BE1027843A1 - Floor element - Google Patents

Abstract

A floor element comprising a top layer bonded to a substrate layer, in which the top layer itself is layered, the top layer comprising - an optional soft polymer backlayer, - a soft or semi-hard polymeric layer, to or in which at least one reinforcement layer is optionally adhered or embedded - and a finishing layer comprising a decorative layer, a wear layer thereon and optionally a coating thereon; the substrate layer being a rigid substrate layer.

Description

FLOOR ELEMENT Technical field The invention relates to floor elements, more particularly to floor elements with a rigid substrate. State of the art Floor elements with a rigid substrate on which a decorative layer has been applied directly are known from, inter alia, WO2018/172959. Such floor elements can be assigned a rather negatively perceived sound reflection property. Summary of the Invention According to a first aspect of the invention there is provided a floor element comprising a top layer adhered to a substrate layer, wherein the top layer itself is layered, the top layer comprising e an optional soft polymer backlayer, e a soft or semi-hard polymeric layer, to or in which at least one reinforcement layer is optionally adhered or embedded, and e a finishing layer comprising a decorative layer, a wear layer thereon and optionally a coating thereon; the substrate layer being a rigid substrate layer.

In some embodiments, at least one reinforcing layer may be attached or embedded to or within the soft or semi-rigid polymeric layer. By rigid is meant that the layer or layers together deflect less than 35 cm under their own weight when the layer or layers protrude 1 meter beyond a fixation point. Preferably, when projecting 1 meter beyond the fixation point, the substrate layer flexes less than 10 cm under its own weight. The top layer is preferably a sheet vinyl.

The sheet vinyl used in this aspect of the invention is typically layered, and comprises e an optional soft PVC backlayer, e a soft or semi-rigid PVC layer, to or in which at least one reinforcement layer is adhered or embedded, and e a finishing layer comprising a decorative layer, a wear layer and optionally a coating on the outside. Optionally, the soft or semi-rigid PVC layer comprises a reinforcement layer, for example a textile reinforcement layer, for example reinforcement layers as described for the reinforcement layers of the subfloor according to the first aspect of the invention. Further within the scope of this invention by soft polymer, e.g. PVC, is meant polymer, e.g. PVC, comprising 40 or more than 40 phr plasticizers. By semi-rigid or semi-soft polymers, e.g. PVC, is meant polymers, e.g. PVC, comprising between 10 and 40 phr plasticizers, where hard polymers, e.g. PVC, comprise less than or just 10 phr. Generally within the scope of this invention, plasticizers include esters of carboxylic acids (e.g. esters of phthalic acid, iso- or terephthalic acid, trimelitic acid and adipic acid), e.g. diisononyl phthalate (DINP), dioctyl terephthalate (DOTP), diisononyl-1, 2-cyclohexanedicarboxylate (DINCH), esters of phosphoric acid, e.g. triaryl or trialkylaryl phosphates, e.g. tricresyl phosphate, chlorinated or unchlorinated hydrocarbons, ethers, polyesters, polyglycols, sulfonamides, or combinations of these.

The optional backlayer is made of soft PVC and typically has a thickness of more than

0.5mm, for example between 0.5mm and 5mm, for example between 0.75mm and

2.5mm. In addition to PVC, the material from which this backlayer consists also comprises fillers (up to 60% w/w relative to the entire PVC material, for example about 50% w/w) and additives, and preferably more than 40 phr plasticizer, more particularly more than 50 phr plasticizer. The backlayer can be foamed or not, and can have a density between 0.3 g/cm? and have 1.9 g/cm. The soft or semi-rigid PVC layer, to or in which optionally a reinforcing layer is attached or embedded, or is preferably a non-woven fabric impregnated with PVC. The PVC used to partially or preferably completely impregnate the nonwoven is preferably soft PVC. In addition to the polymer, the PVC also comprises fillers (up to for example 75%w or up to 50%w with respect to the entire PVC material, for example up to about 40%w) and additives, and preferably more than 40 phr plasticizer, in particular more than 50 phr plasticizer . The thickness of this layer can be up to 0.6mm but is preferably between 0.20mm and 0.40mm, such as about 0.30mm. the density of the PVC used is preferably below 1.9 g/cm 3 , such as for example between 1.4 g/cm and 1.7 cm 3 , for example between 1.5 g/cm 3 and 1.6 g/cm 3 . Preferably a glass fiber fleece (nonwoven) is used which has approximately the same thickness as this layer. The preferred fleece has a thickness of 0.3 mmm and a weight per unit area of 35 g/m². up to 50 gsm. Preferably, another layer of PVC is adhered to this impregnated glass fiber fleece. The PVC used can be substantially identical, but is preferably foamed. This layer can have a thickness of 0.5 mm to 3 mm. Typically, this PVC layer comprises 45 to 75 phr plasticizers, e.g. 55 to 65 phr plasticizer, and 50 to 200 phr filler, preferably 100 to 125 phr filler. The filler is preferably white in colour, so that a white layer of PVC is formed. In addition to fiberglass fleeces, fiberglass fabrics can also be used.

The finish layer typically includes a decorative layer, a wear layer and optionally an exterior coating. The decorative layer may comprise soft PVC with a thickness of between

0.09mm and 0.6mm, for example between 0.4mm and 0.6mm. It can be a PVC layer (for example a foil) which is printed with a decorative motif. The PVC used may be soft PVC. In addition to polymer, this PVC layer also comprises additives and fillers (up to 50% w/w with respect to the entire PVC composition), and plasticizers preferably more than 40 phr, in particular more than 50 phr plasticizer. The PVC may or may not be foamed, but is preferably foamed. In case a foamed PVC material is used, the PVC layer may have a density below 1 g/cm 2 , such as between 0.5 and 0.8 g/cm. With non-foamed PVC, the density is preferably between 1 g/cm? and 1.6 g/cm', such as between 1.2 g/cm and 1.4 g/cm3. The layer can be supplied as pre-printed or non-preprinted film, as emulsion or (micro-)suspension polymerization layers, by calendering or as a plastisol layer.

If necessary, printing is done directly on the soft or semi-rigid PVC layer. This is especially applicable if the soft or semi-rigid PVC layer is provided with an extra PVC layer (foamed or not), on top of a reinforcement layer of glass fiber fleece impregnated with PVC.

A wear layer is provided on this decorative layer, which thickness can be chosen, for example between 0.15 mm and 1.0 mm, for example between 0.2 mm and 0.55 mm. It can preferably be a soft or semi-hard PVC layer, for example a foil. Preferably no fillers are added or used, and the layer is transparent.

In addition to polymer, this PVC layer also comprises additives and plasticizers, preferably more than 20 phr, in particular more than 30 phr plasticizer. Plasticizers up to 40 phr can be provided in this PVC. Preferred ranges for plasticizers are 20 to 45 phr, more preferably 35 to 40 phr. The PVC can have a density preferably between 1 g/cm: and 1.5 g/cm', such as between 1.2 g/cm: and 1.3 g/cm:.

The wear layer is optionally provided with wear particles, for example Al2O: particles. The PVC is typically free of fillers. The layer can be supplied as foil or as emulsion or (micro-)suspension polymerization layers, by calendering or as a plastisol layer.

As a finishing layer, the sheet vinyl can further comprise a lacquer layer or coating on top of the wear layer, which consists of polyurethane (PU), for example a UV curing PU layer. The thickness can be up to 20, even 30 µm, but is preferably about 10 µm thick.

The top layer can be provided with a relief on its top, which can be pressed in during production via embossing.

All PVCs mentioned above are preferably obtained via emulsion or (micro-)suspension polymerization and have a K-value between 50 and 90.

According to some embodiments, one or more reinforcing layers may be bonded or embedded in the vinyl sheet, in the soft or semi-rigid PVC layer.

The at least one, but possibly two or more reinforcement layers are preferably textile reinforcement layers. The textile layer preferably comprises a glass fiber textile, for example a nonwoven glass fiber textile or a woven glass fiber textile. This glass fiber textile preferably has a weight per unit area of 15 to 80, such as from 25 to 55 g/m². Preferably, a woven glass fiber textile has an open structure, for example a mesh structure or mesh fabric. Preferably, the open space between successive warp or weft yarns can be between 1 mm and 1 cm.

The total sum of weight per unit area of the reinforcement layers in the sheet vinyl together have a weight per unit area of preferably greater than 30 g/m², more preferably greater than 50 g/m², such as between 30 and 180 g/m° .

In the case of sheet vinyl, these sheet vinyl elements usually have a larger surface area, and are supplied in rolls of between 0.5 and 4 m wide and 2.5 to 10 m long. However, smaller rolls with a limited width of 0.5 to 1.5 m, for example about 1 m, can be manufactured. Smaller surfaces can be cut from these large surfaces, which surface corresponds to the surface of the substrate layer intermediate products.

On the one hand, sheet vinyl or similar are often made in large volumes and dimensions. On the other hand, the substrate layer is more often first reworked into substrate elements of limited size. Rigid substrate elements often have a rather limited size, and rigid substrate elements can be separately stocked. The simple assembly of pieces of sheet vinyl or similar as a top layer on a rigid substrate element by, for example, bonding or thermal bonding, has the advantage that the finished floor elements do not have to be in stock and can be manufactured on demand. This gives the advantage that fewer products need to be in stock and often only a few incomplete rolls of sheet vinyl or similar need to be stored. A rapidly switchable production can therefore be obtained.

The floor elements preferably have a rectangular or square surface with a short side between 8 and 50 centimeters (preferably between 12 and 30 cm) and a long side between 0.5 and 2 meters (preferably between 1 and 1.2).

According to a first embodiment aspect, the substrate layer may be a wood-based substrate layer.

The rigid substrate layer may be a wood based substrate, for example wood fiber board HDF, MDF, wood chipboard, and the like. For example, for wood chipboard, single or multi-layer wood chipboard can be used. Or a board consisting of a combination of wood chips and wood fibers can be used, whether or not intimately mixed, and/or whether or not layered with wood fiber layers on the outside and/or layered with other (for example finer) wood chips on one or both outsides.

In the wood-based substrates, wood-based material can be bonded together by resins, for example melamine resins, isocyanates, such as methylenediphenyl diisocyanate (MDI), and/or formaldehyde resins.

The density of the MDF or HDF is preferably above 450 g/m°, more preferably above 750 g/m°. For example, thicknesses between 2 and 10 mm can be used. According to a second embodiment aspect, the substrate layer may be a substrate layer based on hydraulic or non-hydraulic binders.

In case the substrate layer is a cement-based substrate layer, the cement may be hydraulic cement or non-hydraulic cement. Examples of suitable hydraulic cements are Portland cements. Preferably, the substrate layer is a fiber cement board comprising portland cement, optionally sand, and cellulose fibres. Optionally, this sheet also comprises other fibres, for example polyvinyl alcohol fibres, as further specified. This fiber cement board can be cured in air or under the influence of temperature and pressure (for example in an autoclave).

Examples of non-hydraulic cements are 0.a. magnesium-based cement, such as magnesium oxide based cement, for example Magnesium oxychloride cement (Sorel cement), magnesium oxysulfate cement and basic magnesium sulfate cement. Preferably, the substrate layer is a magnesium oxide plate, optionally further comprising cellulose, glass or wood fibres.

In an alternative form, the hydraulic binder can be calcium sulphate, for example in case the substrate is plasterboard, or fly ash, blast furnace slag or (quick) lime.

In addition to the binder, the substrate layer optionally further comprises fibers, for example polymeric or natural fibers, for example cellulose fibers, polypropylene fibers, polyethylene fibers, polyester fibers, polyamide fibers, polyaramid fibers, carbon fibers, metal fibers, polyvinyl alcohol fibers, glass fibers, wood fibers or chips and the like and mixtures of these fibers.

In addition to binding agent, the substrate layer further optionally comprises fillers such as sand, gravel, calcium silicate hydrate particles or gel, CaCO3, limestone, lightweight fillers, polymeric particles, for example beads, expanded or non-expanded polystyrene particles, expanded or unexpanded perlite, xonotlite, vermiculite, blown clay, blast furnace slag, fumed silica, silica fume, and the like.

The substrate layer based on hydraulic or non-hydraulic binders may be foamed or unfoamed. This can be obtained by physical foaming, for example by introducing, for example blowing, gas or air, by mixing in and activating foam formers, by mixing in expandable particles, or combinations of these measures.

Densities for example between 0.85 g/cm: and 2 g/cm?, for example between 0.85 g/cm: and 1.5 g/cm? are usable. For example, thicknesses between 2 and 10 mm can be used.

Substrate layers based on hydraulic or non-hydraulic binders have the advantage, inter alia, that these substrate layers tend to be little or non-flammable and are often water resistant. Their intrinsically high weight per volume also ensures that floor elements with such substrate layers are robust and remain in place more easily once installed.

The combination according to this aspect of the invention is mainly the minimal expansion with changing temperature. The polymeric top layer and the substrate layer based on hydraulic or non-hydraulic binders have very similar thermal expansion coefficients, resulting in a very stable product. It has the additional advantage that these expansion coefficients are small and that the provision of shrinkage joints between the elements is virtually non-existent.

The sound reflection has also been noticeably improved. This is generally the case with products according to all aspects of the invention. In a third embodiment aspect, the substrate may be a polymer-based substrate.

Although preferably made of non-polymeric material, the rigid substrate layer may be made of polymer, for example thermoplastic or thermosetting polymer.

Examples of polymeric materials are polyester (PES), polypropylene (PP), polyethylene (PE), polyamide (PA), polyvinyl chloride (PVC), polystyrene (PS), polycarbonate (PC) and the like and mixtures of these polymers.

The polymers may further comprise additives such as plasticizers, antioxidants, UV protectors, fire protection additives, dyes and pigments, antistatic additives, or fillers such as lightweight fillers (e.g. fumed silica, silica fume) and the like, CaCO3, calcium silicate hydrate particles or gel, limestone, expanded or unexpanded polystyrene particles, expanded or unexpanded perlite, xonotlite, vermiculite, blown clay, blast furnace slag, fumed silica, silica fume, and the like.

Preferably, a polymer-based substrate is highly filled, comprising more than 40%w of fillers.

Preferably, a polymer based substrate most preferably comprises less than 12 phr plasticizers. Phr of an ingredient in a polymeric matrix means "parts per houndred resin", and indicates the part by weight of that particular ingredient, per hundred parts by weight of polymer.

The polymer may or may not be foamed. This can be obtained by physical foaming, for example by introducing, for example blowing, gas or air, by mixing in and activating foam formers, by mixing in expandable particles, or combinations of these measures.

Densities between 0.8 and 1.2 kg/l can be used, and the thicknesses can preferably vary between 2 and 10 mm.

According to all aspects of the embodiment, the top layer and the substrate layer can be adhered to each other by means of an adhesive.

The adhesives used are preferably thermally meltable moisture curing adhesives (English; hot melt moisture cured adhesives or HMMC adhesives). An example is a PU HMMC adhesive.

Preferably between 50 and 150 g/m? applied adhesively.

A primer is optionally applied to the side of the substrate layer to be contacted by the top layer. A primer is optionally applied to the side of the top layer to be contacted by the substrate layer.

In an alternative embodiment, the top layer and substrate layer are bonded together by a double-sided adhesive film. A primer is optionally applied to the side of the substrate layer and/or top layer to be contacted by the foil.

In some embodiments, the top layer and the substrate layer may be bonded together by thermal bonding, e.g., thermal lamination.

According to some embodiments, a further backing layer may be provided on the side of the substrate layer facing away from the top layer.

This backing layer preferably consists of foamed polymer, for example expanded polyethylene. The thickness of this backing layer is preferably between 1 and 5 mm. The density of this backing layer is preferably between 15 and 50 kg/m°. The backing layer is preferably adhered by means of an adhesive. The adhesive use is preferably hot melt moisture cured adhesives or HMMC adhesives. An example is a PU HMMC adhesive.

Preferably between 10 and 50 g/m? applied adhesively.

The floor element according to the invention is preferably provided with a coupling means on at least two, preferably four sides, which make it possible to connect similar floor elements to each other. These coupling means can be any known coupling means, such as "fall down" coupling means, tongue-and-groove coupling means, click systems. The coupling means can be designed in such a way that horizontal and/or vertical displacement of two adjacent and coupled floor elements is prevented. The independent and dependent claims set forth specific and preferred features of the embodiments of the invention. Features of the dependent claims may be combined with features of the independent and dependent claims, or with features described above and/or below, in any suitable manner as would be apparent to a person skilled in the art.

The above and other features, features and advantages of the present invention will be illustrated by the following exemplary embodiments, optionally in combination with the drawings.

The description of these exemplary embodiments is provided by way of illustration, without intent to limit the scope of the invention. The reference numerals in the following description refer to the drawings. Same reference numbers in possibly different figures refer to identical or similar elements.

Brief description of the figures With a view to better demonstrating the features of the invention, some preferred embodiments are described below, by way of example without any limiting character, with reference to the accompanying drawings, in which: Figure 1 shows schematically a floor element according to the invention. Description of Embodiments Examples The present invention is described below using specific embodiments.

It should be noted that the term "comprising", as used, for example, in the claims, should not be interpreted in a limiting sense, limiting to the following elements, features and/or steps. The term "comprising" does not exclude the presence of other elements, features or steps. Thus, the scope of an expression "an object comprising the elements A and B" is not limited to an object containing only the elements A and B. The scope of an expression "a method comprising steps A and B" is not limited to a method containing only steps A and B. In the light of the present invention, these terms mean only that the relevant elements and steps respectively for the invention are the elements A and B respectively.

In the following specification reference is made to "an embodiment" or "the embodiment". Such reference means that a specific element or feature described with reference to this embodiment is included in at least this one Embodiment.

However, the occurrence of the terms "in an embodiment" or "in the embodiment" in various places in this specification does not necessarily refer to the same embodiment, although it may refer to a same embodiment.

Furthermore, the features or features may be combined in any suitable manner in one or more embodiments, as would be apparent to those skilled in the art. A floor element 100 is shown in Figure 1. The floor element 100 comprises a top layer 102 adhered to a substrate layer 104, in which the top layer itself is layered, comprising e a polymeric backlayer 122, e a soft or semi-hard polymeric layer 124, to which at least one reinforcement layer 126 is adhered, and e a finish layer comprising a decorative layer 132, a wear layer 134 and a coating 136 on the outside. The backsheet 122 is unfoamed soft PVC; has a thickness between 0.5 and 3 mm and comprises between 55 and 65 phr plasticizer. This layer also includes 100 to 125 phr of filler, primarily CaC O 2 . The soft or semi-rigid polymeric layer 124 is foamed soft PVC; has thickness of

0.5 to 3 mm and also includes 55 to 65 phr plasticizer and 100 to 125 phr filler, preferably TiO 2 .

A textile reinforcement layer is adhered to this layer 124. The textile reinforcement layer comprises a glass fiber fleece with a weight per unit area of 35 to 50 g/m². which is completely impregnated with soft PVC. The PVC used for the impregnation is similar to the PVC used for layer 124. This layer is approximately

0.35 to 0.6mm thick. All PVC preferably has a K value between 67 and 75.

The decorative layer 132 is a printing layer directly on layer 124. The layer is applied by rotary printing.

The wear layer 134 is a transparent PVC layer with up to 50 phr plasticizer and no fillers. The thickness is about 0.3mm.

The coating 136 is a UV curing PU lacquer layer of 15um thickness.

The top surface is embossed by embossing (not shown). This top layer 102 is bonded to a substrate layer by means of an adhesive 140

104. The substrate layer is a rigid substrate layer consisting of a fiber cement material comprising portland cement, sand, cellulose fibers, polyvinyl acetate fibers and cured in air. The substrate layer has a thickness of 4 mm.

The adhesive is a PU HMMC adhesive and applied at a rate of 80 g/m². Beneath the rigid substrate, the floor element 100 is provided with a backing layer 150 consisting of foamed PVC of well 1mm thickness. The density is between 35 and 120 g/m3. The backing layer is adhered to the substrate by a PU HMMC adhesive and applied at a rate of 15 g/m°.

In an alternative embodiment, the fiber cement substrate layer was replaced by an HDF board.

In an alternative embodiment, the fiber cement substrate layer was replaced with a magnesium oxychloride cement (MgO) substrate having similar characteristics as used for the fiber cement Embodiment.

In an alternative embodiment, the fiber cement substrate layer was replaced by a rigid PVC substrate.

The substrate layer is between 2.2 and 8.2 m thick and is formed from PVC with less than 10 phr softener and 100 to 300 phr filler, preferably CaCO3. This substrate can be foamed or non-foamed and have a density between 0.8 and 2.1 kg/l.

It is understood that while the embodiments and/or the materials for furnishing embodiments of the present invention have been discussed, various modifications or changes may be made without departing from the scope and/or spirit of this invention.

The present invention is by no means limited to the embodiments described above, but can be realized according to various variants without departing from the scope of the present invention.

Claims (8)

Conclusions A floor element comprising a top layer adhered to a substrate layer, in which the top layer itself is layered, the top layer comprising e an optional soft polymer backlayer, e a soft or semi-hard polymeric layer, to or in which at least one reinforcement layer is optionally adhered or embedded, and e a finishing layer comprising a decorative layer, a wear layer thereon and optionally a coating thereon; the substrate layer being a rigid substrate layer. A floor element according to claim 1, wherein at least one reinforcement layer is adhered or embedded to or in the soft or semi-hard polymeric layer. A floor element according to claim 1 or 2, wherein the substrate layer is a wood-based substrate layer. A floor element according to claim 1 or 2, wherein the substrate layer is a substrate layer based on hydraulic or non-hydraulic binders. A floor element according to claim 1 or 2, wherein the substrate is a polymer-based substrate. A floor element according to any one of claims 1 to 5, wherein the top layer and the substrate layer are adhered together by means of an adhesive. A floor element according to any one of claims 1 to 5, wherein the top layer and the substrate layer are adhered to each other by thermal bonding, e.g. thermal lamination. A floor element according to any one of claims 1 to 7, wherein a further backing layer is provided on the side of the substrate layer facing away from the top layer.