AT15188U1 - Floor support, arrangement with a floor support and a floor covering as well as apparatus and method for producing the floor support - Google Patents

Abstract

Ground support (10) having a nonwoven fabric layer (12) serving as a carrier layer (11), which has a plurality of perforations (14), wherein the perforations (14) already during the nonwoven fabric production before or during the solidification of the initially unconsolidated nonwoven material (23) with a lower layer (35) of a first layer material (S1) and an upper layer (36) of a second layer material (S2), wherein the first layer material (S1) and the second layer material (S2) comprise a plastic (K) and filler particles (P) of a filler disposed distributed in the plastic (K), and wherein the top layer (36) is disposed on an upper surface (15) of the nonwoven fabric layer (12) and the lower layer (35) is formed on a lower surface (16) of the nonwoven fabric layer (12) is arranged directly and the two layers (35, 36) by means of through the openings (14) extending through connecting webs (38) are connected directly to each other, wherein the Ver connecting webs (38) consist of the first layer material (S1) and / or second layer material (S2).

Description

Description [0001] The invention relates to a ground support, an arrangement having a ground support, and an apparatus and a method for producing the ground support. The floor covering can serve as an intermediate layer between a substrate and a floor covering or even directly represent the floor covering.

[0002] E in low-emission floor covering is known from EP 1 086 176 B1. The floor covering should be wear-resistant, low-emission, resistant to aging and variably colored with an appealing appearance. It is made of a plastic, which is prepared as a polymeric binder at least one elastomer based on at least one polyolefin and at least one graft copolymer. The plastic may have fillers such as quartz flour, kaolin, talc, chalk, wood flour, dolomite. The plastic is applied on one side to a present in web form carrier. As the support, a natural and / or synthetic woven or knitted fabric, textile materials, nonwoven or nonwoven fabric can be used.

DE 32 37 633 A1 describes a method for producing an electrically conductive floor covering, in particular for operating theaters and in hazardous areas. This is made of a top layer and a bottom layer, wherein the top layer consists of a material which has a higher flow viscosity during pressing and vulcanization than the material of the bottom layer. The upper layer can be made of wood, textile, an uncrosslinked rubber or plastic, for example. For the underlayer, a rubber-elastic material such as polyester or polyamide can be used. There are perforations in the topsheet which are filled from the backsheet to the surface of the flooring. The openings can be introduced by punching, cutting or drilling in the upper class.

The invention has for its object to improve the ground support, so that it is easy to manufacture while still achieving a good foot and room sound insulation.

This object is achieved by a ground support with the features of claim 1, an arrangement with the features of claim 25, an apparatus for producing a ground support with the features of claim 26 and a method for producing a ground support with the features of claim 29 solved.

The ground support has a nonwoven fabric layer serving as a carrier layer. The nonwoven fabric layer has a plurality of apertures, wherein the apertures are already produced during the nonwoven fabric production before or during the solidification of the nonwoven material. The nonwoven fabric layer has an upper side and a lower side opposite the upper side. On the underside there is a lower layer of a first layer material and on the upper side an upper layer of a second layer material is arranged. The upper layer and the lower layer are each directly adjacent to the nonwoven fabric layer, wherein a particular cohesive and / or positive connection can be made. The first layer material and the second layer material each have a plastic and a filler arranged distributed in the plastic. The filler consists of a plurality of filler particles, which are distributed as homogeneously as possible in the plastic of the respective layer material.

The upper layer and the lower layer are connected directly by connecting webs. The connecting webs pass through the openings in the nonwoven fabric layer. There is a material connection between the upper layer and the lower layer via the connecting webs. The connecting webs consist of the first layer material and / or the second layer material. The nonwoven fabric layer is held between the upper layer and the lower layer.

The filler is powdery or free-flowing and consists of filler particles having a solid state of aggregation at normal room temperatures or during the production of the ground support.

The ground support can be used advantageously as tread and / or room sound damping pad. The ground support can be placed, for example, on a substrate, such as a screed. It can either be used directly as a floor covering or serve as an intermediate layer between the substrate and another floor covering. On the floor covering any flooring can be placed, for example, parquet, laminate, tiles, flagstones or other particular soundproof floor coverings from all eligible flooring materials. The ground support is not materially connected to the ground to form the arrangement and when used as an intermediate layer between a floor covering and a substrate, but laid floating on the ground. The floor covering is preferably adhesively bonded to the upper layer by means of an adhesive coating. If the bottom support itself serves as a floor covering, a sealing coating can be arranged on the top layer.

The invention is based on the finding that a nonwoven fabric layer, in which the openings are produced before or during the solidification of the nonwoven material, brings significant advantages as a support layer for the ground support. On the one hand, carrier layers made of a fabric are very expensive and inelastic. Carrier layers made of a knitted or knitted fabric are in turn too flexible and also clearly too expensive. A nonwoven fabric layer or nonwoven fabric layer in which the apertures are introduced by punching, cutting or another method of separation obstructs the coating of the carrier layer with the layer materials. The cut off during the separation to produce the openings threads complicate the coating process. In addition, the mechanical stability of a nonwoven fabric layer or nonwoven fabric layer is too low, in particular in the case of a tensile load in the direction of the plane in which the nonwoven fabric layer extends.

Therefore, according to the invention, a nonwoven fabric layer is used. Such a nonwoven fabric layer can be produced in sufficient strength. By solidification, the tensile load of the nonwoven fabric layer in the extension plane is sufficiently large. Characterized in that the nonwoven fabric layer is formed such that it has openings produced at or before the solidification, the severing of fibers in the region of the openings is avoided. The openings are formed by a displacement of the fibers without a Trennvervorgang. As a result, the coating of the nonwoven fabric layer serving as a carrier layer with the upper layer and the lower layer is considerably simplified. Such a ground support can be industrially produced economically.

By means of the ground support a reduction of footfall noise by about 20 dB and reduction of the noise could be achieved by about 30%.

It is advantageous if the first layer material and the second layer material have the same plastic and / or the same filler. For example, the proportions of the filler compared to the plastic in the two layer materials may be different. In a further embodiment, it is also possible that the two layer materials are identical.

In an embodiment in which the second layer material of the upper layer contains a larger proportion by weight of the filler than the first layer material of the lower layer, the abrasion resistance of the upper layer can be increased. The upper layer is usually exposed to greater loads, especially when the ground support serves as a floor covering. The proportion by weight is based on a volume weight of the respective layer material. In other words, in this embodiment, in an identical volume in the first layer material, a smaller amount of the respective filler is contained than in the second layer material.

The filler particles of the first layer material and / or the second layer material may consist of a mineral material and / or of an electrically conductive material. The filler for the first layer material and / or the second layer material may comprise first filler particles of chalk and / or second filler particles of a silicate or a silicate mixture and / or third filler particles of an electrically conductive material. The filler particles of an electrically conductive material are preferably present exclusively in the upper layer, ie in the second layer material, in order to prevent electrostatic charging of the ground support.

As the plastic for the first layer material and / or the second layer material, an acrylate can be used. In one embodiment, the first layer material and / or the second layer material may consist exclusively of an acrylate and a respective filler. The cost of the layer materials are low and the coating of the nonwoven layer is very easy to carry out industrially.

By using an acrylate and / or a filler of chalk and / or a silicate or a silicate mixture, in addition to the simple and cost-effective production of the ground support also advantageously achieved a fire protection class B1 for the ground support.

It is also advantageous if the proportion by weight of the filler in the first layer material and / or the second layer material is smaller than the weight fraction of the plastic based on the basis weight of the respective layer material. The basis weight is the weight of the respective layer material when it covers a given area. Since the proportions by weight of the filler and of the plastic increase or decrease equally with the thickness of the layer material, the weight fraction based on the weight per unit area can be considered here.

It is also advantageous if the first layer material and / or the second layer material additionally contains a plastic and / or elastic deformability facilitating additive. The proportion by weight of the additive may be at least 10% and / or at most 20%, based on the basis weight of the relevant first and / or second layer material. The additive can provide a better adaptation of the ground support to the ground in the lower layer without creating voids which can act as resonance cavities. In the top layer, the additive can provide a suitable match to a floor covering and avoid voids between the top layer and the floor covering. As an additive, for example, a polyacrylate dispersion can be used. In particular, phthalates are avoided as an additive.

The basis weight of the nonwoven fabric layer may be at least 80 g / m 2 in one embodiment.

The nonwoven fabric layer comprises fibers of at least one synthetic fiber material. In one embodiment, the nonwoven fabric layer may include first fibers of a synthetic fiber material and second fibers of another synthetic fiber material. The first fibers may for example consist of viscose. The second fibers may be made of polyester, for example. Other polymeric synthetic fiber materials can also be used for the fibers of the nonwoven fabric layer.

The first and / or second fibers may alternatively also be natural fibers, for example of cotton.

In one embodiment, the nonwoven fabric layer and / or the fibers of the nonwoven fabric layer may also have a finishing agent in order to prevent or restrict the penetration of the relevant layer material into the nonwoven fabric layer during the application of the first or second layer material.

In one embodiment, the weight fraction of the first fibers may be greater than the weight fraction of the second fibers, based on the basis weight of the nonwoven fabric layer. For example, it is possible that the proportion by weight of the first fibers is at most 60% and / or that the proportion by weight of the second fibers is at most 40%.

The nonwoven fabric layer may also contain a binder whose weight fraction is at most 8%, based on the basis weight of the nonwoven fabric layer. According to the proportion by weight of the binder, the proportion by weight of the first fibers and / or the second fibers is reduced.

It is advantageous if the thickness of the nonwoven fabric layer is at least 0.5 mm and / or at most 1.5 mm. In a preferred embodiment, the nonwoven fabric layer has a thickness of 1.0 mm. This provides a sufficient distance between the upper layer and the lower layer. It is also ensured that a direct connection of the first layer material with the second layer material is limited to the openings in the nonwoven fabric layer.

It is also advantageous if the cross-sectional area of each aperture is at least 1.0 mm 2 and / or at most 10.0 mm 2. Preferably, the cross-sectional area of an aperture has a size of 4.0 mm 2. The contour of an opening can be arbitrary. For example, rectangular or other polygonal cross-sectional contours such as circular or elliptical cross-sectional contours may be provided. In the specified range, the cross-sectional area ensures that sufficiently thick connecting webs between the upper layer and the lower layer arise.

The sum of the cross-sectional areas of all apertures of the nonwoven fabric layer forms a total aperture area. The proportion of this total breakthrough area on the surface area of the nonwoven fabric layer is preferably at least 20% and / or at most 60%. On the other hand, the mechanical stability on the one hand and the impact sound insulation and the sound insulation on the other hand are particularly good in this area.

The total thickness of the ground support is in one embodiment at least 1.0 mm and / or a maximum of 5.0 mm and preferably 2.5 mm.

The ground support may have a basis weight of at least 2000 g / m 2.

In addition, in a preferred embodiment, the ground support may have a thermal resistance which is at most 0.15 m2K / W.

It is advantageous that a sealing coating is arranged on the upper coating, in particular when the ground support simultaneously represents the floor covering.

The durability, the abrasion resistance and the resistance to chemicals can be improved.

Preferably, the ground support is placed directly on the ground with the lower layer without producing a cohesive connection. In order to avoid a displacement of the ground support against the substrate and to increase the static friction, an adhesive coating may be present on the lower layer on a side facing away from the nonwoven fabric layer.

It is also preferred if the acoustic characteristic impedance of the filler particles of the filler of the first layer material and / or the second layer material is greater than the acoustic characteristic impedance of the plastic.

With the help of this ground support, an arrangement can be made. The assembly comprises: - a base, [0038] - a floor covering, [0039] - a floor covering, as described above, which is arranged between the base and the floor covering.

The described ground support can be produced by means of a device which has a nonwoven production device for producing a nonwoven fabric layer. This nonwoven production device is adapted to produce a plurality of openings already during the production of the nonwoven fabric layer before or during the solidification of the initially unconsolidated nonwoven material, namely without carrying out a separation process (cutting,

Punching, etc.), but in particular exclusively by displacement of fibers. The apparatus further comprises a coating device configured to apply a lower layer of a first layer material to a lower surface of the nonwoven fabric layer and to apply an upper layer of a second layer material to an upper surface of the nonwoven fabric layer. The first and the second layer material contain a plastic and distributed in plastic filler particles of a filler. The coating device is also adapted to produce during application of the upper layer and / or during application of the lower layer connecting webs, which consist of the first and the second layer material, such that the connecting webs pass through the apertures and a direct connection between the upper layer and the lower layer. The coating device preferably applies the first layer material and / or the second layer material in flowable form to the nonwoven fabric layer, and the layer material then cures.

In a preferred embodiment, the nonwoven production device may be configured to produce a plurality of water jets for solidifying the nonwoven fabric by means of a water jet nozzle arrangement. In this case, the nonwoven production device can also be designed to align and / or move the water jets by means of the water jet nozzle arrangement during solidification of the nonwoven material in such a way that the nonwoven fabric layer is solidified and, in addition, the openings are produced. With such a hydroentanglement, the nonwoven fabric layer with the openings can be produced simply and efficiently.

In addition, in another embodiment, the nonwoven manufacturing device may be adapted to form the openings in an unconsolidated nonwoven material by means of a nub roller arrangement. The nonwoven manufacturing device may also be configured to subsequently solidify the apertured nonwoven material by applying a solidifying fluid. Such a solidifying fluid can, for example, be sprayed onto the still unconsolidated nonwoven material with the apertures.

[0043] A method for producing the ground support with the steps described below can also be carried out independently of the device described with other devices: - Producing a nonwoven fabric layer having a plurality of openings, wherein the openings already in the manufacture of the [0045] application of a lower layer of a first layer material to a lower side of the nonwoven layer, [0046] application of an upper layer of a second layer material to an upper side of the nonwoven layer, Wherein the first layer material and the second layer material comprise a plastic and filler particles of a filler distributed in the plastic, connecting webs being produced from the first and / or second layer material during the application of the upper and / or the lower layer l and which extend through the apertures and wherein the connecting webs connect directly after the application of the upper layer and the lower layer, these two layers.

Advantageous embodiments of the invention will become apparent from the dependent claims, the description and the drawings. Hereinafter, preferred embodiments of the invention will be explained in detail with reference to the accompanying drawings. 1 shows an embodiment of a ground support in a schematic Prin zipdarstellung, Figure 2 shows an embodiment of an arrangement with a ground support and a floor covering on a substrate in a schematic schematic diagram, Fig. 3 and 4 each an embodiment of a nonwoven manufacturing device for

5 shows a schematic basic illustration of a nonwoven fabric layer with openings in plan view, and [0054] FIG. 6 shows an embodiment of a device for producing a floor covering in a schematic, block diagram-like illustration.

In Fig. 1, an embodiment of a bottom support 10 is shown schematically. The bottom support 10 has a multilayer structure and comprises, for example, at least three layers, of which at least two consist of different materials or material mixtures.

The ground support 10 has a carrier layer 11 of textile material. The carrier layer 11 is formed by a nonwoven fabric layer 12 of compacted nonwoven fabric. In Fig. 5, a nonwoven web 13 is schematically illustrated in plan view. A nonwoven web 13 or a plurality of juxtaposed nonwoven webs 13 may be used to form the nonwoven fabric layer 12. The nonwoven web 13 is made by solidifying fibers which are entangled with each other. A loose Gewrfasergelege or a non-dense nonwoven material is solidified by an action, such as a mechanical action and / or a fluidic action and / or a chemical action, so that a tensile forces receiving textile part is formed. The nonwoven web 13 and thus the nonwoven fabric layer 12 has a plurality of openings 14. The apertures 14 may be arranged distributed in a pattern, for example in matrix form in rows and columns in the plane in which the nonwoven web 13 and the nonwoven fabric layer 12 extends.

Each aperture 14 has a cross-sectional area AQ. In Fig. 5, one of the cross-sectional areas AQ is shown schematically by cross-hatching. The amount of the cross-sectional area AQ is in the range of 1.0 mm 2. The contour of the openings 14 may be polygonal, for example rectangular or square, as illustrated in FIG. 5. Deviating from this, the contour of the openings 14 may also be without corners, approximately circular or elliptical. The perforations 14 completely penetrate the nonwoven web 13 or the nonwoven fabric layer 12 from an upper side 15 to a lower side 16.

The sum of all cross-sectional areas AQ of the apertures 14 forms a total aperture area. The total breakdown area has a portion of the surface of the nonwoven fabric layer 12 of at least 20% and at most 60%.

The nonwoven fabric layer 12 in the embodiment has a thickness DV of at least 0.5 mm and a maximum of 1.5 mm, wherein the thickness DV of the nonwoven fabric layer 12 is for example 1.0 mm. The nonwoven fabric layer 12 has, for example, a basis weight of at least 80 g / m 2.

The nonwoven fabric layer 12 or the nonwoven web 13 consists of intertwined fibers, for example synthetic fibers. It may also be a mixture of several synthetic fibers of different materials. In a preferred embodiment, nonwoven fabric layer 12 contains first fibers of a synthetic fiber material, preferably viscose, and second fibers of another synthetic fiber material, preferably polyester. Other fibers made of other materials are not available here. Alternatively, at least a portion of the fibers could also be formed by natural fibers, for example cotton fibers.

By way of example, the proportion by weight of the first fibers of viscose is greater than that

Weight fraction of the second fibers of polyester, based on the basis weight of the nonwoven fabric layer 12. The weight fraction of the viscose fibers in the embodiment is a maximum of 60% and the weight fraction of the polyester fibers is not more than 40%. For bonding the fibers, a binder may be included in the nonwoven fabric layer 12, particularly in the production of the nonwoven fabric layer 12 by a wet-laid process. The binder may have a weight fraction of not more than 8% based on the basis weight of the nonwoven fabric layer 12. Accordingly, the proportion by weight of the first fibers and / or the second fibers decreases. For example, regardless of the amount of binder, the weight ratio of the first fibers to the weight ratio of the second fibers of 3 to 2 is maintained.

The apertures 14 in the nonwoven fabric layer 12 are already made during the manufacture of the nonwoven web 13 before or during solidification by displacement of fibers. This has the advantage that no fibers are cut or separated during the production of the openings 14. This simplifies the further processing, in particular the coating, as described below.

FIGS. 3 and 4 each schematically illustrate a nonwoven manufacturing device 20. In the embodiment according to FIG. 3, the nonwoven production device 20 has a water jet nozzle arrangement 21, of which only one water jet nozzle 22 can be seen in FIG. From the water jet nozzles 22 emerges a needle-like water jet and is directed to the unconsolidated nonwoven material 23. By the water jets the nonwoven material is compacted and solidified. In the embodiment, a pad, on which the still uncompacted nonwoven material 23 rests on holes. As a result of solidification, the fibers are displaced during solidification at the locations where the substrate has holes, as a result of which the openings 14 are formed.

FIG. 4 illustrates an alternative embodiment of the nonwoven manufacturing device 20. The unconsolidated nonwoven material 23 is processed by a roller assembly 24 having at least one roller 25, 26, so that the fibers are brought into the desired position. The roller assembly 24 has at least one roller 25 with nubs or projections 26 on the lateral surface. As the uncompacted nonwoven material 23 is moved past the roller 25 as the roller 25 rotates, the fibers are displaced by the projections 26, thereby forming the apertures 14. The still unconsolidated, perforated nonwoven material 27 is then sprayed with a Festigerfluid 28 from a sprayer 29 and solidifies during curing. In this way, the nonwoven web 13 is produced. In the embodiment in Fig. 4, the roller assembly 24 has a further roller 25 with recesses 30 on the lateral surface. The two rollers 25 rotate in opposite directions, wherein the projections 26 engage in the recesses 25, while the unconsolidated nonwoven material 23 is moved between the two rollers 25 therethrough.

The bottom pad 10 has a bottom layer 35 and an upper layer 36. On the underside 16, the lower layer 35 of a first layer material S1 is applied to the nonwoven fabric layer 12. On the upper side 15 of the nonwoven fabric layer 12, the upper layer 36 is applied from a second layer material S2.

The two layer materials S1, S2 each consist of a plastic K, which is admixed with a filler. The filler consists of free-flowing or pulverulent filler particles P. The filler particles P are preferably distributed homogeneously in the respective plastic K of the relevant layer material S1, S2. The two layer materials S1, S2 may consist of the mixture of the same plastic K and the same filler particles P, wherein they may have different weight proportions of plastic K and filler particles P based on the volume weight of the respective layer material S1, S2 (FIG. 1). Alternatively, the two layer materials S1, S2 may also be identical (FIG. 2). In the exemplary embodiment illustrated in FIG. 1, the proportion by weight of the filler or of the filler particles P in the second layer material S2 is greater than in the first layer material S1, based on the volume weight of the respective layer material S1, S2. The proportion of the filler particles P in the first layer material S1 is larger, so to speak, than in the second layer material S2.

In the preferred embodiment, the plastic K used is an acrylate. The filler particles P may consist of chalk and / or a silicate and / or a silicate mixture. It is therefore possible to use as filler a mixture of several different filler particles P. In the embodiment according to FIG. 1, the upper layer 36 has first filler particles P1 and second filler particles P2. The first and second filler particles P1, P2 are made of different materials. For example, the second filler particles P2 can be made of electrically conductive material, so that the upper layer 36 can be made antistatic. This is advantageous, for example, when the floor support 10 is also used as a floor covering. The proportion by weight of the first filler particles P1 may be different from the weight proportion of the second filler particles P2 in the same layer material.

As illustrated in FIG. 1, the proportion by weight of the filler particles P in the two layers 35, 36 may be different. In the embodiment, the proportion by weight of the filler particles P in the upper layer 36 is greater than in the lower layer 35. As a result, the upper layer 36 can be selectively changed with respect to properties such as abrasion resistance, antistatic properties or the like with respect to the lower layer 25. Also, the material that makes up the filler particles P is chosen to achieve the desired properties.

By way of example, the weight fraction of the filler or of the filler particles P is smaller than the weight fraction of the plastic K in the upper layer 36 and the lower layer 35, based on the basis weight of the respective first or second layer material S1, S2. In some embodiments, the first layer material S1 and / or the second layer material S2 may contain water or a residual moisture, wherein the weight fraction of the water is in particular both smaller than the weight fraction of the filler particles P, and smaller than the weight fraction of the plastic K, based on the basis weight of the respective layer material S1, S2.

The thickness of the upper layer 36 may be different from the thickness of the lower layer 35, wherein the thickness of the upper layer 36 is, for example, smaller than that of the lower layer 35.

As schematically illustrated in FIG. 1, a sealing coating 37 may be present on the side of the upper layer 36 facing away from the nonwoven fabric layer 12. Thus, the upper layer 36 can be selectively protected, for example, against exposure to chemicals, radiation, mechanical damage, etc. The sealing coating 37 is optional and especially provided only when the bottom pad 10 is used as a floor covering.

In the exemplary embodiment illustrated here in FIG. 1, the bottom support 10 has the following components: 1. The sealing coating consists of a polyacrylate and has an areal weight of 200 g / m 2.

2. The first layer material S1 and / or the second layer material S2 consists of a mixture of polyacrylate and filler particles P of a mineral material, such as chalk, wherein the weight fraction of the polyacrylate 2/3 and the weight fraction of the filler particles P 1/3 is. The first layer material S1 or the second layer material S2 has a basis weight of 800 g / m2.

3. The nonwoven layer 12 consists of a nonwoven web 13 having a basis weight of 80 g / m2. This nonwoven web may e.g. produced by hydroentanglement of a Vleimaterials ("spunlace").

The bottom pad 10 has a total thickness DB of at least 1.0 mm and a maximum of 5.0 mm and, for example, 2.5 mm. The thickness of the sealing layer 37 is 0.1 mm, for example. The thickness of the upper layer 36 is, for example, 0.8 mm. The

For example, the thickness of the lower layer 35 is 1.0 mm, and the thickness DV of the nonwoven fabric layer is 0.6 mm, for example.

Fig. 2 shows schematically an arrangement 40, consisting of a substrate 41, the ground support 10 and a floor covering 42. An embodiment of the ground support 10 is disposed between the substrate 41 and the floor covering 42. As the floor covering 42, any known floor covering is usable, for example, tiles, flagstones, concrete slabs, parquet, laminate, cork, etc. In the embodiment of Fig. 2, the first layer material S1 and the second layer material S2 of the lower layer 35 and the upper layer 36 are identical executed. However, the two layer materials S1, S2 could also be different from one another, as explained in connection with FIG.

In contrast to the bottom support 10 from FIG. 1, the bottom support 10 according to FIG. 2 has an adhesive coating 43 on the side of the upper layer 36 facing away from the nonwoven fabric layer 12 and the lower layer 35, respectively. The adhesive coating 43 does not create a firm integral connection between the ground support 10 and the substrate 41 on the one hand and the floor covering 42 on the other. Rather, the static friction is increased, so that a relative movement can not or only to a small extent take place. The adhesive coating used can be a mixture of a polyacrylate dispersion and water, it being possible to use, for example, "Tubicoat A19" as the polyacrylate dispersion The polyacrylate dispersion and the water are mixed in a ratio of 3: 2, for example.

The substrate 41 may be, for example, a screed.

The ground support 10 has a damping effect against impact sound and room sound. The acoustic characteristic impedance of the filler particles P is preferably greater than the acoustic characteristic impedance of the plastic K. The filler particles P can be used to refract the sound waves in the bottom support 10.

The acrylates preferably used as plastic K have flame retardant effect. The floor support 10 can meet the requirements of fire protection class B1. The thermal resistance of the ground support 10 is at most 0.15 m2K / W. The basis weight of the ground support 10 is at least 2000 g / m2.

In the first layer material S1 and / or in the second layer material S2 may additionally contain a plastic and / or elastic deformability facilitating additive. Such an additive may have a weight fraction of 10% to 20%, based on the basis weight or the volume weight of the relevant layer material S1 or S2.

The apertures 14 in the nonwoven fabric layer 12 are penetrated by a respective connecting web 38, which connects the lower layer 35 directly to the upper layer 36. Each connecting web 38 consists of the first layer material S1 of the lower layer 35 and / or of the second layer material S2 of the upper layer 36. Via the connecting webs 38, the two layers 35, 36 are connected to each other directly materially. The nonwoven fabric layer 12 is thereby held in a form-fitting manner between the lower layer 35 and the upper layer 36.

In Fig. 6, a device 50 for producing the ground support 10 is illustrated in block diagram. The device 50 includes a nonwoven manufacturing device 20, with which the nonwoven web 13, which serves as a nonwoven fabric layer 12, is produced. As already explained, it is essential that the openings 14 are produced during the production of the nonwoven web 13 during or before the solidification of the still unconsolidated nonwoven material 23. Exemplary production methods were explained in connection with the embodiments of the nonwoven production device 20 according to FIGS. 3 and 4, so that reference can be made to the above description.

The device 50 guides the nonwoven web 13 to a first coating unit 51. The first layer material S1 is applied to the underside 16 of the nonwoven fabric layer 12 in flowable form on the first coating unit 51. Subsequently, the nonwoven fabric layer 12 coated on the underside 16 is guided through a first furnace 52, in which the first layer material S1 is cured by the action of heat.

When coating the nonwoven fabric layer 12 with the first layer material S1, the connecting webs 38 in the openings 14 can be wholly or partially produced.

Starting from the first furnace 52, the nonwoven fabric layer 12 provided with the lower layer 35 is led further to a second coating unit 53. In the second coating unit 53, the flowable second layer material S2 is applied to the upper side 15 of the nonwoven fabric layer 12. The now coated on both sides nonwoven fabric layer 12 is guided by the second coating unit 51 to a second oven 54, in which the applied upper layer 36 is cured.

The two coating units 51, 53 and the two ovens 52, 54 thus form a coating device 55 for applying and curing the lower layer 35 and the upper layer 36 to the nonwoven fabric layer 12.

The order of applying the two layers 35, 36 to the nonwoven fabric layer 12 can be arbitrarily selected. The two layers 35, 36 could in principle also be applied simultaneously to the nonwoven fabric layer 12.

Regardless of the device 50, a bottom support 10 can also advantageously be produced by other production means with the following steps: First, the nonwoven fabric layer 12 with the plurality of openings 14 is produced. Already before or during the solidification of the unconsolidated nonwoven material 23, these openings 14 are produced without separation process, for example by displacing fibers. Preferably, the nonwoven fabric layer 12 may be prepared by hydroentanglement (FIG. 3).

On the nonwoven fabric layer 12, the lower layer 35 and the upper layer 36 is applied and cured. The order of application of the lower layer 35 and the upper layer 36 is arbitrary. It is also possible to provide a coating device 55 in which the two layers 35, 36 are applied simultaneously to the nonwoven fabric layer 12 and then cured together. As described above, one of the two layers 35, 36 can first be applied and cured before the respective other layer 36 or 35 is applied and cured.

When applying the upper layer 36 and / or the lower layer 35, the connecting webs 38 are formed, which pass through the openings in the nonwoven fabric layer 12 and thus produce a direct connection between the two layers 35, 36.

The invention relates to a base support 10 and a device 50 for the production thereof and a layer structure produced with the aid of the floor support 10 and a floor covering 42, in particular for use in enclosed spaces. The floor covering 10 has a nonwoven fabric layer 12 of consolidated fibers, which is in particular synthetic fibers or a synthetic fiber mixture. Before or during the solidification of the fibers, apertures 14 are produced in the nonwoven material without severing fibers. The nonwoven fabric layer 12 is provided on a lower side 16 with a lower layer 35 and on an opposite upper side 15 with an upper layer 36. The lower layer 35 consists of a first layer material S1 and the upper layer 36 of a second layer material S2. The first and / or second layer material S1, S2 passes through the apertures 14 in the nonwoven fabric layer 12 and forms there connecting webs 38 between the two layers 35, 36. The layer materials S1, S2 each consist of a plastic K, which is mixed with filler particles P.

Claims (34)

claims 1. floor support (10) having a carrier layer (11) serving nonwoven fabric layer (12) having a plurality of openings (14), wherein the openings (14) already in the nonwoven fabric production before or during the solidification of the initially unconsolidated nonwoven material (23 ), comprising a lower layer (35) of a first layer material (S1) and an upper layer (36) of a second layer material (S2), wherein the first layer material (S1) and the second layer material (S2) comprise a plastic material (S1). K) and in the plastic (K) arranged distributed filler particles (P) of a filler, wherein the upper layer (36) on an upper side (15) of the nonwoven fabric layer (12) and the lower layer (35) on a lower side (16) of Nonwoven fabric layer (12) is arranged directly and the two layers (35, 36) by means of through the openings (14) extending through connecting webs (38) are connected directly to each other, wherein the Verbi webs (38) of the first layer material (S1) and / or second layer material (S2) and wherein a direct connection of the first layer material (S1) with the second layer material (S2) on the openings (14) in the nonwoven fabric layer (12) is limited. 2. Ground support according to claim 1, characterized in that the first layer material (51) has the same plastic (K) and / or the same filler as the second layer material (S2) or that the first layer material (S1) and the second layer material (S2) are identical. 3. Ground support according to claim 1 or 2, characterized in that the second layer material (S2) contains a larger proportion by weight of the respective filler than the first layer material (S1) based on a volume weight of the respective layer material (S1, S2). 4. Ground support according to one of the preceding claims, characterized in that the plastic (K) consists of an acrylate. 5. Ground support according to one of the preceding claims, characterized in that the filler particles (P) consist of a mineral material and / or an electrically conductive material. 6. Ground support according to claim 5, characterized in that the mineral material is chalk and / or a silicate. 7. Ground support according to one of the preceding claims, characterized in that the weight fraction of the filler is smaller than the weight fraction of the plastic (K) based on the basis weight of the respective first layer material (S1) and / or the second layer material (S2). 8. Ground support according to one of the preceding claims, characterized in that the first layer material (S1) and / or the second layer material (S2) additionally contains a plastic and / or elastic deformability facilitating additive whose weight fraction is at least 10% based on the Basis weight of the relevant first layer material (S1) and / or the second layer material (S2). 9. Ground support according to one of the preceding claims, characterized in that the first layer material (S1) and / or the second layer material (S2) additionally contains a plastic and / or elastic deformability facilitating additive whose weight fraction is not more than 20% based on the Basis weight of the relevant first layer material (S1) and / or the second layer material (S2). 10. Ground support according to one of the preceding claims, characterized in that the basis weight of the nonwoven fabric layer (12) is at least 80 g / m2. 11. Ground support according to one of the preceding claims, characterized in that the nonwoven fabric layer (12) comprises fibers of at least one synthetic fiber material. 12. Ground support according to one of the preceding claims, characterized in that the nonwoven fabric layer (12) comprises first fibers of a synthetic fiber material and second fibers of another synthetic fiber material. 13. Ground support according to claim 12, characterized in that the first fibers are made of viscose and / or that the second fibers are made of polyester. 14, ground support according to claim 12 or 13, characterized in that the weight fraction of the first fibers is greater than the weight fraction of the second fibers based on the basis weight of the nonwoven fabric layer (12). 15. Ground support according to claim 14, characterized in that the weight fraction of the first fibers is at most 60% and / or that the weight fraction of the second fibers is at most 40%, based on the basis weight of the nonwoven fabric layer (12). 16. Ground support according to one of the preceding claims, characterized in that the nonwoven fabric layer (12) comprises a binder whose weight fraction is at most 8%, based on the basis weight of the nonwoven fabric layer (12). 17. Ground support according to one of the preceding claims, characterized in that the thickness (DV) of the nonwoven fabric layer (12) is at least 0.5 mm. 18. Ground support according to one of the preceding claims, characterized in that the thickness (DV) of the nonwoven fabric layer (12) is a maximum of 1.5 mm. 19. Ground support according to one of the preceding claims, characterized in that the cross-sectional area (AQ) of each aperture (14) is at least 1.0 mm2. 20. Ground support according to one of the preceding claims, characterized in that the cross-sectional area (AQ) of each aperture (14) is a maximum of 10.0 mm2. 21. Ground support according to one of the preceding claims, characterized in that the sum of the cross-sectional areas (AQ) of all apertures (14) forms a total aperture area and the proportion of the total aperture area at the surface of the nonwoven fabric layer (12) is at least 20%. 22. Ground support according to one of the preceding claims, characterized in that the sum of the cross-sectional areas (AQ) of all apertures (14) forms a total aperture area and the proportion of the total aperture area on the surface of the nonwoven fabric layer (12) is at most 60%. 23. Ground support according to one of the preceding claims, characterized in that the total thickness (DB) of the bottom support (10) is at least 1.0 mm. 24. Ground support according to one of the preceding claims, characterized in that the total thickness (DB) of the bottom support (10) is a maximum of 5.0 mm. 25. Ground support according to one of the preceding claims, characterized in that the basis weight of the ground support (10) is at least 2000 g / m2. 26. Ground support according to one of the preceding claims, characterized in that the thermal resistance of the ground support is not more than 0.15 m2K / W. 27, ground support according to one of the preceding claims, characterized in that the upper layer (36) on one of the nonwoven fabric layer (12) facing away from a sealing coating (37) or an adhesive coating (43). 28. Ground support according to one of the preceding claims, characterized in that the lower layer (35) on one of the nonwoven fabric layer (12) facing away from an adhesive coating (43). 29, ground support according to one of the preceding claims, characterized in that the Schallkennimpedanz the filler particles (P) is greater than the acoustic characteristic impedance of the plastic (K). 30. Arrangement (40) comprising: - a base (41), - a floor covering (42), - a floor covering (10) according to one of the preceding claims, which is arranged between the base (41) and the floor covering (42). 31. An apparatus (50) for producing a ground support (10), comprising a nonwoven manufacturing device (20) for producing a nonwoven fabric layer (12), with a water jet nozzle assembly (21) through which a plurality of water jets for solidification of the unconsolidated nonwoven material (23) can be generated and in the solidification of the unconsolidated nonwoven material (23) by aligning and / or moving the water jets by means of the water jet nozzle assembly (21) a nonwoven fabric layer (12) with the openings (14) can be generated, with a coating device (55) through which a lower layer (35) of a first layer material (S1) on a lower side (16) of the nonwoven fabric layer (12) and an upper layer (36) of a second layer material (S2) on an upper side (15) of the nonwoven fabric layer (12) applicable is, wherein the first layer material (S1) and the second layer material (S2) each have a plastic (K) and in the plastic (K) arranged distributed Fü In the case of the application of the upper layer (36) and / or the lower layer (35), connecting webs (38) which can be produced from the first and / or the second layer material (S2 ), and wherein the connecting webs (38) pass through the apertures (14) and produce a direct connection between the upper layer (36) and the lower layer (35). 32. A device (50) for producing a base support (10), comprising a nonwoven manufacturing device (20) for producing a nonwoven fabric layer (12), with a roller assembly (24) through which in an unconsolidated nonwoven material (23) openings (14). wherein the unconsolidated nonwoven material (27) provided with the perforations (14) is subsequently solidifiable by applying a solidifying fluid (28), with a coating device (55) through which a lower layer (35) of a first layer material ( S1) on a lower side (16) of the nonwoven fabric layer (12) and an upper layer (36) of a second layer material (S2) on an upper side (15) of the nonwoven fabric layer (12) can be applied, wherein the first layer material (S1) and the second layer material (S2) each having a plastic (K) and in the plastic (K) arranged distributed filler particles (P), and wherein by the coating device (55) during application of the upper S At least one of the first and second layer material (S2) can be produced, and the connecting webs (38) extend through the apertures (14) and create a direct connection between the upper layer (36) and the lower layer (35). 33. A method for producing the floor covering (10) comprising the steps of: - producing a nonwoven fabric layer (12) having a plurality of openings (14), wherein the openings (14) already during the manufacture of the nonwoven fabric layer (12) before or during the Solidification of the nonwoven material (23), application of a lower layer (35) of a first layer material (S1) to a lower side (16) of the nonwoven fabric layer (12), application of an upper layer (36) of a second layer material (S2 ) on a top side (15) of the nonwoven fabric layer (12), wherein the first layer material (S1) and the second layer material (S2) comprise a plastic (K) and plastic particles (P) distributed in the filler (P) of a filler, wherein the Application of the upper and / or the lower layer (35, 36) connecting webs (38) are generated, which consist of the first and / or second layer material (S1, S2) and hindurc through the openings (14) h and wherein the connecting webs (38) after application of the upper layer (36) and the lower layer (35) connect these two layers (35, 36) directly to each other, wherein a direct connection of the first layer material (S1) with the second Layer material (S2) is limited to the openings (14) in the nonwoven fabric layer (12). 34. The method according to claim 33, characterized in that the solidification of the nonwoven material (23) of the nonwoven fabric layer (12) is effected by water jets and the apertures (14) are produced during solidification of the nonwoven material (23).