DE102006001972A1 - Flexible flooring - Google Patents

Abstract

The invention relates to a flexible, in particular rollable, floor covering with a carrier layer (10) and a cover layer (14) provided thereon and forming a planar and / or structured surface, the cover layer (14) being coated in an abrasion-resistant manner by means of a radiation-curing resin and abrasive fillers Has paper or plastic film, the carrier layer is multilayered and a first polymer layer (10) having filler particles, in particular wood particles and / or wood flour, as well as stabilizing layer (12) formed thereon in the direction of the cover layer to increase the mechanical strength of the polymer layer by means of rigid Body, in particular by means of glass and / or plastic fibers, and between the polymer layer and the paper or plastic film, in particular between the stabilization layer and the paper or plastic film, a stress compensation layer (12) is provided, which is designed so thatWhen the floor covering is bent, the stress compensation layer absorbs a mechanical load on the paper or plastic film by the rigid body.

Description

The The present invention relates to a flexible, in particular rollable floor covering according to the preamble of the main claim.

in the Area of floor technology in principle a distinction is made between roll-up and non-rollable coverings; this rigid, non-rollable floors are typically by means of Elements (tiles) made of plastic (PVC material), from Textiles (carpet), of rubber, of linoleum, of parquet or made of wood-based materials that have a printed decorative surface layer by means of a so-called decorative paper, realized.

On the other hand are rollable (rollable) Flooring the known as generic assumed type typically multi-layer arrangements of flexible, elastic plastics (again in the focus of PVC), linoleum or textiles (carpeting) that are patterned or in bulk the surface are printed. Also, in both types of flooring - rigid and flexible - that Provide supportive support materials from textile fabrics known. The purpose of such carrier materials is the increase the penetration resistance of the floor covering, i. avoidance of damage the surface of the pavement by mechanically generated impressions, additionally the bracing of plastic layers in the manufacturing process.

flexible Flooring in the form of rollable coverings are usually rolled up in about 200 cm wide, 2 to 3.5 mm thick Railways placed on the market. Differences become homogeneous, i.e. above the web thickness uniform built-up coverings and so-called heterogeneous coverings, which consists of several layers of different properties are. These heterogeneous coverings typically have a textile layer on which a (suitable be printed) intermediate layer is provided which again with a usual transparent wear layer is provided. Typically, the Printed layer of highly elastic polymer films or loose Plastisolschaumschichten to the rollability of the material too guarantee.

Potentially However, disadvantageous in such devices is the one limited optical quality, the not comparable to rigid flooring elements because there typically paper-based decor carrier with correspondingly brilliant Print image can be used. At the same time, however, prohibits the structure and the rolling requirement common Polymer films of the printed layer on heterogeneous coverings use a printed paper as a decor carrier due to its lower extensibility (typically would here it comes to cracks or wrinkles in a paper-based decor carrier).

Common rollable floor coverings predominantly exist made of elastic or thermoelastic material and thus offer a typically high level of walking comfort. By contrast, are material-related the surface properties generic rollable flooring in terms of limited to scratch or abrasion resistance, so that such Flooring practically not for Object or industrial environments with heavy loads.

Not rollable Flooring become common in the form of plate-shaped, non-flexible plastic coverings, or in the form of wood flooring (Parquet or laminate) realized. Not flexible plastic coverings structurally common rollable homogeneous products, but are characterized by high filler proportions or different Intermediate layers made rigid and dimensionally stable. In terms of on the optical quality the surface However, even here, the use of paper-based decor carrier is not possible because existing Production methods do not allow the use of non-stretch decorative paper.

One Laminate flooring typically consists of about 6 to 10 mm thick HDF board, the top with a decorative paper as well an abrasion-resistant and transparent overlay paper provided as a cover layer is, which in turn predominantly with thermally curable Melamine resin over a hot pressing process usable be made. Raw plates produced in this way are cut into suitable utility elements and over milling provided with tongue and groove systems, these elements typically floating, i. without glue, to be laid.

While rigid floor coverings in the form of laminate wood-based coverings offer high optical quality and are typically insensitive to mechanical stress, a significant disadvantage is their lack of elasticity, so that such a floor covering offers practically no walking comfort and no structure-borne sound damping properties. Also, such flooring - structurally - not suitable for Vor cracks or bends, and a general weakness of wood-based elements is swellability in contact with moisture, which not only virtually eliminates use in humid environments, but also makes a (wet) cleaning problematic.

In front the background of a growing need for individually patterned and customizable surfaces on flexible materials with high walking comfort, simultaneously however sufficiently durable (and with it for industrial and object areas are suitable) and with little Effort can be maintained, It is therefore an object of the present invention to provide a flexible, especially rollable Flooring to create the high optical quality of the surface, mechanical Resilience and durability (especially Abrasion resistance) with flexibility in use and installation, especially on non-planning sites (like protrusions or stairs), combined, suitable for humid environments at the same time is and also easy to manufacture and economical to manufacture is.

The The object is achieved by the device with the features of the main claim solved; advantageous developments of the invention are described in the subclaims. additionally protection is claimed for a use of the device according to the main claim according to the independent claim 15th

In According to the invention advantageously Way is the flexible and particularly preferably rollable trained flooring as multi-layered or multi-layered (in the context of the present disclosure these terms should be used synonymously) arrangement consisting from a cover layer, a self-multilayer support layer and a voltage compensation layer provided between the cover layer and the support layer realized, it being the purpose of the voltage compensation layer according to the invention is mechanical stress on the topcoat (which typically and mostly a paper sheet as a base) by - the overall mechanical arrangement Strengthening - rigid body the carrier layer (more precisely, the stabilization layer as part of the carrier layer) absorb or compensate.

On This way, on the one hand becomes an elastic and thus potentially rollable and also for non-plane operating environments such as ledges or stair steps are good suitable flooring created by its elasticity requirements walking comfort corresponds, on the other hand, however, the design and mechanical advantages of wood laminates - for instance in terms of high optical surface quality and abrasion resistance - realisert. If, in addition, as further developed and preferred, Particles of the carrier layer be set in the form of wood particles or wood flour, this but within a polymer layer, in the manner of a "rollable wood", a flooring product, which in addition to the described advantages of both traditional Worlds - the rollable floors on the one hand, the rigid laminate floors on the other hand - cheap material costs Realized and yet not subject to the wood inherent problem of swelling Moisture is subject.

Advantageous allows it thereby the voltage compensation layer according to invention, to catch any frictions that just happen during a rolling process between the (typically paper-based) topcoat and the Stabilization layer occur and, without compensation, either to a kinking usually as fibers realized rigid body of the stabilization layer, or a compression or tearing of the paper, would lead. In the realization of the invention For this purpose, the stress compensation layer comprises a polymer or a polymeric mixture which, typically by suitable Additives, allowing a cold flow to some extent, so that the stress compensation layer also has the character of a Sliding layer receives. The organosols or plastisols advantageously used for this purpose (A typical realization is in softening formulations swollen polymer such as e.g. a suitable PVC or a suitable one Polyacrylate) achieve these advantageous properties, by suitable selection and adjustment of the layer thickness and the material for the stabilization layer the desired stress-relieving effect can be achieved.

Especially this effect is effective when the material of the stress compensation layer the stabilizing layer or its rigid body (ie in the preferred embodiment in particular their fibers) at least partially penetrates or saturated, so that, in addition to the described action as a sliding layer, the stress compensation layer also causes mechanical fixing and bonding of the Schich th and in the sequence of layers, the stress compensation layer and the stabilizing layer as a common layer and / or seamless merging into each other Layers arise.

While smooth, planar surfaces are typically realized in the present invention, it is also within the scope of the invention to have suitable structured or patterned surfaces, for example corresponding to a wood grain or a replicated tile, tile or ceramic structure corresponding structuring of the cover layer (or its overhead coating), wherein further education according to a synchronization of such structuring can be done with a suitable decorative printing on the paper or plastic film of the cover layer.

By suitable addition of the inventively provided abrasive fillers is also the flooring according to the invention highly resistant to abrasion; according to a particularly preferred embodiment of the invention can be, based on DIN-EN 13329 (method S42), an abrasion resistance of realize above 1500 revolutions.

In particularly according to the invention Preferably, moreover, the cover layer is multi-layered, namely by means of a first, applied to the paper or plastic film Resin layer (which further preferably impregnates the paper sheet or penetrates), and a second resin layer formed on the first layer, wherein according to the preferred execution the resins are radiation-curing and, more preferably, the first layer is the abrasive fillers has (but not the second layer).

While in addition the use of wood particles or wood flour as filler particles in the context of the carrier layer according to the invention is particularly preferred suitable also other particles, such as recyclates from waste plastic recycling, be used so that inexpensive material makes sense and can be effectively introduced.

in the Framework of a preferred embodiment of the invention carries the floor covering In addition, on its (bottom side) underside a material for impact sound absorption, which in principle can be implemented arbitrarily, but preferred a latex foam or the like. damping means having.

in the Result arises so surprising by the present invention more effective and easier, more economical Way a powerful one Flooring product which has the advantageous properties of rigid, about laminate-based floors with the cheap elasticity, damping and rolling characteristics of traditional rollable flooring combined so that of it It can be assumed that with the present invention numerous fields of application can be developed in an economically advantageous manner.

Further Advantages, features and details of the invention will become apparent the following description of preferred embodiments and by reference the drawings; these show in

1 a schematic and not to scale layer diagram of the floor covering according to a first preferred embodiment of the invention.

The production of the floor covering in the embodiment of 1 happens first by producing a film-shaped polymer layer 10 as known in the art by conventional methods. About recycled plastics (eg polyolefins such as PP or PE) with wood flour (typical addition of 50 wt .-%) are mixed in the extruder process into granules and then processed in a rolling mill to a about 1.5 mm thick web.

On this polymer layer (backside web), a glass web of a basis weight of 40 g / m ² by means of coating an organosol (eg PVC plastisol) is laminated, so that in this way the glass mat as a stabilizing layer 12 (about 0.3 mm thick) is penetrated by the organosol as a stress compensation layer. The organosol is realized by means of the following recipe:

In the same operation, decorative paper is made by means of a gelling drum 14 of the type Nanofin (manufactured and available from WKP Kunststoffplattenwerke GmbH, D-72669 Unteren sing), so that the Organosol wets the paper back. The gelling process leads to a permanent bonding of the layers.

This Decorative paper as a topcoat typically has a 60 microns thick layer of printed paper on which towards her external Top is coated with a first and second resin layer. Specifically, the first resin layer has a radiation curing Resin on (water-based, e.g. IRR 395, 40%), in conjunction with an abrasive, inorganic filler (e.g., Plakor 30). This first layer, in the production of decorative paper for instance by means of a slot nozzle in a typical layer thickness between 10 and 100 microns applied, may additionally Color pigments are included and is for maximum abrasion resistance formulated. In contrast, the resting second layer of the seal and determines the other surface properties, especially gloss, appearance and surface structure. This after the Drying of the first layer applied second layer consists from a radiation-curing Binders, for example in the form of a polyester acrylate, epoxy acrylate or urethane acrylate (e.g., Ebecryl 1016) applied again known coating options like roller, slot nozzle or doctor job. Also can Added matting agent for adjusting a degree of gloss or slip additives become. By irradiation with UV or electron beams through the upper second layer will be the top layer serving decor paper before applying to the other layers cured of the flooring and cross-linked and receives its outstanding abrasion resistance properties by the flooring according to the invention be exploited. At the same time, the embedding or penetration is prevented of the glass fleece with the Organosol, that with a bending or rolling the Overall arrangement of individual fibers of the glass mat to an adverse Piercing, Tear or unfolding the paper, thereby receives the structure through the glass fleece outstanding mechanical strength properties.

The Thus formed Gesamtanordung can weiterbildungsgemäss on their the cover layer opposite side an otherwise known, soft, especially impact sound absorbing additional back layer (not shown) made of PU or latex foam, so that a total thickness of about 4 mm would be achieved.

Claims (15)

Flexible, in particular rollable floor covering with a carrier layer ( 10 ) as well as a covering layer provided thereon, which forms a plane and / or textured surface ( 14 ), characterized in that the cover layer ( 14 ) has an abrasion-resistant coated by means of a radiation-curing resin and abrasive fillers paper or plastic film, the carrier layer is formed of several layers and a first, filler particles, in particular wood particles and / or wood flour, having polymer layer ( 10 ) and in the direction of the cover layer formed thereon stabilizing layer ( 12 ) for increasing a mechanical strength of the polymer layer by means of rigid bodies, in particular by means of glass and / or plastic fibers, and between the polymer layer and the paper or plastic film, in particular between the stabilizing layer and the paper or plastic film, a stress compensation layer ( 12 ) is provided, which is formed so that upon bending of the flooring, the stress compensation layer receives a mechanical load on the paper or plastic film through the rigid body. Floor covering according to claim 1, characterized that the stress compensation layer is located directly between the paper or plastic film and the stabilizing layer is formed. Floor covering according to claim 1 or 2, characterized the stabilization layer is a glass and / or plastic fleece, in particular Polyester fleece, has. Floor covering according to claim 3, characterized in that a basis weight of the glass and / or polyester nonwoven in the range between 20 and 50 gr./m ² . Floor covering according to one of claims 1 to 4, characterized the cover layer has a layer formed on the paper or plastic film, a radiation-curing, but does not prefer a thermosetting resin as well as an abrasive, preferably inorganic filler comprising first layer and on the first layer a second layer is formed, which is a radiation-curing resin and no abrasive Has fillers. Floor covering according to one of claims 1 to 5, characterized a coating of the paper or plastic film of the cover layer, in particular, a cumulative thickness of the first layer and the second Layer having a thickness in the range between 30 and 60 microns. Floor covering according to one of claims 1 to 6, characterized that the topcoat the flooring a abrasion resistance of more 1500 revolutions, preferably more than 2500 revolutions, measured according to DIN EN 13329 (method S42) confers, in particular produced by the dosage of the abrasive fillers. Floor covering according to one of claims 1 to 7, characterized that visible through their coating paper or Plastic film of the cover layer has a sampling. Floor covering according to claim 8, characterized that the coating of the paper or plastic film structuring having the structuring with one on the paper or Plastic film provided sampling or printing synchronized is. Floor covering according to one of claims 1 to 9, characterized that the stress compensation layer is a plasticizer or plasticized plastisols and / or compounds based on PVC and / or polyacrylate contains. Floor covering according to one of claims 1 to 10, characterized the material of the stress compensation layer is the stabilization layer at least partially penetrates and / or soaked. Floor covering according to one of claims 1 to 11, characterized that the polymer layer of the carrier layer as a recycled plastic, in particular Polyolefinrecyclat having Polymer film is realized. Floor covering according to one of claims 1 to 12, characterized that the polymer layer as filler particles Wood flour with a share between 35 and 70 wt .-%, in particular between 45 and 55% by weight of the polymer layer. Floor covering according to one of claims 1 to 13, characterized by an opposite of the cover layer on the carrier layer provided, bottom-side layer for impact sound absorption, which preferably plastic or latex foam has. Use of the floor covering according to one of claims 1 to 14 for covering and sheathing projections and / or joints in the floor area, in particular of steps or protrusions.