DE102020119782A1 - Covering element, in particular for a floor covering, and method for its production - Google Patents

Abstract

The invention relates to a covering element, in particular for the production of a floor covering, which has at least one upper body and one base body, with its upper body/top covering being fixed with its underside/lower surface by means of a connecting means on the top/upper surface of the specially layered base body; and a manufacturing method for such covering elements.

Description

The invention relates to a covering element, in particular for the production of a floor covering, which has at least one upper body and one base body, with its upper body/upper covering being fixed with its underside/lower surface by means of a connecting means on the upper side/upper surface of the base body; and a manufacturing method for such covering elements.

In many different technical fields of application, in particular in the field of construction engineering, multi-layered bodies or flat structures are known in which the different layers take on different functions with the aim of giving the overall structure an overall behavior that largely corresponds to the application-specific requirement profile. This naturally results in a limitation in the optimal equipment of the individual layers insofar as the optimization of the individual layer has to be subordinate to the optimization of the overall structure.

For example, when equipping a floor covering with a footfall sound-insulating underlay, one goal is not to jeopardize the indentation resistance of the covering or, in another example, not to produce an unreasonable deterioration in footfall sound through a very hard thermal insulation underlay. Another example of the combination of hard and brittle coverings with soft underlays is the risk of fracture under vertical load, because the underlay cannot mechanically compensate for the low flexural strength of such coverings with sufficient support. With such hard and brittle coverings, such as ceramics or duroplastics, but also highly filled thermoplastics, people therefore like to connect the underbody directly and rigidly to the covering and do without further underlays. This was and is the case in particular with the widespread ceramic and/or natural stone coverings.

Recently there have been ceramic floor coverings which are provided with an underlayer and which claim the possibility of loose laying, laying which dispenses with rigid adhesion to the subfloor, the underlayer of which is therefore intended to be able to prevent the problems mentioned. In the DE102010005068 A1 For example, a ceramic tile with a cork base is described as a covering element, as well as in DE102011008974 A1 . In both documents, the problem is not addressed, they do not provide a solution to the problem, but aim at application-related questions.

In the following some multi-layer constructions related in the broadest sense of the invention are described in more detail as examples. The bottom layer of the construction is usually referred to as the "carrier". In individual cases, this can mean that a multi-layered "carrier" also falls under this term, as long as it is perceived as a uniformly functional element.

As mentioned above, from the DE102010005068 A1 a floor covering is known which has a single-layer, homogeneously structured, polymer-bound cork carrier layer and dispenses with an intermediate layer for the covering. No information on physical properties can be found in this document.

As mentioned above also describes the DE102011008974 A1 a product in which polymer-bound cork particles are used as an underlay, but in addition a concentration gradient of the binder is generated in the vertical direction, which should approach zero towards the subfloor.

From the DE202010001149 U1 a combination of inorganic surface material, eg slate, with a homogeneous polymer-bound cork base is also known, whereby in a special case the inorganic layer with very thin material already brings an auxiliary layer on the underside from the manufacturing process of this layer. It is not functionally necessary to connect the top and the carrier. A thermal connection is claimed.

the DE 3211770 C2 describes a multi-layer elastic sports floor structure to be built up on site, which core contains a homogeneous mixture of cork and rubber particles, which are either filled with latex binders or other castable, crosslinkable polymers, eg PUR. Hardenable layers of synthetic resin and other intermediate layers are used on the upper side. A distinction between the cork and rubber particles according to the moduli characterizing the elasticity is not required.

In the DE 3309228 A1 a band-like structure is described which consists of vulcanized rubber and in one of the outer sides of which particles of other materials are embedded before vulcanization. However, the remaining cross-section of the rubber is particle-free and the end product does not contain a thermoplastic binder.

From the DE 4244250 C2 a floor covering emerges that contains a cork-containing layer as a core, which is held on the top and bottom by textile supports that are needled vertically through the cork layer. Cross-linking latex is mentioned as the binder and crushed latex as further ingredients PE, PVC, rubber and needle felt waste or recyclates. Use as a support for overlying layers is not intended. A further disclosure of a floor covering can be found in DE 102011089030 A1 . It describes a floor covering with a mineral surface, a textile-reinforced adhesive layer or adhesive film and a carrier layer connected to the top layer as a result, which essentially consists of a polymer/cork mixture (40:60), i.e. has a single-layer, homogeneous design. The top layer is multi-layered. The carrier layer must be flush with the outer material all the way round.
A floor covering with a non-ceramic surface in the form of a wood/plastic (WPC) composite with an underside of cork-containing material is used in the DE 102013011450 A1 described. An intermediate layer is expressly excluded. The so-called "fusible" cork webs are not defined further and are referred to as state of the art, in no way introduced into the knowledge of the professional world as multi-layered. The term fusible indicates a polymer-bound cork sheet with thermoplastic behavior.

The DE 202008007547 U1 . There, the elasticity is generated by the crosslinking and then hardened latex binder, into which harder, less elastic to "rigid" filler particles are incorporated. These fillers can consist of wood, cork or other renewable materials and are distributed so evenly and densely over the cross-section that they only allow the covering to be pushed in slightly under vertical load, i.e. they prevent elastic behavior in the actual sense. The latex content is around 10%, although it is not explained whether and if so, how the elastic properties of the binder can still come into play.

The following can be summarized from this known state of the art. It is known to bring carriers and top layers together to form a multi-layer floor covering. It is known, in particular, to embed cork particles and/or particles of other materials in the carrier in a polymer-bound manner and to thermally attach these carriers to the layer or layers above, ie to the top layers. The particles are distributed homogeneously over the cross section and the polymer can be distributed evenly or unevenly.

Materials that are structured in this way can hardly be changed in their properties. There are not enough variable structure parameters available to satisfactorily balance the opposing property improvements resulting from the different properties of the layers. Many attempts have been made to eliminate or at least limit the problems mentioned, for example with a floor covering according to DE102010005068A1 . Satisfactory optimizations with regard to the entire requirement profile for the entire composite, ie the multi-layer fabric, have not yet resulted from this. Sufficient mechanical strength in combination with sufficiently good sound insulation and/or good horizontal shear strength and high sliding resistance after laying, paired with good gliding properties for easy positioning during laying as a combination, has not previously been possible to a sufficient extent.

However, coverings of this type were used to a comparatively small extent because the disadvantages of the ease of processing were accepted.

Such combined ceramic coverings allow, for example, laying without the usual permanent adhesion to the substrate on which the covering is placed. It goes without saying that other suitable materials can also be used instead of the ceramic top layer. Examples here would be thermoplastics, duroplastics, cement-bound materials or wood-based materials, with any combinations and multi-layered material structures also being possible. A common feature of all of these possible combinations is a prefabricated all-round overhang of the underlying carrier of the covering, which leads to defined gaps between the tops of the covering modules when the tiles are laid by laying the overhangs together. The gaps then have twice the width of the prefabricated overhangs. In a second laying step, they are grouted in a known manner with a grout. The overhangs of the sub-layers can be designed as a horizontal continuation of the sub-layers, but can also be deformed in a suitable way. It is known, for example, to press such projections vertically against the tile flanks. Such suggestions are in DE 10201410167 A1 shown. In all of the variants shown and conceivable, a part of the gap formed remains characteristically unfilled above the prefabricated overhang. This space is used to hold the joint compound mentioned above in the second step of the installation.

With conventionally laid tile materials, the joint materials are hard and inelastic, and do not have to have any elastic properties, because the tiles are rigidly connected to the subsurface in a fixed bed of adhesive, form a rigid body with this and the joint compounds after curing and therefore with vertical or horizontal load on the tiles joint sealants no thrust or shearing forces occur.

If the tiles are not rigidly connected to the substrate, vertical compressive, horizontal shearing and vertical shearing forces are repeatedly generated when the tiles are walked on or loaded, which are transferred to the joints and must be absorbed by the joint filling material without stress cracks or flank shearing occurring there. The risk of such effects is all the greater the softer and more flexible the layers under the tile are and the lower the sliding resistance of the bottom layer of the composite is in relation to the support surface. Of course, the layer thickness of the carrier, i.e. the layer under the tile - often called the underlayer - also has an influence. High layer thicknesses can be deformed horizontally more easily than low layer thicknesses, even if the underside is firmly attached to the substrate, because the corresponding shearing force is also greater due to the larger lever. This also increases the risk of excessive compression, stretching and shearing effects on the joint areas. In contradiction to this, however, a certain soft elasticity of this sub-layer is desired, because this can improve the footfall sound-damping property. It is also important not to reduce the sliding properties of this sub-layer so much that it becomes difficult to position the tiles during laying. The tile must slide horizontally into the desired position easily and without additional effort and then remain in place, even if additional force is applied.

On the other hand, it is imperative that this backsheet provides mechanically sufficient uniform vertically oriented support for the facestock and, in addition, offers sufficient resistance to horizontal shear deformation, especially at higher sheet thicknesses. Particularly rigid upper materials, such as ceramics or natural stone and/or duroplastics, tend to break under pressure and lack of or uneven support from the lower layers, which with conventional laying in a fixed bed of adhesive only occurs in the case of laying errors, such as uneven application of adhesive or insufficient smoothing of the surface subfloor can occur.

The object of the invention is therefore, as stated at the outset, to find a material or a material combination for the carrier, i.e. the underlayer of the multi-layer sheet or in general of the covering element, which brings together and satisfactorily solves the inherently contradictory property goals. The aim of the invention is to provide a multi-layer panel optimized in this way, e.g. a covering element for the production of a floor covering, which optimizes the quality of the entire multi-layer structure via the special conditions of the base layer, referred to below as the base body, so that it can be compared with an existing The subsurface does not need to be firmly connected and no adverse consequential effects are to be feared as a result.

The inventors have found that this sub-layer, i.e. the base body, is the most easily variable part of the overall structure, because the layers above it are much more difficult to access for optimization, since these are mainly products with complicated, lengthy manufacturing processes or even natural products that can hardly be influenced, or curing systems in which the special composition in the ratio of the individual components is subject to narrow limits due to the reaction. In view of this idea, the invention focuses in particular on an improved base body and its combination with the top covering.

Surprisingly, a solution to this problem is shown there quite fundamentally in the combination of materials in a multi-layer base body, which is on a lowest level, see 3 , Bz. 2a, the bottom layer contain horizontally adjacent surface sections that differ significantly in hardness and elasticity from those above and partially in between. Individual surface sections can partially touch, which can result in a network-like structure. It is advantageous if this lowest horizon has randomly or regularly distributed, regularly or irregularly shaped gaps that are partially filled by an overlying layer; please refer 1 , 2 and 3 . Partly means here that this layer does not completely fill the gaps mentioned, but does not quite reach the average horizontal end surface of the bottom layer. As a result, small cavities are created when the covering element is laid on, which, because of the soft elasticity of the bottom layer, are flattened after a while by the dead weight of the covering element and act like suction cups. In the 2 , 3 and 4 this is shown in sketch form. The rule here is that the value/height X _{1 is} greater than the value/height X ₂ and that this size ratio subsequently remains essentially the same. This means that after the first positioning by moving the covering element, a suction effect is created after a short period of time, which in practice surprisingly makes it more difficult to loosen or further move the covering element with respect to the subsoil and thus the described problem of local fixation solves. In addition, the partial penetration of the bottom layer through the layer above means that the combination of layers exerts an increased support function compared to the top layer, i.e. the top covering, see 4 . If the hard-elastic area hits the underbody through the gaps, further vertical compression is practically prevented. At the same time, the initially reduced contact surface with the subsoil is increased by the penetration of particles from the upper layer, which additionally increases the sliding resistance of the covering element. The initially slight horizontal displaceability is largely eliminated after a short period of loading and lying down. The covering element is thus sufficiently fixed horizontally and vertically. The properties achieved are particularly advantageously pronounced if materials containing cork granules are used with at least two different material characteristics in relation to elasticity, see FIG 3 . The use of soft cork and hard cork particles, each embedded in a thermoplastic binder and layered on top of each other, has proven to be advantageous, especially in different quantity combinations, and also meets the necessary requirements in terms of their mechanical behavior, see Table 1.

However, similar results can also be achieved with other, duroplastic and elastic particles, as long as their elastic property differences are similar to the ratios of soft and hard cork. The geometric structure does not change significantly as a result and the fabrics produced from it by pressure and heat behave in an analogous manner.

Prerequisites and terminology for this invention can be found under the following definitions and general conditions.

Hard-elastic means a material that has hard-rubber-like properties over a defined service temperature range. The direction-dependent deformation of the material by pressure is small and is spontaneously reversible when the pressure is relieved by more than 90%, preferably more than 95%.

Soft-elastic means a material that has soft rubber-like properties over a defined service temperature range. The material can also have a foam structure in whole or in part. The deformation of the material due to pressure is large and, when the pressure is relieved by more than 70%, preferably more than 80%, partly spontaneously and then reversible with a delay.

With the selected materials, the difference in the deformation resistance, i.e. the hardness, between the soft-elastic and the hard-elastic particles must be so great that the deformation when pressure is applied occurs predominantly in the soft-elastic particles. It is therefore not an absolute, but a relative material parameter. This ensures that particles of the first type, see 3 , by compressing particles of the second kind, see 3 , slide between the latter and be able to reach the supporting surface. Parameters of the hardness measurements, such as Shore hardness, if known, and similar parameters characterizing elasticity can be used for pre-selection.

Due to its flow behavior, the selected binder must not impede displacements of the embedded particles too much and must show the lowest possible resistance to deformation at application temperatures. Because the mobility of the particles is primarily influenced by size and shape, and naturally also by the concentration in the polymer, no absolute value can be specified for the plastic behavior of the polymer here either, but must be determined as a relative value through experimental preliminary testing of the corresponding mixture variants will.

The sliding resistance of the underside of the base body or its change over time during the laying process cannot be given in absolute terms either, because it has to be adapted to the nature, in particular the roughness, of the subsurface to be covered. This is also done by adjusting the proportions of the hard-elastic and soft-elastic particles, which essentially determine the "cavities" on the underside of the base body. The difference in the sliding resistance of the underside of the base body when laid compared to the loosely laid state during laying is proportional to the actual contact area between the underside of the carrier and the specified subfloor. From the 2 can be seen, also schematically in 4 shown that the contact surface in the laid, i.e. loaded state is considerably larger and thus the sliding resistance of the covering element has naturally increased significantly. According to the laws of nature, the sliding resistance behaves proportionally to the real contact area, i.e. to the sum of the areas of all contact areas. The suction cup-like cavities resulting from the geometry of the underside of the base body and caused by relaxation effects of both types of particles additionally increase the sliding resistance. The effectiveness of the suction areas is reflected in the additional effort that is required when the covering body is loosened vertically from the subsurface.

The further requirement mentioned above for a satisfactory impact sound damping behavior, or the requirement that general optimization of the base body structure should improve the damping behavior ten must not deteriorate significantly is, surprisingly, also fulfilled according to the invention. It has been shown that even an additional conventional soundproofing membrane loosely installed under the covering element does not improve the impact sound improvement (Tab 2)

As polymers, very 3 , Bz. 4, basically all pure polymers or polymer mixtures of different polymers and/or additives that can be formed into a flat structure below a temperature range of 220° C. in a pressing device in a known manner are suitable.

Non-limiting examples of suitable polymers and elastomers as cross-layer binder components are e.g. PVC, PVAC, PE, PP, PLA, EPDM, EVA, TPE, TPU, PS, SBS, PET, PC, POM, EVAC, PA.

Non-limiting examples of fillers and additives are chalk, limestone powder, talc, glass fibers, carbon fibers, carbon black, graphite, expanded clay, aluminum hydrate, carbon fibers, metal fibers, metal particles, magnetizable fillers for magnet adhesion to magnetic substrates, weight-increasing fillers such as barite, etc., for the Use when using lighter and thinner materials as a top layer, corundum or other additives that increase static friction, flame retardants and additives for electrical conductivity.

Non-limiting examples of fiber networks in layers 3 and 4 of 3 are knitted fabrics, knitted fabrics, non-woven fabrics, spacer fabrics and the like made of materials that do not melt below 220°C. Non-limiting examples of hard elastic particles (Bz. 1 in 1 and 3 ) are hard cork, highly cross-linked caoutchouc, hard rubber, old rubber, granulate made of highly cross-linked elastomers, recycling material made of non-thermoplastic plastic mixtures. For non-limiting examples of soft elastic particles, see Bz.2 in 1 and 3 , are soft cork, low-crosslinked rubber, duroplastic foam, TPE, TPU, SBS.

The advantage of the structure of the multi-layer base body according to the invention is also that by suitably combining the thicknesses of its sub-layers and the proportion of gaps in the bottom layer, the laying and lying properties of the covering element can be varied to a large extent and thus adapted to the given material and local conditions.

These advantages achieved by the invention are additionally supported by the optimization of the connection means, see FIG 3 , Bz. 4, i.e. the intermediate layer, which frictionally connects the base body, which is often also called the carrier, and the top covering, often simply called the top layer in advertising brochures, in order to avoid cavities between the top layer and this intermediate layer. Such cavities can arise if the intermediate layer does not completely fill out the relief-like unevenness of the carrier underlayer caused by production. Intermediate layer systems are therefore advantageous which are in a free-flowing state when they are introduced and which harden as a result of chemical and/or physical effects in such a way that there is largely no reduction in volume and the contours mentioned remain filled in with a non-positive fit, see FIG 7 . In the case of mechanical loads and bending deformations of the top covering, this results in a uniform introduction of force first into the base body, and then also into the subsurface after laying due to the described relaxation processes in the base body. This avoids cavities in the covering element, which could promote selective overloading due to excessive bending loads on the covering element.

Thermoplastic fasteners are not suitable because they tend not to be able to guarantee long-term stability over the lifetime of the covering and irreversibly give up their original shape, especially when subjected to frequent point loads. This negative aspect is supported by temperature changes caused by temperature stress, e.g. due to the effects of the sun or underfloor heating. Durable thermoset material avoids these disadvantages.

In the simplest case, the connecting means according to the invention consists of a self-hardening one-component or multi-component system. In order to create conditions that can be optimized here as well, this layer can be provided with fillers and/or fiber fillers which, for example, produce improved thermal conductivity and/or electrical conductivity. It is also possible to embed a textile carrier material or a carrier film in this layer, see 6 . The textile carrier can advantageously be incorporated as a three-dimensional material and can, for example, improve the mechanical stability, shear strength, compressive strength, electrical conductivity or thermal conductivity of this layer and thus support the improvements mentioned below with regard to the base body. In particular, such connecting means protect the product-related peripheral projections of the base body from mechanical damage during transport or during use. The above-mentioned aspects of the invention also allow additional properties to be improved without further impairing the advantageous laying and lying conditions achieved Measures for both the lanyard and the base body.

It is possible and state of the art in general to provide any polymer with fillers and additives in a known manner to control properties. These can be fillers and/or mixtures from the groups of mineral fillers, fiber fillers, metallic fillers or mixtures of these groups. In this way, as is known from the art, mechanical properties can be improved and the thermal conductivity can be influenced ( 5 ), electromagnetic shielding is achieved and/or electrical conductivity or magnetic properties are generated.

An exemplary variant according to the invention of the mechanical reinforcement of the base body consists in the incorporation of a wide-meshed, three-dimensional fiber network, see FIG 6 , whose "mesh size" is larger than the mean particle diameter of the hard-elastic particles, so that these particles can be positioned in the meshes. This can be, for example, commercially available knitted fabrics, hosiery or similar fabrics made from endless fibers or wire-like materials. Metal-containing products of this type are also conceivable, especially if you want to influence electrical, shielding or heat transport effects.

1. 1. Streuen von elastisch verformbaren Weichgranulaten auf eine, bereits auf eine Unterlage gestreute, Schicht von weniger verformbaren Hartgranulaten, beide in einem Vorprozess mit einem thermoplastischen Bindemittel umhüllt (zum Beispiel 90 Teile Granulat, 10 Teile Polymer) im dem gewünschten Verteilungsmuster angepassten Verhältnis der beiden Granulatarten;
2. 2. aufschmelzen der Mischung mittels in einer kontinuierlich arbeitenden Doppelbandpresse unter Druck. Die Schicht aus Hartgranulat bildet hierbei prozessbedingt die Unterseite des zu erzeugenden Flächengebildes;
3. 3. abkühlen des entstehenden Flächengebildes (vertikal umgedrehter Basiskörper);
4. 4. vertikales Wenden des Flächengebildes und Zuführung zur Weiterverarbeitung. Der Basiskörper hat damit die erfindungsgemäße vertikale Orientierung;
5. 5. Auftragen des selbstvernetzenden Verbindungsmittels auf den Basiskörper als Schmelze von oben her;
6. 6. einlegen der Einzelelemente des Oberbelages mit geplanten umlaufenden Zwischenräumen in das noch ungehärtete aufgeschmolzene Verbindungsmittel;
7. 7. aushärten des Verbindungsmittels nebst gleichzeitiger Erzeugung der form- und kraftschlüssigen Verbindung zwischen dem Verbindungsmittel und dem Oberbelag und zwischen dem Verbindungsmittel und dem Basiskörper, wodurch alle Teilkörper des Belagelementes miteinander verbunden sind;
8. 8. mittiges Auftrennen des Trägers entlang der Zwischenräume zur Herstellung der Einzelfliesen mit geplanten Überständen des Trägers / Basiskörper.

The gap portion of the underside of the base body, which essentially determines the properties, as described above, is produced by varying the scattering thicknesses of the different particles. For a better understanding of the structure produced, the manufacturing process (manufacturing method) and the functional mechanism of a polymer-bound cork carrier according to the invention and the finished covering element consisting of base body, connecting layer and top layer are described in more detail below.

1. 1. Scattering of elastically deformable soft granules onto a layer of less deformable hard granules already scattered on a substrate, both coated with a thermoplastic binder in a preliminary process (e.g. 90 parts granules, 10 parts polymer) in the ratio of the two adapted to the desired distribution pattern types of granules;
2. 2. Melting of the mixture in a continuously operating double belt press under pressure. Due to the process, the layer of hard granules forms the underside of the fabric to be produced;
3. 3. Cooling of the resulting sheet (vertically inverted base body);
4. 4. Vertical turning of the fabric and feeding it for further processing. The base body thus has the vertical orientation according to the invention;
5. 5. Application of the self-crosslinking connecting agent to the base body as a melt from above;
6. 6. Insertion of the individual elements of the top covering with the planned circumferential gaps into the still unhardened, melted connection medium;
7. 7. hardening of the connecting means together with simultaneous production of the positive and non-positive connection between the connecting means and the top covering and between the connecting means and the base body, as a result of which all sub-bodies of the covering element are connected to one another;
8. 8. Central separation of the carrier along the gaps to produce the individual tiles with the planned excess length of the carrier/base body.

Without deviating from the invention, it is of course also possible to produce two separate, halves, or distributed in a different ratio base body one after the other and to perforate the flexible part of the base body in any way, e.g. by punching or by scattering granules using a template. Both base body parts can then be laminated to one another thermally or in some other way. However, compared to the process steps mentioned above, this process is technically very complex and far less economical.

The previously known solutions to combined multi-layer tiles, especially ceramic or stone tiles after DE 102010005068 A1 , do not have all the advantageous properties described. Either they do not protrude to make laying easier and must be positioned using a template, in which case the joint material then creates an undesirable adhesion to the subfloor from a structural point of view, or the support and top are not securely connected to each other due to the lack of a connecting layer. It has been shown that thermal lamination on ceramic tiles does not allow a secure connection due to the rapid heat dissipation via the ceramic body. There is also low sliding friction on the underside of other polymer-bound cork layers. So far, these have consisted of “homogeneous” single-layer material, mostly made of duroplastically bonded pressed cork, which, due to the production process, has permanently unchangeable smooth and hard surfaces and thus the inventive temporal functionality of the gaps of the invention the flexible layer according to the invention cannot be represented, ie it does not offer a reduction in the sliding properties over time.

Such alternative flat cork structures are usually produced using the pressed cork process, in which the desired parts are cut from pressed cork blocks containing binder using a veneering process. The upper and lower sides of the end products cannot be distinguished due to the homogeneity of the starting material and are also largely smooth due to the cutting process. They do not have a heterogeneous, relief-like surface structure comparable to the material claimed here.

This relief-like structure only inevitably arises as a result of the choice of composition described according to the invention in the continuous belt pressing process. In the continuous double belt press, a controllable surface pressure is applied to the entire system. In the melting zone of the binder, which no longer significantly inhibits the mobility of the particles relative to one another, the soft-elastic particles are deformed much more strongly than the hard-elastic particles at a given pressure. As a result of this partial deformation, a greatly enlarged contact surface of the soft particles with the upper conveyor belt is obtained in comparison to the original contact surface of the still cold belt with the particles scattered cold as the second layer. The particles are flattened and stretched horizontally, significantly increasing the contact area. The hard particle layer remains little influenced by this conveyor belt with regard to the inner contact surface and is also hardly deformed. When the pressure is relieved and the particles cool down, the resilience of the soft-elastic particles is evidently sufficient to expose part of the adjacent hard-particle level. The horizontal deformation recovers at least partially, as does the compression in the vertical direction. This creates a distance between the upper edge of the hard particle level and the lower edge of the soft particles. The resistance of the binder to the relaxation process increases with decreasing temperature. It is therefore necessary to carry out the pressure relief before the cooling process and it is advantageous to slow down the cooling process, if necessary by means of an annealing section.

Other mentioned similar materials z. B. from polymer-bound cork and / or rubber particles, from foams or fiber materials, all of which are homogeneously structured, so do not have the inventive feature of the special multi-layer, can not offer the inventive functionality. In the known state of the art, no solution to the intentional load-dependent anti-slip feature in relation to the ground seems to be described or realizable.

• 1 zeigt beispielhaft die Unterseite eines Basiskörpers aufgebaut aus Hartkorkpartikel 1 und Weichkorkpartikeln 2 in einem transparenten, daher nicht sichtbaren Polymer in einer vergrößerten Aufnahme. In vertikaler Blickrichtung auf die Zeichnungsebene liegt hier die zweite Schicht, also die Hartkorkpartikel 1, unter der ersten Schicht, also den Weichkorkpartikel 2, und ist partiell darin eingebettet.
• 2 zeigt die realen Berührungsflächen des Beispiels zum Untergrund und von dorther betrachtet, sichtbar gemacht als Farbabdruck auf einem weißen Untergrund. Im linken Bild erkennt man die insgesamt kleine Berührungsfläche bei losem Auflegen, im rechten Bild die erhebliche Vergrößerung der Auflagefläche bei leichtem Andruck, der Verlegesituation entsprechend.
• In 3 ist schematisch und beispielhaft in einer prinzipiellen Skizze der Querschnitt eines Belagelements dargestellt, unmittelbar nach dem Herstellprozess. Es zeigen: die Ziffer 5 den Oberbelag, die Ziffer 3 das duroplastische Verbindungsmittel mit oder ohne Verstärkungsmittel, die Ziffer 2 die teilweise in das Polymer eingebetteten Weichkorkpartikel und den dadurch gebildeten Weichkorkpartikel haltigen Horizont 2a. Die Ziffer 1 zeigt die eingebetteten Hartkorkpartikel, die Ziffer 4 das Polymer..
• 3a zeigt die Veränderungen an der Unterseite des Basiskörpers 10 beim losen Auflegen auf die vorgegebene Unterlage 7. Es bilden sich Luftkammern 6 zwischen der Unterlage 7 und dem Basiskörper 10 bis zum Erreichen des Kräftegleichgewichts aus Gewicht des Belagkörpers 10 und Rückstellkraft der Basisschicht, wobei sich ein Abstand / eine Höhe X₁ einstellt.
• 4 zeigt die Verhältnisse nach Andruck des Belagelementes 11 an die Auflagefläche 7. Die Hartkorkpartikel 1 sind ihrer schweren Verformbarkeit wegen teilweise in die leichter verformbaren Lücken 6 zwischen den Weichkorkpartikeln 2 eingedrückt und erreichen teilweise die Oberseite der Unterlage 7, wodurch ein Gegendruck aufgebaut wird, der ein weiteres Zusammendrücken des Basiskörpers 10 verhindert. Es entsteht ein neues Kräftegleichgewicht, wobei gilt, dass die Höhe X₁ , siehe in 3a, größer ist als die Höhe X₂, siehe in 4. Durch den erfindungsgemäßen Aufbau des Belagelementes 11 , insbesondere seines Basiskörper 10 bilden sich aus einigen ursprünglichen Luftkammern 6 durch Relaxationsvorgänge während der Gleichgewichtseinstellung spezielle Kammern mit vermindertem Luftdruck 8, die den gewünschten, verbesserten Ansaugeffekt bewirken.
• 5 zeigt, als Ausführungsvariante der Erfindung, die Möglichkeit durch die Wahl eines geeigneten Füllstoffgemisches im Polymer des Basiskörpers den Wärmedurchgang gegenüber bekannten Belagelementen zu verbessern, falls dies in besonderen Anwendungen des Belagelements erforderlich ist
• 6 zeigt, als weitere Ausführungsvariante der Erfindung, die Möglichkeit, in die polymergefüllten Partikelzwischenräume des Basiskörpers 10 ein dreidimensional orientiertes Verstärkungsmaterial aus Endlosdrähten einzubetten.
• 7 zeigt einen Schnitt durch ein Belagelement 11, welches auf eine Auflagefläche / Unterlage / Untergrund / Rohfußboden 7 aufgelegt ist. Man erkennt deutlich den erfindungsgemäßen Aufbau des Belagelementes 11, insbesondere die form- und kraftschlüssige sowie die ausgleichende Verbindung zwischen dem Verbindungsmittel 3 und der Oberschicht 5 einerseits und zwischen dem Verbindungsmittel 3 und dem Basiskörper 10 andererseits.

The invention is described below with reference to an 1 , 2 , 3 , 3a , 4 , 5 , 6 and 7 shown embodiment, which does not limit the invention, explained in more detail; in addition, further details according to the invention are shown in Tables Tab. 1 and Tab.

• 1 shows an example of the underside of a base body made up of hard cork particles 1 and soft cork particles 2 in a transparent, and therefore not visible, polymer in an enlarged image. In the vertical viewing direction on the plane of the drawing, the second layer, ie the hard cork particles 1, lies below the first layer, ie the soft cork particles 2, and is partially embedded in it.
• 2 shows the real contact surfaces of the example to the background and viewed from there, made visible as a color print on a white background. In the picture on the left you can see the overall small contact surface when laid loosely, in the picture on the right the considerable enlargement of the contact surface with light pressure, corresponding to the laying situation.
• In 3 is shown schematically and by way of example in a basic sketch of the cross section of a covering element, immediately after the manufacturing process. It shows: the number 5 the top covering, the number 3 the duroplastic connecting means with or without reinforcement means, the number 2 the soft cork particles partially embedded in the polymer and the horizon 2a containing soft cork particles formed thereby. The number 1 shows the embedded hard cork particles, the number 4 the polymer.
• 3a shows the changes on the underside of the base body 10 when loosely placed on the specified base 7. Air chambers 6 are formed between the base 7 and the base body 10 until the equilibrium of forces is reached from the weight of the covering body 10 and the restoring force of the base layer, with a distance / sets a height X _1.
• 4 shows the conditions after the covering element 11 has been pressed against the contact surface 7. Because they are difficult to deform, the hard cork particles 1 are partially pressed into the more easily deformable gaps 6 between the soft cork particles 2 and partially reach the upper side of the base 7, as a result of which a counter-pressure is built up which Further compression of the base body 10 is prevented. A new equilibrium of forces arises, whereby the height X ₁ , see in 3a , greater is than the height X ₂ , see in 4 . Due to the construction of the covering element 11 according to the invention, in particular its base body 10, special chambers with reduced air pressure 8 are formed from some original air chambers 6 through relaxation processes during the establishment of the equilibrium, which cause the desired, improved suction effect.
• 5 shows, as an embodiment of the invention, the possibility of improving the heat transfer compared to known covering elements by choosing a suitable filler mixture in the polymer of the base body, if this is necessary in special applications of the covering element
• 6 shows, as a further embodiment of the invention, the possibility of embedding a three-dimensionally oriented reinforcement material made of endless wires in the polymer-filled particle interstices of the base body 10 .
• 7 shows a section through a covering element 11, which is placed on a bearing surface/underlay/underground/unfinished floor 7. The structure of the covering element 11 according to the invention can be clearly seen, in particular the form-fitting, non-positive and balancing connection between the connecting means 3 and the top layer 5 on the one hand and between the connecting means 3 and the base body 10 on the other.

Table Tab. 1 gives an overview of the influence of the mixing ratio of the particle types according to the invention on the compressibility of the base body. In terms of the invention, this is not significantly changed by increasing the proportion of soft particles.

Table Tab. 2 shows the sufficiently good impact sound improvement measure of the cork-containing base layers, which are constructed according to the invention. It can only be slightly improved by additional underlying sound insulation layers of the same thickness.

As already mentioned above, the invention is not limited to the exemplary embodiment described. The new special covering element according to the invention can not only be used for the production of floor coverings, but can also be used in the furniture industry, in particular in the production of special furniture, such as laboratory equipment, in particular laboratory tables or similar equipment, or in the advertising industry, e.g. in trade fair construction, where visible surfaces of objects, such as tables, cupboards, presentation boards, etc., are to be changed in their appearance and their use within a very short time window.

Reference List

1

hard cork particles

1b

spaces

2

soft cork particles

2a

horizon

3

thermoset fastener

4

polymer

5

Top covering / top layer part

6

air chambers

7

Bearing surface / underlay / subsurface (e.g. unfinished floor)

8th

Negative pressure chambers (negative pressure areas)

9

- free -

10

base body (carrier)

11

covering element

X1

Distance (height of base body 10 without load)

X2

Clearance (height of base body 10 with load)

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102010005068 A1 [0004, 0006, 0014, 0043]
• DE 102011008974 A1 [0004, 0007]
• DE 202010001149 U1 [0008]
• DE 3211770 C2 [0009]
• DE 3309228 A1 [0010]
• DE 4244250 C2 [0011]
• DE 102011089030 A1 [0011]
• DE 102013011450 A1 [0011]
• DE 202008007547 U1 [0012]
• DE 10201410167 A1 [0016]

Claims (15)

Covering element (11), in particular for the production of a floor covering, which has at least one upper body (5) and one base body (10), wherein • the upper body (5) is fixed with its underside/lower surface with a connecting means (3) on the top/upper surface of the base body (10), • the base body (10) is multi-layered and has polymer-bound particles, wherein • at least two types of particles (1; 2) are included, which differ in their compressibility. covering element after claim 1 , in which • the polymer is a thermoplastic polymer, or • the polymer is a thermoplastic elastomer, or • the polymer is an elastic polymer. covering element after claim 1 , in which the polymer contains fillers from the groups of mineral fillers, fiber fillers, metallic fillers or mixtures of these groups. covering element after claim 1 , in which the polymer contains wide-meshed three-dimensional fiber networks that penetrate the interstices of the particles. covering element after claim 1 , in which the named particle types (1, 2) each differ in the particle dimension so that the particles of higher compressibility are larger on average. covering element after claim 1 , in which the particle types (1; 2) mentioned correspond in their average diameter to up to two-thirds of the height of the finished base body 10, preferably half this dimension. covering element after claim 1 , in which at least one layer of the polymer is formed in the base body (10) on the underside, which layer predominantly contains particles with high compressibility and above it at least one layer of the polymer that exclusively contains particles of low compressibility. covering element after claim 1 , in which the particles of higher compressibility consist of soft cork (2) and the particles of lower compressibility of hard cork (1). covering element after claim 1 , in which the particles of higher compressibility consist of soft cork (2) and the particles of lower compressibility consist of rubber-containing material. covering element after claim 1 , in which the particles of higher compressibility consist of duroplastic foams and or of mixtures with other materials of high compressibility according to the preceding claims. covering element after claim 1 , in which the volume fraction of the polymer based on the total volume is 20% or less, preferably 15% or less, but at least 2%. Covering element according to at least one of the preceding claims, in which the connecting means is a connecting layer made of crosslinked polymers with duroplastic properties, which contains fillers and/or one or more embedded textile carriers as stabilizers. Covering element according to at least one of the preceding claims, which has an at least one-layer upper body which: - consists of mineral material, and/or - consists of plastic, and/or - is made from renewable raw materials, and/or - Is provided with further decorative and / or surface-enhancing layers. Covering element according to at least one of the aforesaid claims, in which the areal extension of the base body is such that a common circumferential overhang relative to the upper body remains. Process for the production of covering elements, which according to at least one of Claims 1 until 14 are characterized by the following process steps: a) Scattering of elastically deformable soft granules onto a layer of less deformable hard granules previously applied to a substrate, both coated with a thermoplastic binder in a preliminary process (e.g. 90 parts granules, 10 parts polymer ) in the ratio of the two types of granulate adapted to the desired distribution pattern; b) heating the mixture in a continuously operating double belt press under pressure until the polymer or polymer mixture melts; c) cooling of the resulting fabric, the base body; d) vertical turning of this fabric and feeding it for further processing, as a result of which the base body is given the vertical orientation according to the invention; e) application of the self-crosslinking connecting agent in the temperature range of its flowability from above onto the base body; f) inserting the upper layers/upper body with planned circumferential gaps in the uncured molten fastener; g) hardening of the connecting means together with simultaneous production of the positive and non-positive connection between the connecting means and the top covering and between the connecting means and the base body, as a result of which all sub-bodies of the covering element are connected to one another; h) Vertical severing of the resulting combination of covering elements, in the middle along the intermediate spaces, for the production of individual covering elements, each with circumferential overhangs of the base body.

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