CZ13095A3 - Self-lying floor covering and process for producing thereof - Google Patents

Abstract

The new floor covering consists of a textile outer layer (1) and at least one under layer (2). The under layer (2) is composed of a granulated and/or fibrous filler whose grains or fibers are coated with a film of polymer binder. Pores are formed between the individual binder-coated grains and/or fibers of the filler, and fibers protruding from the underside of the textile material are submerged in the binder adhering to the top side of the under layer. The process of manufacturing the floor covering consists in coating the granulate and/or fibers with the polymerizing binder in liquid state, spreading the mixture on an even substrate (11) for the under layer (2) and bringing it into contact with the underside of a layer of textile material (1), the two layers being pressed together. The polymerization can thereupon run to completion.

Description

Self-lying floor covering and method of its production

Technical field

The present invention relates to a self-laying floor covering consisting of a facing textile layer and at least one backing layer, and to a method of making the covering.

BACKGROUND OF THE INVENTION

AND

A characteristic feature of self-lying floor coverings is that they can be laid on a flat, most often concrete substrate and used without the need to adhere to the substrate. They are characterized by a ductile backing layer which adheres to the substrate by its own weight over its entire surface and its underside has non-slip properties.

There are known self-lying floor coverings in which the substrate

Ί The fabric forms a layer of bitumen. A disadvantage of these known coverings is that the compact bitumen layer does not allow water to penetrate into the substrate. This limits their use «in the open air. Another drawback is difficult RECYKO H _f cheapness shell fabric after wear. Bitumen penetrates so much into the fabric that both layers can only be separated on a special device, and only partially.

DE 39 02 419 A1 discloses a floor or wall lining board made of granulate of old filler-forming tires and a two-component binder forming

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In synthetic resin with admixed hardener. The filler is mixed with a binder in which both components are present in a stoichiometric ratio, the mixture is spread / spread on the bottom of a flat mold, placed in a press in which curing at near ambient temperatures occurs. ambient temperature. The disadvantage of such a board is the limited possibility of use - only for riding areas and open areas. The surface formed from these plates does not meet the aesthetic requirements of the interior and releases the odor of the recycled rubber used. Upon curing, toxic gases are released into the atmosphere. · * · · ^;% · Tk. ¹ 'i,.'. PCT patent application WO 93/19654 <is / is known, the following method for manufacturing carpet of plates: A mixture of an amorphous olefin polymer is heated, _t is melted and spread on the movement '.mu.Ci of the endless belt. A thin layer of liquid amorphous oleic polymer is deposited on the back of the fabric. and the fabric, the underside is not rolled onto the layer lying on the endless belt and is firmly bonded. This is followed by * '*. . '-i'. .1, ',', 1 ^; cooling with a cooling plate placed under the belt, separating the carpet strip from the belt and cutting it. A similar method is described in EP patent application 0 570-236 A1, except that magnesium hydroxide and glass or polyester fibers are used as fillers in the carpet backing layer and the layer is intended to form a bond between the tex. and the backing layer is. fed between the two layers as a rigid film. The first part of the endless belt is heated from below, the second part is then cooled. These technologies do not result in a self-laying floor covering, the worn fabric cannot be easily separated from the substrate, in both cases the production is complicated by the application of additional interlayers necessary to bond the fabric to the substrate;

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SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide self-laying floor coverings utilizing a plinth. to a large extent recycled raw material, which would allow. easy recycling while meeting the aesthetic requirements while maintaining the necessary mechanical properties, including the possibility of water leakage. It is an object of the present invention to provide a simple technology for the production of this covering without any negative effects on the environment.

SUMMARY OF THE INVENTION

This object is achieved by a self-laying floor covering consisting of a topsheet of the fabric and at least one backing layer consisting of a filler of granular and / or fibrous material and a binder of a polymerizing material, characterized in that the binder is 10 to 30 wt. % of the backing layer forms a film on the granules and / or filler fibers between. granules and / or fibers in the binder-coated backing layer are provided with vents, with fibers extending from the bottom surface of the fabric into the binder adhering to the filler in the top surface of the backing layer.

The filler of the backing layer is preferably made of recycled rubber granules whose granules have a diameter of 0.5 to 5 mm, the backing layer comprises polyurethane as a binder, and the textile layer consists of a non-woven fabric of polypropylene fibers.

Preferably, the covering may consist of a topsheet of the fabric and at least two backing layers differing in composition.

The essence of the method for producing a self-laying floor covering is to coat the granules and / or filler fibers with a liquid-polymerizing binder film such that the binder is 10 to 30 wt. % Of the mixture, the mixture is spread on rov4 πού pad, and comes into surface contact with the backing layer of the fabric, the binder in the backing layer is allowed to polymerize, wherein both layers are compressed at a pressure of 20 up _to 200 kPa, followed by completion of polymerization and the possible splitting, coverings required surface formations.

The fabric layer can be applied to the top surface of the backing layer spread over the backing, or the fabric layer is first laid upside down on and below the bed. . The mixture of granules and / or filler fibers with a binder is spread.

The polymerization in the backing layer and the compression of the two layers can take place in the rest state or during the movement of the two layers applied to each other, which is the essence of the discontinuous resp. continuous production method. - y. ’$

The granulate and the polyurethane binder are preferably prior to mixing; during mixing and / or heated in the layer to a temperature of 100 to 600 ° C. ./, ··. * / Ζ'Ζ ¹ '';''i>'·' \

Before spreading the mixture of filler and layer, the granules and the pellets are coated. fibers ' ¹ ', 1. film of polymerizing binder / in the liquid state. At relatively low pressure exerted on the layer, the binder granules and / or filler fibers are only interconnected as a result of the polymerization at the points of contact with each other, while the thinly bled vents remain bound therebetween in the filler. Another advantageous consequence, we found that the granules and / or .vlákna'plniva only film coating binders is that at the interface of the substrate and fabric layers phenomenon moment of attaching the fabric only a small amount of the liquid in ^{',' Jr} '. _ - _r . . - = = polymer. Thus, the polymer does not flow into the fabric, but only the fibers protruding from the back surface of the fabric are embedded in it. Thus, preferably, a connection is obtained which eliminates the mutual shear of the two layers,

However, it allows clean. separation of the fabric from the backing layer and separate recycling of the two layers.

Figures in the drawing

The invention will be further elucidated by means of the drawing, in which Fig. R schematically shows the discontinuous production of the floor covering and Fig. 2 a continuous production of the floor covering.

DETAILED DESCRIPTION OF THE INVENTION

Self-laying floor coverings have been developed in which the upper textile layer 1 consists of a non-woven polypropylene staple and the lower base layer 2 consists of a recycled rubber granulate and a polyurethane binder. The size of the granules per screen ranges from 0.5 to 5 mm. The surface weight of the covering is about 4 kg / m ² , the covering shows good abrasion resistance, its resistance to wear by a wheelchair is at least double compared to the fabric itself without the underlay.

Likewise, polyester, polyamide or wool fibers in various treatments and combinations, as well as other fibers used in floor coverings, can be used as the material of the facing textile layer.

In addition to recycled rubber granules, various textile fibers, wood chips and the like can be used as the filler of the base layer, all in combination with each other, optionally supplemented with inorganic granules such as ground slag, sand, and the like. and inorganic fibers such as glass, asbestos fibers and the like.

Possible binders are those polymers which allow the filler particles to be wrapped in a thin film and, after forming the backing layer, form a viscous film on the contact surface of the layer into which the fibers exiting the enclosed fabric are anchored. In addition to the aforementioned polyurethane, for example, polyethylene, butyl rubber, a fluoroelastomer and others are suitable.

. '1

In an exemplary discontinuous method of manufacturing a floor covering according to the invention, the granulate and the liquid polyurethane binder are fed from the granulate container 3 and the binder container 4 into the container 5. From there the mixture is discharged into a flat mold 6 A fabric blank 1 is laid and the mold 6 with both layers 1, 2 is placed in a warm press 7 whose table 8 is heated to 140 ° C and whose ram 9 is heated to 90 ° C. After 5 min. under slight pressure, the polymerization of the binder is completed and the mold is ejected from the press, the covering is removed from it, allowed to cool and cut to the desired dimensions.

In the exemplary continuous production method *, the individual components are already heated in the tanks 2 and 3, respectively. 4, the heating continues in the wrapping container 5, the mixture is pushed out of it by the slit 10 into a uniform layer on the surface of the endless belt 11, on the backing layer 2. wherein the temperature of the lower calender rollers 12 is 14 ° C and the upper rollers 12 9 (° C.) After passing the covering through the hot part 13 of the line for a maximum of 5 minutes, during which the polymerization of the backing layer 2 is substantially complete. The floor covering is then cut to the required dimensions. *

Particularly in the continuous production process, it is also possible to extrude the layer from the granulate mixture and the binder onto the layer of fabric 1 deposited on the surface of the endless belt 1 by means of the slit 10. In this case, the upper calender rolls 12 will be heated to a higher temperature than the lower rolls 12.

The floor covering according to the invention produced in the described manner finds wide application in interiors and exteriors, preferably in the form of self-lying squares, which can be laid β for a limited time and then easily moved to another area and recycled after the service life.

Claims (11)

Ρ A Τ Ε Ν T O VÉ. NÁR .O..Kχ i First Samoležící'podlahová coverings consisting of upper VRST '.i ^1', ','. you ..textilie and at least one substrate layer is formed, a granular filler-and / or fiber <material and binder material from'póiýmerujícího-,, characterized in that the binder, which / make I0 ^T to the 30th % by weight '; It forms granules and / or filler fibers ,. film between the granules and / or fibers in the undercoat coated with the intoxicating layer. the vents are left, wherein the binder adhering to the filler in the upper surface of the substrate ³ . ií. '. · A ¹ . ¹ '· ·· < The layers are embedded with fibers that protrude from the bottom / surface of the fabric. ¹ ' ·. ¹ ·. *, '·. . . '. ¹ ''. . · * ?. · ₄ ir. 1 "·" · r>. . · 'Μ. · '' ··. The covering according to claim 1, characterized in that the filler of the backing layer consists of a granulate of recycled rubber whose granules have a diameter of 0.5 to 5 mm. - ^p l. * '; ,. ¹ ·. In i '''.'', Ϊ '' Roofing according to claim 1,. characterized in that the backing layer comprises polyurethane ... as a binder A covering according to claim 1, characterized in that the textile layer comprises a non-woven fabric of polypropylene fibers. .> '* / A covering according to claim 1, characterized in that it consists of an upper fabric layer and at least two backing. ^r · I ' ^4-1 visits differing in' composition '. · L> o / a 2 ze./ - A method of manufacturing a floor covering according to claim 1, characterized in that the granules and / or filler fibers are coated with a film of polymerizing binder in a liquid state such that the binder constitutes 10 to 30 wt. The binder in the backing layer is allowed to polymerize by compressing the two layers at a pressure of 20 to 200 kPa, followed by completion of the polymerization and possibly cutting the covering to the desired level. areal formations. The method of claim 6, wherein the fabric layer is applied to the top surface of the backing layer spread over the backing. Method according to claim 6, characterized in that the backing layer is first laid on the backing and the mixture of granules and / or filler fibers with a binder is spread over it. Method according to claim 6, characterized in that the polymerization in the backing layer and the compression of the two layers takes place in the rest state. Method according to claim 6, characterized in that the polymerization in the backing layer and the compression of the two layers takes place. as the two layers move on top of each other. Process according to claim 6, characterized in that the granulate and the polyurethane binder are mixed before the mixing, at a temperature of á ° C. and / or heated in the layer to a temperature of 100 to 15