EP3673123A1 - Drop impact-resistant and adaptive flooring - Google Patents

Drop impact-resistant and adaptive flooring

Info

Publication number
EP3673123A1
EP3673123A1 EP18762239.4A EP18762239A EP3673123A1 EP 3673123 A1 EP3673123 A1 EP 3673123A1 EP 18762239 A EP18762239 A EP 18762239A EP 3673123 A1 EP3673123 A1 EP 3673123A1
Authority
EP
European Patent Office
Prior art keywords
flooring board
flooring
cement composition
fibre
fibre cement
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Withdrawn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
EP18762239.4A
Other languages
German (de)
French (fr)
Inventor
Endl THOMAS
Gondermann FRANK
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.)
Swisspearl Group AG
Original Assignee
Swisspearl Group AG
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 Swisspearl Group AG filed Critical Swisspearl Group AG
Publication of EP3673123A1 publication Critical patent/EP3673123A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/08—Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/20—Mortars, concrete or artificial stone characterised by specific physical values for the density
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to flooring boards and to a process for manufacturing such flooring boards.
  • the material used has good resistance against abrasion, low flammability, low VOC emissions, good sound dampening, mechanical properties and allows for ease of installation.
  • wood based materials engineered wood, wood-based high density fibreboard (HDF)
  • HDF high density fibreboard
  • tiles can be fragile because they may eventually crack when subjected to a drop impact. This is a result of the relatively high modulus of elasticity of the tiles which are made of materials such as ceramics or quarried stone. Because of the rigidity of the tile, the energy transferred to the tile upon impact cannot be easily dissipated by deformation of the tile and is then dissipated by a cohesive failure of the material, i.e. formation of a crack. Such a crack may be a fissure that extends across the entire thickness of the tile or may manifest itself by formation of spall, i.e. chipping, or by the formation of an imprint or crack. In some cases, the spall or crack will form on the underside of the tile.
  • tiles While tiles do not display this sensitivity with respect to humidity changes, the tiles can be cumbersome to install on the floor since they must be fastened to the floor by binder material such as glue or cement and moreover can be heavy because of their high density.
  • the higher density is not desirable because of the weight but also because denser materials tend to more easily transmit noise through their bulk, such as for example treading noise.
  • More porous, and thereby lighter materials such as wood or MDF have better dampening properties and allow for easier installation.
  • a flooring board that combines the advantages of wood based or polymeric based floorings and of ceramic tiles, i.e. a flooring board that has good resistance against abrasion, has good sound dampening, good mechanical properties such as impact resistance, moisture resistance and dimensional stability and which may moreover be easily installed.
  • EP 2 172 434 discloses a fibre-cement product composition
  • a fibre-cement product composition comprising reinforcing fibres comprising polypropylene fibres (A) and other synthetic organic fibres (B), where the use of fibres (A) with a Young's modulus of a least 160 cN/dtex and/or an elongation at break not higher than 17% and the composition provides fibre-cement articles with enhanced impact properties.
  • FR 2 860 511 discloses bevel siding panels based on a fibre-cement composition that has a modulus of rupture of more than 7 Mpa when wet and of more than 10 MPa when dry.
  • WO2006/086842 discloses a fibre reinforced cement flooring sheet for use in wet area which is able to withstand a high load, yet maintain a dry density below 1.5 or 1.25g/cm3 to accommodate installation methods such as nailing
  • DE 10 2014 003260 discloses a fibre-cement product composition comprising cement, fibre, silica and limestoneflour and pigments.
  • EP 1 875 01 1 Al discloses a floor panel having a core layer of a mineral material in which the mineral material has been cold-pressed at high pressure and has a density of more than 1000 kg/m3.
  • the mineral material embeds a reinforcing fibre which may be cellulose fiber obtained from waste paper and which may be present in an amount of 5 to 25% by volume.
  • the above-mentioned problems can be solved by providing a flooring board, or a flooring board precursor from which the flooring board can be obtained, which has material properties that allow it to survive a drop impact without formation of cracks or chipping while at the same time having good dampening properties moisture resistance and dimensional stability and which may moreover be easily installed.
  • It is an object of the present invention to provide a flooring board or flooring board precursor comprising at least one load-bearing layer formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid, characterized in that said material forming the at least one load-bearing layer, the load-bearing layer, the flooring board or flooring board precursor has a modulus of rupture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m.
  • MOR modulus of rupture
  • MOE modulus of elasticity
  • Fig. 1 shows the flow chart of the manufacturing process for the flooring board, in which a scale for the cellulose (1) and a water tank (2) determine the amount of cellulose provided to the pulper and refiner (3), from which the formed cellulose pulp is directed to the cellulose pulp tanks (4, 5). From the cellulose pulp tanks (4, 5), cellulose pulp is dosed to the mixer II (10). From the cement slurry mixer I (9), a cement slurry is dosed to the mixer II (10). The cement slurry is prepared by dosing dry cement from the cement tank (6), water from the water tank (8), and filler from the filler tank (7) to the cement slurry mixer I (9) and mixing the dry cement, water and filler.
  • the cement slurry and the cellulose pulp are mixed and dosed to a horizontal mixer III (11), from where the composition for forming the flooring board is conveyed to the Hatschek machine (12) in which the unshaped wet green web (13) is formed and then shaped into a given shape in the stamp (14). Any wet green stamping waste (15) can be recycled into the horizontal mixer III (1 1) The wet green webs are then conveyed to a stack press (16) to be pressed and form the wet green sheets.
  • the wet green sheets are stacked and subsequently allowed to cure in the curing chamber (17) to form flooring board blanks, after which the individual flooring board blanks are un-stacked (18) and conveyed to a drying apparatus (19), in which the individual flooring board blanks are further dried to desired moisture content.
  • the flooring board blanks may be temporarily stored in a stock (20), and may then be finished into multilayer flooring board blanks in a finishing line (21) for example in the case of multilayer flooring boards.
  • the thus formed flooring board or multilayer flooring board blanks are then formed into flooring boards or multilayer flooring boards by machining said blanks in a milling apparatus (22).
  • the lines (15) and (23) indicate recirculation means that enable to recirculate stamp waste and water, respectively, into the horizontal mixer III (11) and the water tanks (2, 8).
  • Fig. 2 shows a part of a multi-layered interlocking flooring board having a top layer (24) and a load-bearing-layer (25), where a first interlocking element is formed into a tongue (27) having a bulge (26) on the lower side of the tongue.
  • Fig. 3 a part of a multi-layered interlocking flooring element for indoor use having a top layer (24) and a load-bearing-layer (25), where a second interlocking element which is complementary to a first interlocking element shown in Fig. 2, is formed into a groove (30) having a recess (31) on the lower side of the groove (30).
  • It is an object of the present invention to provide a flooring board or flooring board precursor comprising at least one load-bearing layer formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based fibrous processing aid, characterized in that said material forming the at least one load- bearing layer has a modulus of rupture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m.
  • MOR modulus of rupture
  • MOE modulus of elasticity
  • the material forming the at least one load- bearing layer has at a modulus of rupture (MOR) of from 23 to 31 GPa, and/or a modulus of elasticity (MOE) of from 10 to 19 GPa and/or a strain at break of from 3 to 10 mm/m.
  • MOR modulus of rupture
  • MOE modulus of elasticity
  • the flooring board of the present invention may include further layers that are different in composition and function from the load-bearing layer.
  • the flooring board may include a top wear layer which may be transparent and may have scuff resistance properties and which may be formed of a polymer.
  • the flooring board of the present invention may further include a decorative layer underlying the top transparent layer and on top of the load-bearing layer.
  • the flooring board may further include a bottom backing layer that is formed from paper or foam.
  • the mechanical properties of the flooring board or of its precursor are essentially determined by, and are thus essentially the same as, the mechanical properties of the load-bearing layer which is made, i.e. comprises or consists of, the fibre cement material. While other layers such as the top wear layer, decorative layer or backing layer have their own mechanical properties that will depend on the material used for said layers, they are such that the overall mechanical properties of the flooring board or its precursor are "dominated" by, and therefore essentially correspond to the mechanical properties of the load-bearing layer.
  • the flooring board or flooring board precursor of the present invention comprises at least one load-bearing layer formed from a material comprising a fibre cement composition.
  • the load-bearing layer can be formed by cutting slabs of the desired shape and size from a larger slab of material comprising a fibre cement composition and the further layers such as the top wear layer, the decorative layer and the backing layer may then be applied to the load-bearing layer.
  • the flooring board can be obtained by cutting a flooring board of the appropriate shape and size from a larger slab of flooring board in which the further layers have already been applied.
  • the flooring board or flooring board precursor of the present invention comprises at least one load-bearing layer formed from a material comprising a fibre cement composition, which composition comprises a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid.
  • the cementitious binder may be chosen from a hydraulic binder material such as cement. Suitable cements are Portland cement, blast-furnace Portland cement, trass cement, and others. Several types of Portland clinker cements can be used, but ordinary Portland cement is particularly preferred.
  • the cementitious binding material is a hydraulic binder
  • solidification is brought about in a known manner by addition of water to the hydraulic binder to allow the hydraulic binder to cure.
  • the cementitious binding material is present of from 60 to 90, preferably of from 65 to 75 dry weight percent, and in particular when the cementitious binding material is a hydraulic binder material such as Portland cement according to EN 197-1 of the Type I, II, III, IV, and/or V.
  • the cementitious binding material serves the purpose of binding fibrous material together such as for example the polymeric fibres and/or cellulosic fibres upon solidification, i.e. hydration/curing, of the cementitious binding material.
  • the polymeric fibres of the fibre cement composition are polyolefins in general, and it has been found that in particular fibres made from polyacrylonitrile (PAN), polypropylene (PP) or polyvinyl alcohol (PVA) can advantageously be used in the fibre cement composition for manufacturing a flooring board.
  • PAN polyacrylonitrile
  • PP polypropylene
  • PVA polyvinyl alcohol
  • the polymeric fibres are in general present in the fibre cement composition of from 1.5 to 3, preferably of from 1.7 to 2.3 dry weight percent.
  • the polymeric fibres are in general chosen from fibres having a tenacity of more than 8 cN/dtex or of between 8 and 25 cN/dtex, preferably of more than 10 cN/dtex or of between 10 and 25 cN/dtex and/or a young modulus of more than 200 cN/dtex or of between 200 cN/dtex and 500cN/dtex, preferably of more than 220 cN/dtex or of between 220 cN/dtex and 500cN/dtex; and preferably are made of polyacrylonitrile (PAN), polypropylene (PP) or polyvinyl alcohol (PVA), and preferably are made of polyvinyl alcohol (PVA).
  • PAN polyacrylonitrile
  • PP polypropylene
  • PVA polyvinyl alcohol
  • the polymeric fibres may further have an average linear mass density of 0,5 to 10 dtex and preferably of from 0,7 to 3 dtex and/or an average length of from 2, or 3, to 10 mm, and preferably of from 4 to 6 mm.
  • the polymeric fibre length distribution is bimodal, i.e. two different lengths of polymeric fibres are present in the composition for manufacturing a flooring board of the present invention, namely one having a shorter length and one having a longer length.
  • the cellulosic fibres are present in the fibre cement composition of from 1 to 25 dry weight percent, preferably of from 1 to 5 dry weight percent; wherein the cellulosic fibres are preferably chosen from synthetic cellulosic fibres or natural cellulosic fibres, or combinations thereof; and/or wherein the cellulosic fibres are either virgin or recycled fibres, or combinations thereof.
  • Examples of synthetic cellulosic fibres are rayon, viscose or surface-modified cellulosic fibres, whereas natural cellulosic fibres can be chosen from pulp, which can either be sourced from plant material such as wood (virgin wood pulp) or be sourced from paper waste streams such as recycled paper or cardboard (recycled wood pulp). Wood pulp can either be used as premanufactured slurry or as dried wood pulp sheets, blocks, chips or powder. Alternatively, the cellulosic fibers can be chosen from fibres which are not sourced from wood such as flax fiber, jute fiber, hemp fiber or sisal.
  • the cellulosic fibres in the fibre cement composition are present as a cellulosic fibre blend, wherein the cellulosic fibre blend comprises cellulosic fibres having a first degree of SR fineness and cellulosic fibres having a second degree of SR fineness, when measured according to ISO 5267-1, and wherein the first degree of SR fineness is in the range of from 5 to 45, preferably of from 20 to 40, and the second degree of SR fineness is in the range of from 45 to 80, preferably of from 50 to 70.
  • the weight ratio between the cellulosic fibres having at least a first degree of SR fineness and a second degree of SR fineness is of from 1 : 1 to 3: 1.
  • a composition for manufacturing a flooring board for indoor use according to the present invention may exhibit a weight ratio between the cellulosic fibres having at least a first degree of SR fineness and a second degree of SR fineness of 3:1 , 2: 1 or of 1 : 1.
  • the cellulosic fibres act as reinforcing fibres in the fibre cement composition. Using fibres of different fineness allows striking a balance between rigidity and flexibility, especially in conjunction with the use elastomeric material in the form of elastomeric material particles, in which case the impact resistance is increased.
  • the fibre cement composition further comprises silica, filler, pigments, or additives, or combinations thereof.
  • the filler preferably is calcium carbonate.
  • the filler for example calcium carbonate is preferably present in an amount of less than 30, preferably of from 10 to 25 dry weight percent. If present in the fibre cement composition, the silica content is less than 20 dry weight percent, preferable from 1 to 10 dry weight percent.
  • the calcium carbonate can be ground or precipitated calcium carbonate, and can be sourced from limestone, chalkstone, chalk, or marble. While the filler mostly serves as cost-reducing replacement for some of the hydraulic binder, the silica serves to control the density of the flooring board. The silica may furthermore act as filler of the pores of the cellulose and protects the cellulose from degradation due to the alkaline environment by mineralisation of the cellulose - so called "lumen loading".
  • the silica may be supplied in powder form or as slurry. If present in the fibre cement composition, the silica has a particle size of about 50, or 100, to 200 nra, and/or is amorphous silica, preferably having a density at 20°C of no more than 1000 kg/m3, and preferably of from 150 to 750 kg/m 3 . If present in the fibre cement composition further additive may be chosen e.g. wollastonite or mica in order to improve fire behaviour, strength and allow ease of production.
  • the flooring board or flooring board precursor is a loose lay flooring board or loose lay flooring board precursor, and further comprises at least one lateral male interlocking element and at least one lateral female interlocking element being formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid, characterized in that said material forming the at least one lateral male interlocking element and at least one lateral female interlocking element has at a modulus of napture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m.
  • MOR modulus of napture
  • MOE modulus of elasticity
  • the assembly of the flooring onto the subfloor can be conducted in a more convenient manner, since the interlocking element can snap into each other easily without breaking and also the flexibility of the interlocking elements allows to accommodate any unevenness of the subfloor or floor onto which the flooring boards are laid.
  • the load-bearing layer and the lateral interlocking elements are formed in one piece
  • the lateral interlocking elements are formed into a tongue having a bulge on the upper side of the tongue and a groove having a recess on the corresponding side of the groove, respectively, such that when adjacent flooring boards are joined during assembly of a flooring, the bulge of the at least one lateral male interlocking element is fitted into recess of the groove of the at least one lateral female interlocking element of an adjacent flooring board.
  • two adjoining flooring boards are forced laterally against each other such that the tongue and the groove snap together by elastically deforming for a moment. The fitting of the bulge of the tongue into the recess of the groove allows the lateral locking of two adjoining flooring boards.
  • the fibre cement composition can essentially be free of polymeric fibres, i.e. the fibre cement composition cement composition comprises a cementitious binding material and cellulosic fibres and optionally a fibre-based processing aid and further silica, filler, pigments, or additives, or combinations thereof and no polymeric fibres.
  • the fibre cement composition further comprises an elastomeric material in the form of elastomeric material particles dispersed within the fibre cement composition. The elastomeric material further increases the resistance of the flooring board against impact force, i.e. it allows providing a flooring board in which the occurrence of cracks or chipping in response to impact is reduced.
  • the elastomeric material is present in the fibre cement composition in an amount of from 0.1 to 15 dry weight percent, preferably of from 1 to 10 dry weight percent, more preferably of from 2 to 6 dry weight percent.
  • the mechanical properties can be favourably adapted by already comparatively small amounts of elastomeric material below 15% dry weight percent, for example by using 5% dry weight percent.
  • the particles of elastomeric material in the fibre cement composition have a diameter of from 0.01 to 1.0 mm with preferably a d 5 o of 0.7 mm.
  • the particles of elastomeric material have a diameter of from 0.1 to 0.7 mm with preferably a d$o of 0.5 mm; and more preferably the particles of elastomeric material have a diameter of from of from 0.1 to 0.5 mm with preferably a d 5 o of 0.3 mm.
  • the elastomeric material is a crosslinked natural rubber such as polyisoprene rubber or synthetic rubber such as chloroprene rubber, butadiene rubber, ethylene- propylene-diene rubber, styrene-butadiene rubber.
  • the elastomeric material is a synthetic rubber which is free from chlorine.
  • the elastomeric material has a Shore A hardness of from 10 to 90, preferably of from 30 to 80, more preferably of from 50 to 70.
  • the elastomeric material may be buffing dust.
  • the elastomeric material may be added in the Hatschek process in one of the mixing steps, eg. step 3, 9 or 10 as lined out in Figure 1.
  • the elastomeric material is added in step three after refining the cellulose.
  • compositions for the manufacturing a flooring boards were formed by combining different amounts in dry weight of the cement CEM I 42.5 R, limestone, silica, cellulose, PVA fibre, jute fibre and buffing dust according to the below Table 1.
  • the compositions were processed according to the Hatschek-type process depicted in Fig. 1 to be formed into flooring boards for which the modulus of rupture (MOR), the modulus of elasticity (MOE), and the strain at break were recorded.
  • the compositions that have a modulus of rupture (MOR) of from 5 to 40 GPa, a modulus of elasticity (MOE) of from 5 to 18 GPa, as well as a strain at break of 2 to 10 mm/m outperform other compositions in terms of impact resistance (less is better), which compositions do not cumulatively have a modulus of rupture (MOR) of from 5 to 40 GPa, a modulus of elasticity (MOE) of from 5 to 18 GPa, as well as a strain at break of 2 to 10 mm/m.
  • MOR modulus of rupture
  • MOE modulus of elasticity
  • MOR modulus of rupture
  • MOE modulus of elasticity
  • the impact resistance is determined according to EN 438-2.
  • the flooring boards according to the present invention having a load-bearing layer having a modulus of rupture (MOR) of from 5 to 40 GPa, a modulus of elasticity (MOE) of from 5 to 18 GPa, as well as a strain at break of 2 to 10 mm/m display excellent impact resistance.
  • MOR modulus of rupture
  • MOE modulus of elasticity

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Chemical & Material Sciences (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Floor Finish (AREA)

Abstract

A flooring board or flooring board precursor comprising at least one load-bearing layer formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid, characterized in that said material forming the at least one load-bearing layer has at a modulus of rupture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m.

Description

TITLE DROP IMPACT-RESISTANT AND ADAPTIVE FLOORING
TECHNICAL FIELD
The present invention relates to flooring boards and to a process for manufacturing such flooring boards.
PRIOR ART
When applying flooring to cover a floor, there exist multiple options in terms of materials to be used. Ideally, the material used has good resistance against abrasion, low flammability, low VOC emissions, good sound dampening, mechanical properties and allows for ease of installation. Before the advent of engineered flooring materials, traditionally wood timber but also tiles from quarried stone have been installed. Nowadays, a plethora of man-made materials are available such as for example wood based materials (engineered wood, wood-based high density fibreboard (HDF)), polymeric flooring board or ceramic tiles.
While the appearance of ceramic or stone tiles is aesthetically desirable, tiles can be fragile because they may eventually crack when subjected to a drop impact. This is a result of the relatively high modulus of elasticity of the tiles which are made of materials such as ceramics or quarried stone. Because of the rigidity of the tile, the energy transferred to the tile upon impact cannot be easily dissipated by deformation of the tile and is then dissipated by a cohesive failure of the material, i.e. formation of a crack. Such a crack may be a fissure that extends across the entire thickness of the tile or may manifest itself by formation of spall, i.e. chipping, or by the formation of an imprint or crack. In some cases, the spall or crack will form on the underside of the tile. In the worst case a spall, an imprint or a crack will be formed on the front side of the tile. On the other hand, materials that have a lower m odulus of elasticity, i.e. which require less force to be deformed, do not suffer from the above propensity for cracking upon impact. Such materials are however problematic because of other considerations. As an example, wood-based or polymer based floors may suffer from considerable dimensional shrinkage and/or expansion in response to varying degrees of humidity or temperatures, which can easily cause visually detectable warping of the flooring surface. In addition, the proper installation of such floor coverings requires a subfloor surface with no imperfections.
While tiles do not display this sensitivity with respect to humidity changes, the tiles can be cumbersome to install on the floor since they must be fastened to the floor by binder material such as glue or cement and moreover can be heavy because of their high density.
The higher density is not desirable because of the weight but also because denser materials tend to more easily transmit noise through their bulk, such as for example treading noise.
More porous, and thereby lighter materials such as wood or MDF have better dampening properties and allow for easier installation.
It is thus desirable to provide a flooring board that combines the advantages of wood based or polymeric based floorings and of ceramic tiles, i.e. a flooring board that has good resistance against abrasion, has good sound dampening, good mechanical properties such as impact resistance, moisture resistance and dimensional stability and which may moreover be easily installed.
EP 2 172 434 discloses a fibre-cement product composition comprising reinforcing fibres comprising polypropylene fibres (A) and other synthetic organic fibres (B), where the use of fibres (A) with a Young's modulus of a least 160 cN/dtex and/or an elongation at break not higher than 17% and the composition provides fibre-cement articles with enhanced impact properties.
FR 2 860 511 discloses bevel siding panels based on a fibre-cement composition that has a modulus of rupture of more than 7 Mpa when wet and of more than 10 MPa when dry.
WO2006/086842 discloses a fibre reinforced cement flooring sheet for use in wet area which is able to withstand a high load, yet maintain a dry density below 1.5 or 1.25g/cm3 to accommodate installation methods such as nailing
DE 10 2014 003260 discloses a fibre-cement product composition comprising cement, fibre, silica and limestoneflour and pigments.
EP 1 875 01 1 Al discloses a floor panel having a core layer of a mineral material in which the mineral material has been cold-pressed at high pressure and has a density of more than 1000 kg/m3. The mineral material embeds a reinforcing fibre which may be cellulose fiber obtained from waste paper and which may be present in an amount of 5 to 25% by volume.
SUMMARY OF THE INVENTION
The above-mentioned problems can be solved by providing a flooring board, or a flooring board precursor from which the flooring board can be obtained, which has material properties that allow it to survive a drop impact without formation of cracks or chipping while at the same time having good dampening properties moisture resistance and dimensional stability and which may moreover be easily installed. It is an object of the present invention to provide a flooring board or flooring board precursor comprising at least one load-bearing layer formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid, characterized in that said material forming the at least one load-bearing layer, the load-bearing layer, the flooring board or flooring board precursor has a modulus of rupture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m.
Further embodiments of the invention are laid down in the dependent claims.
Due to the improved flexibility of the flooring board, imperfections of the subfloor are absorbed because the flooring board can adapt to the subfloor, thus forming a nearly planar flooring surface on top of an uneven subfloor. n BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described in the following with reference to the drawings, which are for the purpose of illustrating the present preferred embodiments of the invention and not for the purpose of limiting the same. In the drawings,
Fig. 1 shows the flow chart of the manufacturing process for the flooring board, in which a scale for the cellulose (1) and a water tank (2) determine the amount of cellulose provided to the pulper and refiner (3), from which the formed cellulose pulp is directed to the cellulose pulp tanks (4, 5). From the cellulose pulp tanks (4, 5), cellulose pulp is dosed to the mixer II (10). From the cement slurry mixer I (9), a cement slurry is dosed to the mixer II (10). The cement slurry is prepared by dosing dry cement from the cement tank (6), water from the water tank (8), and filler from the filler tank (7) to the cement slurry mixer I (9) and mixing the dry cement, water and filler. In the mixer II (10), the cement slurry and the cellulose pulp are mixed and dosed to a horizontal mixer III (11), from where the composition for forming the flooring board is conveyed to the Hatschek machine (12) in which the unshaped wet green web (13) is formed and then shaped into a given shape in the stamp (14). Any wet green stamping waste (15) can be recycled into the horizontal mixer III (1 1) The wet green webs are then conveyed to a stack press (16) to be pressed and form the wet green sheets. The wet green sheets are stacked and subsequently allowed to cure in the curing chamber (17) to form flooring board blanks, after which the individual flooring board blanks are un-stacked (18) and conveyed to a drying apparatus (19), in which the individual flooring board blanks are further dried to desired moisture content. Following the drying, the flooring board blanks may be temporarily stored in a stock (20), and may then be finished into multilayer flooring board blanks in a finishing line (21) for example in the case of multilayer flooring boards. The thus formed flooring board or multilayer flooring board blanks are then formed into flooring boards or multilayer flooring boards by machining said blanks in a milling apparatus (22). The lines (15) and (23) indicate recirculation means that enable to recirculate stamp waste and water, respectively, into the horizontal mixer III (11) and the water tanks (2, 8).
Fig. 2 shows a part of a multi-layered interlocking flooring board having a top layer (24) and a load-bearing-layer (25), where a first interlocking element is formed into a tongue (27) having a bulge (26) on the lower side of the tongue.
Fig. 3 a part of a multi-layered interlocking flooring element for indoor use having a top layer (24) and a load-bearing-layer (25), where a second interlocking element which is complementary to a first interlocking element shown in Fig. 2, is formed into a groove (30) having a recess (31) on the lower side of the groove (30).
DESCRIPTION OF PREFERRED EMBODIMENTS
It is an object of the present invention to provide a flooring board or flooring board precursor comprising at least one load-bearing layer formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based fibrous processing aid, characterized in that said material forming the at least one load- bearing layer has a modulus of rupture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m. In a preferred embodiment of the present invention, the material forming the at least one load- bearing layer has at a modulus of rupture (MOR) of from 23 to 31 GPa, and/or a modulus of elasticity (MOE) of from 10 to 19 GPa and/or a strain at break of from 3 to 10 mm/m.
In the context of the present invention all values are derived from a three point flexural test. The modulus of rupture (MOR) of a material is determined via EN 12467 the modulus of elasticity (MOE) of a material is determined via EN 12467and the strain at break of a material is determined via ISO 178. The flooring board of the present invention may include further layers that are different in composition and function from the load-bearing layer. For instance, the flooring board may include a top wear layer which may be transparent and may have scuff resistance properties and which may be formed of a polymer. The flooring board of the present invention may further include a decorative layer underlying the top transparent layer and on top of the load-bearing layer. The flooring board may further include a bottom backing layer that is formed from paper or foam. In general, the mechanical properties of the flooring board or of its precursor are essentially determined by, and are thus essentially the same as, the mechanical properties of the load-bearing layer which is made, i.e. comprises or consists of, the fibre cement material. While other layers such as the top wear layer, decorative layer or backing layer have their own mechanical properties that will depend on the material used for said layers, they are such that the overall mechanical properties of the flooring board or its precursor are "dominated" by, and therefore essentially correspond to the mechanical properties of the load-bearing layer.
The flooring board or flooring board precursor of the present invention comprises at least one load-bearing layer formed from a material comprising a fibre cement composition. The load-bearing layer can be formed by cutting slabs of the desired shape and size from a larger slab of material comprising a fibre cement composition and the further layers such as the top wear layer, the decorative layer and the backing layer may then be applied to the load-bearing layer. Alternatively, the flooring board can be obtained by cutting a flooring board of the appropriate shape and size from a larger slab of flooring board in which the further layers have already been applied. The flooring board or flooring board precursor of the present invention comprises at least one load-bearing layer formed from a material comprising a fibre cement composition, which composition comprises a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid. In an embodiment of the flooring board or flooring board precursor of the present invention, the cementitious binder may be chosen from a hydraulic binder material such as cement. Suitable cements are Portland cement, blast-furnace Portland cement, trass cement, and others. Several types of Portland clinker cements can be used, but ordinary Portland cement is particularly preferred. In the case where the cementitious binding material is a hydraulic binder, solidification is brought about in a known manner by addition of water to the hydraulic binder to allow the hydraulic binder to cure. In an embodiment of the flooring board or flooring board precursor of the present invention, the cementitious binding material is present of from 60 to 90, preferably of from 65 to 75 dry weight percent, and in particular when the cementitious binding material is a hydraulic binder material such as Portland cement according to EN 197-1 of the Type I, II, III, IV, and/or V. In essence, the cementitious binding material serves the purpose of binding fibrous material together such as for example the polymeric fibres and/or cellulosic fibres upon solidification, i.e. hydration/curing, of the cementitious binding material.
In an embodiment of the flooring board or flooring board precursor of the present invention, the polymeric fibres of the fibre cement composition are polyolefins in general, and it has been found that in particular fibres made from polyacrylonitrile (PAN), polypropylene (PP) or polyvinyl alcohol (PVA) can advantageously be used in the fibre cement composition for manufacturing a flooring board. In the case polymeric fibres are included, the polymeric fibres are in general present in the fibre cement composition of from 1.5 to 3, preferably of from 1.7 to 2.3 dry weight percent. If the amount of polymeric fibres is below the lower limit of 1 dry weight percent, the reinforcing effect achieved in the final flooring boards becomes insufficient, whereas adding more than the upper limit of 3 dry weight percent of polymeric fibres will result in complications of the Hatschek-type manufacturing process. The polymeric fibres are in general chosen from fibres having a tenacity of more than 8 cN/dtex or of between 8 and 25 cN/dtex, preferably of more than 10 cN/dtex or of between 10 and 25 cN/dtex and/or a young modulus of more than 200 cN/dtex or of between 200 cN/dtex and 500cN/dtex, preferably of more than 220 cN/dtex or of between 220 cN/dtex and 500cN/dtex; and preferably are made of polyacrylonitrile (PAN), polypropylene (PP) or polyvinyl alcohol (PVA), and preferably are made of polyvinyl alcohol (PVA). The polymeric fibres may further have an average linear mass density of 0,5 to 10 dtex and preferably of from 0,7 to 3 dtex and/or an average length of from 2, or 3, to 10 mm, and preferably of from 4 to 6 mm. In a preferred embodiment, the polymeric fibre length distribution is bimodal, i.e. two different lengths of polymeric fibres are present in the composition for manufacturing a flooring board of the present invention, namely one having a shorter length and one having a longer length.
In an embodiment of the flooring board or flooring board precursor of the present invention, the cellulosic fibres are present in the fibre cement composition of from 1 to 25 dry weight percent, preferably of from 1 to 5 dry weight percent; wherein the cellulosic fibres are preferably chosen from synthetic cellulosic fibres or natural cellulosic fibres, or combinations thereof; and/or wherein the cellulosic fibres are either virgin or recycled fibres, or combinations thereof. Examples of synthetic cellulosic fibres are rayon, viscose or surface-modified cellulosic fibres, whereas natural cellulosic fibres can be chosen from pulp, which can either be sourced from plant material such as wood (virgin wood pulp) or be sourced from paper waste streams such as recycled paper or cardboard (recycled wood pulp). Wood pulp can either be used as premanufactured slurry or as dried wood pulp sheets, blocks, chips or powder. Alternatively, the cellulosic fibers can be chosen from fibres which are not sourced from wood such as flax fiber, jute fiber, hemp fiber or sisal.
In an embodiment of the flooring board or flooring board precursor of the present invention, the cellulosic fibres in the fibre cement composition are present as a cellulosic fibre blend, wherein the cellulosic fibre blend comprises cellulosic fibres having a first degree of SR fineness and cellulosic fibres having a second degree of SR fineness, when measured according to ISO 5267-1, and wherein the first degree of SR fineness is in the range of from 5 to 45, preferably of from 20 to 40, and the second degree of SR fineness is in the range of from 45 to 80, preferably of from 50 to 70. The weight ratio between the cellulosic fibres having at least a first degree of SR fineness and a second degree of SR fineness is of from 1 : 1 to 3: 1. For instance, a composition for manufacturing a flooring board for indoor use according to the present invention may exhibit a weight ratio between the cellulosic fibres having at least a first degree of SR fineness and a second degree of SR fineness of 3:1 , 2: 1 or of 1 : 1. The cellulosic fibres act as reinforcing fibres in the fibre cement composition. Using fibres of different fineness allows striking a balance between rigidity and flexibility, especially in conjunction with the use elastomeric material in the form of elastomeric material particles, in which case the impact resistance is increased.
In an embodiment of the flooring board or flooring board precursor of the present invention, the fibre cement composition further comprises silica, filler, pigments, or additives, or combinations thereof.
If present in the fibre cement composition, the filler preferably is calcium carbonate. The filler, for example calcium carbonate is preferably present in an amount of less than 30, preferably of from 10 to 25 dry weight percent. If present in the fibre cement composition, the silica content is less than 20 dry weight percent, preferable from 1 to 10 dry weight percent. The calcium carbonate can be ground or precipitated calcium carbonate, and can be sourced from limestone, chalkstone, chalk, or marble. While the filler mostly serves as cost-reducing replacement for some of the hydraulic binder, the silica serves to control the density of the flooring board. The silica may furthermore act as filler of the pores of the cellulose and protects the cellulose from degradation due to the alkaline environment by mineralisation of the cellulose - so called "lumen loading". The silica may be supplied in powder form or as slurry. If present in the fibre cement composition, the silica has a particle size of about 50, or 100, to 200 nra, and/or is amorphous silica, preferably having a density at 20°C of no more than 1000 kg/m3, and preferably of from 150 to 750 kg/m3. If present in the fibre cement composition further additive may be chosen e.g. wollastonite or mica in order to improve fire behaviour, strength and allow ease of production.
In an embodiment of the flooring board or flooring board precursor of the present invention, the flooring board or flooring board precursor is a loose lay flooring board or loose lay flooring board precursor, and further comprises at least one lateral male interlocking element and at least one lateral female interlocking element being formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid, characterized in that said material forming the at least one lateral male interlocking element and at least one lateral female interlocking element has at a modulus of napture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m. When the interlocking elements are manufactured from the above-mentioned composition, the assembly of the flooring onto the subfloor can be conducted in a more convenient manner, since the interlocking element can snap into each other easily without breaking and also the flexibility of the interlocking elements allows to accommodate any unevenness of the subfloor or floor onto which the flooring boards are laid. In a preferred embodiment, the load-bearing layer and the lateral interlocking elements are formed in one piece
In an embodiment of the flooring board or flooring board precursor of the present invention, the lateral interlocking elements are formed into a tongue having a bulge on the upper side of the tongue and a groove having a recess on the corresponding side of the groove, respectively, such that when adjacent flooring boards are joined during assembly of a flooring, the bulge of the at least one lateral male interlocking element is fitted into recess of the groove of the at least one lateral female interlocking element of an adjacent flooring board. In order to assemble the flooring, two adjoining flooring boards are forced laterally against each other such that the tongue and the groove snap together by elastically deforming for a moment. The fitting of the bulge of the tongue into the recess of the groove allows the lateral locking of two adjoining flooring boards.
In an embodiment of the flooring board or flooring board precursor of the present invention, the fibre cement composition can essentially be free of polymeric fibres, i.e. the fibre cement composition cement composition comprises a cementitious binding material and cellulosic fibres and optionally a fibre-based processing aid and further silica, filler, pigments, or additives, or combinations thereof and no polymeric fibres. In an embodiment of the flooring board or flooring board precursor of the present invention, the fibre cement composition further comprises an elastomeric material in the form of elastomeric material particles dispersed within the fibre cement composition. The elastomeric material further increases the resistance of the flooring board against impact force, i.e. it allows providing a flooring board in which the occurrence of cracks or chipping in response to impact is reduced.
In an embodiment of the flooring board or flooring board precursor of the present invention, the elastomeric material is present in the fibre cement composition in an amount of from 0.1 to 15 dry weight percent, preferably of from 1 to 10 dry weight percent, more preferably of from 2 to 6 dry weight percent. The mechanical properties can be favourably adapted by already comparatively small amounts of elastomeric material below 15% dry weight percent, for example by using 5% dry weight percent. In an embodiment of the flooring board or flooring board precursor of the present invention, the particles of elastomeric material in the fibre cement composition have a diameter of from 0.01 to 1.0 mm with preferably a d5o of 0.7 mm. Preferably, the particles of elastomeric material have a diameter of from 0.1 to 0.7 mm with preferably a d$o of 0.5 mm; and more preferably the particles of elastomeric material have a diameter of from of from 0.1 to 0.5 mm with preferably a d5o of 0.3 mm.
In an embodiment of the flooring board or flooring board precursor of the present invention, the elastomeric material is a crosslinked natural rubber such as polyisoprene rubber or synthetic rubber such as chloroprene rubber, butadiene rubber, ethylene- propylene-diene rubber, styrene-butadiene rubber. Preferably, the elastomeric material is a synthetic rubber which is free from chlorine.
In an embodiment of the flooring board or flooring board precursor of the present invention, the elastomeric material has a Shore A hardness of from 10 to 90, preferably of from 30 to 80, more preferably of from 50 to 70.
For instance, the elastomeric material may be buffing dust. The elastomeric material may be added in the Hatschek process in one of the mixing steps, eg. step 3, 9 or 10 as lined out in Figure 1. Preferably the elastomeric material is added in step three after refining the cellulose.
EXAMPLES
Compositions for the manufacturing a flooring boards were formed by combining different amounts in dry weight of the cement CEM I 42.5 R, limestone, silica, cellulose, PVA fibre, jute fibre and buffing dust according to the below Table 1. The compositions were processed according to the Hatschek-type process depicted in Fig. 1 to be formed into flooring boards for which the modulus of rupture (MOR), the modulus of elasticity (MOE), and the strain at break were recorded. As can be seen from the Table 1 , the compositions that have a modulus of rupture (MOR) of from 5 to 40 GPa, a modulus of elasticity (MOE) of from 5 to 18 GPa, as well as a strain at break of 2 to 10 mm/m outperform other compositions in terms of impact resistance (less is better), which compositions do not cumulatively have a modulus of rupture (MOR) of from 5 to 40 GPa, a modulus of elasticity (MOE) of from 5 to 18 GPa, as well as a strain at break of 2 to 10 mm/m.
All values are derived from a three point flexural test. The modulus of rupture (MOR) was determined via EN 12467 the modulus of elasticity (MOE) was determined via EN 12467 and the a strain at break of a material was determined via ISO 178.
The impact resistance is determined according to EN 438-2.
Thus, the flooring boards according to the present invention, having a load-bearing layer having a modulus of rupture (MOR) of from 5 to 40 GPa, a modulus of elasticity (MOE) of from 5 to 18 GPa, as well as a strain at break of 2 to 10 mm/m display excellent impact resistance.
1 2 3 4 5 6 cement 68,7 70.7 68,7 68,7 68,7 68,7 limestone 23,3 23,3 23,3 13,3 18,3 23,3 silica 3 3 3 3 3 3 cellulose 3 3 3 3 3 3
PVA fiber 2 2 2 2 jute fibers 2
buffing dust 10 5
MOE [kN/mm2] 19,9 22,7 20,5 14,7 17,9 20,8
MOR [N/mm2] 31,4 22,5 21,1 28,8 30,2 33,2
Density [kg/m3] 1817 1892 1838 1769 1801 1823
Strain at break 1,8 1 ,1 1.3 5.2 3,5 1 ,7
[mm/m]
Impact 11 crack 12 7 8 11 resistance [mm]
TABLE 1 LIST OF REFERENCE SIGNS
1.. .scale for the cellulose 16.. .stack press
2.. .water tank 17.. .curing chamber
3.. .pulper and refiner 18.. . blanks are un-stacked
4.. .cellulose pulp tank 19.. .drying apparatus
5.. .polymeric fibre tank 20.. .stock
6.. .cement tank 21 .. .finishing line
7.. .filler tank 22.. .milling apparatus
8.. .water tank 23.. .recirculation
9.. .mixer I 24.. .top layer
10 ...mixer II 25.. .load-bearing layer
1 1 . ..horizontal mixer III 26.. ..bulge
12 ...Hatschek machine 27.. .tongue
13 ... wet green web 28.. ..groove
14 ...stamp 29.. ..recess
15 ... stamping waste

Claims

1. A flooring board or flooring board precursor comprising at least one load-bearing layer formed from a material comprising, or consisting of, a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid, characterized in that said material, said load-bearing layer, said flooring board or said flooring board precursor has a modulus of rupture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m.
2. The flooring board or flooring board precursor according to claim 1 , wherein the flooring board or flooring board precursor is a loose lay flooring board or loose lay flooring board precursor, and further comprises at least one lateral male interlocking element and at least one lateral female interlocking element being formed from a material comprising a fibre cement composition, said fibre cement composition comprising a cementitious binding material, polymeric fibres and/or cellulosic fibres and optionally a fibre-based processing aid, characterized in that said material forming the at least one lateral male interlocking element and at least one lateral female interlocking element has a modulus of rupture (MOR) of from 5 to 40 GPa and/or a modulus of elasticity (MOE) of from 5 to 18 GPa, and/or a strain at break of 2 to 10 mm/m.
3. The flooring board or flooring board precursor according to claim 1 or 2, wherein the fibre cement composition further comprises an elastomeric material in the form of elastomeric material particles dispersed within the fibre cement composition.
4. The flooring board or flooring board precursor according to claim 1, wherein the particles of elastomeric material in the form of particles have a diameter of from 0.01 to 1.0 mm with preferably a d5o of 0.7 mm; preferably of from 0.1 to 0.7 mm with preferably a d50 of 0.5 mm; more preferably of from 0.1 to 0.5 mm with preferably a d50 of 0.3 mm.
5. The flooring board or flooring board precursor according to claim 1 or 2, wherein the fibre cement composition comprises of from 0.1 to 15 dry weight percent of elastomeric material, preferably of from 1 to 10 dry weight percent of elastomeric material, more preferably of from 2 to 5 dry weight percent of elastomeric material.
6. The flooring board or flooring board precursor according to any of the previous claims, wherein the elastomeric material comprises a crosslinked natural rubber such as polyisoprene rubber or synthetic rubber such as chloroprene rubber, butadiene rubber, ethylene-propylene-diene rubber, styrene-butadiene rubber.
7. The flooring board or flooring board precursor according to any of the previous claims, wherein the elastomeric material has a Shore A hardness of from 10 to 90, preferably of from 30 to 80, more preferably of from 50 to 70.
8. The flooring board or flooring board precursor according to any of the previous claims, wherein the fibre cement composition comprises the cementitious binding material in an amount of from 60 to 90, preferably of from 65 to 75 dry weight percent.
9. The flooring board or flooring board precursor according to any of the previous claims, wherein the fibre cement composition comprises the polymeric fibres in an amount of from 1.5 to 3, preferably of from 1.7 to 2.3 dry weight percent.
10. The flooring board or flooring board precursor according to any of the previous claims, wherein the fibre cement composition comprises the cellulosic fibres in an amount of from 1 to 25 dry weight percent, preferably of between 1 to 5 dry weight percent.
EP18762239.4A 2017-08-21 2018-08-21 Drop impact-resistant and adaptive flooring Withdrawn EP3673123A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP17187145 2017-08-21
PCT/EP2018/072508 WO2019038260A1 (en) 2017-08-21 2018-08-21 Drop impact-resistant and adaptive flooring

Publications (1)

Publication Number Publication Date
EP3673123A1 true EP3673123A1 (en) 2020-07-01

Family

ID=59699518

Family Applications (1)

Application Number Title Priority Date Filing Date
EP18762239.4A Withdrawn EP3673123A1 (en) 2017-08-21 2018-08-21 Drop impact-resistant and adaptive flooring

Country Status (2)

Country Link
EP (1) EP3673123A1 (en)
WO (1) WO2019038260A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018138273A1 (en) 2017-01-26 2018-08-02 Etex Services Nv Fiber cement flooring products and methods for the production thereof

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114957830A (en) * 2022-04-19 2022-08-30 财纳福诺木业(中国)有限公司 Panel substrate

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2045306B (en) * 1979-02-09 1983-02-02 Cape Boards & Panels Ltd Boards and sheets
AUPO612097A0 (en) * 1997-04-10 1997-05-08 James Hardie Research Pty Limited Building products
FR2860511B1 (en) 2003-10-02 2005-12-02 Saint Gobain Mat Constr Sas PLASTIC CEMENT PRODUCT AND METHOD OF MANUFACTURE
EP1856340A4 (en) 2005-02-15 2013-12-04 Hardie James Technology Ltd Flooring sheet and modular flooring system
DE102005017392A1 (en) 2005-04-14 2006-10-19 Witex Ag flooring
EP2172434B1 (en) 2008-10-02 2015-03-11 Redco S.A. Fibre-cement product compositions and shaped products obtained therefrom.
US9133616B2 (en) * 2013-12-23 2015-09-15 Nano And Advanced Materials Institute Limited High performance cementitious materials for flooring underlayment with enhanced impact sound insulation
DE102014003260A1 (en) 2014-02-18 2015-09-03 Hülsta-Werke Hüls Gmbh & Co. Kg Building panel, in particular for use as a floor, wall or ceiling panel

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018138273A1 (en) 2017-01-26 2018-08-02 Etex Services Nv Fiber cement flooring products and methods for the production thereof

Also Published As

Publication number Publication date
WO2019038260A1 (en) 2019-02-28

Similar Documents

Publication Publication Date Title
TWI411591B (en) Fiber cement board with modified fiber
BRPI0718296A2 (en) ENGINEERED WOOD PRODUCT
US5637362A (en) Thin, sealant-coated, fiber-reinforced gypsum panel
US12030290B2 (en) Building panel comprising mineral-based layer
MXPA03002948A (en) Composite building material.
US11788302B2 (en) Building panel comprising mineral-based layer
JP2009506236A (en) Lightweight panels
WO2017191319A2 (en) Compositions for the manufacture of flooring elements
WO2019038260A1 (en) Drop impact-resistant and adaptive flooring
CN102206957B (en) The manufacture method of Wood cement board
CN115279981A (en) Panel for constructing floor or wall coverings
US20210237402A1 (en) Floor Panel and Method of Manufacturing a Floor Panel
AU2017295061B2 (en) Compositions for the manufacture of flooring elements for indoor use
EP0655966B1 (en) Continuous processing equipment for making fiberboard
NL2034068B1 (en) Panel for forming a floor or wall covering
US12044008B2 (en) Building panel with sections
NL2033198B1 (en) Panel, composition for impregnating or coating a panel, and a method for producing a panel
WO2024198012A1 (en) Composite floor containing fiber layer
EP1102904A1 (en) Building board and its production
KR20150065314A (en) Decorative plywood mosaicfloor board and method thereof
WO2021152153A1 (en) Panel for forming a floor covering and such floor covering
WO2024069279A1 (en) Method for producing a geopolymeric panel, and geopolymeric panel obtained therewith
WO2019048547A1 (en) Loose-lay rigid subfloor with finishing layer

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

17P Request for examination filed

Effective date: 20200122

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION HAS BEEN WITHDRAWN

18W Application withdrawn

Effective date: 20200903