Floor panel and method for manufacturing a floor panel

Abstract

A floor panel and a method for manufacturing a floor panel. The floor panel (10) comprises a substrate (20), a decorative layer (22) and a transparent component (24). The decorative layer (22) is located between the substrate (20) and the transparent component (24). At least one of the substrate (20), the decorative layer (22) and the transparent component (24) comprises a thermoplastic synthetic material. The transparent component (24) has an upper surface (30) opposite the decorative layer (22). The floor panel (10) further comprises a reinforcing component (32) provided on the upper surface (30) of the transparent component (24). The thickness of the reinforcing component (32) varies along a cross-section of the floor panel (10).

Description

Technical Field

[0001] This invention relates to a floor panel and a method for manufacturing the floor panel.

[0002] More specifically, the present invention relates to a floor panel comprising at least a substrate, a decorative layer, and a translucent or transparent component above the decorative layer. The invention is particularly applicable to floor panels in which at least one of the substrate, the decorative layer, and the transparent component comprises a thermoplastic synthetic material. Background Technology

[0003] The floor panels described above are well-known in themselves. For example, this can involve so-called vinyl tiles or so-called LVT (Luxury Vinyl Tiles), or wall-to-wall coverings. In these cases, the thermoplastic material involves so-called soft PVC (polyvinyl chloride), or PVC comprising a certain percentage (e.g., 5 to 20% by weight or even up to 35% by weight or more) of plasticizer. In this context, the decorative layer involves prints whose decoration can be in the form of wood or stone patterns or any other pattern (such as fancy patterns). A transparent element is provided above the decorative layer of the panel. The transparent element protects the decorative layer from abrasion and increases the abrasion resistance of the floor panel. Paint and / or embossing or structures, such as wood or stone structures, can be provided on the transparent element. Due to the properties of the thermoplastic materials used in such floor panels, relatively thick transparent elements are generally required. When relatively thick transparent elements are provided with paint and / or embossing in a manner known in the art, the result is that the floor panel does not have a completely natural appearance, especially when viewed from different angles and / or under different lighting conditions.

[0004] Document WO2018 / 065859 relates to a floor panel comprising a substrate and a top layer disposed above the substrate, and preferably directly above the substrate. The top layer includes a decorative layer, a thermoplastic transparent or translucent abrasion-resistant layer, and a paint layer disposed above the abrasion-resistant layer. The floor panel has an upper surface displaying an embossed design, characterized in that the embossing has a maximum depth greater than 100 micrometers, and the abrasion-resistant layer and paint layer are embossed to form the embossing. As a result of these features, glossy spots can be avoided.

[0005] Document EP2883712 relates to a floor panel overlay having at least a substrate layer, a decorative layer, and a transparent wear-resistant layer, wherein an embossed design is implemented in the wear-resistant layer, the embossing including recesses, characterized in that the transparent wear-resistant layer comprises at least two paint layers, namely a first paint layer located at the bottom of at least one of the recesses and a second paint layer interrupted at the location of the respective recess. Utilizing these features, structured sections with mutually different gloss levels can be achieved.

[0006] While the aforementioned literature may each provide solutions to the problem of unnatural appearance of floor panels due to gloss-related issues, none of them provide solutions to the problem of floor panels not having a natural appearance when viewed from different angles and / or under different lighting conditions. Summary of the Invention

[0007] The present invention primarily aims to provide an alternative flooring panel that offers a natural appearance. Specifically, the present invention is dedicated to imparting an improved natural appearance to flooring panels comprising thermoplastic synthetic materials.

[0008] For this purpose, the present invention relates to floor panels and methods as defined in the appended independent claims, wherein preferred embodiments are defined in the dependent claims.

[0009] According to a first aspect, the present invention relates to a floor panel comprising a substrate, a decorative layer, and a transparent component. The decorative layer is located between the substrate and the transparent component. At least one of the substrate, the decorative layer, and the transparent component comprises a thermoplastic synthetic material. The transparent component has an upper surface opposite to the decorative layer. Preferably, the upper surface of the transparent component generally extends in a plane of the upper surface. The floor panel further comprises a reinforcing component disposed on the upper surface of the transparent component, the thickness of the reinforcing component varying along the cross-section of the floor panel.

[0010] A more natural appearance can be achieved by incorporating a reinforcing member on the upper surface of the transparent component, which has a non-uniform thickness above the floor panel. The varying thickness of the reinforcing member can influence its visual appearance on the floor panel and provide an improved natural look. By varying the thickness of the reinforcing member along the cross-section of the floor panel, a floor panel with a natural appearance when viewed from different angles and / or under different lighting conditions can be achieved.

[0011] The thickness variation of the reinforcing member can be achieved in a variety of ways, individually or in combination. For example, the reinforcing member can be disposed discontinuously on the upper surface of the transparent member, such that the upper surface can include one or more covered areas covered by the reinforcing member, and one or more free areas not covered by the reinforcing member.

[0012] An improved natural appearance is achieved by discontinuously placing the reinforcing members on the upper surface. In the free zone, the upper surface of the transparent member is visible, while in the covered zone, a reinforcing member material of varying thickness covers the transparent member, giving the floor panel a natural appearance when viewed from different angles and / or under different lighting conditions. Furthermore, the free zone allows for improved abrasion resistance and lifespan of the floor panel, as the transparent member can be adapted to be more abrasion-resistant than the reinforcing member.

[0013] In one embodiment, an embossing can be implemented in the upper surface of the transparent component, the embossing including recesses, and reinforcing members can be disposed in some of these recesses, preferably in most of these recesses, and more preferably in all of these recesses. Preferably, the embossing thus extends from the plane of the upper surface of the transparent component toward the decorative layer.

[0014] A further improved natural appearance can be achieved by creating an embossed design on the upper surface of the transparent component and providing reinforcing elements in at least some of the recesses of the embossed design. Furthermore, the embossing provides a natural feel. The pattern of the embossed design, and therefore the pattern of the reinforcing elements, can preferably be adapted to the print on the decorative layer, and they can be aligned with or not aligned with the print. Through these features, the floor panel maintains a natural appearance even when viewed from different angles and / or under different lighting conditions.

[0015] Variations in the thickness of the reinforcing member can be achieved by varying the amount of reinforcing member in the recesses between different recesses and / or along the cross-section of the floor panel. Preferably, the recesses have a depth measured from the upper surface plane of the transparent member, and this depth can vary along the cross-section of the floor panel. In this way, and to the extent that the reinforcing member reaches at least some of the lowest portions of the recesses, the shortest distance between the reinforcing member and the decorative layer will vary along the cross-section of the floor panel.

[0016] According to some embodiments, the depth of the recess can vary in the range of 1 μm to 1000 μm, preferably in the range of 150 μm to 600 μm. According to some embodiments, the depth of the recess can also vary in the interval of 15 μm to 20 μm, wherein these recesses are preferably referred to as "microstructures".

[0017] According to some embodiments, recesses with a greater depth (e.g., between 150 μm and 600 μm) and microstructures with a lesser depth (e.g., between 15 μm and 20 μm) may exist adjacent to each other. Additionally and / or alternatively, recesses with a greater depth (e.g., between 150 μm and 600 μm) and microstructures with a lesser depth (e.g., between 15 μm and 20 μm) may be superimposed on each other, such that one or more regions of the microstructure exist within one or more recesses, preferably along the inner surface of said recess.

[0018] The reinforcing member does not need to fill all the recesses evenly. Instead, the reinforcing member can partially fill one or more recesses provided by the reinforcing member.

[0019] By partially filling the recesses with the reinforcing element, the reinforcing element is better protected from wear and tear, thus improving the lifespan of the floor panel. Furthermore, partially filling the recesses gives the floor panel an improved natural appearance, especially when viewed from different angles.

[0020] Alternatively, the reinforcing member may completely fill one or more recesses provided by the reinforcing member.

[0021] By fully filling the recesses with reinforcing components, a smoother surface is provided on the floor panel. This makes the floor panel easier to clean.

[0022] At least one of the covered areas may include a surface region having a greater roughness than adjacent surface regions. Preferably, the greater roughness is achieved by the presence of one or more microstructured regions having a depth that can vary in the range of 15 μm to 20 μm.

[0023] According to some embodiments, the roughness is determined to be the arithmetic mean roughness as defined by the ISO 4287:1997 standard. Preferably, the surface region having a greater roughness may have a roughness of at least 1.5 μm Ra, more preferably at least 2.0 μm Ra, and more preferably at least 2.5 μm Ra.

[0024] According to some embodiments, recesses with greater depth (such as between 150 μm and 600 μm) and microstructures with smaller depth (such as between 15 μm and 20 μm) may exist adjacent to each other, wherein the relief is generally obtained through one or more recesses, and wherein greater roughness is obtained through one or more microstructure regions.

[0025] The reinforcing component will adhere more easily to surface areas with greater roughness. Furthermore, in surface areas with greater roughness, a higher amount of reinforcing component is absorbed, and the reinforcing component penetrates more deeply into the transparent component. Therefore, the visual appearance of the floor panel can be further improved and become more natural. As an example, a grayscale effect can be achieved. The reinforcing component can be paint, coating, etc., and can be opaque, translucent, or completely transparent, depending on the desired appearance of the floor panel.

[0026] To ensure compatibility between the reinforcing component and other materials in the floor panel, the reinforcing component can be a water-based and / or solvent-based product, such as a water-based UV-curable product. Alternatively, the reinforcing component can be an oil-based product.

[0027] For ease of application, the reinforcing component can be a paint, preferably an acrylic paint, more preferably an energy-curable acrylic paint, and even more preferably a UV-curable acrylic paint.

[0028] Reinforcing components can serve as carriers for additives, which can impart specific properties to the flooring panels. For example, reinforcing components may include one or more of the following: colored pigments, dyes, metallic pigments, pearlescent pigments, matting agents, abrasion-resistant particles, stain-resistant additives, easy-cleaning additives, mildew-resistant additives, and antibacterial additives.

[0029] In certain embodiments, the reinforcing component may include abrasion-resistant particles. Therefore, the transparent component, typically used as the abrasion-resistant layer, can be made thinner. For example, the thickness of the transparent component can be 0.2 mm or less, preferably 0.1 mm or less.

[0030] To protect the reinforced parts from wear and / or contamination, a sealant and / or topcoat may be applied over the reinforced parts.

[0031] The transparent component may include a wear-resistant layer and / or a primer layer and / or a topcoat layer, wherein at least one of the layers constituting the transparent component includes a thermoplastic synthetic material.

[0032] To improve the compatibility between the layers constituting the floor panel, in certain embodiments, each of the substrate, decorative layer, and transparent component may include a thermoplastic composite material. A suitable thermoplastic composite material may be polyvinyl chloride (PVC), preferably flexible PVC.

[0033] According to a second aspect, the present invention relates to a method for manufacturing floor panels, the method comprising the following steps:

[0034] a. Preparing a semi-finished product comprising a substrate, a decorative layer, and a transparent component, wherein the decorative layer is located between the substrate and the transparent component, and wherein at least one of the substrate, the decorative layer, and the transparent component comprises a thermoplastic synthetic material;

[0035] Its characteristic is that the method further includes the following steps:

[0036] b. The reinforcing member is applied to the upper surface of the transparent member, opposite to the decorative layer, in such a manner that the thickness of the reinforcing member varies along the cross-section of the floor panel.

[0037] Preferably, the upper surface of the transparent component generally extends in the plane of the upper surface. A more natural appearance is achieved by providing a reinforcing member on the upper surface of the transparent component, which has a non-uniform thickness above the floor panel. The varying thickness of the reinforcing member affects its visual appearance on the floor panel and provides an improved natural look. By varying the thickness of the reinforcing member along the cross-section of the floor panel, a floor panel with a natural appearance when viewed from different angles and / or under different lighting conditions is achieved.

[0038] Step b) may further include: applying the reinforcing member in a discontinuous manner, such that the upper surface includes one or more covered areas covered by the reinforcing member and one or more free areas not covered by the reinforcing member.

[0039] An improved natural appearance is achieved by discontinuously placing the reinforcing elements on the upper surface. In the free zone, the upper surface of the transparent element is visible, while in the covered zone, the reinforcing element material of varying thickness covers the transparent element, thus giving the floor panel a natural appearance when viewed from different angles and / or under different lighting conditions. Furthermore, the free zone allows for improved abrasion resistance and lifespan of the floor panel, as the transparent element can be adapted to be more abrasion-resistant than the reinforcing elements.

[0040] The method may further include the following steps:

[0041] c. Embossing is applied to the semi-finished product to create a relief pattern on the upper surface of the transparent component, the relief pattern including recesses.

[0042] Furthermore, step b) may include: providing reinforcing members in some of these recesses, preferably in most of these recesses, and more preferably in all of these recesses. Preferably, the relief thus extends from the upper surface plane of the transparent member toward the decorative layer.

[0043] A further improved natural appearance can be achieved by creating an embossed design on the upper surface of the transparent component and providing reinforcing elements in at least some of the recesses of the embossed design. Additionally, the embossing provides a natural feel. The pattern of the embossed design, and therefore the pattern of the reinforcing elements, can preferably be adapted to the print on the decorative layer, and they can be aligned with or not aligned with the print. Through these features, the floor panel maintains a natural appearance even when viewed from different angles and / or under different lighting conditions.

[0044] Depending on the viscosity of the reinforcing component, it can be applied using at least one roller and / or scraper. Alternatively, the reinforcing component can be applied by polishing and / or wiping the upper surface. Those skilled in the art will understand that different visual effects and surface properties can be obtained depending on the chosen application method.

[0045] The method may further include the following steps:

[0046] d. After the reinforcing component is applied to the upper surface of the transparent component, the reinforcing component is mechanically treated, such as by brushing and / or grinding.

[0047] In this way, the entire surface or a selected area can be treated to give a specific effect.

[0048] Depending on the desired effect, reinforcing members can be applied to partially or completely fill one or more recesses provided by the reinforcing members.

[0049] Each of these recesses will have a surface opening having an opening area, and the reinforcing component will have viscosity, wherein the amount of reinforcing component in each of these recesses can be controlled by adjusting the opening area and / or viscosity.

[0050] The amount of reinforcing material in each of these recesses can be controlled or further controlled by drying and evaporating at least a portion of the reinforcing material.

[0051] The method may further include the following steps:

[0052] e. On the upper surface of the transparent component, at least one surface region with a roughness greater than that of the adjacent surface region is formed;

[0053] Furthermore, at least one of these covered areas may include at least one surface area with greater roughness.

[0054] The reinforcing component will adhere more easily to surface areas with greater roughness. Furthermore, in surface areas with greater roughness, a higher amount of reinforcing component is absorbed, and the reinforcing component penetrates more deeply into the transparent component. Therefore, the visual appearance of the floor panel can be further improved and become more natural. As an example, a grayscale effect can be achieved. The transparent component may include a wear-resistant layer and / or a primer layer and / or a topcoat layer, wherein at least one of the layers constituting the transparent component comprises a thermoplastic synthetic material.

[0055] The transparent component may include a wear-resistant layer and may further include a primer layer and / or a topcoat layer, and the method may further include the following steps:

[0056] f. Partially curing the primer and / or topcoat layers before embossing the semi-finished product; and

[0057] g. After applying the reinforcing components, fully cure the primer and / or topcoat layers.

[0058] The aforementioned steps of partially curing the primer and / or topcoat layers, and / or only fully curing these layers after embossing, allow for embossing of the relevant layers with minimal risk of defects. Furthermore, the structure of the embossed element will be more easily and fully replicated in the corresponding layer; that is, all the details set on the embossed element will be transferred to the corresponding layer to be embossed to the greatest extent possible. Simultaneously, the semi-finished product is easier to handle in production because the semi-cured component may contain less liquid than in its uncured state.

[0059] The aforementioned steps of fully curing the primer and / or topcoat layers only after the reinforcement is applied allow for enhanced adhesion of the reinforcement. One or both of the primer or topcoat layers then act as an adhesive layer that adheres to the reinforcement.

[0060] The method may further include the following steps:

[0061] h. Apply a topcoat over the reinforced component.

[0062] Applying a topcoat over the reinforcement can protect it from wear or contamination and / or better secure it to the product.

[0063] The method may further include the following steps:

[0064] i. Apply a sealant over the reinforced part before applying or forming the topcoat.

[0065] Sealant can include abrasion-resistant particles, such as corundum, to improve the lifespan of floor panels.

[0066] It is conceivable that sealants and topcoats can have different gloss levels. Preferably, as measured according to DIN 67530, the difference in gloss involves at least 6 points, preferably 10 points. Preferably, this difference makes one coat perceived as matte and the other as glossy.

[0067] For ease of application, the reinforcing component can be paint, coating, etc. Therefore, it is preferable that the reinforcing component is applied in liquid form.

[0068] The method may further include using an embossing roller for step c). The embossing roller may be a steel roller. If hot embossing is to be performed, the steel roller may be heated to a temperature between 180°C and 200°C.

[0069] The method may include using a counter-pressure roller with an embossing roller, preferably the counter-pressure roller having a rubber or synthetic rubber peripheral surface.

[0070] In one embodiment, the embossing roller has raised embossing corresponding to the relief to be applied to the transparent component, as well as areas without the raised embossing. Step c) can then be performed under pressure, such that the areas without the raised embossing contact the upper surface of the transparent component. In this way, shiny areas on the upper surface of the transparent component can be avoided or at least mitigated.

[0071] The method may include the following steps after step c) but before step b):

[0072] j) Chemically and / or mechanically degrease the upper surface of the transparent component.

[0073] In this way, better adhesion of subsequent layers can be promoted.

[0074] In particular, when a relatively large number of reinforcing components are to be applied to the upper surface of a transparent component, it may be advantageous if step b) is performed in multiple separate application steps.

[0075] The method may include the following steps: mechanically treating the covered upper surface of the transparent part, for example by grinding and / or brushing, before applying the topcoat to the sealant. Attached Figure Description

[0076] To better illustrate the features of the invention, some preferred embodiments are described below with reference to the accompanying drawings, as examples without any limiting features, wherein:

[0077] Figure 1 A floor panel according to the present invention is presented;

[0078] Figure 2 A cross-section of the floor panel of the present invention is shown;

[0079] Figures 3a to 3e Presented in a magnified manner by Figure 2 The diagram indicated by F3 in the image;

[0080] Figures 4a to 4b Presented in a magnified manner by Figure 3e The diagram indicated by F4 in the image.

[0081] Figure 5 Presented along Figure 1 Simplified cross section of line VV in the diagram;

[0082] Figure 6 A method according to the invention, applicable to the manufacture of floor panels of the present invention, is presented, and

[0083] Figure 7 A method for applying reinforcing components to the upper surface of a transparent component of a floor panel is presented. Detailed Implementation

[0084] In the accompanying drawings, reference numeral 10 generally denotes a floor panel according to the invention. The floor panel is generally rectangular and has a first pair of opposite sides 12, 13 and a second pair of opposite sides 14, 15. Figure 1 In this invention, the first pair of opposite sides is longer than the second pair of opposite sides; however, it should be understood that the principles of this invention apply to panels and tiles of any shape, including tiles with sides of equal length. Such tiles include square or polygonal tiles.

[0085] To allow multiple floor panels to be laid to form a floating floor, each floor panel may have integrated connecting portions 16, 17 at least one pair of opposite edges 12 to 13, allowing for mechanical connection between adjacent floor panels. Figure 5 Examples of such connecting portions 16 and 17 are described in more detail. The floor panel 10 further includes a top surface 18, which constitutes the surface of the floor panel 10 that is visible when the floor panel is installed on the underlying surface or subfloor.

[0086] As from Figure 2 As can be seen, the floor panel 10 of the present invention comprises multiple layers, including a substrate 20, a decorative layer 22, and a transparent component 24. At least one of these layers comprises a thermoplastic material. Figure 2 In the illustrated embodiment, substrate 20 optionally includes a first substrate layer 26 and a second substrate layer 28. The first substrate layer 26 may be rigid, semi-rigid, or flexible. The first substrate layer 26 may comprise a thermoplastic synthetic material, which may be foamed or non-foamed. By way of example only, the first substrate layer 26 may comprise PVC, soft PVC, polypropylene, or thermoplastic polyurethane. Alternatively, the first substrate layer 26 may involve a wood base layer such as MDF or HDF. Preferably, the first substrate layer 26 constitutes the majority of the thickness T of the floor panel 10. Typically, the floor panel according to the invention may have a thickness of 3.0 mm to 12.0 mm.

[0087] The second substrate layer 28 serves as an embossed layer and is located below the decorative layer 22, and preferably directly below the decorative layer. Advantageously, the embossed layer 28 comprises a material that is softer than the first substrate layer 26. This means that the floor panel 10 can be easily embossed to form a relief on the top surface 18. Furthermore, the relatively soft material imparts advantageous sound-absorbing properties to the panel. Preferably, the embossed layer 28 is combined with the first substrate layer 26 below it, which is more rigid than the embossed layer 28. Thus, in one embodiment, the first substrate layer 26 may be made of a rigid thermoplastic or wood-based material (e.g., MDF or HDF). The more rigid first substrate layer 26 can impart additional advantages to the floor panel of the present invention. For example, a strong mechanical connection can be achieved by providing integrated connecting portions 16, 17 in this layer. In addition, the more rigid material is less likely to transmit irregularities of the underlying floor (so-called "telegraphing") through the panel. Of course, it should be understood that the substrate 20 may also include other layers besides the first and second substrate layers.

[0088] like Figure 2As further shown, the decorative layer 22 is located between the substrate 20 and the transparent component 24. Therefore, the transparent component 24 serves as a wear-resistant layer and protects the underlying decorative layer 22 from dust and moisture. The decorative layer can be a preferably flexible thermoplastic film or foil, such as soft PVC foil. The decorative layer can be provided with decorations, which preferably depict natural products such as wood, stone, or ceramics. Preferably, the decorations of the decorative layer 22 are printed or embossed. This can be achieved using any of the following printing techniques: offset printing, gravure printing, or digital printing, where, for example, a digital printer or inkjet printer is used. However, other printing techniques are not excluded. In one variation, the decorations of the decorative layer 22 are directly embossed or printed onto the substrate 20, thereby forming the decorative layer 22 itself. However, it is not excluded that the decorations are embossed or printed onto a primer present on the substrate 20.

[0089] In another variation, the decorative elements of the decorative layer 22 are embossed or printed onto the lower surface of the transparent component 24. Here, the decorative elements themselves also form the decorative layer 22.

[0090] The transparent component 24 may comprise one or more layers. Each layer is transparent or translucent, allowing the decoration on the decorative layer 22 to be visible through the transparent component 24. The maximum thickness of the transparent component may be less than 0.5 mm, preferably less than 0.2 mm, and more preferably less than 0.1 mm. Preferably, the transparent component 24 serves as a wear-resistant layer. The wear-resistant layer may comprise a thermoplastic synthetic material, such as PVC or soft PVC. Preferably, the wear-resistant layer is directly above the decorative layer 22.

[0091] The transparent component 24 has an upper surface 30 opposite to the decorative layer 22. The upper surface 30 of the transparent component 24 generally extends in an upper surface plane 31. When the floor panel 10 of the present invention is laid on the subfloor, the upper surface plane 31 will be substantially parallel to the surface of the subfloor. According to the present invention, the floor panel 10 further includes a reinforcing component 32. The reinforcing component is disposed on the upper surface 30 of the transparent component 24. As will be explained below with reference to the drawings in more detail, the reinforcing component 32 has a thickness t that varies along the cross-section of the floor panel 10. ec .

[0092] The reinforcing component 32 can be a paint, coating, dye, etc., and can be water-based, oil-based, or solvent-based. In one variation, the reinforcing component is an acrylic paint, which may or may not be UV-curable. The reinforcing component 32 can be opaque, translucent, or completely transparent.

[0093] Preferably, when applied to the transparent component 24, the reinforcing component 32 includes regions of the reinforcing component 32 that have opacity, the opacity being expressed by a density number of 0.8 or greater as measured by a reflectance densitometer. Preferably, the reinforcing component 32 applied to the transparent component 24 includes at least two regions of the reinforcing component 32 that have mutually different density numbers. Preferably, in the first region, the density number is 1 or less, while in the second region, the density number is greater than 1.

[0094] Preferably, the density number of the reinforcing member 32 can be varied by the thickness or amount of the applied reinforcing member 32. Preferably, by changing the applied thickness from 10 μm to 200 μm, the density number can be increased by at least 0.3, and more preferably by at least 0.5.

[0095] In one variation, the reinforcing component 32 may include one or more of the following: colored pigments, dyes, organic particles, inorganic particles, metallic pigments, pearlescent pigments, matting agents, abrasion-resistant particles, antifouling additives, easy-cleaning additives, antifungal additives, and antibacterial additives. The amount of pigments, dyes, particles, reagents, and / or additives determines the properties of the reinforcing component 32. In one variation, the abrasion-resistant particles may be abrasion-resistant. Such particles preferably comprise hard inorganic materials, and the particle diameter is preferably greater than 30 μm, more preferably greater than 100 μm, and even more preferably up to 200 μm. In another variation, the abrasion-resistant particles may be scratch-resistant particles, preferably comprising hard inorganic materials. The diameter of such particles is preferably less than 30 μm.

[0096] When the transparent component 24 is used as a wear-resistant layer with a thickness of less than 0.2 mm, or more particularly less than 0.1 mm, or no wear-resistant layer at all, a particularly advantageous alternative is obtained by using the reinforcing component 32, which includes wear-resistant particles.

[0097] In one embodiment of the invention, the upper surface 30 of the transparent member 24 includes an area covered by the reinforcing member 32 and an area not covered by the reinforcing member. In other words, the reinforcing member 32 is disposed discontinuously on the upper surface 30 of the transparent member 24. Figure 3a One such embodiment is shown. Compared to some other embodiments of the invention, the upper surface 30 of the transparent member 24 is generally smooth. The reinforcing member 32 is disposed on the upper surface of the transparent member in such a way that the thickness t of the reinforcing member is... ec The cross-section varies along the floor panel 10.

[0098] Figure 3b Another exemplary embodiment of the invention is illustrated below. In this embodiment, an embossed relief including a recess 34 is implemented in the upper surface 30 of the transparent member 24, the recess having a depth d measured from the plane 31 of the upper surface of the transparent member.r The recess 34 is used to simulate the texture of natural products, such as wood grain. Preferably, although not required, the recess 34 is aligned with the decoration of the decorative layer 22. The depth d of the recess 34 r The depth d can vary along the cross-section of the floor panel 10. r It can vary within the range of 1μm to 1000μm, preferably within the range of 150μm to 600μm.

[0099] As in Figure 3b As can be seen, reinforcing members 32 are disposed in at least some of the recesses 34. The amount of reinforcing members 32 can vary between different recesses 34. The variation in the amount of reinforcing members can be achieved by providing recesses 34 with different volumes. The volume can vary due to differences in depth and / or width and / or length. Figure 3b , the depth d of the recess 34 r The thickness t varies along the cross-section of the floor panel 10. The reinforcing member 32 substantially completely fills the recess 34 provided therein, such that the thickness t of the reinforcing member 32 varies depending on the viscosity of the reinforcing member during its application to the upper surface 30 of the transparent member 24. ec It will tend to correspond to the depth d of the recess 34. r Due to the depth d of the recess 34 r The thickness t of the reinforcing component 32 changes, therefore ec The amount of reinforcement 32 will also vary, as the recesses 34 have varying volumes. Preferably, the reinforcement 32 is disposed in most of the recesses 34, and in the most preferred embodiment, substantially all recesses 34 include some form of reinforcement 32.

[0100] As from Figure 3b It can also be seen that the substrate of the floor panel 10 includes an embossed layer 28 directly beneath the decorative layer 22. Since the embossed layer 28 is relatively soft and the decorative layer 22 is flexible, the pressure generated when the recess 34 is formed will cause plastic deformation of both the decorative layer 22 and the embossed layer 28. Therefore, the thickness of the transparent component 24 remains substantially constant.

[0101] Figure 3c Another exemplary embodiment is shown. Similar to the second exemplary embodiment, an embossed design including recesses 34 is implemented in the upper surface 30 of the transparent member 24, and reinforcing members 32 are disposed in at least some of the recesses 34. Figure 3bCompared to the previous embodiment, the reinforcing member 32 only partially fills the recess 34 provided by the reinforcing member. Furthermore, the substrate 20 does not include the embossed layer 28. To provide the floor panel 10 with the necessary stability, the substrate 20 is relatively rigid. Therefore, the relief in the form of the recess 34 in the upper surface 30 of the transparent member 24 will not be replicated in the substrate 20. Moreover, since the substrate 20 is relatively rigid, the decorative layer 22 will remain substantially flat on the upper surface of the substrate 20.

[0102] exist Figure 3c In the diagram, the recesses 34 are shown to have different depths. Due to the varying depths of the recesses 34 and the fact that the decorative layer 22 is substantially flat, the shortest distance L between the reinforcing member 32 and the decorative layer 22 in each recess will vary along the cross-section of the floor panel 10.

[0103] Figure 3d Another exemplary embodiment is illustrated. In this embodiment, the floor panel 10 includes a first substrate layer 26, an embossed layer 28, a decorative layer 22, a transparent component 24, and a reinforcing component 32. Compared to the previously described embodiments, Figure 3d In this embodiment, the transparent component 24 is in the form of a primer and / or topcoat layer directly covering the decorative layer 22. The primer and / or topcoat layer may include a clear varnish, such as an acrylic primer, which may or may not be UV-curable. Preferably, the primer layer is below the reinforcing component 32, more preferably directly below the reinforcing component. The primer may be an acrylic primer, which may or may not be UV-curable. Recesses 34 are formed in the upper surface 30 of the floor panel 10 by deforming the embossed layer 28 and the decorative layer 22, and the transparent component 24 follows the thus deformed surface of the decorative layer 22. The reinforcing component 32 is disposed in the recesses 34. In this embodiment, the transparent component 24 is not intended to serve as an abrasion-resistant layer. Alternatively, the reinforcing component 32 may include abrasion-resistant particles. The reinforcing component 32 may be covered by a sealant 36. Preferably, the sealant 36 comprises scratch-resistant particles. The thickness of the primer, topcoat, and / or sealant may be from 5 μm to 25 μm.

[0104] In one variation, at least one of the topcoat layer, sealant 36, topcoat, and reinforcing component 32 of the transparent component 24 has a gloss level different from that of at least one of the other components. Preferably, as measured according to DIN 67530, the difference in gloss involves at least 6 points or more, preferably 10 points. Preferably, this difference causes at least one of the topcoat layer, sealant 36, topcoat, and reinforcing component 32 of the transparent component 24 to be perceived as matte, while at least one of the other components is perceived as glossy.

[0105] Figure 3e and Figure 4aAnother exemplary embodiment is shown. In this embodiment, the floor panel 10 includes a first substrate layer 26, an embossed layer 28, a decorative layer 22, a transparent component 24, and a reinforcing component 32. In this embodiment, the transparent component 24 can serve as a wear-resistant layer. An embossed design including recesses 34 is implemented in the upper surface 30 of the transparent component 24. Furthermore, the upper surface 30 of the transparent component 24 includes a surface region A provided with microstructures 38, and therefore has a greater roughness than adjacent regions of the upper surface 30. The microstructures 38 can have varying depths d. ms The depth d of the microstructure 38 ms It can vary along the cross-section of the floor panel 10. Typically, the depth d ms The roughness can vary within the range of 15 μm to 20 μm. Surface region A with greater roughness may or may not include one or more recesses 34. If surface region A with greater roughness includes recesses 34, then microstructure 38 may be disposed outside and / or inside the recesses 34.

[0106] The reinforcing member 32 can be disposed in both the recess 34 and the microstructure 38. The thickness t of the reinforcing member 32... ec The shortest distance L between the reinforcing member 32 and the decorative layer 22 will vary along the cross-section of the floor panel 10. Preferably, but not necessarily, the reinforcing member 32 is disposed in a large portion of the microstructure 38 in the surface region A with greater roughness. More preferably, the reinforcing member 32 is disposed throughout the entire microstructure 38. The thickness t of the reinforcing member 32 ec It can vary within the range of 1μm to 600μm, preferably within the range of 50μm to 600μm, and more preferably within the range of 50μm to 100μm.

[0107] Figure 4b Another exemplary embodiment is shown. This embodiment is similar to... Figure 4a In the embodiment described above, however, the microstructure 38 is also disposed in the recess 34. In this embodiment, the microstructure 38 has a depth d measured vertically along the inner surface of the recess 34 from a locally tangential direction to the surface plane 33. ms .

[0108] As mentioned above, Figure 5A floor panel 10 according to the invention is shown, which is further provided with connecting portions 16, 17. Connecting portions 16, 17 allow locking between two floor panels in this type of floor panel in the vertical direction V and the horizontal direction H, perpendicular to the connecting edge. The connecting portions 16, 17 shown are of the type that allow two such floor panels 10 to be connected together by a rotational movement W. Here, this relates to a specific type of connecting portion because the connecting portion also allows the floor panels 10 to be connected by performing a snap-fit ​​action, moving substantially horizontally relative to each other. This last mentioned connection method is not shown.

[0109] The connecting portions 16 and 17 may be in the form of a tongue 40 and a groove 42, wherein the groove 42 is defined by an upper lip edge 44 and a longer lower lip edge 46. Complementary locking elements 48 and 50 are provided, which counteract or even prevent the tongue 40 and the groove 42 from moving apart in the horizontal direction H. The locking element 48 is in the form of a protrusion on the lower surface of the tongue 40. This protrusion is adapted to interact with the locking surface of the locking element 50 on the longer lower lip edge 46.

[0110] The connecting portions 16 and 17 are essentially, and indeed entirely, manufactured as a single piece with the floor panel 10 and made of the same material as the floor panel. However, it should be understood that the connecting portions 16 and 17 may alternatively be configured as separate parts integrally connected to the floor panel 10.

[0111] Of course, other types of connection parts can be used. For example, a connection part can be set that only allows connection by rotational movement. Another type is the so-called "push-lock" connection part, which allows the floor panels to be connected by downward and substantially vertical movement.

[0112] It is not excluded that the second pair of opposite sides 14, 15 may also be provided with integrated mechanical connecting parts. These may be of the same type as the connecting parts on the first pair of opposite sides, but this is not necessarily the case. A specific embodiment is one in which a rotating connecting part is applied on the longer pair of sides, while a push-lock connecting part is applied on the shorter pair of sides. In this way, when the two floor panels 10 are engaged by rotating along their adjacent long sides, the short side of the rotated panel will engage with the push-lock connecting part on the short side of the third panel 10.

[0113] Figure 5 The top surface 18 of the floor panel 10 depicted in the image is provided with a bevel 52, which typically extends at least along the first pair of opposing edges 12, 13. It should be noted that the bevel 52 does not form part of the relief, considering that the bevel is primarily intended to simulate the effect of wood paneling rather than natural grain. Therefore, when determining the depth d of the recess 34... rWhen considering this, the depth of the inclined surface 52 should not be taken into account. However, the inclined surface may also be provided with reinforcing members, which illustrate the features of the present invention and / or its preferred embodiments. It should be understood that in this case, the thickness and depth are measured perpendicular to the inclined surface.

[0114] Although not shown in the accompanying drawings, the substrate 20 of the floor panel 10 may include one or more reinforcing layers. The reinforcing layers are preferably composed of reinforcing fibers, such as glass fibers. The reinforcing layers may be in the form of nonwoven or knitted glass fiber cloth or open mesh.

[0115] The floor panel 10 of the present invention may also have a backing layer provided on the surface of the floor panel opposite to the top surface 18. The backing layer can serve as a balancing layer to mitigate warping of the floor panel. Depending on the material of the backing layer, it can also provide other effects, such as sound damping. One useful material for the backing layer is cork. Another is a thermoplastic material. This material can provide a flexible or semi-rigid backing layer to improve sound damping. However, in alternative embodiments, it can provide a rigid backing to improve the floor panel 10's resistance to telegraphic vibrations.

[0116] Another aspect of the invention relates to a method for manufacturing a floor panel 10 having the features listed in the claims. This method in... Figure 6 It is shown schematically in the diagram.

[0117] In the first step, referred to as step a) Sa, a semi-finished product 54 is prepared. The semi-finished product 54 includes a substrate 20, a decorative layer 22, and a transparent component 24. Although the production of the semi-finished product 54 or its included layers is not shown, it should be understood that any suitable technique, such as stretching, extrusion, and / or calendering, can be used to achieve this purpose.

[0118] In one embodiment, the method includes an optional step, referred to as step f)Sf. In this embodiment, the transparent component 24 includes a primer layer and / or a topcoat layer, and in step f)Sf, the primer layer and / or topcoat layer are partially cured or pre-cured. For this purpose, one or more UV lamps 56 may be used, but other curing devices are not excluded.

[0119] The method may include various optional steps, referred to as step c)Sc, in which the semi-finished product 54 is embossed to form a relief in the upper surface 30 of the transparent component 24. Embossing can be performed using a structural element 58 via mechanical embossing techniques. The structural element 58 includes a structure for creating recesses 34 for the relief. The structural element 58 may be, for example, a pressure plate or a roller. In continuous production processes, it may be advantageous to use an embossing roller as the structural element 58, wherein the embossing roller has raised embossing corresponding to the relief to be applied to the transparent component. Optionally, the embossing roller may be a steel roller. The steel roller may be heated to, for example, between 180°C and 200°C, to achieve hot embossing. It may be advantageous to use a counter-pressure roller, for example, a counter-pressure roller with a rubber or synthetic rubber peripheral surface. By using a counter-pressure roller, it can be ensured that the embossing roller applies sufficient pressure such that the area of ​​the embossing roller without raised embossing will contact the upper surface 30 of the transparent component 24, which is generally located in the upper surface plane 31. In this way, shiny areas on the upper surface of transparent parts can be avoided or at least reduced.

[0120] Optionally, the method includes an optional step referred to as step e)Se, in which a surface region A with a greater roughness than adjacent surface regions is generated on the upper surface 30 of the transparent component 24. For this purpose, a structuring element 58 is used. The structuring element 58 includes structures for generating microstructures 38, through which greater surface roughness is achieved. Similarly, the structuring element 58 can be, for example, a pressing element or a roller, particularly a roller of the type described above.

[0121] Preferably, steps c)Sc and e)Se can be performed simultaneously. In a preferred embodiment, the structuring element 58 includes both a structure for creating the recess 34 in a single pressing operation and a structure for creating the microstructure 38. Alternatively, these steps can be performed separately, either by creating the recess 34 first and then the microstructure 38, or by creating the microstructure 38 first and then the recess 34.

[0122] The method further includes step b)Sb, in which the reinforcing member 32 is applied to the upper surface 30 of the transparent member 24. In a variation, the reinforcing member 32 can be applied by a roller 60, which can be made of rubber or any other suitable material. Other non-limiting options for applying the reinforcing member 32 may be by a blade or scraper, and by polishing and / or wiping the upper surface 30 of the transparent member 24.

[0123] In step b)Sb, the reinforcing member 32 may be applied in a discontinuous manner, such that the upper surface 30 of the transparent member 24 includes one or more covered areas covered by the reinforcing member 32, and one or more free areas not covered by the reinforcing member 32.

[0124] In the method of performing step c)Sc before step b)Sb, the reinforcing member 32 may be applied in step b)Sb to provide the reinforcing member in some of the recesses 34, preferably in most of the recesses, and more preferably in all of the recesses.

[0125] Similarly, in the method of performing step e)Se prior to step b)Sb, a reinforcing member 32 may be provided on at least one surface region A with greater roughness in step b)Sb. Preferably, but not necessarily, the reinforcing member 32 is provided in most of the microstructure 38 of the surface region A with greater roughness. More preferably, the reinforcing member 32 is provided throughout the entire microstructure 38.

[0126] In step b)Sb, the reinforcing member 32 may be applied such that, with the reinforcing member 32 provided, it can partially or substantially completely fill any recess 34 and / or microstructure 38. Each of the recesses 34 has a surface opening having an opening area, and the reinforcing member 32 has viscosity upon application. The amount of reinforcing member 32 in each recess 34 can be controlled by adjusting the opening area and / or viscosity. In a variation, the amount of reinforcing member 32 can be controlled or further controlled by drying and evaporating at least a portion of the reinforcing member 32.

[0127] If the method includes step f)Sf, then the method may also preferably include step g)Sg. In step g)Sg, the primer and / or topcoat layer, which is at least partially covered by the reinforcing member 32, is fully cured after step b)Sb. For this purpose, one or more UV lamps 56 may be used, but other curing devices are not excluded.

[0128] In one embodiment, the method includes an optional step referred to as step d)Sd. This step is not explicitly shown in the figures. In step d)Sd, the reinforcing member 32 is mechanically treated, such as by grinding and / or brushing. This is then combined with... Figure 7 Describe this step.

[0129] In one embodiment, the method includes an optional step referred to as step i)Si. In this step, a sealant 36 is applied over the reinforcing member 32. For this purpose, a roller or other suitable device may be used. After the sealant is applied, it may optionally be cured by heating and / or radiation and / or (forced) drying. The sealant 36 may include abrasion-resistant particles, such as corundum.

[0130] In one embodiment, the method includes an optional step referred to as step h)Sh. In this step, a topcoat is applied over the reinforcing member 32 and / or the sealant 36. For this purpose, a roller or other suitable device may be used. After the topcoat is applied, it may optionally be cured by heating and / or radiation and / or (forced) drying.

[0131] Figure 7 A variation of the above method is illustrated schematically. For clarity, Figure 7 The above has already been shown regarding Figure 6 The described structured element 58 is a semi-finished transparent component 24 after embossing. Before applying reinforcing components, the upper surface 30 of the transparent component 24 can be chemically and / or mechanically degreased to improve the adhesion of subsequent components to the upper surface. This degreasing step is designated as step j)Sj. The upper surface 30 of the transparent component can then be dried in a drying step k)Sk. Drying can be carried out by natural convection or forced convection. Reinforcing components 32 are then applied in a first application step b)Sbl, or more specifically, at least some reinforcing components are applied. As described above regarding... Figure 6 As explained, the reinforcing member 32 can be applied by a roller 60, which can be made of rubber or any other suitable material. Other non-limiting options for applying the reinforcing member 32 may be by a blade or scraper, and by polishing and / or wiping the upper surface 30 of the transparent member 24. To ensure that the reinforcing member adequately fills any microstructures 38, it may be advantageous to subsequently subject the upper surface 30 of the transparent member to a rolling operation, such as a rolling operation performed by one or more steel rollers 62.

[0132] In particular, when the relief in the upper surface of the transparent component includes relatively deep recesses 34, it may be advantageous to apply the reinforcing member in multiple application steps. Therefore, as indicated by reference numeral Sb2, the method of the present invention may include a second application step b)Sb2. The same or similar equipment used in the first application step b)Sb1 can be used for the second application step b)Sb2. Depending on the amount of reinforcing member 32 to be applied to the upper surface of the transparent component, it is certainly conceivable to provide more than two application steps. To ensure a uniform distribution of the amount of reinforcing member 32 applied, the upper surface 30 of the transparent component 24 may optionally undergo one or more rolling operations downstream of the second application step b)Sb2. The rolling operations (one or more) can be performed by… Figure 7 The reference numeral 64 in the figure indicates one or more rollers. The rollers 64 may be made of steel or rubber.

[0133] Once the desired amount of reinforcing material has been applied to the upper surface of the transparent component, a sealant 36 can be applied in step i)Si. This can be done using one or more rollers 66 or other suitable devices. The sealant may include abrasion-resistant particles, such as corundum, to improve the lifespan of the floor panel. After the sealant is applied, in step d)Sd, the upper surface of the thus-covered transparent component can be mechanically treated, such as by grinding and / or brushing. Finally, a topcoat 68 can be applied over the sealant 36. This step is labeled as step h)Sh in the figures and can be applied using rollers 70 or other suitable devices. After the topcoat is applied, it can optionally be cured by heating and / or radiation and / or (forced) drying.

[0134] The resulting laminate can then be cut and / or machined to produce floor panels according to the invention.

[0135] Preferred embodiments and variations of the invention are defined in the following numbered items:

[0136] 1. A floor panel 10, comprising: a substrate 20, a decorative layer 22, and a transparent component 24, the decorative layer 22 being located between the substrate 20 and the transparent component 24, wherein at least one of the substrate 20, the decorative layer 22, and the transparent component 24 comprises a thermoplastic synthetic material, the transparent component 24 having an upper surface 30 opposite to the decorative layer 22, wherein the floor panel 10 further comprises a reinforcing component 32 disposed on the upper surface 30 of the transparent component 24, and wherein the thickness t of the reinforcing component 32 is... ec The cross-section varies along the floor panel 10.

[0137] 2. The floor panel 10 according to Item 1, wherein the reinforcing member 32 is disposed discontinuously on the upper surface 30 of the transparent member 24, such that the upper surface 30 includes one or more covered areas covered by the reinforcing member 32, and one or more free areas not covered by the reinforcing member 32.

[0138] 3. The floor panel 10 according to item 1 or 2, wherein an embossed design is provided in the upper surface 30 of the transparent member 24, the embossed design including recesses 34, and wherein the reinforcing member 32 is disposed in some of the recesses 34, preferably in most of the recesses, and more preferably in all of the recesses.

[0139] 4. The floor panel 10 according to item 3, wherein the amount of the reinforcing member 32 in the recess 34 varies between different recesses 34 and / or varies along the cross section of the floor panel 10.

[0140] 5. The floor panel 10 according to item 3 or 4, wherein the recess 34 has a depth d r And wherein the depth d r The cross-section varies along the floor panel 10.

[0141] 6. The floor panel 10 according to any one of items 3 to 5, wherein the shortest distance L between the reinforcing member 32 and the decorative layer 22 varies along the cross section of the floor panel 10.

[0142] 7. The floor panel 10 according to any one of items 3 to 6, wherein the reinforcing member 32 partially fills one or more recesses 34 of the reinforcing member.

[0143] 8. The floor panel 10 according to any one of items 3 to 6, wherein the reinforcing member 32 substantially completely fills one or more recesses 34 in which the reinforcing member is disposed.

[0144] 9. The floor panel 10 according to any one of items 2 to 8, wherein at least one of the covered areas includes a surface area A, the surface area having a greater roughness than the adjacent surface areas.

[0145] 10. The floor panel 10 according to any one of the preceding items, wherein the reinforcing member 32 is paint, coating, etc.

[0146] 11. The floor panel 10 according to item 10, wherein the reinforcing member 32 is opaque.

[0147] 12. The floor panel 10 according to item 10, wherein the reinforcing member 32 is translucent.

[0148] 13. The floor panel 10 according to item 10, wherein the reinforcing member 32 is completely transparent.

[0149] 14. The floor panel 10 according to any one of items 10 to 13, wherein the reinforcing member 32 is a water-based product and / or a solvent-based product.

[0150] 15. The floor panel 10 according to any one of items 10 to 14, wherein the reinforcing member 32 is a water-based UV-curable product.

[0151] 16. The floor panel 10 according to any one of items 10 to 13, wherein the reinforcing member 32 is an oil-based product.

[0152] 17. The floor panel 10 according to any one of items 10 to 12, wherein the reinforcing member 32 is a paint, preferably an acrylic paint, more preferably an energy-curable acrylic paint, and even more preferably a UV-curable acrylic paint.

[0153] 18. The floor panel 10 according to any one of items 10 to 17, wherein the reinforcing component 32 comprises one or more of the following: colored pigments, dyes, metallic pigments, pearlescent pigments, matting agents, abrasion-resistant particles, stain-resistant additives, easy-cleaning additives, mildew-resistant additives, and antibacterial additives.

[0154] 19. The floor panel 10 according to item 18, wherein the reinforcing member 32 comprises abrasion-resistant particles, and wherein the thickness of the transparent member 24 is 0.2 mm or less, preferably 0.1 mm or less.

[0155] 20. The floor panel 10 according to any one of the preceding items, wherein a sealant 36 and / or a topcoat are disposed on the top of the reinforcing member.

[0156] 21. The floor panel 10 according to any of the foregoing items, wherein the transparent component 24 includes an abrasion-resistant layer and / or a primer layer and / or a topcoat layer, wherein at least one layer constituting the transparent component 24 comprises a thermoplastic synthetic material.

[0157] 22. The floor panel 10 according to any one of the preceding items, wherein the substrate 20, the decorative layer 22 and the transparent component 24 comprise thermoplastic synthetic materials.

[0158] 23. The floor panel 10 according to any one of the preceding items, wherein the thermoplastic synthetic material is polyvinyl chloride, preferably flexible polyvinyl chloride.

[0159] 24. A floor panel comprising a substrate 20, a decorative layer 22, and a transparent member 24, the decorative layer 22 being located between the substrate 20 and the transparent member 24, wherein at least one of the substrate 20, the decorative layer 22, and the transparent member 24 comprises a thermoplastic synthetic material, the transparent member 24 having an upper surface 30 opposite to the decorative layer 22, wherein the floor panel 20 further comprises a reinforcing member 32, wherein the reinforcing member 32 is disposed discontinuously on the upper surface 30 of the transparent member 24 such that the upper surface 30 includes one or more covered areas covered by the reinforcing member 32, and one or more free areas not covered by the reinforcing member 32, wherein at least one of the covered areas includes a surface area A, the surface area being provided with microstructures 38 and thus having a greater roughness than adjacent surface areas, wherein the reinforcing member 32 is disposed throughout the microstructures 38, and the thickness t of the reinforcing member 32 is... ec The cross-section along the floor panel 10 varies in the range of 1 μm to 600 μm.

[0160] 25. A floor panel 10 comprising a substrate 20, a decorative layer 22, and a transparent component 24, the decorative layer 22 being located between the substrate 20 and the transparent component 24, wherein at least one of the substrate 20, the decorative layer 22, and the transparent component 24 comprises a thermoplastic synthetic material, the transparent component 24 having an upper surface 30 opposite to the decorative layer 22, wherein the floor panel 10 further comprises a reinforcing component 32 disposed on the upper surface 30 of the transparent component 24, the upper surface 30 of the transparent component having an embossed design, wherein a majority of the volume of the reinforcing component disposed on the upper surface of the transparent component is contained within the embossed design.

[0161] 26. The floor panel 10 according to item 25, wherein the relief is in the form of a recess 34 having varying depths.

[0162] The present invention is not limited to the embodiments shown in the accompanying drawings and described above, but may be varied in different ways within the scope of the appended claims.

Claims

1. A floor panel, comprising: The substrate (20), decorative layer (22), and transparent component (24) are provided, wherein the decorative layer (22) is located between the substrate (20) and the transparent component (24), wherein at least one of the substrate (20), the decorative layer (22), and the transparent component (24) comprises a thermoplastic synthetic material, the transparent component (24) having an upper surface (30) opposite to the decorative layer (22), wherein an embossed relief is formed in the upper surface (30) of the transparent component (24), the embossed relief comprising a recess (34), wherein the floor panel (10) further comprises a reinforcing component (32) disposed in the recess (34), and wherein the thickness (t) of the reinforcing component (32) is specified. ec The cross-sectional variation along the floor panel (10) is characterized in that the reinforcing member (32) is disposed discontinuously on the upper surface (30) of the transparent member (24), such that the upper surface (30) includes one or more covered areas covered by the reinforcing member (32) and one or more free areas not covered by the reinforcing member (32); and wherein at least one of the covered areas includes a surface region (A) having a roughness greater than that of the adjacent surface region.

2. The floor panel according to claim 1, wherein, The reinforcing member (32) is disposed in a portion of the recess (34).

3. The floor panel according to claim 2, wherein, The amount of reinforcing member (32) in the recess (34) varies between different recesses (34) and / or along the cross section of the floor panel (10).

4. The floor panel according to claim 2 or 3, wherein, The recess (34) has a depth (dr), and the depth (dr) varies along the cross section of the floor panel (10).

5. The floor panel according to claim 2 or 3, wherein, The shortest distance (L) between the reinforcing member (32) and the decorative layer (22) varies along the cross section of the floor panel (10).

6. The floor panel according to claim 2 or 3, wherein, The reinforcing member (32) partially fills one or more recesses (34) of the reinforcing member.

7. The floor panel according to claim 2 or 3, wherein, The reinforcing member (32) completely fills one or more recesses (34) where the reinforcing member is disposed.

8. The floor panel according to any one of claims 1 to 3, wherein, The reinforcing component (32) is a coating.

9. The floor panel according to claim 8, wherein, The reinforcing component (32) is opaque.

10. The floor panel according to claim 8, wherein, The reinforcing component (32) is translucent.

11. The floor panel according to claim 8, wherein, The reinforcing component (32) includes one or more of the following: colored pigments, dyes, metallic pigments, pearlescent pigments, matting agents, abrasion-resistant particles, antifouling additives, easy-cleaning additives, antifungal additives, and antibacterial additives.

12. The floor panel according to claim 11, wherein, The reinforcing component (32) includes wear-resistant particles, and the transparent component (24) has a thickness of 0.2 mm or less.

13. The floor panel according to any one of claims 1 to 3, wherein, A sealant (36) and / or a topcoat are applied above the reinforcing member (32).

14. The floor panel according to claim 2, wherein, The reinforcing member (32) is disposed in most of the recess.

15. The floor panel according to claim 14, wherein, The reinforcing member (32) is disposed in the entire recess.

16. The floor panel according to claim 8, wherein, The coating is lacquer.

17. The floor panel according to claim 12, wherein, The thickness of the transparent component (24) is 0.1 mm or less.

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