film has a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film may be 1-50% of the minimum locking groove distance.
In another example wherein the thermoplastic film has a thickness of 0.55-1 mm, the thickness of the thermoplastic film may be 2-100% of the minimum locking groove distance.
According to the second and/or third aspect, the panel may comprise digitally printed décor.
The substrate may comprise one or more extruded substrate layers.
The substrate may comprise at least one laminated substrate layer.
The laminated substrate layer may be arranged on one of said extruded substrate layers.
The at least one laminated substrate layer may be a plasticized layer.
The coating layer may be adhered directly on the printed thermoplastic film,
The panel may further comprise along at least a second edge a locking groove extending into the substrate from the second surface of the substrate and extending along the second edge, the locking groove being configured to receive a locking strip of an adjacent panel for joining the panel to the adjacent panel along the second edge in at least one direction,
The thickness of the thermoplastic film may be 1-100% of the minimum locking groove distance, such as 1.5-80% of the minimum locking groove distance, such as 2-50% of the minimum locking groove distance.
In one example, the thickness of the thermoplastic film may be 5-25% of the minimum locking groove distance.
The thickness of the thermoplastic film may be 1-50% of the minimum locking groove distance, such as 1.5-45% of the minimum locking groove distance.
In one example, the thickness of the thermoplastic film may be 2-20% of the minimum locking groove distance.
The locking groove being configured to receive the locking strip may be configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
The locking strip may comprise a locking element configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
The panel may further comprise along at least the second edge a joint lip extending from the second edge and extending along the second edge, the joint lip being configured to extend over the insertion groove when being joined to an adjacent panel, wherein the joint lip has a thickness in a direction perpendicular to the plane of the first surface of the substrate, wherein the thickness of the thermoplastic film is at least 2.5% of the thickness of the joint lip.
The thickness of the thermoplastic film may be 2.5-100% of the thickness of the joint lip, such as 2.5-50% of the thickness of the joint lip.
The panel may further comprise a locking strip extending from the first and/or the second edge and extending along the first and/or the second edge, the locking strip being configured to cooperate with a locking groove of an adjacent panel for joining the panel to an adjacent panel in at least one direction.
The locking strip being configured to cooperate with the locking groove may be configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
The locking strip may comprise a locking element configured for locking the panel to an adjacent panel in at least one direction, such as a vertical direction and/or a horizontal direction.
A thickness of the thermoplastic film may be or exceed 0.05 mm. The thickness of the thermoplastic film may be 0.05-1 mm. The thickness of the thermoplastic film may be 0.05-0.55 mm. The thickness of the thermoplastic film may be 0.07-0.3 mm.
The panel may further comprise a primer applied between the first surface of the substrate and the thermoplastic film.
The panel may further comprise a primer applied on the thermoplastic film.
The thermoplastic film may comprise one or more plasticizers.
The thermoplastic film may comprise, e.g., advantageously no more than 50 phr plasticizer, such as less than 35 phr plasticizer, for example less than 10 phr plasticizer.
The thermoplastic film may comprise one or more plasticizer in an amount of 1-50 phr, such as 5-35 phr.
The thermoplastic film may comprise, e.g., advantageously no more than 40 wt % plasticizer, such as less than 25 wt % plasticizer, for example, less than 10 wt % plasticizer. The thermoplastic film may comprise one or more plasticizer in an amount of 0.5-40 wt %, such as 3-25 wt %.
The thermoplastic film may comprise at least one filler. The filler or fillers may be present in the thermoplastic film in an amount of less than 50 phr, such as 5-40 phr, for example 10-30 phr.
The thermoplastic film may comprise at least one filler in an amount of 1-55 phr.
The thermoplastic film may comprise at least one filler in an amount of 0.5-50 wt %, such as 0.5-25 wt %.
The filler or fillers of the thermoplastic film may be CaCO3, talc, fly ash, or a stone material, such as stone powder. Pigments may have a similar function as a filler, and may therefore be included in the term “filler” if present.
The filler may be inorganic and/or organic fillers. The inorganic filler may be a mineral material, for example CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk. The organic filler may be a wood material, a bamboo material, cork, or rice husks. For example, the wood material may be wood fibres, wood flour and/or wood dust, and the bamboo material may be bamboo dust.
The fillers, including pigments and non-pigments, may be included in the thermoplastic film in an amount of 1-55 phr.
The thermoplastic film may further include a reinforcement, such as a fibre reinforcement, such as glass fibre reinforcement, carbon fibre reinforcement, aramid fibre reinforcement, and/or basalt fibre reinforcement.
The thermoplastic film may further comprise stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents.
The thermoplastic film may consist of the thermoplastic material, plasticizer, filler, stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents.
The thermoplastic film may consist of the thermoplastic material, plasticizer/s, filler/s, and/or additives chosen from the group consisting of lubricants, process aids, modifiers, stabilizers, UV absorbents, blowing agents. The thermoplastic film may be free from any paper layer.
The thermoplastic material of thermoplastic film may be PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or copolymer thereof, or a combination thereof.
The thermoplastic material of thermoplastic film may be a copolymer such as PP/PE copolymer, PVC/PVAc copolymer, PET-G (polyethylene-terephthalate-glycol), ABS (acrylonitrile butadiene styrene), different polyamide grades, and different polyester grades.
The coating layer may comprise or be a UV curable coating.
The coating layer may comprise or be an EB curable coating.
The thermoplastic film may comprise an embossed structure.
The embossed structure may be a digitally applied embossed structure.
The substrate may comprise a thermoplastic material and calcium carbonate.
At least one layer of the substrate layer, such as at least one extruded substrate layer, may comprise a thermoplastic material and calcium carbonate.
The thermoplastic film may be pigmented.
The pigment may be or comprise titanium dioxide, and/or other inorganic pigments such as calcium carbonate, talc, zinc sulphide, or barium sulphate.
A density of the substrate may be 1000-2500 kg/m3.
A density of at least one of the substrate layers, such as at least one of the extruded substrate layers, may be 1000-2500 kg/m3.
The substrate may comprise at least one foamed substrate layer, such as at least one foamed extruded substrate layer.
The panel may further comprise a backing layer and/or a reinforcement layer to a second surface of the substrate, opposite the first surface.
The thermoplastic film coated by the coating layer may form surface layer of the panel, which is intended to be the visible surface of the panel when installed as, for example, a floor panel.
The present disclosure will by way of example be described in more detail with reference to the appended schematic drawings, which show examples of the present disclosure.
Specific embodiments of the disclosure will now be described with reference to the accompanying drawings. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the disclosure. In the drawings, like numbers refer to like elements. Generally, in this disclosure, terms like “below” or “lower” typically imply closer to the back surface of the panel or a plane thereof, whereas “above” or “upper” implies closer to the front surface or a plane thereof. Further, the thickness direction of the panel is defined as the vertical direction when the panel lays flat on a surface. The horizontal and vertical directions are the applicable definition when the building panel is laid flat on, e.g., a floor. Instead of horizontal and vertical directions, the description will also refer to a direction parallel with extension of the front surface of the building panel and a direction perpendicular to the extension of the front surface of the building panel. When a building panel lays flat on, e.g., a floor, the horizontal direction is the same as the direction parallel with the extension of the front surface of the building panel and the vertical direction is the same as the direction perpendicular to the extension of the front surface of the building panel.
By “horizontal plane” is meant a plane, which extends parallel to the outer main surface of the surface layer, or in examples wherein no surface layer is provided, a plane, which extends parallel to an upper surface of the substrate. Immediately juxta-posed upper parts of two adjacent joint edges of two joined building panels together define a “vertical plane”, perpendicular to the horizontal plane.
The term “panel” is intended to include both square panels, which may be referred to as tiles, and non-square panels.
In the present disclosure, “phr” means parts per hundred resin.
The method comprises extruding a substrate 2 through a die of an extruder 11. The substrate 2 may be extruded as one layer, or may comprise one or more extruded substrate layers forming the substrate 2. The extruded substrate layers may have different compositions. For example, at least one layer of the extruded substrate layers may be foamed.
The extruder 11 may in one example be a co-extruder (not shown), such that at least one substrate layer is co-extruded to another substrate layer, to form the substrate 2.
The substrate 2 comprises a thermoplastic material. The thermoplastic material may comprise thermoplastic polymers, such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof.
The substrate 2 may comprise the thermoplastic material in an amount of 10-40 wt %, such as 15-35 wt %.
The substrate 2 may further comprise an inorganic and/or organic filler, preferably in an amount exceeding 40 wt %, more preferably exceeding 60 wt %, such as 50-90 wt % or 60-80 wt %.
For example, the inorganic filler may be a mineral material, for example CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
A density of the substrate 2 may be 1000-2500 kg/m3, or a density of at least one of the extruded substrate layers may be 1000-2500 kg/m3.
The extruder 11 extrudes the substrate 2 in continuous form. The substrate 2 is in continuous form after having left the die of the extruder 11.
After the substrate 2 has left the die of the extruder 11, the substrate 2 may still have a temperature exceeding room temperature, such as a temperature at a surface of the substrate 2 exceeds 22° C., preferably exceeds 100° C.
The substrate 2 is conveyed between rollers of a roller arrangement 20. The roller arrangement 20 may comprise at least two rollers 21, 22, 23, 24.
A thermoplastic film 3 is laminated to a first surface 2a of the substrate 2. For example, the thermoplastic film 3 may be applied to the substrate 2 between the first and second roller 21, 22, or may be applied to the substrate 2 between the third and fourth roller 23, 24. In the example shown in
The thermoplastic film 3 may be continuously applied to the substrate 2. The thermoplastic film 3 may be applied to the substrate 2 in continuous form. The substrate 2 may be in continuous form when the thermoplastic film 3 is laminated to the substrate 2.
The thermoplastic film 3 is laminated to the substrate 2 by applying pressure to the thermoplastic film 3 and/or substrate 2, for example by the at least two rollers 21, 22, 23, 24.
Further, the thermoplastic film 3 is laminated to the substrate 2 at least partly by heat from the extruded substrate 2. For example, the first surface 2a of the substrate 2 may have temperature of 130-220° C., such as 160-210° C., such as 170-190° C., when the thermoplastic film 3 is laminated to the substrate 2.
The substrate 2 may remain at an elevated temperature, wherein the heat maintaining the substrate 2 at the elevated temperature originates from the extrusion process, or at least partially originates from the extrusion process.
Heat may also be added to the thermoplastic film 3, and/or the substrate 2.
The thermoplastic film 3 may be laminated to the substrate 2 in a continuous process, wherein the substrate 2 is continuous from the die of the extruder 11 to the lamination process wherein the thermoplastic film 3 is laminated to the substrate 2.
The thermoplastic film 3 may be laminated to the substrate 2 adjacent the extruder 11. The thermoplastic film 3 may be laminated to the substrate 2, e.g., advantageously no later than 30 minutes after the substrate 2 has left the die of the extruder 11, such as no later than 15 minutes or no later than 5 minutes after the substrate 2 has left the die.
The time after the die of the extruder 11 to the lamination is dependent on the length of the production line and/or the line speed. For a production line having a length exceeding 20 m and a line speed of approximately 1 m/min, the time from die to lamination may be close to 30 minutes. For a shorter production line and/or higher line speed, the time from die to lamination is reduced.
Heat may also be applied to the substrate 2 and/or the thermoplastic film 3, as an alternative or complement to heat originating from the extruded substrate 2. Heat may be applied by the at least two rollers 21, 22, 23, 24.
The thermoplastic film 3 may be laminated to the substrate 2 prior to cooling the substrate 2. The thermoplastic film 3 may be laminated to the substrate 2 in vicinity, for example in close vicinity, after the substrate 2 has passed the die of the extruder 11.
In the example shown in
However, it is within the scope of the present disclosure that a primer may be arranged between the first surface 2a of the substrate 2 and the thermoplastic film 3. It is within the scope of the present disclosure that one or more layer, such as one or more polymer-based layers, may be arranged between the first surface 2a of the substrate 2 and the thermoplastic film 3.
The thermoplastic film 3 may comprise a homopolymer such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof.
The thermoplastic film 3 may comprise copolymers such as PP/PE copolymer, PVC/PVAc copolymer, PET-G (polyethylene-terephthalate-glycol), ABS (acrylonitrile butadiene styrene), different polyamide grades, for example PA Dec. 6, 1966, and different polyester grades, for example Co-PET.
The thermoplastic film 3 may comprise one or more plasticizer. The total amount of plasticizer or plasticizers may be 0-50 phr, such as 0-35 phr, for example 0-10 phr.
The thermoplastic film 3 may comprise one or more plasticizer in an amount of 1-50 phr, such as 5-35 phr.
The thermoplastic film 3 may comprise, e.g., advantageously no more than 40 wt % plasticizer, such as less than 25 wt % plasticizer, for example, less than 10 wt % plasticizer. The thermoplastic film 3 may comprise one or more plasticizer in an amount of 0.5-40 wt %, such as 3-25 wt %.
The thermoplastic film 3 may comprise one or more fillers. The total amount of the filler or fillers may be 0-50 phr, such as 5-40 phr, for example 10-30 phr. The filler may be CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
The thermoplastic film 3 may further comprise stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents. The thermoplastic film 3 may have a composition according to examples listed in Table 1.
The thermoplastic film 3 may comprise at least one filler in an amount of 1-55 phr.
The thermoplastic film 3 may comprise at least one filler in an amount of 0.5-50 wt %, such as 0.5-25 wt %.
The thermoplastic film 3 may be pigmented. Pigments may be chosen to match the décor to be printed on the thermoplastic film 3 in a later step of the process. In one example, the thermoplastic film 3 comprises titanium dioxide. Titanium dioxide is an example of a white pigment. Other pigments may be calcium carbonate, talc, zinc sulphide, barium sulphate.
Pigments may have a similar function as a filler, and may therefore be included in the term “filler” if present. The fillers, including pigments and non-pigments, may be included in the thermoplastic film in an amount of 1-55 phr.
The thermoplastic film 3 may further comprise a reinforcement, such as a fibre reinforcement, such as glass fibre reinforcement. The fibres may be carbon fibres, aramid fibres, and/or basalt fibres.
The thermoplastic film 3 may have a thickness t1 being equal to or exceeding 0.05 mm, such that having a thickness of 0.05-1 mm, for example 0.05-0.55 mm or 0.07-0.3 mm.
In the example shown in
After having left the roller arrangement 20, the substrate 2 with the laminated thermoplastic film 3 is still in continuous form. However, the substrate 2 with the laminated thermoplastic film 3 may be divided into board element members 10 by a cutting arrangement 40. The size of the board element member 10 may exceed a size of a panel 100, such that the board element member 10 may be divided into two or more panels 100 in a later step. The board element member 10 may have a length corresponding to a length of the panel 100 to be formed but have a width corresponding to a width of two or more panels 100 to be formed. In another example, the substrate 2 with the laminated thermoplastic film 3 may be cut directly to a shape and size corresponding to a panel 100.
The board element member 10 is conveyed to a digital printing device 50. The digital printing device 50 may be an inkjet printer, such as a piezo-electric DOD (Drop on Demand) inkjet printer. In another example, a thermal DOD inkjet printer may be used. The ink may be an aqueous ink, a UV curable ink, and/or a solvent based ink. The digital printing device 50 may comprise at least one print head. The print may be applied in a contactless manner. CMYK and/or spot colours may be used.
The digital printing device 50 is configured to print a décor on the thermoplastic film 3. The décor is printed on a surface of the thermoplastic film 3 by the digital printing device 50. The surface of the thermoplastic film 3 configured to be printed is facing away from the substrate 2.
It is within the scope of the present disclosure that a print primer is applied to the surface of the thermoplastic film 3 intended to be printed prior to printing. Such a print primer is configured to improve printing, improve bonding between ink and surface, and/or increase wettability of the surface. Such a print primer is different from a thermoplastic film, thermoplastic foil, paper, or any other kind of layer. As an alternative or complement to a print primer, the surface of the thermoplastic film intended to be printed may be pre-treated a by a corona, plasma or flame treatment.
After the thermoplastic film 3 has been digitally printed, a coating is applied directly on the printed surface of the thermoplastic film 3. The coating may be applied by a coating device 60, such as roller coating, curtain coating and/or spray coating.
The coating applied may be UV curable coating. The coating may comprise acrylate oligomers, methacrylate oligomers, and/or unsaturated polyester. In one example, the coating applied may be an EB curable coating. The coating may be applied in an amount of 40-240 g/m2, such as 45-210 g/m2, such as 55-180 g/m2.
The coating applied may form a coating layer 5 arranged on the printed surface of the thermoplastic film 3. The coating layer 5 may cover the printed surface of the thermoplastic film 3. The coating layer may be continuous over the printed surface of the thermoplastic film 3.
In a further step (not shown), the coating is cured, for example by UV curing or EB curing, depending on the type of coating applied. A thickness of the coating layer 5 may be 35-300 μm, such as 45-220 μm, such as 50-180 μm.
A board element 1, or a board element member 10, is thereby formed. The board element 1, or the board element member 10, comprises the substrate 2, the thermoplastic layer 3 and the coating layer 5, as shown in
The digital printing device 50, or an additional digital printing device (not shown), may, in addition to printing a décor on the thermoplastic film 3, print an embossed structure on the printed surface of the thermoplastic film 3. The digital printing device may digitally print a substance on the printed surface of the thermoplastic film 3, wherein the substance is configured to form an embossed structure. In one example, the substance is cured to form the embossed structure. If an embossed structure is provided on the printed of the thermoplastic film 3, the coating is applied on the embossed structure of the printed of the thermoplastic film 3.
The process shown in
The method comprises extruding a substrate 2 through a die of an extruder 11, similar to the method described above with reference to
The extruder 11 may in one example be a co-extruder (not shown), such that at least one substrate layer is co-extruded to another substrate layer, to form the substrate 2.
The substrate 2 comprises a thermoplastic material. The thermoplastic material may comprise thermoplastic polymers, such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof. The substrate 2 may comprise the thermoplastic material in an amount of 10-40 wt %, such as 15-35 wt %. The substrate 2 may further comprise an inorganic or organic filler, preferably in an amount exceeding 40 wt %, more preferably exceeding 60 wt %, such as 50-90 wt % or 60-80 wt %. For example, the inorganic filler may be a mineral material, for example CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
A density of the substrate 2 may be 1000-2500 kg/m3, or a density of at least one of the extruded substrate layers may be 1000-2500 kg/m3.
The extruder 11 extrudes the substrate 2 in continuous form. The substrate 2 is in continuous form after having left the die of the extruder 11.
After the substrate 2 has left the die of the extruder 11, the substrate 2 may still have a temperature exceeding room temperature. The first surface 2a of the substrate 2 may have a temperature exceeding 50° C., such as exceeding 100° C.
The substrate 2 is conveyed between rollers of a roller arrangement 30. The roller arrangement may comprise at least two pair of rollers 31, 32, 33, 34, 35, 36.
In the method shown in
The substrate 2 may remain at an elevated temperature, wherein the heat maintaining the substrate 2 at the elevated temperature originates from the extrusion process, or at least partially originates from the extrusion process.
Heat may also be added to the thermoplastic film 3, and/or the substrate 2.
The thermoplastic film 3 is laminated to a first surface 2a of the substrate 2. In the example shown in
The thermoplastic film 3 may be laminated to the substrate 2, e.g., advantageously no later than 30 minutes after the substrate 2 has left the die, such as no later than 15 minutes or no later than 5 minutes after the substrate 2 has left the die, dependent on the length of the production line and/or line speed as described above.
The thermoplastic film 3 may be continuously applied to the substrate 2. The thermoplastic film 3 may be applied to the substrate 2 in continuous form. The substrate 2 may be in continuous form when the thermoplastic film 3 is laminated to the substrate 2.
The thermoplastic film 3 is laminated to the substrate 2 by applying pressure to the thermoplastic film 3 and/or substrate 2, for example by the second pair of rollers 33, 34.
Further, the thermoplastic film 3 is laminated to the substrate 2 at least partly by heat from the extruded substrate 2. For example, the first surface 2a of the substrate 2 may have temperature of 130-220° C., such as 160-210° C., such as 170-190° C., when the thermoplastic film 3 is laminated to the substrate 2.
Heat may also be applied to the substrate 2 and/or the thermoplastic film 3, as an alternative or complement to heat originating from the extruded substrate 2. Heat may be applied by the second pair of rollers 33, 34.
The substrate 2 with the thermoplastic film 3 laminated thereto may be further calibrated by the third pair of rollers 35, 36.
The thermoplastic film 3 may be laminated to the substrate 2 prior to cooling the substrate 2. The thermoplastic film 3 may be laminated to the substrate in close vicinity after the substrate 2 has passed the die of the extruder 11.
In the example shown in
However, it is within the scope of the present disclosure that a primer may be arranged between the first surface 2a of the substrate 2 and the thermoplastic film 3. It is within the scope of the present disclosure that one or more layer, such as one or more polymer-based layers, may be arranged between the first surface 2a of the substrate 2 and the thermoplastic film 3.
The thermoplastic film 3 may comprise a homopolymer such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof.
The thermoplastic film 3 may comprise a copolymer such as PP/PE copolymer, PVC/PVAc copolymer, PET-G (polyethylene-terephthalate-glycol), ABS (acrylonitrile butadiene styrene), different polyamide grades, for example, PA Dec. 6, 1966, and different polyester grades, for example, Co-PET.
The thermoplastic film 3 may comprise one or more plasticizers. The total amount of plasticizer or plasticizers may be 0-50 phr, such as 0-35 phr, for example 0-10 phr.
The thermoplastic film 3 may comprise one or more plasticizer in an amount of 1-50 phr, such as 5-35 phr.
The thermoplastic film 3 may comprise, e.g., advantageously no more than 40 wt % plasticizer, such as less than 25 wt % plasticizer, for example, less than 10 wt % plasticizer. The thermoplastic film 3 may comprise one or more plasticizer in an amount of 0.5-40 wt %, such as 3-25 wt %.
The thermoplastic film 3 may comprise one or more fillers. The total amount of the filler or fillers may be 0-50 phr, such as 5-40 phr, for example 10-30 phr.
The thermoplastic film 3 may comprise at least one filler in an amount of 1-55 phr.
The thermoplastic film 3 may comprise at least one filler in an amount of 0.5-50 wt %, such as 0.5-25 wt %.
The filler may be CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
The thermoplastic film 3 may further comprise stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents. The thermoplastic film 3 may have a composition according to examples listed in Table 1.
The thermoplastic film 3 may be pigmented. Pigments may be chosen to match the décor to be printed on the thermoplastic film 3 in a later step of the process. In one example, the thermoplastic film 3 comprises titanium dioxide. Titanium dioxide is an example of a white pigment. Other pigments, such as calcium carbonate, talc, zinc sulphide, barium sulphate, may be included.
Pigments may have a similar function as a filler, and may therefore be included in the term “filler” if present. The fillers, including pigments and non-pigments, may be included in the thermoplastic film in an amount of 1-55 phr.
The thermoplastic film 3 may further comprise a reinforcement, such as a fibre reinforcement, such as glass fibre reinforcement. The fibres may be carbon fibres, aramid fibres, and/or basalt fibres.
The thermoplastic film 3 may have a thickness t1 being equal to or exceeding 0.05 mm, such that having a thickness of 0.05-1 mm, for example 0.05-0.55 mm or 0.07-0.3 mm.
In the example shown in
After having left the roller arrangement 30, the substrate 2 with the laminated thermoplastic film 3 is still in continuous form. However, the substrate 2 with the laminated thermoplastic film 3 may be divided into board element members 10 by a cutting arrangement 40. The size of the board element member 10 may exceed a size of a panel 100, such that the board element member 10 may be divided into two or more panels 100. The board element member 10 may have a length corresponding to a length of the panel 100 to be formed but have a width corresponding to a width of two or more panels 100 to be formed.
In another example, the substrate 2 with the laminated thermoplastic film 3 may be cut directly to a shape and size corresponding to a panel.
The board element member 10 is conveyed to a digital printing device 50. The digital printing device 50 may be an inkjet printer, such as a piezo-electric DOD (Drop on Demand) inkjet printer. The digital printing device 50 may be an inkjet printer, such as a piezo-electric DOD (Drop on Demand) inkjet printer. In another example, a thermal DOD inkjet printer may be used. The ink may be an aqueous ink, a UV curable ink, and/or a solvent based ink. The digital printing device 50 may comprise at least one print head. The print may be applied in a contactless manner. CMYK and/or spot colours may be used.
The digital printing device 50 is configured to print a décor on the thermoplastic film 3. The décor is printed on a surface of the thermoplastic film 3 by the digital printing device 50. The surface of the thermoplastic film 3 configured to be printed is facing away from the substrate 2.
It is within the scope of the present disclosure that a print primer is applied to the surface of the thermoplastic film 3 intended to be printed prior to printing. Such a print primer is configured to improve printing, improve bonding between ink and surface, and/or increase wettability of the surface. Such a print primer is different from a thermoplastic film or foil. As an alternative or complement to a print primer, the surface of the thermoplastic film intended to be printed may be pre-treated a by a corona, plasma or flame treatment.
After the thermoplastic film 3 has been digitally printed, a coating is applied directly on the printed surface of the thermoplastic film 3. The coating may be applied by a coating device 60, such as roller coating, curtain coating and/or spray coating.
The coating applied may be UV curable coating. The coating may comprise acrylate oligomers, methacrylate oligomers, and/or unsaturated polyester. In one example, the coating applied may be an EB curable coating. The coating may be applied in an amount of 40-240 g/m2, such as 45-210 g/m2, such as 55-180 g/m2.
The coating applied may form a coating layer 5 arranged on the printed surface of the thermoplastic film 3. The coating layer 5 may cover the printed surface of the thermoplastic film 3. The coating layer may be continuous over the printed surface of the thermoplastic film 3.
In a further step (not shown), the coating is cured, for example by UV curing or EB curing, depending on the type of coating applied. A thickness of the coating layer 5 may be 35-300 μm, such as 45-220 μm, such as 50-180 μm.
A board element 1, or a board element member 10, is thereby formed. The board element 1, or the board element member 10, comprises the substrate 2, the thermoplastic layer 3 and the coating layer 5, as shown in
The digital printing device 50, or an additional digital printing device (not shown), may, in addition to printing a décor on the thermoplastic film 3, print an embossed structure on the printed surface of the thermoplastic film 3. The digital printing device may digitally print a substance on the printed surface of the thermoplastic film 3, wherein the substance is configured to form an embossed structure. In one example, the substance is cured to form the embossed structure. If an embossed structure is provided on the printed of the thermoplastic film 3, the coating is applied on the embossed structure of the printed of the thermoplastic film 3.
The board element 1 comprises the extruded substrate 2, comprising one or more substrate layers. In
The substrate 2 comprises a thermoplastic material. The thermoplastic material may comprise thermoplastic polymers, such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAC, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof. The substrate 2 may comprise the thermoplastic material in an amount of 10-40 wt %, such as 15-35 wt %. If a combination of thermoplastic materials are included, the amount refers to the total amount of thermoplastic materials.
The substrate 2 may further comprise an inorganic or organic filler, preferably in an amount exceeding 40 wt %, more preferably exceeding 60 wt %, such as 50-90 wt % or 60-80 wt %. If two or more fillers are included, the amount refers to the total amount of fillers. For example, the inorganic filler may be a mineral material, for example CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
The thickness of the substrate 2 may be 3-15 mm, for example 3-10 mm, such as 3.5-7 mm.
A density of the substrate 2 may be 1000-2500 kg/m3, or a density of at least one of the extruded substrate layers, may be 1000-2500 kg/m3. The substrate layers may have different compositions. At least one substrate layer may be foamed, or the substrate may be foamed.
A reinforcement layer or backing layer 4 is adhered to the second surface 2b of the substrate. The board element 1 may in other examples have no reinforcement layer or backing layer.
The printed thermoplastic film 3 is arranged on the first surface 2a of the substrate 2. The printed thermoplastic film 3 may be directly arranged on the first surface 2a of the substrate 2. In other examples, a primer may be present, for example to enhance adhesion to the substrate 2. The digitally printed décor is indicated by reference number 6 on the surface of the thermoplastic film 3, facing away from the substrate 2.
The printed thermoplastic film 3, coated by the coating layer 5, is configured to form the surface layer of the panel 100 when installed in a room.
The printed thermoplastic film 3 may comprise a homopolymer such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof.
The printed thermoplastic film 3 may comprise a copolymer such as PP/PE copolymer, PVC/PVAc copolymer, PET-G (polyethylene-terephthalate-glycol), ABS (acrylonitrile butadiene styrene), different polyamide grades, and different polyester grades.
The thermoplastic film 3 may comprise one or more plasticizers in an amount of 0-50 phr, such as 0-35 phr, for example 0-10 phr. If two or more plasticizers are included, the amount refers to the total amount of plasticizers.
The thermoplastic film 3 may comprise one or more plasticizer in an amount of 1-50 phr, such as 5-35 phr.
The thermoplastic film 3 may comprise, e.g., advantageously no more than 40 wt % plasticizer, such as less than 25 wt % plasticizer, for example, less than 10 wt % plasticizer. The thermoplastic film 3 may comprise one or more plasticizer in an amount of 0.5-40 wt %, such as 3-25 wt %.
The printed thermoplastic film 3 may comprise one or more filler in an amount of 0-50 phr, such as 5-40 phr, for example 10-30 phr. If two or more fillers are included, the amount refers to the total amount of fillers. The filler may be CaCO3, limestone, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
The thermoplastic film 3 may further comprise stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents. The thermoplastic film 3 may have a composition according to examples listed in Table 1.
The printed thermoplastic film 3 may be pigmented. Pigments may be chosen to match the décor to be printed on the thermoplastic film. In one example, the thermoplastic film 3 comprises titanium dioxide. Titanium dioxide is an example of a white pigment. Other pigments, such as calcium carbonate, talc, zinc sulphide, barium sulphate, may be included.
Pigments may have a similar function as a filler, and may therefore be included in the term “filler” if present. The fillers, including pigments and non-pigments, may be included in the thermoplastic film in an amount of 1-55 phr.
The thermoplastic film 3 may further comprise a reinforcement, such as a fibre reinforcement, such as glass fibre reinforcement. The fibres may be carbon fibres, aramid fibres, and/or basalt fibres.
The printed thermoplastic film 3 may have a thickness t1 being equal to or exceeding 0.05 mm, such that having a thickness of 0.05-1 mm, for example 0.05-0.55 mm or 0.07-0.3 mm.
The thermoplastic film 3 may also be referred to as a print layer or a cover layer.
The coating layer 5 is adhered directly to the printed thermoplastic film 3. The coating layer 5 may comprise an UV curable coating. The coating layer 5 may comprise acrylate oligomers, methacrylate oligomers, and/or unsaturated polyester. In other example, the coating layer 5 may comprise an EB curable coating. The coating may be applied in an amount of 40-240 g/m2, such as 45-210 g/m2, such as 55-180 g/m2.
The coating layer 5 may cover the printed surface of the thermoplastic film 3. The coating layer 5 may be continuous over the printed surface of the thermoplastic film 3. The coating layer 5 may comprise wear resistant particles such as corundum. A thickness of the coating layer 5 may be 35-300 μm, such as 45-220 μm, such as 50-180 μm.
The method comprises extruding a substrate 2 through a die of an extruder 11. The substrate 2 may be extruded as one layer, or may comprise one or more extruded substrate layers forming the substrate 2. The extruded substrate layers may have different compositions. For example, at least one layer of the extruded substrate layers may be foamed. In one example, the substrate 2 is extruded as one layer and the substrate 2 is foamed.
The extruder 11 may in one example be a co-extruder (not shown), such that at least one substrate layer is co-extruded to another substrate layer, to form the substrate 2.
The extruder 11 extrudes the substrate 2 in continuous form. The substrate 2 is in continuous form after the die of the extruder 11.
After the substrate 2 has left the die of the extruder 11, the substrate 2 may still have a temperature exceeding room temperature.
The substrate 2 comprises a thermoplastic material. The thermoplastic material may comprise thermoplastic polymers, such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAC, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof. The substrate 2 may comprise the thermoplastic material in an amount of 10-40 wt %, such as 15-35 wt %.
The substrate 2 may further comprise an inorganic or organic filler, preferably in an amount exceeding 40 wt %, more preferably exceeding 60 wt %, such as 50-90 wt % or 60-80 wt %. For example, the inorganic filler may be a mineral material, for example CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
A density of the substrate 2 may be 1000-2500 kg/m3, or a density of at least one of the extruded substrate layers may be 1000-2500 kg/m3.
In the example shown in
In alternative examples, the top substrate layer 2c may be adhered to the extruded substrate 2 by an adhesive. In further examples, the top substrate layer 2c may be formed by a plastisol.
The top substrate layer 2c may comprise a plasticized thermoplastic material, such as plasticized PVC.
A thermoplastic film 3 is laminated to the extruded substrate 2. The thermoplastic film 3 may be laminated directly to the extruded substrate 2. In the example shown in
The thermoplastic film 3 may be laminated to the substrate 2 by a second roller 72 of the roller arrangement.
The thermoplastic film 3 may be continuously applied to the substrate 2. The thermoplastic film 3 may be applied to the substrate 2 in continuous form. The substrate 2 may be in continuous form when the thermoplastic film 3 is laminated to the substrate 2.
The thermoplastic film 3 is laminated to the substrate 2 by applying pressure to the thermoplastic film 3 and/or substrate 2, for example by the second roller 71.
The thermoplastic film 3 is laminated to the substrate 2 at least partly by heat from the extruded substrate. For example, the surface of the substrate 2 may have temperature of 120-180° C., such as 130-170° C., such as 140-160° C., when the thermoplastic film 3 is laminated to the substrate 2.
The substrate 2 may remain at an elevated temperature, wherein the heat maintaining the substrate 2 at the elevated temperature originates from the extrusion process, or at least partially originates from the extrusion process.
Heat may also be applied to the substrate 2 and/or the thermoplastic film 3, as an alternative or complement to heat originating from the extruded substrate 2. Heat may be applied by the second roller 71.
The thermoplastic film 3 may be laminated to the substrate 2 prior to cooling the substrate 2 in a cooling zone 80 as shown in
In one example, the substrate 2 may pass a cooling zone after the extruder 11 to stop any foaming process in the substrate 2. The substrate 2 may be cooled to a temperature below 140° C. prior to laminating the thermoplastic film 3 to the substrate 2. Even if the substrate 2 has passed a cooling zone after the extruder 11, the substrate 2 may still have a temperature above room temperature, i.e. above 22° C., such as having a temperature exceeding 50° C. at its surface.
The thermoplastic film 3 may be laminated to the substrate 2, e.g., advantageously no later than 30 minutes after the substrate 2 has left the die, such as no later than 15 minutes or no later than 5 minutes after the substrate 2 has left the die, dependent on the length of the production line and/or line speed as described above.
The thermoplastic film 3 may comprise a homopolymer such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof.
The thermoplastic film 3 may comprise a copolymer such as PP/PE copolymer, PVC/PVAc copolymer, PET-G (polyethylene-terephthalate-glycol), ABS (acrylonitrile butadiene styrene), different polyamide grades and different polyester grades.
The thermoplastic film 3 may comprise one or more plasticizers in an amount of 0-50 phr, such as 0-35 phr, for example 0-10 phr. If two or more plasticizers are included, the amount refers to the total amount of plasticizers.
The thermoplastic film 3 may comprise one or more plasticizer in an amount of 1-50 phr, such as 5-35 phr.
The thermoplastic film 3 may comprise, e.g., advantageously no more than 40 wt % plasticizer, such as less than 25 wt % plasticizer, for example, less than 10 wt % plasticizer. The thermoplastic film 3 may comprise one or more plasticizer in an amount of 0.5-40 wt %, such as 3-25 wt %.
The thermoplastic film 3 may comprise one or more filler in an amount of 0-50 phr, such as 5-40 phr, for example 10-30 phr. If two or more fillers are included, the amount refers to the total amount of fillers. The filler may be CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
The thermoplastic film 3 may further comprise stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents. The thermoplastic film 3 may have a composition according to examples listed in Table 1.
The thermoplastic film 3 may be pigmented. Pigments may be chosen to match the décor to be printed on the thermoplastic film 3 in a later step of the process. In one example, the thermoplastic film 3 comprises titanium dioxide. Titanium dioxide is an example of a white pigment. Other pigment such as calcium carbonate, talc, zinc sulphide, barium sulphate, may be included.
Pigments may have a similar function as a filler, and may therefore be included in the term “filler” if present. The fillers, including pigments and non-pigments, may be included in the thermoplastic film in an amount of 1-55 phr.
The thermoplastic film 3 may further comprise a reinforcement, such as a fibre reinforcement, such as glass fibre reinforcement. The fibres may be carbon fibres, aramid fibres, and/or basalt fibres.
The thermoplastic film 3 may have a thickness t1 being equal to or exceeding 0.05 mm, such that having a thickness of 0.05-1 mm, for example 0.05-0.55 mm or 0.07-0.3 mm.
In the example shown in
After having left the roller arrangement and the cooling zone 80, the substrate 2 with the laminated thermoplastic film 3 is still in continuous form. However, the substrate 2 with the laminated thermoplastic film 3 may be divided into board element members 10 by a cutting arrangement 40. The size of the board element member 10 may exceed a size of a panel 100, such that the board element member 10 may be divided into two or more panels 100. The board element member 10 may have a length corresponding to a length of the panel 100 to be formed but have a width corresponding to a width of two or more panels 100 to be formed.
In another example, the substrate 2 with the laminated thermoplastic film 3 may be cut directly to a shape and size corresponding to a panel.
The board element member 10 is conveyed to a digital printing device 50. The digital printing device 50 may be an inkjet printer, such as a piezo-electric DOD (Drop on Demand) inkjet printer. In another example, a thermal DOD inkjet printer may be used. The ink may be an aqueous ink, a UV curable ink, and/or a solvent based ink. The digital printing device 50 may comprise at least one print head. The print may be applied in a contactless manner. CMYK and/or spot colours may be used.
The digital printing device 50 is configured to print a décor on the thermoplastic film 3. The décor is printed on a surface of the thermoplastic film 3 by the digital printing device 50. The surface of the thermoplastic film 3 configured to be printed is facing away from the substrate 2.
It is within the scope of the present disclosure that a print primer is applied to the surface of the thermoplastic film 3 intended to be printed prior to printing. Such a print primer is configured to improve printing, improve bonding between ink and surface, and/or increase wettability of the surface. Such a print primer is different from a thermoplastic film or foil. As an alternative or complement to a print primer, the surface of the thermoplastic film intended to be printed may be pre-treated a by a corona, plasma or flame treatment.
After the thermoplastic film 3 has been digitally printed, a coating is applied directly on the printed surface of the thermoplastic film 3. The coating may be applied by a coating device 60, such as roller coating, curtain coating and/or spray coating.
The coating applied may be a UV curable coating. The coating may comprise acrylate oligomers, methacrylate oligomers, and/or unsaturated polyester. In one example, the coating applied may be an EB curable coating. The coating may be applied in an amount of 40-240 g/m2, such as 45-210 g/m2, such as 55-180 g/m2.
The coating applied may form a coating layer 5 arranged on the printed surface of the thermoplastic film 3. The coating layer 5 may cover the printed surface of the thermoplastic film 3. The coating layer may be continuous over the printed surface of the thermoplastic film 3.
In a further step (not shown), the coating is cured, for example by UV curing or EB curing, depending on the type of coating applied. A thickness of the coating layer 5 may be 35-300 μm, such as 45-220 μm, such as 50-180 μm.
A board element 1, or a board element member 10, is thereby formed. The board element 1, or the board element member 10, comprises the substrate 2, the thermoplastic layer 3 and the coating layer 5, as shown in
The digital printing device 50, or an additional digital printing device (not shown), may, in addition to printing a décor on the thermoplastic film 3, print an embossed structure on the printed surface of the thermoplastic film 3. The digital printing device may digitally print a substance on the printed surface of the thermoplastic film 3, wherein the substance is configured to form an embossed structure. In one example, the substance is cured to form the embossed structure. If an embossed structure is provided on the printed of the thermoplastic film 3, the coating is applied on the embossed structure of the printed of the thermoplastic film 3.
In an alternative method, the substrate 2 is not divided into board element members 10 prior to printing by the digital printing device 50. The thermoplastic film 3 may be printed when the substrate 2 with the thermoplastic film 3 laminated thereto is in continuous form, similarly to the disclosure in
The board element 1 comprises the extruded substrate 2. The extruded substrate 2 may be foamed, or at least one substrate layer may be foamed. The substrate 2 may comprise one or more substrate layers.
The substrate 2 comprises a top substrate layer 2c. The top substrate layer 2c is adhered to the extruded substrate 2 by lamination, or by an adhesive. The top substrate layer 2c may comprise a plasticized thermoplastic material, such as plasticized PVC, or a plastisol. A surface of the top substrate layer 2c facing away from the substrate 2 forms the first surface 2a of the substrate 2.
The substrate 2 comprises a thermoplastic material. The thermoplastic material may comprise thermoplastic polymers, such as PVC, PE, PP, TPU, PET, EVA, PA PS, PVAC, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof. The substrate 2 may comprise the thermoplastic material in an amount of 10-40 wt %, such as 15-35 wt %. If two or more thermoplastic materials are included, the amount refers to the total amount of thermoplastic materials. The substrate 2 may further comprise an inorganic or organic filler, preferably in an amount exceeding 40 wt %, more preferably exceeding 60 wt %, such as 50-90 wt % or 60-80 wt %. If two or more fillers are included, the amount refers to the total amount of fillers. For example, the inorganic filler may be a mineral material, for example CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
The thickness of the substrate 2 may be 3-15 mm, for example 3-10 mm, such as 3.5-7 mm.
A density of the substrate 2 may be 1000-2500 kg/m3, or a density of at least one of the extruded substrate layers may be 1000-2500 kg/m3.
A reinforcement layer or backing layer 4 is adhered to the second surface 2b of the substrate. The board element 1 may in other examples have no reinforcement layer or backing layer.
The printed thermoplastic film 3 is arranged on the top substrate layer 2c of the substrate 2. The printed thermoplastic film 3 may be directly arranged on the top substrate layer 2c of the substrate 2. In other examples, a primer may be present, for example to enhance adhesion to the top substrate layer 2c.
The printed thermoplastic film 3 may comprise a homopolymer PVC, PE, PP, TPU, PET, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a combination thereof
The printed thermoplastic film 3 may comprise a copolymer such as PP/PE copolymer, PVC/PVAc copolymer, PET-G (polyethylene-terephthalate-glycol), ABS (acrylonitrile butadiene styrene), different polyamide grades and different polyester grades.
The thermoplastic film 3 may comprise one or more plasticizers in an amount of 0-50 phr, such as 0-35 phr, for example 0-10 phr. If two or more plasticizers are included, the amount refers to the total amount of plasticizers.
The thermoplastic film 3 may comprise one or more plasticizer in an amount of 1-50 phr, such as 5-35 phr.
The thermoplastic film 3 may comprise, e.g., advantageously no more than 40 wt % plasticizer, such as less than 25 wt % plasticizer, for example, less than 10 wt % plasticizer. The thermoplastic film 3 may comprise one or more plasticizer in an amount of 0.5-40 wt %, such as 3-25 wt %.
The printed thermoplastic film 3 may comprise one or more filler in an amount of 0-50 phr, such as 5-40 phr, for example 10-30 phr. If two or more fillers are included, the amount refers to the total amount of fillers.
The thermoplastic film 3 may comprise at least one filler in an amount of 1-55 phr.
The thermoplastic film 3 may comprise at least one filler in an amount of 0.5-50 wt %, such as 0.5-25 wt %.
The filler may be CaCO3, talc, fly ash, or a stone material, such as stone powder. Examples of CaCO3 may be limestone, marble, and chalk.
The thermoplastic film 3 may further comprise stabilizer, lubricants, process aids, pigment, modifiers, and/or other additives such as UV absorbents. The thermoplastic film 3 may have a composition according to examples listed in Table 1.
The printed thermoplastic film 3 may be pigmented. Pigments may be chosen to match the décor to be printed on the thermoplastic film. In one example, the thermoplastic film 3 comprises titanium dioxide. Titanium dioxide is an example of a white pigment. Other pigments, such as calcium carbonate, talc, zinc sulphide, barium sulphate, may be included.
Pigments may have a similar function as a filler, and may therefore be included in the term “filler” if present. The fillers, including pigments and non-pigments, may be included in the thermoplastic film in an amount of 1-55 phr.
The printed thermoplastic film 3 may further comprise a reinforcement, such as a fibre reinforcement, such as glass fibre reinforcement. The fibres may be carbon fibres, aramid fibres, and/or basalt fibres.
The printed thermoplastic film 3 may have a thickness t1 being equal to or exceeding 0.05 mm, such that having a thickness of 0.05-1 mm, for example 0.05-0.55 mm or 0.07-0.3 mm.
The thermoplastic film 3 may also be referred to as a print layer or a cover layer.
The coating layer 5 is adhered directly to the printed thermoplastic film 3. The coating layer 5 may comprise an UV curable coating. The coating layer 5 may comprise acrylate oligomers, methacrylate oligomers, and/or unsaturated polyester. In other example, the coating layer 5 may comprise an EB curable coating. The coating may be applied in an amount of 40-240 g/m2, such as 45-210 g/m2, such as 55-180 g/m2.
The coating layer 5 may cover the printed surface of the thermoplastic film 3. The coating layer 5 may be continuous over the printed surface of the thermoplastic film 3. The coating layer 5 may comprise wear resistant particles such as corundum. A thickness of the coating layer 5 may be 35-300 μm, such as 45-220 μm, such as 50-180 μm.
Common for all method disclosed above is that the board element 1, or the board element member 10 may be divided into panels 100. The panels 100 may be provided with a mechanical locking system, which will be further described with reference to
Compared to printing directly on a substrate, the thermoplastic film 3, which may form a cover layer on the substrate 2, improves the strength of the locking system. The thermoplastic film 3 at least reduces the risk of damages on the mechanical locking system when the panels, for example forming a flooring, is exposed to static and/or dynamic forces. By printing on the thermoplastic film 3, the panel 100 becomes less brittle and the mechanical locking system is at least partly less prone to damage and breaking.
A stiffer and/or more rigid printed thermoplastic film at least reduces the risk of damages on the mechanical locking system compared to a conventional wear layer, being softer compared to the thermoplastic film of the present disclosure. For example, the thermoplastic film 3 may comprise less plasticizer compared to a conventional wear layer. Further, the thermoplastic film 3 may comprise fillers, such as calcium carbonate, talc or lime, making the thermoplastic film stiffer and/or more rigid compared to a conventional wear layer. The thermoplastic film 3 may comprise pigments, which may make the thermoplastic film stiffer and/or more rigid compared to a conventional wear layer. A conventional wear layer does not include filler, such as calcium carbonate, talc or lime and/or pigments since such components would negatively influence the transparency of the wear layer.
In one example of the present disclosure, the board element 1, the board element member 10, or the panel 100 consists of the substrate 2, the printed thermoplastic film 3 and the coating layer 6, optionally with the backing layer or reinforcement layer 4.
In one example, the term “first long side edge” may be referred to as a first edge, “second long side edge” may be referred to as a second edge, “first short side edge” may be referred to as a third edge, “second short side edge” may be referred to as fourth edge. The first edge and the second edge may be opposite edges. The third edge and the fourth edge may be opposite edges.
The mechanical locking system may also be referred to as a mechanical locking device.
The panel 100, 100′, 100″ may be provided with a mechanical locking system of a first type along long side edges, configured to join the long side edge of a third panel 100″ to a long side edge of an adjacent, first panel 100, as shown in
The panel 100, 100′, 100″ comprises along a first long side edge 101 an insertion groove 111 and a locking strip 115. The insertion groove 111 may also be referred to as a tongue groove 111. The panel 100, 100′, 100″ comprises along a second long side edge 102 a tongue 112 and a locking groove 116.
The panel 100, 100′, 100″ comprises along a first short side edge 103 an insertion groove 111 and a locking strip 115. The insertion groove 111 may also be referred to as a tongue groove 111. The panel 100, 100′, 100″ comprises along a second short side edge 104 a displacement groove 121 and a locking groove 116. A displaceable tongue 120 may be arranged in the insertion groove 111 and/or the displacement groove 121.
The mechanical locking system may be described as comprising a first mechanical locking system and a second mechanical locking system. The first mechanical locking system may be configured to horizontally and vertically lock the first long side edge 101 of the panel 100 to the second long side edge 102″ of the adjacent panel 100″.
The second mechanical locking system may be configured to horizontally and vertically lock the first short side edge 104″ of the panel 100″ to the second short side edge 103″ of the adjacent panel 100′. Any disclosure relating to the panel 100 also relates to the first panel 100, a second panel 100′ and a third panel 100″. The panel 100 and at least one adjacent panel 100′, 100″ may be referred to as a set of panels, comprising the first panel 100, the second panel 100′ and/or the third panel 100″.
The panels 100, 100′, 100″ have an extension in a length direction L, in a width direction W, and in a vertical direction V, as illustrated in
The mechanical locking system disclosed in
The mechanical locking system disclosed in
The thermoplastic film 3 has a thickness t1 in a direction perpendicular to the plane of the first surface 2a of the substrate 2. The direction perpendicular to the plane of the first surface 2a of the substrate 2 is a vertical direction V in
The substrate 2 may have a thickness of 3-15 mm, for example 3-10 mm, such as 3.5-7 mm in a direction perpendicular to the plane of the first surface of the substrate, i.e., in the vertical direction V in
The panel 100 comprises along its first long side edge 101 an insertion groove 111 and a locking strip 115. The insertion groove 111 extends into the substrate 2 from the first long side edge 101. The insertion groove 111 extends along the first long side edge 101. The locking strip 115 protrudes from the first long side edge 101. The locking strip 115 extends along the first long side edge 101.
The adjacent, second panel 100′ comprises along its second long side edge 102′ a tongue 112 and a locking groove 116. The tongue 112 protrudes from the second long side edge 102′. The tongue 112 extends along the second long side edge 102′. The locking groove 116 extends into the substrate 2 from the second surface 2b of the substrate 2. The locking groove 116 extends along the second long side edge 102′.
The tongue 112 is configured to be received in the insertion groove 111, such that a locking surface 114 of the tongue 112 is cooperating with a locking surface 113 of the insertion groove 111 for locking the panels 100, 100′ in a vertical direction. The locking strip 115 has a locking element 119 configured to be received in the locking groove 116, such that a locking surface 117 of the locking element 119 is cooperating with a locking surface 118 of the locking groove 116 for locking the panels 100, 100′ in a horizontal direction.
The insertion groove 111 is extending into the substrate 2 from the edge of the panel 100.
Consequently, the first mechanical locking system may comprise the locking strip 115 having the locking element 119 configured to be received in the locking groove 116 for locking the panels 100, 100′ in the horizontal direction, and the tongue 112 configured to be received in the insertion groove 111 for locking the panels 100, 100′ in the vertical direction.
A minimum insertion groove distance d1 is defined as a shortest distance between the first surface 2a of the substrate 2 to the insertion groove 111 in the direction perpendicular to a plane of the first surface 2a of the substrate 2, i.e., in the vertical direction V illustrated in
When measuring the minimum insertion groove distance d1, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film 3 is at least 2% of the minimum insertion groove distance d1, such as 2-200% of the minimum insertion groove distance d1, such as 4-150% of the minimum insertion groove distance d1, such as 5-75% of the minimum insertion groove distance d1.
The thickness of the thermoplastic film 3 may be 7-45% of the minimum insertion groove distance d1.
In one example, the thickness of the thermoplastic film 3 may be 2-110% of the minimum insertion groove distance d1, such as 4-100% of the minimum insertion groove distance d1, for example 5-75% of the minimum insertion groove distance d1, such as 7-45% of the minimum insertion groove distance d1.
In one example wherein the thermoplastic film 3 has a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 2-110% of the minimum insertion groove distance d1, such as 4-75% of the minimum insertion groove distance d1, such as 7-45% of the minimum insertion groove distance d1.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 20-200% of the minimum insertion groove distance d1, such as 40-200% of the minimum insertion groove distance d1.
The locking groove 16 is extending into the substrate 2 from the second surface 2b of the substrate 2 along the edge. A minimum locking groove distance d2 is defined as a shortest distance between the first surface 2a of the substrate a to the locking groove 116 in the direction perpendicular to a plane of the first surface of the substrate, i.e., in the vertical direction V in
When measuring the minimum locking groove distance d2, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum locking groove distance d2, such as 2-100% of the minimum locking groove distance d2, such as 1.5-80% of the minimum locking groove distance d2, such as 2-50% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 5-25% of the minimum locking groove distance d2.
The thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2, such as 1.5-45% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 2-20% of the minimum locking groove distance d2.
In one example wherein the thermoplastic film 3 as a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 2-100% of the minimum locking groove d2.
The thermoplastic film 3 has a thickness t1 in a direction perpendicular to the plane of the first surface 2a of the substrate 2. The direction perpendicular to the plane of the first surface 2a of the substrate 2 is a vertical direction V in
The substrate 2 may have a thickness of 3-15 mm, for example 3-10 mm, such as 3.5-7 mm in a direction perpendicular to the plane of the first surface of the substrate, i.e., in the vertical direction V in
The panel 100 comprises along its first long side edge 101 an insertion groove 111 and a locking strip 115. The insertion groove 111 extends into the substrate 2 from the first long side edge 101. The insertion groove 111 extends along the first long side edge 101. The locking strip 115 protrudes from the first long side edge 101. The locking strip 115 extends along the first long side edge 101.
The adjacent, second panel 100′ comprises along its second long side edge 102′ a tongue 112 and a locking groove 116. The tongue 112 protrudes from the second long side edge 102′. The tongue 112 extends along the second long side edge 102′. The locking groove 116 extends into the substrate 2 from the second surface 2b of the substrate 2. The locking groove 116 extends along the second long side edge 102′.
The tongue 112 is configured to be received in the insertion groove 111, such that a locking surface 114 of the tongue 112 is cooperating with a locking surface 113 of the insertion groove 111 for locking the panels 100, 100′ in a vertical direction. The locking strip 115 has a locking element 119 configured to be received in the locking groove 116, such that a locking surface 117 of the locking element 119 is cooperating with a locking surface 118 of the locking groove 160 for locking the panels 100, 100′ in a horizontal direction.
The insertion groove 111 is extending into the substrate 2 from the edge of the panel 100.
In the example shown in
The joint lip 130 has a thickness d3 in a direction perpendicular to the plane of the first surface 2a of the substrate 2, i.e., in the vertical direction in
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2.5% of the thickness t3 of the joint lip 130, such as be 2.5-200% of the minimum insertion groove distance.
The locking groove 16 is extending into the substrate 2 from the second surface 2b of the substrate 2 along the edge. A minimum locking groove distance d2 is defined as a shortest distance between the first surface of the substrate to the locking groove 116 in the direction perpendicular to the plane of the first surface 2a of the substrate 2, i.e., in the vertical direction in
When measuring the minimum locking groove distance d2, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum locking groove distance d2, such as 2-100% of the minimum locking groove distance d2, such as 1.5-80% of the minimum locking groove distance d2, such as 2-50% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 5-25% of the minimum locking groove distance d2.
The thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2, such as 1.5-45% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 2-20% of the minimum locking groove distance d2.
In one example wherein the thermoplastic film 3 as a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 2-100% of the minimum locking groove d2.
The thermoplastic film 3 has a thickness t1 in a direction perpendicular to the plane of the first surface 2a of the substrate 2. The direction perpendicular to the plane of the first surface 2a of the substrate 2 is a vertical direction V in
The substrate 2 may have a thickness of 3-15 mm, for example 3-10 mm, such as 3.5-7 mm in a direction perpendicular to the plane of the first surface of the substrate, i.e., in the vertical direction V in
The second panel 100′ comprises along its first short side edge 103′ an insertion groove 111 and a locking strip 115. The insertion groove 111 extends into the substrate 2 from the first short side edge 103′. The insertion groove 111 extends along the first short side edge 103′. The locking strip 115 protrudes from the first short side edge 103′. The locking strip 115 extends along the first short side edge 103′.
The adjacent, third panel 100″ comprises along its second short side edge 104″ a tongue groove 121 and a locking groove 116. The tongue groove 121 extends into the substrate 2 from the second short side edge 104″. The tongue groove 121 extends along the second short side edge 104″. The locking groove 116 extends into the substrate 2 from the second surface 2b of the substrate 2. The locking groove 116 extends along the second short side edge 104″.
The locking strip 115 has a locking element 119 configured to be received in the locking groove 116, such that a locking surface 117 of the locking element 119 is cooperating with a locking surface 118 of the locking groove 116 for locking the panels 100′, 100″ in a horizontal direction.
A displaceable tongue 120 is configured to be arranged in the insertion groove 111. During joining, such as locking, the panels 100′, 100″ to each other by a vertical movement, the displaceable tongue 120 is displaced into the insertion groove 111 and thereafter springs back into its extended position into the tongue groove 121. Thereby, a locking surface 122 of the displaceable tongue 120 is cooperating with a locking surface 123 of the tongue groove 121 for locking the panels 100′, 100″ in the vertical direction V.
The insertion groove 111 is extending into the substrate 2 from the edge of the panel 100′.
Consequently, the second mechanical locking system may comprise the locking strip 115 having the locking element 119 configured to be received in the locking groove 116 for locking the panels 100′, 100″ in the horizontal direction, and the displaceable tongue 120 configured to be received in the insertion groove 111 for locking the panels 100′, 100′ in the vertical direction.
A minimum insertion groove distance d1 is defined as a shortest distance between the first surface 2a of the substrate 2 to the insertion groove 111 in the direction perpendicular to a plane of the first surface 2a of the substrate 2, i.e., in the vertical direction V in
When measuring the minimum insertion groove distance d1, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum insertion groove distance d1, such as 2-200% of the minimum insertion groove distance d1, such as 4-150% of the minimum insertion groove distance d1, such as 5-75% of the minimum insertion groove distance d1.
The thickness of the thermoplastic film 3 may be 7-45% of the minimum insertion groove distance d1.
In one example, the thickness of the thermoplastic film 3 may be 2-110% of the minimum insertion groove distance d1, such as 4-100% of the minimum insertion groove distance d1, for example 5-75% of the minimum insertion groove distance d1, such as 7-45% of the minimum insertion groove distance d1.
In one example wherein the thermoplastic film 3 has a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 2-110% of the minimum insertion groove distance d1, such as 4-75% of the minimum insertion groove distance d1, such as 7-45% of the minimum insertion groove distance d1.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 20-200% of the minimum insertion groove distance d1, such as 40-200% of the minimum insertion groove distance d1.
The locking groove 16 is extending into the substrate 2 from the second surface 2b of the substrate 2 along the edge. A minimum locking groove distance d2 is defined as a shortest distance between the first surface 2a of the substrate 2 to the locking groove 116 in the direction perpendicular to the plane of the first surface 2a of the substrate 2, i.e., in the vertical direction V in
When measuring the minimum locking groove distance d2, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum locking groove distance d2, such as 2-100% of the minimum locking groove distance d2, such as 1.5-80% of the minimum locking groove distance d2, such as 2-50% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 5-25% of the minimum locking groove distance d2.
The thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2, such as 1.5-45% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 2-20% of the minimum locking groove distance d2.
In one example wherein the thermoplastic film 3 as a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 2-100% of the minimum locking groove d2.
Further, a distance can be measured from the first surface 2a of the substrate 2 to the displacement groove 121. A minimum displacement groove distance d4 is defined as a shortest distance between the first surface 2a of the substrate 2 to the displacement groove 121 in the direction perpendicular to the plane of the first surface 2a of the substrate 2, i.e., in the vertical direction V in
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum displacement groove distance d4, such as 2-200% of the minimum displacement groove distance d4, such as 4-150% of the minimum displacement groove distance d4, such as 5-75% of the minimum displacement groove distance d4.
The mechanical locking system of
In the example shown in
The joint lip 130 has a thickness d3 in a direction perpendicular to the first surface 2a of the substrate 2. The thickness is defined as the shortest distance between the first surface 2a of the substrate 2 and a lower surface of the joint lip in the direction perpendicular to the plane of the first surface 2a of the substrate 2, i.e., in the vertical direction V in
The mechanical locking system of the example shown in
The thermoplastic film 3 has a thickness t1 in a direction perpendicular to the plane of the first surface 2a of the substrate 2. The direction perpendicular to the plane of the first surface 2a of the substrate 2 is a vertical direction V in
The substrate 2 may have a thickness of 3-15 mm, for example 3-10 mm, such as 3.5-7 mm in a direction perpendicular to the plane of the first surface of the substrate, i.e., in the vertical direction V in
The second panel 100′ comprises along its first short side edge 103′ an insertion groove 111′ and a locking strip 115. The insertion groove 111′ extends into the substrate 2 from the first short side edge 103′. The insertion groove 111′ extends along the first short side edge 103′. The locking strip 115 protrudes from the first short side edge 103′. The locking strip 115 extends along the first short side edge 103′.
The adjacent, third panel 100″ comprises along its second short side edge 104″ a locking groove 116. The locking groove 116 extends into the substrate 2 from the second surface 2b of the substrate 2. The locking groove 116 extends along the second short side edge 104″.
The locking strip 115 has a locking element 119 configured to be received in the locking groove 116, such that a locking surface 117 of the locking element 117 is cooperating with a locking surface 118 of the locking groove 116 for locking the panels 100′, 100″ in a horizontal direction.
The locking strip 115 is further provided with a locking protrusion 118 configured to be received in a locking recess 117 of in the locking groove 116. The locking protrusion 118 has a locking surface configured to cooperate with a locking surface of the locking recess 117 for locking the panels 100′, 100″ in a vertical direction V.
The locking groove 16 is extending into the substrate 2 from the second surface 2b of the substrate 2 along the edge. A minimum locking groove distance d2 is defined as a shortest distance between the first surface of the substrate to the locking groove 116 in the direction perpendicular to a plane of the first surface 2a of the substrate 2, in the vertical direction V in
When measuring the minimum locking groove distance d2, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum locking groove distance d2, such as 2-100% of the minimum locking groove distance d2, such as 1.5-80% of the minimum locking groove distance d2, such as 2-50% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 5-25% of the minimum locking groove distance d2.
The thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2, such as 1.5-45% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 2-20% of the minimum locking groove distance d2.
In one example wherein the thermoplastic film 3 as a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 2-100% of the minimum locking groove d2.
The thermoplastic film 3 has a thickness t1 in a direction perpendicular to the plane of the first surface 2a of the substrate 2. The direction perpendicular to the plane of the first surface 2a of the substrate 2 is a vertical direction V in
The substrate 2 may have a thickness of 3-15 mm, for example 3-10 mm, such as 3.5-7 mm in a direction perpendicular to the plane of the first surface of the substrate, i.e., in the vertical direction V in
The second panel 100′ comprises along its first short side edge 103′ an insertion groove 111 and a locking groove 116. The insertion groove 111 extends into the substrate 2 from the first short side edge 103′. The insertion groove 111 extends along the first short side edge 103′. The locking groove 116 extends into the substrate 2 from the second surface 2b of the substrate 2. The locking groove 116 extends along the first short side edge 103′.
The adjacent, third panel 100″ comprises along its second short side edge 104″ a tongue groove 121 and a locking strip 115. The tongue groove 121 extends into the substrate 2 from the second short side edge 104″. The locking strip 115 protrudes from the second short side edge 104″. The locking strip 115 extends along second short side edge 104″.
The locking strip 115 has a locking element 119 configured to be received in the locking groove 116, such that a locking surface 117 of the locking element 119 is cooperating with a locking surface 118 of the locking groove 116 for locking the panels 100′, 100″ in a horizontal direction.
A displaceable tongue 120′ is configured to be arranged in the insertion groove 111. During joining, such as locking, the panels 100′, 100″ to each other by a vertical movement, the displaceable tongue 120′ is displaced into the insertion groove 111 and thereafter springs back into its extended position into the tongue groove 121. Thereby, a locking surface 122′ of the displaceable tongue 120′ is cooperating with a locking surface 123′ of the tongue groove 121 for locking the panels 100′, 100″ in the vertical direction V.
The insertion groove 111 is extending into the substrate 2 from the edge of the panel 100′.
A minimum insertion groove distance d1 is defined as a shortest distance between the first surface 2a of the substrate 2 to the insertion groove 111 in the direction perpendicular to a plane of the first surface 2a of the substrate 2, i.e., in the vertical direction V in
When measuring the minimum insertion groove distance d1, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum insertion groove distance d1, such as 2-200% of the minimum insertion groove distance d1, such as 4-150% of the minimum insertion groove distance d1, such as 5-75% of the minimum insertion groove distance d1.
The thickness of the thermoplastic film 3 may be 7-45% of the minimum insertion groove distance d1.
In one example, the thickness of the thermoplastic film 3 may be 2-110% of the minimum insertion groove distance d1, such as 4-100% of the minimum insertion groove distance d1, for example 5-75% of the minimum insertion groove distance d1, such as 7-45% of the minimum insertion groove distance d1.
In one example wherein the thermoplastic film 3 has a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 2-110% of the minimum insertion groove distance d1, such as 4-75% of the minimum insertion groove distance d1, such as 7-45% of the minimum insertion groove distance d1.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 20-200% of the minimum insertion groove distance d1, such as 40-200% of the minimum insertion groove distance d1.
The locking groove 16 is extending into the substrate 2 from the second surface 2b of the substrate 2 along the edge. A minimum locking groove distance d2 is defined as a shortest distance between the first surface of the substrate to the locking groove 116 in the direction perpendicular to the plane of the first surface of the substrate, i.e., in the vertical direction V in
When measuring the minimum locking groove distance d2, any layer beneath the thermoplastic film 3 are defined as substrate layers, forming the substrate 2.
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum locking groove distance d2, such as 2-100% of the minimum locking groove distance d2, such as 1.5-80% of the minimum locking groove distance d2, such as 2-50% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 5-25% of the minimum locking groove distance d2.
The thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2, such as 1.5-45% of the minimum locking groove distance d2.
In one example, the thickness of the thermoplastic film 3 may be 2-20% of the minimum locking groove distance d2.
In one example wherein the thermoplastic film 3 as a thickness of 0.05-0.55 mm, the thickness of the thermoplastic film 3 may be 1-50% of the minimum locking groove distance d2.
In another example wherein the thermoplastic film 3 has a thickness of 0.55-1 mm, the thickness of the thermoplastic film 3 may be 2-100% of the minimum locking groove d2.
Further, a distance can be measured from the first surface 2a of the substrate 2 to the displacement groove 121. A minimum displacement groove distance d4 is defined as a shortest distance between the first surface 2a of the substrate 2 to the displacement groove 121 in the direction perpendicular to the plane of the first surface 2a of the substrate 2, i.e., in the vertical direction V in
In order to at least partly reduce damages on the mechanical locking system, the thickness of the thermoplastic film is at least 2% of the minimum displacement groove distance d4, such as 2-200% of the minimum displacement groove distance d4, such as 4-150% of the minimum displacement groove distance d4, such as 5-75% of the minimum displacement groove distance d4.
A bevel may be provided in the thermoplastic film 3, adjacent any edge of the panel 100, 100′, 100′, as visible in
It is contemplated that there are numerous modifications of the embodiments described herein, which are still within the scope of the disclosure.
A bending test including beam bending force and strain was performed. Test samples was prepared by dividing a panel, comprising a substrate and a thermoplastic film arranged on the substrate, according to Tables 2 and 3 below into test samples 200 as shown in
Test samples 200 according to tables 2 and 3 below were prepared by pressing the substrate 201b and the thermoplastic film 201a with the following lamination process in a static press. Lamination process: start at 50° C., heating to and stay at 140° C. for 1000 s, cooling to 50° C. for 400 s, the pressure is at 10 bar for the whole cycle.
Reference A has been pressed in one lamination cycle such that the reference is compressed equally to the examples.
The test samples 200 were placed in a test rig as shown in
Tensile test machine used is Lloyd LRX plus, software used is Nexygenplus 4.0. The result is presented below in Tables 4, 5, 6 7, 8 and 9.
Strain at 80% of maximum load is measured after maximum strain has been passed.
Samples according to Table 10 and 11 were prepared and tested as described above with the only differences that the samples had a width of 30 mm, instead of 60 mm as described above. The result is presented below in Tables 12-14.
With a reinforcing thermoplastic film arranged as a top layer on the substrate, the bending strength and maximum applied force, and/or strain at maximum load, or strain at 80% of maximum load, get higher for the samples tested above. This indicates that the samples are stronger and/or less brittle and that the locking systems will be less prone to damage and breaking.
A stiffer thermoplastic film, such as a print film, gives a better result in term of strength than a softer thermoplastic film, being less stiff, such as the soft wear layers being tested. A thermoplastic film having a higher plasticizer content results in higher strain at maximum load, and/or at 80% of maximum load. For example, the TPU film was too soft and gave lower maximum force results. With the thicker PVC films (0.3 and 0.5 mm thickness), the films resulted in lower maximum force results, but typically, higher strain values.
When the thickness relation between thermoplastic film and substrate becomes to be too dominating by the thermoplastic film, the effect described above may be reduced, at least concerning force.
The PP samples had a higher breaking force than the SPC samples. Only the PETG film added strength to the CaCO3 filled PP substrate. The PP and the TPU films were too flexible and generated a lower breaking force, however they typically show increased strain before break.
1. A method to produce a board element (1), comprising:
2. The method according to item 1, wherein the thermoplastic film (3) is laminated to the substrate (2) by heat and pressure.
3. The method according to item 1 or 2, wherein the thermoplastic film (3) is laminated to the substrate (2) at least partly by heat from the extruded substrate (2).
4. The method according to any one of the preceding items, wherein the thermoplastic film (3) is pigmented.
5. The method according to any one of the preceding items, wherein the thermoplastic film (3) is laminated to the substrate (2) as a continuous web.
6. The method according to any one of the preceding items, wherein the thermoplastic film (3) is continuously applied to the substrate (2), such as applied by rollers.
7. The method according to any one of the preceding items, wherein the substrate (2) is in continuous form when the thermoplastic film (3) is laminated to the substrate (2).
8. The method according to any one of the preceding items, wherein a temperature on the first surface (2a) of the substrate (2) is 120-240° C., such as 130-230° C., such as 140-220° C., when the thermoplastic film (3) is laminated to the first surface (2a) of the substrate (2).
9. The method according to any one of the preceding items, wherein the thermoplastic film (3) has a temperature of 18-170° C. when being laminated to the substrate (2).
10. The method according to any one of the preceding items, wherein a thickness of the thermoplastic film (3) is or exceeds 0.05 mm, such as 0.05-1 mm, such as 0.05-0.55 mm or 0.07-0.3 mm.
11. The method according to any one of the preceding items, wherein the substrate (2) comprises at least one substrate layer (2c) being laminated to the substrate (2) after extrusion, such that the substrate (2) comprises one or more extruded substrate layers (2) and at least one laminated substrate layer (2c).
12. The method according to any one of the preceding items, wherein the thermoplastic film (3) comprises no more than 50 phr plasticizer, such as 0-50 phr plasticizer, such as 0-35 phr plasticizer, such as 0-10 phr plasticizer.
13. The method according to any one of the preceding items, wherein the thermoplastic film (3) comprises at least one filler, such as 0-50 phr filler, such as 5-40 phr filler, such as 10-30 phr filler.
14. The method according to item 13, wherein the filler, or fillers, comprises or is CaCO3.
15. The method according to any one of the preceding items, wherein the coating (5) is a UV curable coating.
16. The method according to any one of the preceding items, wherein the coating (5) is an EB curable coating.
17. The method according to any one of the preceding items, wherein the digital printing device is an inkjet printer, preferably a piezo-electric DOD (Drop on Demand) inkjet printer.
18. The method according to any one of the preceding items, wherein the printing further comprises digitally printing an embossed structure on the thermoplastic film (3) when the thermoplastic film (3) has been laminated to the substrate (2).
19. The method according to any one of the preceding items, further comprising applying a backing layer and/or a reinforcement layer (4) to a second surface (2b) of the substrate (2), opposite the first surface (2a).
20. The method according to any one of the preceding items, further comprising, after the thermoplastic film (3) has been laminated to the substrate (2), dividing the board element (1) into board element members (10) or panels (100).
21. The method according to item 20, wherein the step of printing is performed prior to dividing the board element (1) into board element members (10) or panels (100).
22. The method according to item 20, wherein the step of printing is performed after dividing the board element (1) into board element members (10) or panels (100).
23. The method according to any one of the preceding items, further comprising conveying the substrate (2) between at least two rollers (21, 22, 23, 24; 31, 32, 33, 34, 35, 36) after the substrate (2) has passed the die.
24 The method according to item 23, wherein the thermoplastic film (3) is laminated to the substrate (2) by at least one of said rollers (21, 22, 23, 24; 31, 32, 33, 34, 35, 36).
25. The method according to item 23 or 24, wherein a temperature on the first surface (2a) of the substrate (2) is 130-220° C., such as 160-210° C., such as 170-190° C., when the thermoplastic film (3) is laminated to the substrate (2).
26. The method according to any one of the preceding items, wherein the substrate (2) comprises a thermoplastic material and calcium carbonate.
27. The method according to any one of items 1-23, further comprising conveying the substrate (2) through at least one cooling zone (80).
28. The method according to item 27, wherein the thermoplastic film (3) is laminated to the substrate by at least one roller, prior or after the cooling zone (80).
29. The method according to item 27 or 28, wherein a temperature on the first surface (2a) of the substrate (2) is 120-180° C., such as 130-170° C., such as 140-160° C., when the thermoplastic film (3) is laminated to the substrate (2).
30. The method according to any one the preceding items, wherein the substrate (2) comprises at least one foamed substrate layer.
31. The method according to any one of the preceding items, further comprising providing the panels (100) with a mechanical locking system.
32. The method according to item 31, wherein the mechanical locking system comprises along at least a first edge (101, 101′, 101″; 103, 103′, 103″) of the panel an insertion groove (111) being configured to receive a tongue (112; 120) configured for joining the panel to an adjacent panel along the first edge (101, 101′, 101″) in at least one direction,
33. The method according to item 31 or 32, wherein the mechanical locking system comprises along at least a second edge (102, 102′, 102″; 104, 104′, 104″) of the panel a locking groove (116) extending into the substrate (2) from the second surface (2b) of the substrate (2) and extending along the second edge (102, 102′, 102″; 104, 104′, 104″), the locking groove being configured to receive a locking strip (115) of an adjacent panel for joining the panel to the adjacent panel along the second edge (102, 102′, 102″; 104, 104′, 104″) in at least one direction,
34. The method according to any one of items 31-33, wherein the mechanical locking system comprises along at least the second edge (102, 102′, 102″; 104, 104′, 104″) of the panel a joint lip (130) extending from the second edge (102, 102′, 102″; 104, 104′, 104″) and extending along the second edge (102, 102′, 102″; 104, 104′, 104″), the joint lip being configured to extend over the insertion groove (111) when being joined to an adjacent panel, wherein the joint lip (130) has a thickness (d3) in a direction perpendicular to the plane of the first surface (2a) of the substrate (2), wherein the thickness (t1) of the thermoplastic film (3) is at least 2.5% of the thickness (d3) of the joint lip (130), such as 2.5-100% of the thickness (d3) of the joint lip (130).
35. The method according to any one of items 31-34, wherein the mechanical locking system further comprises a locking strip (115) extending from the first (101, 101′, 101″; 103, 103′, 103″) and/or the second edge (102, 102′, 102″; 104, 104′, 104″) and extending along the first and/or the second edge, the locking strip (115) being configured to cooperate with the locking groove (116) of an adjacent panel for joining the panel to the adjacent panel in at least one direction.
36. The method according to any one of the preceding items, wherein a thickness (t1) of the thermoplastic film (3) is or exceeds 0.05 mm, such as 0.05-1 mm, such as 0.05-0.55 mm or 0.07-0.3 mm.
37. A panel (100, 100′, 100″), comprising
38. A panel (100, 100′, 100″), comprising
39 The panel according to item 37, further comprising along at least a second edge (102, 102′, 102″; 104, 104′, 104″) a locking groove 116) extending into the substrate (2) from the second surface (2a) of the substrate (2) and extending along the second edge (102, 102′, 102″; 104, 104′, 104″), the locking groove (116) being configured receive a locking strip (115) of an adjacent panel for joining the panel to the adjacent panel along the second edge (102, 102′, 102″; 104, 104′, 104″) in at least one direction
40. The panel according to any one of items 37-39, further comprising along at least the second edge (102, 102′, 102″; 104, 104′, 104″) a joint lip (130) extending from the second edge (102, 102′, 102″; 104, 104′, 104″) and extending along the second edge (102, 102′, 102″; 104, 104′, 104″), the joint lip being configured to extend over the insertion groove (111) when being joined to an adjacent panel, wherein the joint lip (130) has a thickness (d3) in a direction perpendicular to the plane of the first surface (2a) of the substrate (2), wherein the thickness (t1) of the thermoplastic film (3) is at least 2.5% of the thickness (d3) of the joint lip (130), such as such as 2.5-100% of the thickness (d3) of the joint lip (130).
41. The panel according to any one of items 37-40, further comprising a locking strip (115) extending from the first (101, 101′, 101″; 103, 103′, 103″) and/or second edge (102, 102′, 102″; 104, 104′, 104″) and extending along the first and/or the second edge, the locking strip (115) being configured to cooperate with the locking groove (116) of an adjacent panel for joining the panel to the adjacent panel in at least one direction.
42. The panel according to any one of items 37-41, wherein a thickness (t1) of the thermoplastic film (3) is or exceeds 0.05 mm, such as 0.05-1 mm, such as 0.05-0.55 mm or 0.07-0.3 mm.
43. The panel according to any one of items 37-42, wherein the thermoplastic film (3) comprises no more than 50 phr plasticizer, such as 0-50 phr plasticizer, such as 0-35 phr plasticizer, such as 0-10 phr plasticizer.
44. The panel according to any one of items 37-43, wherein the thermoplastic film (3) comprises at least one filler, such as 0-50 phr filler, such as 5-40 phr filler, such as 10-30 phr filler.
45. The panel according to item 44, wherein the filler, of fillers, comprises or is CaCO3.
46. The panel according to any one of items 37-45, wherein the coating (5) is directly adhered to the thermoplastic film (3).
47. The panel according to any one of items 37-46, wherein the coating (5) is a UV curable coating.
48. The panel according to any one of items 37-46, wherein the coating (5) is an EB curable coating.
49. The panel according to any one of items 37-48, wherein the thermoplastic film (3) comprises an embossed structure.
50. The panel according to any one of items 37-49, wherein the substrate (2) comprises a thermoplastic material and calcium carbonate.
51. The panel according to any one of items 37-50, wherein the substrate (2) comprises at least one foamed substrate layer.
52. The panel according to any one of items 37-51, wherein the thermoplastic film (3) is pigmented.
53. The panel according to any one of items 37-52, further comprising a primer applied between the first surface (2a) of the substrate (2) and the thermoplastic film (3).
54. The panel according to any one of items 37-53, further comprising a primer applied on the thermoplastic film (3).
55. The panel according to any one of items 37-54, further comprising a backing layer and/or a reinforcement layer (4) arranged on a second surface (2b) of the substrate (2), opposite the first surface (2a).
56. The method according to any one of items 1-36, wherein the thermoplastic material of thermoplastic film (3) is PVC, PE, PP, TPU, PET, PETG, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a copolymer thereof, or a combination thereof.
57. The method according to item 32, wherein the thickness (t1) of the thermoplastic film (3) is 2-110% of the minimum insertion groove distance (d1).
58. The method according to item 32, wherein the thickness (t1) of the thermoplastic film (3) is 7-45% of the minimum insertion groove distance (d1).
59. The method according to item 33, wherein the thickness (t1) of the thermoplastic film (3) is 1-50% of the minimum locking groove distance (d2).
60. The method according to item 33, wherein the thickness (t1) of the thermoplastic film (3) is 5-25% of the minimum locking groove distance (d2).
61. The method according to item 33, wherein the thickness (t1) of the thermoplastic film (3) is 2-20% of the minimum locking groove distance (d2).
62. The panel according to any one of items 37-55, wherein the thermoplastic material of thermoplastic film (3) is PVC, PE, PP, TPU, PET, PETG, EVA, PA PS, PVAc, PMMA, PVB, PC, ABS, PAM, PBT, CPVC, or a copolymer thereof, or a combination thereof.
63. The panel according to item 37, wherein the thickness (t1) of the thermoplastic film (3) is 2-110% of the minimum insertion groove distance (d1).
64. The panel according to item 37, wherein the thickness (t1) of the thermoplastic film (3) is 7-45% of the minimum insertion groove distance (d1).
65. The panel according to item 38 or 39, wherein the thickness (t1) of the thermoplastic film (3) is 1-50% of the minimum locking groove distance (d2).
66. The panel according to item 38 or 39, wherein the thickness (t1) of the thermoplastic film (3) is 5-25% of the minimum locking groove distance (d2).
67. The panel according to item 38 or 39, wherein the thickness (t1) of the thermoplastic film (3) is 2-20% of the minimum locking groove distance (d2).
| Number | Date | Country | Kind |
|---|---|---|---|
| 2450022-5 | Jan 2024 | SE | national |
