EP0493534A1 - Surface covering material - Google Patents

Surface covering material

Info

Publication number
EP0493534A1
EP0493534A1 EP90917885A EP90917885A EP0493534A1 EP 0493534 A1 EP0493534 A1 EP 0493534A1 EP 90917885 A EP90917885 A EP 90917885A EP 90917885 A EP90917885 A EP 90917885A EP 0493534 A1 EP0493534 A1 EP 0493534A1
Authority
EP
European Patent Office
Prior art keywords
layer
covering material
surface covering
material according
backing layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP90917885A
Other languages
German (de)
French (fr)
Inventor
Ian David Walters
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP0493534A1 publication Critical patent/EP0493534A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63C—SKATES; SKIS; ROLLER SKATES; DESIGN OR LAYOUT OF COURTS, RINKS OR THE LIKE
    • A63C19/00—Design or layout of playing courts, rinks, bowling greens or areas for water-skiing; Covers therefor
    • A63C19/04—Mats or carpets for courts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D06N3/009—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin by spraying components on the web
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0078—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as a hot melt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042—Polyolefin (co)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/06—Melt
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/126—Permeability to liquids, absorption
    • D06N2209/128—Non-permeable
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2213/00—Others characteristics
    • D06N2213/06—Characteristics of the backing in carpets, rugs, synthetic lawn
    • D06N2213/068—Releasability between at least two of the layers

Definitions

  • the present invention is concerned with surface covering materials, and, in particular, textile-based surface covering materials, which in some embodiments are useful as floor covering for hospitals and the like.
  • Liquid-impermeable textile-based floor coverings are known (for example, the floor covering commercially available under the trade mark "Flotex", which comprises polya ide flocked intp a PVC base). Such impermeable floor coverings find applications in indoor areas where there is a risk of spillages, such as in kitchens, patient areas in hospitals and the like.
  • the material according to the present invention comprises a laminate comprising, in the order specified:
  • a backing layer in which the outer layer is bonded to the backing layer by means of the bonding layer in such a way that the adhesive penetrates through the textile fabric to encapsulate fibres which run substantially parallel to the major faces of the backing layer and form a substantially liquid-impermeable layer from which substantially only fibres running transverse to the major faces of the backing layer protrude to form an outer surface of said layer.
  • the outer layer may be a woven, tufted or non-woven fabric (such as a needle felt) of a conventional textile fibrous material, such as polypropylene, or a polyamide, which may, in some embodiments, be conventional Wilton or Axminster carpeting material. Because of the preferred uses of the surface covering material according to
  • the fibrous material should be such that it is either inherently soil-resistant (such as polypropylene), or treated so as to have good soil-resistance qualities.
  • the hot melt adhesive employed in the laminate according to the invention is typically a thermoplastic synthetic hydrocarbon polymer-based formulation, such as atactic polypropylene or other amorphous polyolefin, such as polybutene.
  • the adhesive is preferably one which retains some tack at room temperature, and which is substantially incurable by means of elevated temperature alone.
  • the adhesive formulation should be hygroscopic and substantially free of any hygroscopic ingredients.
  • the hot melt adhesive is applied in such a way that it surrounds (or encapsulates) substantially all of the individual fibres making up the base of the outer layer (the "bundles" in a woven or tufted fabric).
  • the hot melt adhesive may, in a preferred embodiment of the invention, contain a biocide (that is, a bactericide of fungicide), typically in an amount of up to 10% by weight, based on the weight of the hot melt adhesive; the biocide should, of course, be thermally resistant.
  • a biocide that is, a bactericide of fungicide
  • the backing layer may comprise a hydrophobic, substantially liquid-impermeable, flexible polymer sheet material.
  • the backing layer may be in the form of a flexible foam (in which case it is preferably a closed cell foam of a hydrophobic polymer, such as polyethylene or ethylene-vinyl acetate copolymer), or a polymer film (when again it is preferably of a hydrophobic polymer, such as polyethylene or ethylene-vinyl acetate copolymer).
  • the backing layer may be of a textile fabric, which may be woven, non-woven, or tufted; such a backing layer need not be of synthetic material and may, for example, be of a scrim of hessian or the like.
  • the laminate according to the invention may be in the form of tiles or other space-filling shapes.
  • the laminat may be in the form of a room-filling module (that * is, a single body of the laminate may fill substantially the entire floor area in a room) .
  • the laminates may be used for other purpose such as, for example, vehicle floor covering or wall covering.
  • the laminate may be provided with a layer of pressure-sensitive adhesive on the undersurface of the backing layer, by means of which the laminate according to the invention may be secured to a floor or the like.
  • a removable backing layer is preferably provided over th layer of pressure-sensitive adhesive, such that the backing layer acts as a 'peel and stick' layer.
  • Such a removable backing layer may be of, for example, silicone-coated paper.
  • the hot melt adhesive should be sprayed, in a molten state, into a space between the upper surface of the backing layer and the undersurface of the outer layer.
  • the layers are then preferably passed through rollers (such a pinch rollers) so as to effect lamination and penetration of the fabric constitutin the outer layer.
  • the hot melt adhesive should be sprayed at a temperature close to its carbonisation temperature (that is, within about 30°C, preferably within 20°C and sometimes even within 10°C of the carbonisation temperature), and substantially above the softening point of the fibres or backing layer to which it is applied.
  • a temperature close to its carbonisation temperature that is, within about 30°C, preferably within 20°C and sometimes even within 10°C of the carbonisation temperature
  • hot melts are not applied at such high temperatures, and manufacturers instructions invariably suggest that hot melt adhesives should be applied at substantially below the carbonisation temperature thereof.
  • the conventional methods of applying hot melt adhesives are not preferred becaus such methods may cause too much heat transfer and therefore th risk of softening the relevant fabric, and, furthermore, may -4-
  • Figure 1 illustrates (not to scale) a typical layer structure for use as a surface covering material according to the invention.
  • Figure 2 is a schematic illustration of part of an exemplary production process for a surface covering material according to tie invention.
  • a laminate comprising a tufted outer layer 1 comprising a woven fabric 2 and tufts 3, and a backing layer 4 comprising a hydrophobic, liquid-impermeable, flexible polymer sheet material.
  • the backing layer 4 and the outer layer 1 are bonded together by means of a continuous layer 5 of hot melt adhesive which encapsulates the 'bundle' portion 6 of the tufts 3 as well as woven fabric 2.
  • a spray gun 11 has molten adhesive supplied thereto by supply conduit 12; the molten adhesive is sprayed from nozzle 13 to the space 14 between outer layer 1 and backing layer 4 (using the same reference numerals as in Figure 1).
  • the coated surfaces of layer 1 and layer 4 are brought into contact using forming rollers 17 and 18, and then further pressed together using nip rolls 19 and 20. This pressure causes partial penetration of the hot melt into the outer layer 1, such that the hot melt forms a liquid-impermeable layer from which only tufted fibres (not shown in Figure 2) protrude to form the upper surface of the resulting laminate.
  • the present invention has been described in terms of a laminate suitable for use as a floor covering, and a method of production thereof; the presnt invention further comprises a floor having thereon a layer of a laminate according to the invention.

Abstract

Le matériau est un stratifié contenant dans l'ordre spécifié, a) une couche extérieure d'un tissu textile préformé (1) (tel qu'un tissu touffeté) ayant une base (2) et des touffes (3); b) une couche de liaison continue (5) d'adhésif hydrophobe thermofusible (5) qui encapsule la partie en forme de faisceau (6) des touffes (3) ainsi que la base (2) et laisse seulement les extrémités libres des touffes dépasser de la surface de manière à ce que le stratifié soit imperméable aux liquides; et c) une couche de support (4).The material is a laminate containing in the specified order, a) an outer layer of a preformed textile fabric (1) (such as a tufted fabric) having a base (2) and tufts (3); b) a continuous bonding layer (5) of hydrophobic hot-melt adhesive (5) which encapsulates the bundle-shaped part (6) of the tufts (3) as well as the base (2) and leaves only the free ends of the tufts protruding from the surface so that the laminate is impermeable to liquids; and c) a support layer (4).

Description

Surface Covering Material
The present invention is concerned with surface covering materials, and, in particular, textile-based surface covering materials, which in some embodiments are useful as floor covering for hospitals and the like.
Liquid-impermeable textile-based floor coverings are known (for example, the floor covering commercially available under the trade mark "Flotex", which comprises polya ide flocked intp a PVC base). Such impermeable floor coverings find applications in indoor areas where there is a risk of spillages, such as in kitchens, patient areas in hospitals and the like.
We have developed an improved liquid-impermeable surface covering material suitable for uses of this nature.
The material according to the present invention comprises a laminate comprising, in the order specified:
(a) an outer layer comprising a preformed synthetic textile fabric;
(b) a bonding layer comprising a hydrophobic hot melt adhesive; and
(c) a backing layer, in which the outer layer is bonded to the backing layer by means of the bonding layer in such a way that the adhesive penetrates through the textile fabric to encapsulate fibres which run substantially parallel to the major faces of the backing layer and form a substantially liquid-impermeable layer from which substantially only fibres running transverse to the major faces of the backing layer protrude to form an outer surface of said layer.
The outer layer may be a woven, tufted or non-woven fabric (such as a needle felt) of a conventional textile fibrous material, such as polypropylene, or a polyamide, which may, in some embodiments, be conventional Wilton or Axminster carpeting material. Because of the preferred uses of the surface covering material according to
* the invention (as referred to above), it is preferred that the fibrous material should be such that it is either inherently soil-resistant (such as polypropylene), or treated so as to have good soil-resistance qualities.
The hot melt adhesive employed in the laminate according to the invention is typically a thermoplastic synthetic hydrocarbon polymer-based formulation, such as atactic polypropylene or other amorphous polyolefin, such as polybutene. The adhesive is preferably one which retains some tack at room temperature, and which is substantially incurable by means of elevated temperature alone. The adhesive formulation should be hygroscopic and substantially free of any hygroscopic ingredients. The hot melt adhesive is applied in such a way that it surrounds (or encapsulates) substantially all of the individual fibres making up the base of the outer layer (the "bundles" in a woven or tufted fabric).
The hot melt adhesive may, in a preferred embodiment of the invention, contain a biocide (that is, a bactericide of fungicide), typically in an amount of up to 10% by weight, based on the weight of the hot melt adhesive; the biocide should, of course, be thermally resistant.
The backing layer may comprise a hydrophobic, substantially liquid-impermeable, flexible polymer sheet material. The backing layer may be in the form of a flexible foam (in which case it is preferably a closed cell foam of a hydrophobic polymer, such as polyethylene or ethylene-vinyl acetate copolymer), or a polymer film (when again it is preferably of a hydrophobic polymer, such as polyethylene or ethylene-vinyl acetate copolymer).
In an alternative embodiment, the backing layer may be of a textile fabric, which may be woven, non-woven, or tufted; such a backing layer need not be of synthetic material and may, for example, be of a scrim of hessian or the like. The laminate according to the invention may be in the form of tiles or other space-filling shapes. The laminat may be in the form of a room-filling module (that* is, a single body of the laminate may fill substantially the entire floor area in a room) . The laminates may be used for other purpose such as, for example, vehicle floor covering or wall covering.
The laminate may be provided with a layer of pressure-sensitive adhesive on the undersurface of the backing layer, by means of which the laminate according to the invention may be secured to a floor or the like. In this case, a removable backing layer is preferably provided over th layer of pressure-sensitive adhesive, such that the backing layer acts as a 'peel and stick' layer. Such a removable backing layer may be of, for example, silicone-coated paper.
It is particularly preferred that the hot melt adhesive should be sprayed, in a molten state, into a space between the upper surface of the backing layer and the undersurface of the outer layer. The layers are then preferably passed through rollers (such a pinch rollers) so as to effect lamination and penetration of the fabric constitutin the outer layer.
It is particularly preferred that the hot melt adhesive should be sprayed at a temperature close to its carbonisation temperature (that is, within about 30°C, preferably within 20°C and sometimes even within 10°C of the carbonisation temperature), and substantially above the softening point of the fibres or backing layer to which it is applied. Conventionally, hot melts are not applied at such high temperatures, and manufacturers instructions invariably suggest that hot melt adhesives should be applied at substantially below the carbonisation temperature thereof. The conventional methods of applying hot melt adhesives (that is, by roller application or dipping) are not preferred becaus such methods may cause too much heat transfer and therefore th risk of softening the relevant fabric, and, furthermore, may -4-
not result in sufficient penetration of the outer layer so as to render the outer layer liquid-impermeable.
The present invention will now be described, by way of example only, with reference made to the accompanying drawings; in which:
Figure 1 illustrates (not to scale) a typical layer structure for use as a surface covering material according to the invention; and
Figure 2 is a schematic illustration of part of an exemplary production process for a surface covering material according to tie invention.
Referring to Figure 1, there is shown a laminate comprising a tufted outer layer 1 comprising a woven fabric 2 and tufts 3, and a backing layer 4 comprising a hydrophobic, liquid-impermeable, flexible polymer sheet material. The backing layer 4 and the outer layer 1 are bonded together by means of a continuous layer 5 of hot melt adhesive which encapsulates the 'bundle' portion 6 of the tufts 3 as well as woven fabric 2.
Referring to Figure 2, a spray gun 11 has molten adhesive supplied thereto by supply conduit 12; the molten adhesive is sprayed from nozzle 13 to the space 14 between outer layer 1 and backing layer 4 (using the same reference numerals as in Figure 1). The coated surfaces of layer 1 and layer 4 are brought into contact using forming rollers 17 and 18, and then further pressed together using nip rolls 19 and 20. This pressure causes partial penetration of the hot melt into the outer layer 1, such that the hot melt forms a liquid-impermeable layer from which only tufted fibres (not shown in Figure 2) protrude to form the upper surface of the resulting laminate.
The present invention has been described in terms of a laminate suitable for use as a floor covering, and a method of production thereof; the presnt invention further comprises a floor having thereon a layer of a laminate according to the invention.

Claims

Clai s :
1. A surface covering material, which comprises a laminate comprising, in the order specified,
(a) an outer layer comprising a preformed synthetic textile fabric;
(b) a bonding layer comprising a hydrophobic hot melt adhesive; and
(c) a backing layer; characterised in that the outer lay is bonded to the backing layer by means of the bonding layer in such a way that the adhesive penetrates through the textile fabric to encapsulate fibres which run substantially parallel to the major faces of the backing layer and form a substantially liquid-impermeable layer from which substantially only fibres running transverse the major faces of the backing layer protrude to form an outer surface of said layer.
2. A surface covering material according to claim 1, wherei said hot melt adhesive is a thermoplastic synthetic hydrocarbon polymer-based formulation.
3. A surface covering material according to claim 1 or 2, wherein the adhesive retains some tack at room temperature, and is substantially incurable by means of elevated temperature alone.
4. A surface covering material according to any of claims 1 to 3, wherein the adhesive is hygroscopic and substantially free of any hygroscopic ingredients.
5. A surface covering material according to any of claims 1 to 4, wherein the adhesive contains a biocide. 5. A surface covering material according to any of claims 1 to 4, wherein the backing layer comprises a hydrophobic, substantially liquid-impermeable, flexible polymer sheet material.
6. A surface covering material according to any of claims 1 to 5, wherein the backing layer is in the form of a flexible foam, which is preferably a closed cell foam of a hydrophobic polymer.
6. A surface covering material according to any of claims 1 to 5, wherein the backing layer is of a textile fabric.
7. A surface covering material according to any of claims 1 to 6, which is provided with a layer of pressure-sensitive adhesive on the undersurface of the backing layer, and, optionally, a removable backing layer provided over the layer of pressure-sensitive adhesive.
8. A method of producing a surface covering material according to any of claims 1 to 6, wherein the hot melt adhesive is sprayed, in the molten state, into a space between the upper surface of the backing layer and the undersurface of the outer layer.
9. A method according to claim 8, wherein said layers are passed through rollers after application of said hot melt adhesive.
10. A method according to claim 8 or 9, wherein said hot melt adhesive is sprayed at a temperature within 30°C of the carbonisation temperature) thereof.
11. A floor having thereon a layer of a surface covering material according to any of claims 1 to 7.
EP90917885A 1989-07-07 1990-07-09 Surface covering material Withdrawn EP0493534A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8915662 1989-07-07
GB898915662A GB8915662D0 (en) 1989-07-07 1989-07-07 Surface covering material

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EP0493534A1 true EP0493534A1 (en) 1992-07-08

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EP90917885A Withdrawn EP0493534A1 (en) 1989-07-07 1990-07-09 Surface covering material

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EP (1) EP0493534A1 (en)
JP (1) JPH05501083A (en)
AU (1) AU5944690A (en)
CA (1) CA2063566A1 (en)
GB (1) GB8915662D0 (en)
WO (1) WO1991000804A1 (en)

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DE9205610U1 (en) * 1992-04-24 1992-06-11 Silu Verwaltung Ag, Littau, Ch
WO1994020662A1 (en) * 1993-03-04 1994-09-15 Feltex Modular Carpets Pty. Ltd. High twist yarn bonded carpet
US6966963B2 (en) 2003-07-31 2005-11-22 O'connor Investment Corporation Method of applying a covering for boards
DE102005060450A1 (en) * 2005-12-17 2007-06-28 Vorwerk & Co. Interholding Gmbh Process for the initial coating of a carpet
US7993717B2 (en) 2007-08-02 2011-08-09 Lj's Products, Llc Covering or tile, system and method for manufacturing carpet coverings or tiles, and methods of installing coverings or carpet tiles
US20220324199A9 (en) * 2014-11-06 2022-10-13 Marine Mat, Inc. Fabric Reinforced Traction Mat

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BE538252A (en) * 1962-05-31
DE1508894B1 (en) * 1966-03-03 1971-01-28 Messer Griesheim Gmbh Device for the removal of cut parts of the cast strand
US3542613A (en) * 1966-06-25 1970-11-24 Polymer Corp Method of making woven pile fabric carpets
US3519526A (en) * 1966-07-21 1970-07-07 Union Carbide Corp Elastomer-backed carpet
DE2009182A1 (en) * 1969-05-07 1970-11-19
DE2502025A1 (en) * 1974-02-08 1975-08-14 Leuna Werke Veb TEXTILE FLOORING WITH THERMOPLASTIC FOAM SUB-FLOOR AND A METHOD FOR ITS MANUFACTURING
US3940525A (en) * 1974-12-30 1976-02-24 E. I. Du Pont De Nemours And Company Tufted carpet having a polyolefin film as the secondary backing
US4579762A (en) * 1984-12-24 1986-04-01 Monsanto Company Stain resistant carpet with impervious backing
US4824709A (en) * 1988-05-24 1989-04-25 Collins & Aikman Corporation Textile product with backcoating comprising smoke suppressant and/or flame retardant intumescent particles

Non-Patent Citations (1)

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See references of WO9100804A1 *

Also Published As

Publication number Publication date
JPH05501083A (en) 1993-03-04
CA2063566A1 (en) 1991-01-08
GB8915662D0 (en) 1989-08-23
AU5944690A (en) 1991-02-06
WO1991000804A1 (en) 1991-01-24

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