Floor element and method for manufacturing floor elements

Abstract

A floor element includes a decorative top layer on a polymer substrate. The sides of the floor element have a profile along a section with a surface at right angles to the decorative top layer. The floor panel is provided with a water-repellent coating on at least one side. For each side and along the entire length of the side, at least a part of the profile is coated with a water-repellent coating.

1 . A floor element comprising:
 a decorative top layer located on a water-resistant polymer substrate, wherein sides of the floor element have a profile along a section with a surface at right angles to the decorative top layer,   wherein two opposing sides of the floor element are provided with coupling means configured to couple two adjacent floor elements together, wherein at least one of said opposing sides of the floor element is provided with a water-repellent coating in such manner that the water-resistant polymer substrate is covered with the water-repellant coating, and wherein said water-resistant polymer substrate comprises polymers and fillers.   
     
     
         2 . The floor element of  claim 1 , wherein both said opposing sides of the floor element are provided with a water-repellent coating. 
     
     
         3 . The floor element of  claim 1 , wherein the polymers are chosen from the list of: polyvinyl chloride, polypropylene, polyethylene, polyurethane, polyamide or polyester, such as polyethylene terephthalate. 
     
     
         4 . The floor element of  claim 3 , wherein the fillers are chosen from the list of: glass fibers, calcium hydroxide (slaked lime), calcium carbonate, calcium hydrogen carbonate, CaMg(CO 3 ) 2 , talcum, and/or microsphere. 
     
     
         5 . The floor element of  claim 4 , wherein the water-resistant polymer substrate comprises at least 70 wt % of fillers. 
     
     
         6 . The floor element of  claim 1 , wherein the water-resistant polymer substrate comprises less than 10 phr of plasticizers. 
     
     
         7 . The floor element of  claim 1 , wherein the water-repellent coating comprises at least one of epoxy resin, fluoride-functionalized epoxy resin, fluoropolymers, fluorocopolymers, fluoride-functionalized acrylate or combinations thereof. 
     
     
         8 . The floor element of  claim 1 , wherein the water-repellent coating in equilibrium has a contact angle with water which is greater than 100°, wherein this contact angle is measured by the water droplet. 
     
     
         9 . The floor element of  claim 1 , wherein the water-resistant polymer substrate consist of several substrate layers and comprises a first substrate layer directly under the decorative top layer and a second substrate layer directly under the first substrate layer, wherein the first substrate layer is softer than the second substrate layer. 
     
     
         10 . The floor element of  claim 1 , wherein the water-resistant polymer substrate is foamed. 
     
     
         11 . The floor element of  claim 1 , wherein the water-resistant polymer substrate comprises other substances chosen from the list of: pigments and colorants, preservatives, anti-fungi, thermal stabilizers, UV-stabilizers, blowing agents, viscosity control agents. 
     
     
         12 . The floor element of  claim 1 , wherein the decorative top layer comprises a wood veneer layer, wherein the wood veneer layer is covered with the water-repellant coating. 
     
     
         13 . A method for manufacturing a floor element, comprising the following steps:
 providing a rectangular or square water-resistant polymer substrate, wherein a decorative top layer is located on the water-resistant polymer substrate, and wherein sides of the water-resistant polymer substrate have a profile along a section with a surface at right angles to the decorative top layer, wherein two opposing sides are provided with coupling means;   providing at least one of said two opposing sides with a solvent-based cover layer, said solvent-based cover layer comprising water-repellent components;   removing the solvent from the solvent-based cover layer until a water-repellent coating is obtained.   
     
     
         14 . The method of  claim 13 , wherein the water-repellent components comprise epoxy resin and/or fluoride-functionalized epoxy resin and/or fluoropolymers and/or fluorocopolymers and/or fluoride-functionalized acrylate. 
     
     
         15 . The method as in  claim 13 , wherein providing a solvent-based cover layer is achieved by spraying on the solvent-based cover layer or by applying it with a brush or via a transfer roller. 
     
     
         16 . The method as in  claim 13 , wherein the opposing sides are both provided with the solvent-based cover layer along the entire length of the opposing sides. 
     
     
         17 . The method of  claim 13 , wherein the water-resistant polymer substrate comprises polymers chosen from the list of: polyvinyl chloride, polypropylene, polyethylene, polyurethane, polyamide or polyester, such as polyethylene terephthalate. 
     
     
         18 . The method of  claim 17 , wherein the water-resistant polymer substrate comprises fillers chosen from the list of: glass fibers, calcium hydroxide (slaked lime), calcium carbonate, calcium hydrogen carbonate, CaMg(CO 3 ) 2 , talcum, and/or microsphere. 
     
     
         19 . The method of  claim 18 , wherein the water-resistant polymer substrate comprises at least 70 wt % of fillers. 
     
     
         20 . The method of  claim 13 , wherein the water-resistant polymer substrate comprises less than 10 phr of plasticizers.