EP0628104B1 - Wear-resistant, fibre-reinforced floor covering, process for producing it and its use - Google Patents

Abstract

In a wear-resistant, fibre-reinforced floor covering (1) with a substrate (7) and a layer of cork (2) and a binder (3) thereon, the layer of cork (2) and the binder (3) is arranged between the substrate (7) and a covering layer (6) and the three layers are bonded together by means of needled fibres (4), with the cork (2) in particle form. In order to produce this wear-resistant, fibre-reinforced floor covering, a core layer of cork particles is laid on a substrate, a covering layer is laid on the cork layer lying on the substrate, the three layers are needled together by retaining fibres taken from the covering layer and/or the substrate through the core layer containing cork particles through which they can be passed and, after needling, the floor covering is impregnated with a binder. This provides a floor covering suitable as a substitute for linoleum and which can, however, be made more elastic than linoleum.

Description

The invention relates to an abrasion-resistant, fiber-reinforced Floor covering with a backing layer and on top of it Layer of cork and a binder, a process for its manufacture and its use.

Such floor coverings are known under the name linoleum. Linoleum, a layered structure made from a layer of jute fabric as a carrier and a spread layer of cork flour filled, solidified linseed oil and dye, is a popular Flooring, which is manufactured in particular as a sheet or sheet and is relocated. Because the linseed oil binding each one The solidified product exhibits particles of cork powder relatively high rigidity. Mostly the surface is still additionally sealed, which increases strength affects. Linoleum is hard and used as flooring abrasion resistant, but not sound absorbing and relatively inelastic.

A fabric that can be used as a floor covering is e.g. also known from EP-A-0089018. There is a procedure for continuous production of fiber-reinforced webs, described, in which a core layer made of particles such as granules made of vulcanized rubber, foamable elastomers Rubber or plastic between a backing and one Be brought top layer. The top layer shows the Sheets an actively needled layer containing fibers on and these fibers are through the core layer between the non-pierceable particles into the carrier layer needled into it.

The granulate made of vulcanized rubber that is used there in particular is a relatively heavy material, so that the finished product has a weight per unit area of more than 4 kg / m ² . For many applications, this fabric is disadvantageous, difficult to handle during transport and processing. In addition, vulcanized rubber tends to age in continuous use, which means that such sheet-like fabrics can show disruptive properties over time for some applications.

DE-A-1435762 discloses multi-layer, needled fabrics known as the core layer passively needled Fabrics etc. in granular form, e.g. Cork shot. However, it has been shown that such fabrics last longer permanent stresses, e.g. as a floor covering or as a layer under a floating screed (example 2 there) is not sufficient able to withstand what is probably on it can be attributed to that existing as the core layer Layer of cork shot mechanically relatively unstable over time is. Cork shot can crumble.

From DE-A-1560651 another can be used as a floor covering Known fabric in which a fiber layer with a compact, tough, film-like layer is needled, where the needles with fraying in the direction of penetration provided hole edges form sound channels. There is suspected that the sound-absorbing effect of the fabric described is due to the fact that on the one hand by needling the sound absorption of the film-like layer is increased and on the other hand with the sound absorption of between the fibers existing, air-filled cavities is coupled. By existing binder, as is provided for in the generic type, but this effect is destroyed. There can be another Layer of cork shot.

The invention has for its object a new, the To create linoleum-like flooring, but also elastic and is sound absorbing.

This object is characterized by that in claim 1 Floor covering loosened. With the new floor covering, the layer is over Cork and the binder between the backing and one Cover layer arranged and the three layers are by means of needled fibers joined together.

An advantageous use of the flooring is that of Linoleum replacement.

Especially through the use of cork grains instead of the cork flour in the known linoleum you get a floor covering, which is more elastic and soundproof than linoleum, during this flooring by impregnation with a Binder is more durable than that known from DE-A-1435762 Fabrics.

Such a new flooring is also less fragile, as known cork board floors or linoleum and leaves cut well because the cork grains are also tied the impregnating and crosslinking binder through the needled fibers is obtained.

According to a particular embodiment of the invention the cork grains inflated before. This will increase the elasticity of the Flooring increased further because the expanded cork grains lighter can be pressed together.

Especially when using a substantially clear one Binder can be found in the core layer next to the Cork grains Fiber aggregates made of spherically entangled fibers be arranged. These increase the elasticity of the floor covering, by using different colored fiber aggregates pattern the flooring in a special way.

But besides the cork grains pieces or Strips of plastic, e.g. Polyethylene, in particular Waste pieces or strips of polyethylene can be arranged. The pieces of polyethylene used here preferably have a grain size of 1 to 5 mm while the strips are made Polyethylene, especially from a polyethylene film, a Have a length of up to 10 mm.

According to one embodiment, the binder contains oil and especially has linseed oil, wood oil or the like. on. Such establishes a good connection to the cork grains.

The binder can also contain water, namely e.g. a latex, especially a natural latex, as he generally used in carpet manufacturing. This can with Sulfur can be activated.

It is not absolutely necessary that the binding agent immediate surface of the flooring forms, it can Rather, fibers in particular on the carrier layer partially protrude from the opposite side of the binder. This gives the floor covering a carpet-like surface. The protruding fibers are not only the needling of the three layers, but especially through the binder held.

According to another embodiment, the fibers are the Top layer, the backing layer and the needled fibers of the binder included. This can be done in particular be achieved that the flooring an additional Has surface binder coating.

In addition, in the binder and / or in the Surface binder coating fillers, in particular different colored sample pieces can be incorporated. By These additional fillers can further increase elasticity to be changed. These fillers are advantageous particulate, but it can also in particular colored individual fibers be.

According to a special embodiment, the fillers Waste materials and preferably consist of shredded polyethylene, Polyvinyl chloride, needle punch carpets or rubber.

The floor covering preferably has at least one side the top layer has a pattern so that its aesthetic Appearance can meet certain specifications.

Advantageous processes for the preparation of the invention Flat structures result from claims 18 to 25.

So is used to manufacture an abrasion resistant, fiber reinforced Floor covering on a support layer from a core layer Cork particles arranged on the lying on the support layer The core layer is a top layer, the three layers are with each other from the top layer and / or the Carrier layer removed holding fibers through the pierceable Core layer containing cork grains needled together and the flooring is covered with a binder after needling impregnated.

When needling the core layer containing cork grains on the one hand, the needling needles push between the cork grains through, on the other hand, other cork grains from which the Needling through the core layer If necessary, pierce the needles together with the fibers. Here the individual cork grain can be split, but it can also remain intact and penetrated by the needled fibers be, whereby the single grain of cork "threaded" on the fibers is.

Depending on the binder used, this will be after application cross-linked if no self-binding binder is used.

According to a special process step, the cork grains inflated before application to the carrier layer, so that inflated cork grains can be used. In the Use of previously inflated cork grains, on which pressure during needling and / or subsequent rolling is exercised, the cork grains lie after needling or after rolling under a pretension so that the individual Cork grains are pressed against each other.

According to a special embodiment of the method after needling the three layers and applying the Binder of the flooring passed through reducing rollers and the binder is at least pressed into the core layer is what the binder is cured and the Cork grains are cross-linked.

So the needled and impregnated flooring can between Reducing rollers pressed and the final thickness of the to be manufactured Floor coverings are set before the binder hardens or networked.

Oily or aqueous binders are preferred applied to the needled flooring.

The floor covering with binder is e.g. between the reducing rollers the surfaces are rolled to level them, after which the binder is cured.

The surface of the floor covering is preferably additional structured and / or colored with a pattern.

Such a floor covering can be produced continuously and is easy to roll after production.

Various embodiments are described below with reference to the drawing the invention briefly explained:

Fig. 1

einen vernadelten und mit einem Bindemittel gebundenen Bodenbelag mit einer Kernschicht aus verschieden großen Korkkörnern im Schnitt;

Fig. 2

einen ähnlichen Bodenbelag wie Fig. 1, in dem noch zusätzlich Faseraggregate angeordnet sind, und

Fig. 3

einen ähnlichen Bodenbelag wie Fig. 1, in dem noch zusätzlich Stücke aus Polyethylen angeordnet sind.

It shows:

Fig. 1

a needled and bound with a binder flooring with a core layer of different sized cork grains in section;

Fig. 2

a similar flooring as Fig. 1, in which additional fiber aggregates are arranged, and

Fig. 3

a similar flooring as Fig. 1, in which additional pieces of polyethylene are arranged.

A floor covering 1 has a carrier layer 7 on which a core layer of cork grains 2 and a binder 3 is arranged which is covered by a cover layer 6. In In the core layer, far more cork bodies 2 are arranged than were drawn in the drawing for illustrative reasons.

The three layers are interconnected by means of needled fibers 4 connected, here the fibers 4 of the cover layer 6 are removed. The fibers can also be the carrier layer 7 or both layers, ie the cover layer 6 and the carrier layer 7, be removed if needled from two sides has been. In practice there are a lot more fibers, both in the top layer 6 and in the underlay 7, as well as needled Fibers 4 present.

The cork grains 2 are of different sizes, which among other things is a consequence of needling, since cork grains are partially 2 broken by the needles.

In the embodiment according to Figure 1 is on the cover layer 6 an additional surface binder coating 9 available, e.g. also consist of linseed oil can.

2 are in the core layer in addition to the cork grains 2, fiber aggregates made of spherical tangled fibers arranged e.g. with the cork grains mixed as a core layer. Especially can separate fiber aggregates here before needling Core layer of cork grains 2 are deposited. Then is suitable this layer consisting of a large number of fiber aggregates to be used as cover layer 6.

3 are in the core layer in addition to the cork grains 2 pieces of polyethylene, arranged in particular pieces of polyethylene, the one Can have grain size of 1 to 5 mm.

The fibers used can be polyester or polyamide, but it can also be jute fibers come into use.

Reference list

1

Flooring

2nd

Cork grains

3rd

binder

4th

needled fibers

5

Polyethylene pieces

6

Top layer

7

Carrier layer

8th

Fiber aggregates

9

additional surface binder coating

Claims (26)

1. Wear-resistant fibre-reinforced floor covering (1) with a carrier layer (7) and a layer of cork (2) and a binder (3) applied to it, characterised in that the layer of cork (2) and the binder (3) is arranged between the carrier layer (7) and a covering layer (6) and the three layers are joined together by means of needled fibres (4).
2. Floor covering according to claim 1, characterised in that the cork (2) is present in the form of particles and has a grain size of from 0.01 to 10 mm, preferably from 0.1 to 5 mm.
3. Floor covering according to one of the foregoing claims, characterised in that the cork grains (2) are present in expanded form.
4. Floor covering according to one of the foregoing claims, characterised in that fibre aggregates (8) of fibres wound into balls are arranged in the core layer in addition to the cork grains (2).
5. Floor covering according to one of the foregoing claims, characterised in that in addition to the cork grains (2) pieces (5) or strips of plastics, e.g. polyethylene, in particular pieces or strips of polyethylene scrap, are present.
6. Floor covering according to claim 5, characterised in that the pieces (5) of plastics have a grain size of from 1 to 5 mm.
7. Floor covering according to claim 5, characterised in that the strips of polyethylene, in particular of polyethylene film, have a length of from to 10 mm.
8. Floor covering according to one of the foregoing claims, characterised in that the binder (3) is oil-based and in particular comprises a linseed oil, wood oil or the like.
9. Floor covering according to one of claims 1 to 7, characterised in that the binder (3) is water-based.
10. Floor covering according to claim 9, characterised in that the binder (3) is a latex, in particular a natural latex.
11. Floor covering according to one of the foregoing claims, characterised in that the fibres project partially beyond the binder (3) on the side opposite the carrier layer (7).
12. Floor covering according to one of the foregoing claims, characterised in that the fibres of the covering layer (6), the carrier layer (7) and the needled fibres (4) are enclosed by the binder (3).
13. Floor covering according to one of the foregoing claims, characterised in that the floor covering (1) has an additional surface binder coating (9).
14. Floor covering according to one of the foregoing claims, characterised in that fillers (5), in particular different-coloured pattern pieces, are worked into the binder (3) and/or into the surface binder coating (9).
15. Floor covering according to claim 14, characterised in that the fillers (5) are in the form of particles.
16. Floor covering according to claim 14 or 15, characterised in that the fillers (5) are scrap materials and preferably comprise rendered-down polyethylene, polyvinyl chloride, needle-felted carpets or rubber.
17. Floor covering according to one of the foregoing claims, characterised in that the floor covering (1) has a pattern, at least on the covering layer side (6).
18. Method of manufacturing a wear-resistant fibre-reinforced floor covering according to one of the foregoing claims, in which a core layer of cork particles is arranged on a carrier layer and the layers are joined together with a binder, characterised in that a covering layer is deposited on the core layer lying on the carrier layer, the three layers are needled together by fibres taken from the covering layer and/or the carrier layer through the core layer containing piercable cork grains and at least the cork is impregnated with a binder before or after the needling step.
19. Method according to claim 18, characterised in that the binder is cross-linked at the latest after the needling step.
20. Method according to claim 18 or 19, characterised in that expanded cork grains are introduced.
21. Method according to one of claims 18 to 20, characterised in that after the needling step on the three layers and the possible subsequent application of the binder the floor covering is passed through reducing rollers and the binder is forced at least into the core layer, whereupon the binder is cured and the cork grains are bonded together.
22. Method according to one of claims 18 to 21, characterised in that the needled and impregnated floor covering is pressed between reducing rollers and the final thickness of the floor covering which is to be produced is set before the binder is cured or cross-linked.
23. Method according to one of claims 18 to 22, characterised in that oily or aqueous binder is applied to the needled floor covering.
24. Method according to one of claims 21 to 23, characterised in that the floor covering treated with binder is rolled between the reducing rollers to level the surface, after which the binder is cured.
25. Method according to one of claims 18 to 24, characterised in that the surface of the floor covering is additionally structured with a pattern and/or coloured.
26. The use of the floor covering according to one of claims 1 to 17 as a floor covering instead of linoleum.

Images