EP3827145B1 - Acoustic panel for producing a floor covering - Google Patents

Description

Technical area

The present invention relates to the technical sector of floor coverings and more particularly to a multilayer panel for producing a floor covering or the like. The panel according to the invention has a slab or strip shape and has good mechanical and acoustic properties.

Prior art

It is well known to make floor coverings from modular elements in the form of strips or slabs. These modular elements can be glued to the ground or laid free-standing, in particular when they have male-female assembly means. Such male-female connecting or panel assembly means are described in particular in the documents UK 2,256,023 , EP 1 026 341 , WO 2012/004701 , EP 2 843 153 or WO 2016/030627 .

Floor coverings in the form of strips and slabs made from one or more layers of non-flexible or rigid PVC are known in particular, these being particularly advantageous because they are easier to transport than rolls of PVC flooring. Their installation is also simple and fast. They are therefore often used in renovation to cover existing floors. In order to improve the dimensional stability of this type of coating, a reinforcing glass veil is sometimes used embedded in the thickness of a layer of PVC.

However, this type of coating generally has poor acoustic properties, in particular in terms of sound insulation, sound when walking, shock absorption and comfort when walking.

It is also known the document WO2012/034548 which describes the preamble of claim 1, and the document WO02/10504 which describes a plastic floor covering made by coating and whose reverse side consists of a textile sheet. The connection between the textile structure and the reverse face of the base support is achieved by an additional layer of plastisol which penetrates, over a minority part of the thickness of the textile structure and which, after gelation, ensures the joining of this textile to the back of the base support in thermoplastic material. The document EP 3 330 055 A1 also describes such a floor panel.

Disclosure of Invention

One of the aims of the invention is therefore to propose a panel for the production of a floor covering having good performance in terms of walking sound and acoustic insulation while retaining good mechanical properties.

Another example is to provide a panel comprising male-female connecting or assembly means.

Another object of the invention is to propose a panel having improved shock absorption properties according to standard EN14808, in particular greater than 3%.

An object of the invention is also to provide a panel classified A or even B according to the NF S31 074 standard in terms of sound when walking, that is to say having an Ln,e,w value of less than 75db. This measurement is made according to the NF S31 074 standard, using a microphone measuring the standardized impact noise level in the room where the floor covering is laid.

An object of the invention is also to provide an acoustic panel having a weighted impact noise reduction (ΔLw) according to the ISO 10140-3 standard and the classification according to ISO 717-2:2013 greater than 12db.

To this end, a multilayer panel is proposed for the production of a floor covering according to claim 1.

It is thus important that part of the thickness of the nonwoven textile layer remains free and not impregnated by the top and back layers. By free thickness is meant that the fibers of the nonwoven textile layer are free to move in this thickness, in the same way that they can move in the textile layer before it is bonded to the upper layers and upside down. In the free thickness, the textile fibers are not impregnated by any means used to bond the nonwoven textile layer to the top and back layers.

According to the present invention, the nonwoven textile layer consists of the so-called free thickness bordered by two so-called bonding thicknesses with the upper layer and the backing layer, the sum of the bonding thicknesses is less than or equal to l free thickness.

The so-called binding thicknesses of the nonwoven textile layer are functions of the means(s) used to bind the nonwoven textile layer to the upper layer and to the backing layer. The nonwoven textile layer can in particular be bonded to the backing layer or to the upper layer by thermo lamination, cold bonding, hot bonding, extrusion of the backing layer on the nonwoven textile layer, by powdering hot melt glue or by using a double-sided adhesive. The bonding thickness will for example be a few microns if the nonwoven textile layer is bonded by thermo lamination. For example, it is possible to heat bond a backing layer made from PVC and a layer of non-woven fabric made from polyester fibers.

It is also possible to bond the nonwoven textile layer to the upper layer and/or to the backing layer by cold or hot bonding, for example using a hotmelt glue. The impregnation of the adhesive is in this case limited to the fibers arranged at the surface of the nonwoven textile layer. It is also contemplated to bond the non-woven fabric layer using a hot melt powder glue. This process is described in particular in the patent application EP 1570 920 B1 of the applicant, in particular by powdering with polyester, co-polyester or EVA (ethylene vinyl acetate) glue. Conventional bond thicknesses will be between 25 μm and 300 μm, preferentially between 50 μm and 130 μm in the case of bonding by bonding.

Alternatively, it is possible to bind the layer of nonwoven textile to the upper layer or to the backing layer by using a layer of plastisol deposited in the liquid state on the layer of nonwoven textile then gelled. By gelling the plastisol layer will impregnate the fibers of the non-woven textile layer on the bonding thickness. A gelled plastisol layer can in particular be a PVC plastisol layer with a thickness of at least 50 μm and generally less than 1 mm after gelling, preferably between 50 μm and 0.5 mm.

Due to its position in the multilayer panel, the layer of non-woven textile makes it possible to attenuate impact noises and to limit their transmission from the upper layer to the back layer while maintaining a so-called free thickness. This free thickness makes it possible to retain a quantity of air inside the layer of nonwoven textile. The invention thus makes it possible to obtain a multilayer panel for the production of a floor covering having sound insulation properties. Depending on the thickness of the non-woven fabric and the composition of the panel, it may be classified A or even B according to standard NF S31 074 in terms of sound when walking, i.e. having an Ln value, e,w less than 75db. On the other hand, the invention makes it possible to obtain an acoustic panel having a weighted impact noise reduction (ΔLw) according to the ISO 10140-3 standard and the classification according to ISO 717-2:2013 greater than 12db.

The nonwoven textile layer has a thickness generally between 0.5 mm and 2 mm and a surface weight between 80 g/m ² and 250 g/m ² . Preferably, the non-woven textile layer has a thickness of between 0.65 mm and 1.1 mm and a basis weight between 120 g/m ² and 200 g/m ² in order to present a good compromise between acoustic performance and the puncture resistance of the floor covering according to the invention.

Advantageously, the nonwoven textile layer comprises natural textile fibers such as cellulose, cotton, linen fibers, synthetic textile fibers, in particular polyester, polyamide, polyethylene terephthalate, aramid, Nomex, polyethylene naphthalate, polypropylene or also synthetic mineral textile fibers such as glass fibers or basalt fibers. Preferably, the layer of non-woven textile comprises only polyester fibers because these have good acoustic properties without generating too high a manufacturing cost.

Advantageously, the upper layer and the nonwoven textile layer of the multilayer panel according to the invention are bonded together by a first bonding layer impregnating less than 50% of the thickness of the nonwoven textile layer. An impregnation of less than 50% of the thickness of the nonwoven textile layer makes it possible to obtain good cohesion of the upper layer to the nonwoven textile layer. Preferably, the top layer and the layer of nonwoven fabric are bonded together by a first bonding layer impregnating less than 30%, more preferably less than 15%, of the thickness of the layer of nonwoven fabric. By decreasing the impregnation thickness, a greater thickness of nonwoven textile layer can be left free. The greater the thickness of the free nonwoven textile layer, the more the acoustic properties of the panel according to the invention will be improved. Advantageously, the first bonding layer is a gelled plastisol layer or a hot-melt glue.

Advantageously, the backing layer and the nonwoven textile layer are bonded together by a second bonding layer impregnating less than 45% of the thickness of the nonwoven textile layer. Preferably, the top layer and the layer of nonwoven fabric are bonded together by a second bonding layer impregnating less than 30%, more preferably less than 15%, of the thickness of the layer of nonwoven fabric. By decreasing the impregnation thickness, a greater thickness of nonwoven textile layer can be left free. Generally, in an exemplary method for manufacturing the multilayer panel according to the invention, the top layer, the first bonding layer and the layer of nonwoven fabric are assembled together in a first manufacturing step. The resulting by-product is then bonded to the backing layer by the second tie layer.

Advantageously, the second bonding layer is an adhesive, for example a double-sided adhesive.
The top layer providing wear resistance and decorative functions is for example made of polyvinyl chloride and generally has a thickness of between 0.10 and 1 mm, preferably between 0.20 and 0.70 mm. According to the invention, the upper layer may comprise a wear layer transparent to visible light so that a decoration printed on the back of the wear layer or even on a printed film placed between the wear layer and the nonwoven fabric can be seen through the wear layer. According to the invention, the upper layer can also be a decorative layer obtained by pressing or calendering tinted polymer granules or by coating and gelation of a tinted plastisol. Advantageously, the upper layer comprises a reinforcement reinforcement embedded in the thickness of the upper layer. The presence of a reinforcement reinforcement makes it possible to improve the dimensional stability of the upper layer. On the other hand, the reinforcement can be used as a coating support in order to obtain an upper layer from a plastisol. The plastisol being coated on one or two faces of the reinforcement and then gelled.

The backing layer of the panel according to the invention comprises at least one non-flexible layer made from a thermoplastic material, that is to say it has a bending stiffness greater than the bending stiffness. maximum bending to satisfy international standard ISO 24344:2008. In this method, flexibility is defined as the ability of a panel or layer of flooring to be wrapped around a 20mm mandrel, without cracks or cracks forming. Thus, the non-flexible layer of the backing layer subjected to this test would exhibit permanent breaks, cracks, cracks and other defects. The non-flexible layer can in particular be made from PVC.

The backing layer of the panels according to the invention generally has a thickness of between 0.5 mm and 6 mm. Thus, the panel according to the invention has stable dimensions, the backing layer having good properties of dimensional and mechanical stability while having good acoustic properties.

Advantageously, the back layer of the panel according to the invention back layer comprises at least one rigid layer. Preferably, the back layer of the panel according to the invention is sufficiently rigid so that male-female assembly means can be machined therein, formed by injection molding or cut out on the edges of said layer. The assembly of said male-female assembly means allows the panels to be blocked together under normal conditions of use, this blocking preventing the panels from being disassembled in at least one direction. A person skilled in the art will be able to define the different compositions and thicknesses of the layer or layers forming the backing layer in order to achieve the expected stiffness.

Advantageously, the back layer of the panel according to the invention comprises at least one rigid layer whose modulus value for 1% elongation is greater than 20 daN/cm and whose flexibility value is preferably greater than 25N for 20mm .

The use of a layer having these elongation characteristics makes it possible to obtain a panel according to the invention whose dimensions are stable according to the temperature variations of the room where it is installed.

Advantageously, the back layer of the panel according to the invention has a modulus for 1% elongation whose value is greater than 20 daN/cm and whose flexibility value is preferably greater than 25N for 20 mm. The use of a layer having these elongation characteristics makes it possible to obtain a panel according to the invention whose dimensions are more stable according to the temperature variations of the room where it is installed.

Advantageously, the back layer of the panel according to the invention comprises at least one rigid layer whose modulus value for 1% elongation is greater than 45 daN/cm and whose flexibility value is preferably greater than 90N for 20mm of deflection. The use of a layer having these elongation characteristics makes it possible to further improve the dimensional stability of the panel according to the temperature variations of the room where it is installed, in particular when the latter is laid in a so-called free manner, ie without the addition of glue.

Advantageously, the back layer of the panel according to the invention has a modulus for 1% elongation whose value is greater than 45 daN/cm and whose flexibility value is greater than 90N for 20 mm of deflection. The use of a layer having these elongation characteristics makes it possible to obtain a very rigid panel and thus to improve the dimensional stability of the panel according to the temperature variations of the room where it is installed. In particular, a backing layer having such characteristics makes it possible to obtain a panel which can be laid in a so-called free manner in places particularly exposed to the rays of the sun.

All the modulus values for 1% elongation set out in this application are obtained according to the M1-Ueatc method according to standard NF 189.

All the flexibility values for 20mm of deflection presented in this application are obtained according to standard NF EN ISO 24344: April 2012.

The desired values of elongation and flexibility of each layer and in particular of the backing layer can easily be obtained by those skilled in the art depending on the thermoplastic material used for its production. Thermoplastic materials such as PVC, thermoplastic polyurethane or thermoplastic polyolefins, such as polyethylene or polypropylene, may be used to obtain the backing layer, one of the layers of the backing layer or of all layers of the back layer. PVC is preferred for its ease of processing and its mechanical properties. It is for example well known that in the case of PVC, the quantity of filler and/or of liquid plasticizer used in the composition of the layer makes it possible to vary its behavior on elongation and on bending. Alternatively, the thermoplastic material may be totally or partially replaced by rubber, natural or synthetic, or even linoleum.

Advantageously, the backing layer or at least one rigid layer of the backing layer is obtained from a composition comprising at least PVC and at least one liquid plasticizer, the proportion of liquid plasticizer by mass of the layer obtained being less than 10%, preferably less than or equal to 5%. A proportion of liquid plasticizer of less than 10% increases the rigidity of the panel while allowing this layer to be produced by conventional calendering or extrusion processes. A proportion of liquid plasticizer less than or equal to 5% further increases the rigidity of the multilayer panel as well as the dimensional stability of the panel.

The incorporation of a quantity of liquid plasticizer of less than 10% by mass of the rigid layer allows it to be simpler to transform and to be less brittle while retaining good properties of dimensional stability. The presence of a low level of liquid plasticizer, i.e. less than 10% by mass of the layer obtained, also facilitates the implementation of PVC at a temperature less than or equal to 180°C, thus limiting the risks of degradation of the matter. This property is particularly advantageous in processes for manufacturing a rigid layer by calendering. The incorporation of a quantity of liquid plasticizer of less than 5%, more preferably between 1 and 5% by mass of the layer, makes it possible to obtain a better compromise between the properties of dimensional stability and ease of manufacture.

Advantageously, the backing layer or at least one rigid layer of the backing layer is obtained from a composition comprising at least PVC and shock absorbers. The incorporation of shock absorbers makes it possible to make the layer obtained less brittle, in particular at low temperature, depending on the applications considered for the panel according to the invention.

Advantageously, the shock absorbers that can be used are elastomeric polymer particles. These elastomeric polymer particles are called “core-shell particles” in the English language and are well known to those skilled in the art. These are formed of a "hard" thermoplastic shell, preferably based on an acrylate polymer, for example polymethyl methacrylate (PMMA), and an elastomeric core generally based on butadiene, often copolymerized with styrene. , or acrylic-based.

Mention may in particular be made, for obtaining an elastomeric core, of acrylonitrile-butadiene-styrene (ABS) polymers, acrylonitrile styrene acrylate (ASA) polymers, methacrylate-butadiene-styrene (MBS) polymers, methacrylate-acrylonitrile - butadiene-styrene (MABS), ethylene/vinyl acetate (EVA), ethylene/vinyl acrylate (E/VAC) copolymers, vinyl chloride/vinyl-acrylate/ethylene (E/VAC/VC) grafted terpolymers, polyethylene chlorinated (CPE); polyurethane elastomers (PUR), butadiene/2-vinylpyridine, butadiene/methyl isoproprenyl ketone, butadiene/fumaric ester copolymers and mixtures thereof.

These shock absorbers thus contain a crosslinked or slightly crosslinked elastomeric core, surrounded by a thermoplastic shell, often a polymer of methyl methacrylate (PMMA). Licences US 3,985,703 , US 4,304,709 , US 6,433,091 , EP 1256615 Or US 6,869,497 in particular describe such particles, which are thus well known to those skilled in the art. Core-shell polymers are available from many suppliers.

By way of example, it is possible to use as shock absorbers the MBS Clearstrength C301, C303H, C223, C350, C351, E920 or C859 particles from the company Arkema, the MBS C301 and C303H being preferred. The Durastrength D300 or D340 particles from Arkema, having an acrylic core surrounded by a PMMA envelope can also be used. Similarly, it is also possible to use the MBS developed by the company Rohm and Haas, in particular Paraloid ^™ BTA 753, Advastab, or Advalube, the styrene/maleic anhydride-maleic copolymers modified by a rubber such as the polymers of the Elix 300 series marketed by Monsanto. Other shock absorbers such as Hytrel 3495 polymers marketed by the company DuPont, or CPE marketed under the brand name Tyrin by the company DuPont, as well as the range called Kane Ace MX marketed by the company Kaneka can also be used. Other shock absorbers having an acrylic core surrounded by a rubber envelope can be used.

Advantageously, the shock absorbers are polymeric plasticizers. Polymeric plasticizers which can also be used according to the invention are copolymers and terpolymers of the Elvaloy and Elvaloy HP series marketed by the company Dupont, the thermoplastic polyurethane (TPU) particles marketed in particular by the company BASF under the Elastollan range, or by the company Lanxess under the Baymod range. These TPUs can be aromatic, more preferentially aliphatic, formed from polyether polyols, or more preferentially formed from polyester polyols, formed from caprolactone derivatives or formed from thermoplastic copolyesters.
The various shock absorbers mentioned can be used alone or as a mixture.

Preferably, the proportion of shock absorbers by mass of the back layer or of the rigid layer of the back layer is less than 25%, preferably between 1% and 15% by mass of the layer . The quantity of shock absorbers by weight of the layer depends on the grade of shock absorbers used, and in particular on the chain length of the longest of the polymers forming the shock absorber. This quantity can easily be adapted by those skilled in the art according to the glass transition temperature of the composition of the layer obtained.

Preferably and in order to improve the acoustic insulation of the panel according to the invention, the backing layer comprises a damping underlayer intended to be in contact with the ground. A damping underlayer may in particular consist of a layer of polyurethane foam, a layer of polyolefin foam such as polyethylene, a layer of PVC foam, a layer of rubber foam or else a layer of non-woven textile. A damping underlay generally has a thickness of between 0.5 mm and 3 mm.

The fillers that can be used are in particular inorganic fillers, for example clays, silica, kaolin, talc, calcium carbonate.

Advantageously, the backing layer comprises between 0% and 90% of fillers by weight of the layer, advantageously between 10% and 60% by weight of the layer.

The liquid plasticizers which can be used in each of the layers of the floor covering according to the invention are in particular plasticizers such as Diisononyl Phthalate (DINP), Diisodecyl Phthalate (DIDP), 2-Ethylhexyl Diphenyl Phosphate (DPO), Dioctyl terephthalate (DOTP), 1,2-cyclohexane dicarboxylic acid diisononyl ester (DINCH), plasticizers from the benzoate family, plasticizers from the adipate family, plasticizers sold under the PEVALEN ^® brand by Perstorp, l epoxidized soybean oil (HSE), epoxy octyl stearate (ESO), totally or partially biosourced plasticizers such as plasticizers from the polysorb ^® ID 37 range marketed by Roquette Pharma, plasticizers from the citrofol marketed by the company Jungbunzlauer International AG, or else the plasticizers of the soft-n-safe range marketed by the company Danisco. The liquid plasticizers can be used alone or in admixture.

The panels according to the invention are in the form of strips or slabs, each panel comprising an upper face intended to be in contact with the user, a lower face intended to be in contact with the ground and four edges. Preferably, the back layer comprises male-female means for connecting or assembling several panels together.

The edges of the backing layer of the panels according to the invention can be machined to present male-female assembly means making it possible to connect several panels together. By means of male-female assembly means in particular means comprising a groove machined on one of the edges of a panel and configured to be assembled with a tab machined on the opposite edge of an adjacent panel. Male-female assembly means assembling perpendicular to the ground and using machining profiles in the shape of dovetails are also envisaged.

The panels according to the invention have a thickness generally between 2.5 mm and 10 mm, preferably between 3.5 mm and 6 mm. This thickness is measured between the upper face of the upper layer intended to be in contact with the user and the lower face of the back layer intended to be in contact with the floor. The panels according to the invention have a width of between 8 cm and 70 cm, preferably between 15 cm and 25 cm and a length of between 50 cm and 240 cm, preferably between 100 and 150 cm.

In a non-limiting manner, the panels according to the invention may be grained and/or covered with a varnish on the surface, in particular in order to facilitate their maintenance and to protect them against wear.

Brief description of the figures

• la figure 1 illustre, de manière schématique une vue en coupe transversale d'un premier mode de réalisation d'un panneau multicouche pour la réalisation d'un revêtement de sol selon l'invention ;
• la figure 2 est une représentation schématique similaire à celle de la figure 1, d'un second mode de réalisation d'un panneau multicouche pour la réalisation d'un revêtement de sol selon l'invention ;
• la figure 3 est une représentation schématique similaire à celle de la figure 2, la couche d'envers comprenant une couche rigide ;
• la figure 4 est une représentation schématique similaire à celle de la figure 2, la couche d'envers comprenant une couche rigide complexée entre deux couches non-flexibles ;

Other advantages and characteristics will emerge better from the description which follows, given by way of non-limiting example, with reference to the appended figures in which:

• there figure 1 schematically illustrates a cross-sectional view of a first embodiment of a multilayer panel for producing a floor covering according to the invention;
• there figure 2 is a schematic representation similar to that of the figure 1 , of a second embodiment of a multilayer panel for producing a floor covering according to the invention;
• there picture 3 is a schematic representation similar to that of the picture 2 , the back layer comprising a rigid layer;
• there figure 4 is a schematic representation similar to that of the picture 2 , the back layer comprising a rigid layer complexed between two non-flexible layers;

Detailed Description of the Invention

• une couche supérieure (2) assurant des fonctions de résistance à l'usure et de décor ;
• une couche de textile non-tissé (3) ;
• une couche d'envers (4) comprenant au moins une couche non-flexible (4a) réalisée à partir d'une matière thermoplastique.

With reference to figures 1 to 4 , the multilayer panel (1) for producing a floor covering according to the invention having sound insulation properties successively comprises:

• a top layer (2) providing wear resistance and decorative functions;
• a layer of non-woven fabric (3);
• a back layer (4) comprising at least one non-flexible layer (4a) made from a thermoplastic material.

The layers (2, 3, 4) are bonded together to form the multilayer panel (1). The nonwoven textile layer (3) comprises a so-called free thickness in which the textile fibers are free and not impregnated. In the free thickness, the textile fibers of the nonwoven textile layer (3) are not impregnated by the top (2) and back (4) layers.

The nonwoven textile layer (3) consists of a so-called free thickness bordered by two so-called bonding thicknesses with the upper layer (2) and the backing layer (4), the sum of the bonding thicknesses is lower or equal to the free thickness.

Optionally, the backing layer (4) of the floor covering (1) according to the invention also comprises a damping underlayer (7) intended to be in contact with the ground.

The non-woven textile layer (3) can in particular be bonded to the backing layer (4) and/or to the top layer (2) without adding material, for example by thermo lamination. The bond thickness will then be a few tens of microns. It is for example possible to heat bond a backing layer (4) made from PVC and a layer of non-woven fabric (3) made from polyester fibres. An example of a process for manufacturing the panel according to the invention (1) may comprise a step consisting in extruding the backing layer (4) and in laminating the layer of non-woven fabric (3) directly from the extruder onto the back layer (4) in order to bind them. The back layer (4) is then hot enough to obtain a good bond between the two layers (3, 4°).

It is also possible to cold or hot glue the layer of non-woven fabric (3) to the back layer (4) and/or to the upper layer (2), for example using a hotmelt glue, the impregnation of the glue being limited to the fibers arranged on the surface of the non-woven textile layer (3). It is also envisaged to bind the layer of non-woven fabric (3) using a hot-melt powder glue. This process is described in particular in the patent application EP 1570 920 B1 of the applicant, in particular by powdering with polyester, co-polyester or EVA (ethylene vinyl acetate) glue. An alternative may consist of bonding the layer of non-woven fabric (3) to the backing layer (4) and/or to the upper layer (2) using an adhesive, for example a double-sided adhesive. or even thanks to a thermofusible film.

Conventional bond thicknesses will be between 25 μm and 300 μm, preferentially between 50 μm and 130 μm in the case of bonding by bonding.

Alternatively, it is possible to bind the layer of non-woven fabric (3) to the upper layer (2) or to the back layer (4) using a gelled layer of plastisol which will impregnate the fibers of the layer of non-woven fabric (3) on the binding thickness. A gelled plastisol layer can in particular be a PVC plastisol layer with a thickness of at least 50 μm and generally less than 1 mm, preferably between 50 μm and 0.5 mm.

Preferably and according to the figures 2 to 4 , the top layer and the backing layer are thus bonded together by a first bonding layer (5a) impregnating less than 50% of the thickness of the nonwoven textile layer (3). The first bonding layer is, for example, a gelled plastisol layer or even a hot-melt adhesive. Different types of plastisol can be used, in particular a PVC plastisol. A layer of gelled PVC plastisol has the advantage of being able to be deposited continuously on the upper layer (2) or on the non-woven textile layer (3) quickly, in particular on manufacturing lines having a running speed greater than 10 meters per minute, this solution then being the most economical. After deposition of the plastisol on the upper layer (2) or on the layer of non-woven textile, the layer to be bonded is deposited on the still liquid plastisol or pre-gelled, then the by-product formed by the upper layers (2), binding and non-woven fabric (3) pass through an oven or any other gelling means making it possible to completely gel the plastisol.

The use of a hot-melt glue makes it possible to limit the impregnation thickness of the nonwoven textile by the bonding layer. Thermofusible polyurethane adhesives, “hotmelt” in English, may in particular be used.

Always according to figures 2 to 4 , the backing layer (4) and the nonwoven textile layer (3) can be bonded together by a second bonding layer (5b) impregnating less than 45% of the thickness of the nonwoven textile layer. woven (3). The second bonding layer is for example an adhesive, for example a double-sided adhesive. A thermofusible film, such as a copolyamide film could also be used. An adhesive or a hot-melt film also limits the impregnation thickness of the non-woven textile by the bonding layer (5a, 5b).

The non-woven textile layer (3) has a thickness generally between 0.5 mm and 2 mm and a basis weight between 80 g/m ² and 250 g/m ² , preferably between 120 g/m ² and 200 g/m ² . More preferentially, the layer of non-woven textile has a thickness of between 0.65 mm and 1.1 mm and a basis weight of between 120 g/m ² and 200 g/m ² .

Advantageously, the non-woven textile layer (3) comprises natural fibers such as cellulose, cotton, linen fibers, synthetic fibers, in particular polyester, polyamide, polyethylene terephthalate, aramid, Nomex, polyethylene naphthalate, polypropylene or else synthetic mineral fibers such as glass fibers or basalt fibers.

The upper layer (2) is for example obtained from tinted granules, for example made from PVC then pressed or else by coating and gelation of a tinted plastisol, by extrusion in a flat die or by calendering.

According to figures 3 and 4 , the upper layer (2) may also comprise a transparent wear layer (2a) and a decorative layer (2b). According to the invention, the layer wear layer (2a) is sufficiently transparent to visible light for a decoration printed on the back of the wear layer or even on a printed film placed directly in contact with the back of the wear layer to be visible through the transparent wear layer (2a). The decorative layer (2b) can therefore consist of a layer printed on the back of the wear layer (2a), a printed film or even a layer printed on the face of the layer directly opposite the back of the layer. wear (2a). A decorative layer (2b) can be printed by any known technique, in particular by photogravure or by inkjet printing.

The transparent wear layer (2a) can for example be made from unfilled plasticized PVC, in particular gelled PVC plastisol, polyurethane or even polyolefin. The thickness of the transparent wear layer is generally between 0.1 mm and 1 mm, preferably between 0.20 and 0.70 mm. This thickness is determined according to the desired traffic resistance. The transparent wear layer (2a) is generally obtained by coating with plastisol, by flat die extrusion or by calendering.

The transparent wear layer (2a) can be varnished to improve stain and scratch resistance.

According to figures 3 and 4 , the upper layer may also comprise a layer of gelled plastisol (2c) comprising a reinforcement reinforcement (2d) embedded in the thickness of the layer of gelled plastisol (2c). A reinforcement reinforcement (2d) can for example be a reinforcement grid or a layer of non-woven fabric such as a glass or polyester veil. Materials in the form of fibers that can be used to obtain a reinforcement reinforcement (2d) are in particular polyethylene, polyethylene terephtlate (PET), glass fibers, polyester, aramid, carbon fibers, nitrile fibres, ethylene vinyl acetate (EVA), high density polyethylene (HDPE), low density polyethylene (LDPE), polyvinyl chloride (PVC).

Advantageously, the reinforcement (2d) is a layer of non-woven textile with a thickness of less than 1 mm, preferably a veil of glass fibers or polyester. More preferably, the reinforcement reinforcement (2d) is a layer of non-woven textile with a thickness of less than 0.6 mm

A gelled layer (2c) can be obtained by coating then gelling of a plastisol on one or each face of a reinforcement reinforcement (2d) so as to embed it in the gelled layer. Generally and in a manner well known to those skilled in the art, a gelled layer (2c) comprising a reinforcement reinforcement (2d) can be obtained from a composition comprising a thermoplastic polymer, for example PVC, a plasticizer, fillers and optionally stabilizers, lubricants, additives and a reinforcement reinforcement whose thickness is completely impregnated in the thickness of the reinforced layer.

Alternatively, a decorative layer (2b) can be printed on the upper face of the gelled layer (2c). In order to obtain a good rendering of the decor layer, it can be envisaged to deposit a layer of smoothing plastisol on the gelled layer (2c) and to print the decor layer on the gelled smoothing layer of plastisol (not shown) . Advantageously, it is also possible to obtain graining of the upper layer by printing a decorative layer on a smoothing layer comprising an expansion agent. Thus, by printing a decorative layer according to a first pattern with an ink without an expansion inhibitor and by printing a second decorative layer on the reinforced layer with an ink containing an expansion inhibitor, the expansion of the smoothing layer will be partially inhibited.

• enduire et gélifier une première couche de plastisol (2c) sur une armature de renfort (2d) de manière à l'imprégner totalement ;
• optionnellement, enduire et gélifier une seconde couche de plastisol de lissage liquide sur la face de la couche de plastisol (2c) destinée à être imprimée ;
• imprimer un motif sur la couche de plastisol (2c) ou le cas échéant sur la couche de lissage gélifiée de manière à obtenir une couche décor (2b) ;
• enduire et gélifier ou complexer une couche d'usure (2a) sur la couche décor (2b) ;

A method of manufacturing the upper layer (2) can therefore comprise the following steps which consist of:

• coating and gelling a first layer of plastisol (2c) on a reinforcement reinforcement (2d) so as to completely impregnate it;
• optionally, coating and gelling a second layer of liquid smoothing plastisol on the face of the layer of plastisol (2c) intended to be printed;
• printing a pattern on the plastisol layer (2c) or, where appropriate, on the gelled smoothing layer so as to obtain a decorative layer (2b);
• coating and gelling or complexing a wear layer (2a) on the decorative layer (2b);

• enduire et gélifier une première couche de plastisol sur une première armature de renfort de manière à l'imprégner totalement ;
• enduire et pré-gélifier une seconde couche de plastisol liquide comprenant un agent d'expansion sur la face de la première couche de plastisol renforcée destinée à être imprimée ;
• imprimer un motif sur la seconde couche de plastisol pré-gélifiée avec une encre comprenant des agents inhibiteurs d'expansion de manière à obtenir une couche décor ;
• enduire une couche d'usure sur la couche décor ;
• gélifier la seconde couche de plastisol et la couche d'usure de manière à obtenir une couche supérieure grainée.

Alternatively, a process for manufacturing the upper layer (2) can therefore comprise the following steps which consist of:

• coating and gelling a first layer of plastisol on a first reinforcement reinforcement so as to completely impregnate it;
• coating and pre-gelling a second layer of liquid plastisol comprising an expanding agent on the face of the first layer of reinforced plastisol intended to be printed;
• printing a pattern on the second pre-gelled plastisol layer with an ink comprising expansion inhibiting agents so as to obtain a decorative layer;
• coating a wear layer on the decorative layer;
• gel the second layer of plastisol and the wear layer so as to obtain a grainy upper layer.

According to figures 2 to 4 , the back layer (4) may comprise means of assembly or male-female connection (6a, 6b). For this, the edges of the backing layer (4) of the panels according to the invention can be machined to present male-female assembly means (6a, 6b) making it possible to connect several panels together. In general, the male-female connection means comprise a first machining profile machined on one edge of a panel and configured to be assembled with a second machining profile machined on an opposite edge of an adjacent panel . The panels thus obtained can thus have one or more generally two pairs of machining profile, each pair comprising a first and a second machining profile on two opposite edges of a panel. The first and second machining profiles of each pair are not necessarily similar, in particular depending on the length of the edge considered and the desired assembly direction. The assembly of the panels can in particular take place in a direction perpendicular to the ground in the case of so-called "vertical" assembly means, in a direction parallel to the ground in the case of so-called "horizontal" assembly means, or even in more complex directions, for example by rotation and/or translation of a male assembly means in a female assembly means. Such assembly means are described in particular in the documents UK 2,256,023 , EP 1 026 341 , WO 2012/004701 or WO 2016/030627 . Preferably, the assembly means, once assembled, block the movement of two panels both in a vertical direction, that is to say perpendicular to the ground, and in a direction which is perpendicular to the edge of the panel on which the assembly means considered is machined and parallel to the plane formed by the ground. The assembly means and their machining profiles can in particular be obtained by in-line machining, by injection molding of the panel or even by cutting, in particular with a punch.

According to figures 1 2 and 4 , the backing layer (4) comprises at least one non-flexible layer (4a) made from a thermoplastic material, for example from plasticized PVC. A non-flexible layer (4a) has a flexural stiffness greater than the maximum flexural stiffness to satisfy International Standard ISO 24344:2008.

According to an alternative embodiment illustrated on the figures 3 and 4 , the backing layer (4) may comprise a rigid layer (4b) in order to improve the dimensional stability of the panel.

According to an alternative embodiment illustrated in the figure 4 , the back layer (4) comprises a rigid layer (4b) complexed between two non-flexible layers (4a, 4c). This alternative embodiment makes it possible to obtain a backing layer (4) whose dimensions are stable, whose acoustic properties are improved and whose weight is limited. This embodiment of the backing layer (4) in combination with a layer of non-woven fabric (3) according to the invention makes it possible to obtain a panel having acoustic properties and reduced weight.

Optionally, the backing layer (4) of the floor covering (1) according to the invention also comprises a damping underlayer (7) intended to be in contact with the ground. A damping underlayer (7) may in particular consist of a layer of polyurethane foam, a layer of rubber foam or even a layer of non-woven fabric. A damping underlayer (7) generally has a thickness of between 0.5 mm and 3 mm. The advantage of such a damping underlayer is to provide the panel according to the invention with good acoustic insulation performance.

A damping underlayer (7) consisting of a layer of non-woven textile with a thickness of between 0.5 mm and 3 mm makes it possible to guarantee a good compromise between the acoustic insulation performance and the resistance of male means- assembly women (6a, 6b) to traffic and this for most of the machining profiles of these assembly means (6a, 6b). It may in fact happen that male-female assembly means (6a, 6b) used in combination with a shock-absorbing underlayer (7) made of non-woven fabric with a thickness greater than 3 mm disassemble or break under the effect traffic, the thickness of the non-woven fabric making the entire panel too flexible and increasing the stresses on the assembly means (6a, 6b). On the other hand, a thickness of damping underlayer (7) made of non-woven fabric of less than 0.5 mm can limit the sound insulation provided by the panel.

Advantageously, the damping underlayer (7) has a thickness of between 1 mm and 2.5 mm. This range of thicknesses makes it possible to reach a better compromise between the sound insulation performance and the resistance of the assembly means to traffic if the backing layer includes it, in particular sound attenuation according to the higher ISO 10140-3 standard. at 15dB.

Preferably, the non-woven textile damping underlayer comprises a compressive strength greater than or equal to 20 Kpa, more preferably greater than or equal to 100 KPa. The resistance to compression is an important property of the damping underlayer, this is decisive for maintaining good acoustic insulation over time provided by the underlayer while contributing to the resistance of the assembly means to traffic. The compressive strength is measured according to the CEN / TS 16354:2012 standard which itself refers to the NF EN 826 standard of May 2013. This method corresponds to a compression measurement for a deformation of 0.5mm.

A shock-absorbing underlayer in non-woven textile comprising a compressive strength greater than or equal to 20 Kpa makes it possible to provide good acoustic insulation while contributing to the resistance of the assembly means to traffic. However, when the surface is subjected to heavy traffic, particularly in reception halls or corridors, it is preferable that the damping non-woven textile underlay has a compressive strength greater than or equal to 100Kpa in order to maintain its acoustic properties over time.

More preferentially, the shock-absorbing non-woven textile underlayer (7) comprises a compressive strength greater than or equal to 400 KPa. This makes it possible to achieve a better result both for the preservation of the acoustic insulation performance over time and the resistance of the assembly means to traffic. It is in fact observed that a compressive strength greater than or equal to 400 kPa allows the underlayer to retain its thickness despite repeated traffic of heavy loads and creates less stress at the level of the assembly means. It is for example observed that the assembly means having a so-called "vertical" assembly direction, namely perpendicular to the plane of the ground covered by the floor covering panel, present less risk of unclipping if they are used in combination with a non-woven textile underlayer comprising a compressive strength greater than or equal to 400KPa.

Advantageously, the damping underlayer (7) of non-woven textile comprises natural fibers such as cellulose fibers, cotton, linen, synthetic fibers, in particular polyester fibers, polyamide, polyethylene terephthalate, aramid, Nomex, polyethylene naphthalate, polypropylene or even synthetic mineral fibers such as glass fibers or basalt fibers.

Advantageously, the damping underlayer (7) of non-woven textile is made from a mixture of natural fibers and synthetic fibers and/or synthetic mineral fibers. In a non-limiting manner, the shock-absorbing non-woven textile underlayer has a surface mass greater than 100 g/m ² and less than 600 g/m ² . In a non-limiting manner, the damping underlayer (7) made of non-woven textile has a ratio corresponding to its basis weight over its thickness greater than 200 g/m ² per millimeter of thickness.

The damping underlayer (7) can be bonded to the non-flexible layer (4a) or to the rigid layer (4b) by any known means, in particular by thermo lamination, cold bonding, hot bonding, extrusion of the layer (4a, 4b) on the damping underlay (7), by powdering with hot-melt glue or by using a double-sided adhesive or a hot-melt film. Alternatively, it is possible to bond the damping underlayer (7) to the non-flexible (4a) or rigid (4b) layer, using a gelled plastisol layer.

Example of realization :

In order to carry out acoustic and mechanical tests, nine examples of panels (1) according to the picture 3 are prepared.

• D'une couche de vernis polyuréthane (non représentée) d'épaisseur inférieure à 20µm ;
• D'une couche d'usure (2a) obtenue à partir d'un plastisol PVC gélifié non chargé ;
• D'une couche décor (2b) imprimée par héliogravure sur la face de la couche de plastisol gélifié (2c) au regard de la couche d'usure (2a) d'environ 0,15 mm ;
• D'un voile de fibres de verre (2d) d'une masse surfacique de 55 g/m² noyé dans une couche de plastisol gélifié (2c) d'une épaisseur de 0,62 mm ;
• D'une couche de textile non-tissé (3) en polyester;
• D'une couche d'envers (4) constituée d'une couche rigide (4b) de 4,5 mm d'épaisseur à base de PVC et optionnellement d'une sous-couche amortissante (7) ;

These panels (1) consist successively:

• A layer of polyurethane varnish (not shown) with a thickness of less than 20 μm;
• A wear layer (2a) obtained from an unfilled gelled PVC plastisol;
• A decorative layer (2b) printed by photogravure on the face of the gelled plastisol layer (2c) facing the wear layer (2a) by approximately 0.15 mm;
• A veil of glass fibers (2d) with a surface mass of 55 g/m ² embedded in a layer of gelled plastisol (2c) with a thickness of 0.62 mm;
• A layer of non-woven fabric (3) made of polyester;
• A backing layer (4) consisting of a rigid layer (4b) 4.5 mm thick based on PVC and optionally a damping underlayer (7);

The layers being bonded together to form the multilayer panel (1).

The composition of the rigid layer (4b) is detailed in table 1 below (the designation “% (w/w)” corresponds to the percentage by mass of the constituent relative to the total mass of the composition). Table 1 %(w/w) PCR PVC 25 100 Calcium carbonate (filler) 70 280 Chlorinated polyethylene (CPE) 2 8 Thermal stabilizer (Ca/Zn) 1.3 5.2 Process aids 1.7 6.8

Process aids may in particular include optical brighteners, internal or external lubricants, pigments, titanium dioxide, etc.

The rigid layer (4b) obtained has a modulus value for 1% elongation of 52.3 daN/cm and a flexibility of 105 N for 20 mm of deflection.

Male-female connection or assembly means (6a, 6b) allowing several panels to be assembled are machined on the four sides in the rigid layer (4b). These means make it possible to assemble the blades in a direction perpendicular to the ground and are described in the patent application WO 2016/030627 of the applicant whose content is incorporated in this application.

The nonwoven textile layer (3) and the top layer (2) are bonded together by the impregnation of the gelled plastisol layer (2d). The thickness of the first bonding layer (5a) measured is about 50 μm. In the bond thickness, the fibers of the nonwoven textile layer (3) are completely impregnated by the gelled layer (2d). The rigid layer (4b) and the non-woven fabric layer (3) are bonded by a polyurethane hotmelt adhesive. The thickness of the second bonding layer (5b) is about 50 μm.

The thicknesses and characteristics of each of the assembled panels are described in tables 2 and 3 below. Table 2 Wear layer thickness (2a) Layer thickness (2c) Thickness of the non-woven fabric layer (3) Weight of the non-woven fabric layer (3) Example 1 0.15mm 0.62mm 1mm ^125gsm Example 2 0.15mm 0.62mm 1mm ^125gsm Example 3 0.15mm 0.62mm 1mm ^125gsm Example 4 0.5mm 0.62mm 0.65mm ^80gsm Example 5 0.5mm 0.62mm 0.65mm ^80gsm Example 6 0.5mm 0.62mm 0.65mm ^80gsm Example 7 0.30mm 0.62mm 1.36mm ^180gsm Example 8 0.30mm 0.62mm 1.36mm 180gsm Example 9 0.30mm 0.62mm 1.36mm ^180gsm % impregnation of the thickness of the nonwoven fabric layer (3) by the first bonding layer (5a) % impregnation of the thickness of the nonwoven fabric layer (3) by the second bonding layer (5b) Cushioning underlay thickness (7) Weight of the cushioning underlay (7) Composition of the shock-absorbing underlay (7) Example 1 5% 5% No underlay No underlay Polyester Example 2 5% 5% 1.1mm ^125gsm Polyester Example 3 5% 5% 1.6mm (-/+0.3mm) ^200gsm Polyester Example 4 7.7% 7.7% No underlay No underlay Polyester Example 5 7.7% 7.7% 1.1mm ^125gsm Polyester Example 6 7.7% 7.7% 1.6mm (-/+0.3mm) ^200gsm Polyester Example 7 3.7% 3.7% No underlay No underlay Polyester Example 8 3.7% 3.7% 1.1mm ^125gsm Polyester Example 9 3.7% 3.7% 1.6mm (-/+0.3mm) ^200gsm Polyester

If necessary, the damping underlayer (7) is bonded to the rigid layer (4b) using a double-sided adhesive coated on both sides with acrylic glue.

• D'une couche d'usure transparente
• D'une couche décor, à savoir un film PVC imprimé
• D'une couche d'envers
• Optionnellement d'une sous-couche amortissante

The different examples of panel (1) according to the invention are compared with existing floor coverings. These reference panels are made up successively:

• With a transparent wear layer
• A decorative layer, namely a printed PVC film
• With a back layer
• Optionally a shock-absorbing underlay

The different layers being bonded together to form the reference floor covering. The characteristics of the references are detailed in table 4. Table 4 Wear layer thickness Decor film thickness Backing layer type Back layer thickness Shock-absorbing underlay Reference 1 0.46mm 0.08mm Rigid 4.5mm No Reference 2 0.46mm 0.08mm Rigid 4.5mm Yes: polyolefin foam 1 mm thick and approximately 300 g/m ² Reference 3 0.55mm 0.1mm Non-flexible 4.5mm No

The composition of the rigid backing layers of references 1 and 2 is identical to the composition of the rigid layer (4b) detailed in table 1.

The non-flexible backing layer of reference 3 comprises approximately 33% PVC, 10% plasticizers (DINP), 4% additives (process aids, stabilizers, pigments), 3% PVC particles mixed with glass fibers and 50% fillers. The non-flexible layer obtained has a modulus value for 1% elongation of 21.4 daN/cm and a flexibility of 27.3 N for 20 mm of deflection.

The acoustic properties of references and examples measured in dB are shown in Table 5. Table 5 ISO 10140-3 (sound insulation) ΔLw Walking sound (NFS31-074) L n,e,w Class (NF S31 074) Reference 1 2 80 VS Reference 2 18 76 VS Reference 3 4 77 VS Example 1 15 72 B Example 2 20 72 B Example 3 19 71 B Example 4 11 73 B Example 5 19 73 B Example 6 20 72 B Example 7 16 71 B Example 8 21 71 B Example 9 21 70 B

The results obtained show that the panels (1) according to the invention all reach class B according to standard NF S31 074 for the classification of walking sound (Table 6). The references compared are all less efficient in terms of acoustic insulation and/or noise when walking. The insulation results also show ΔLw values which are always greater than 12db and which can reach 21db for the panels according to the invention. Table 6 Class Level L _n,e,w in dB AT L _n,e,w < 65 B 65 ≤ _Ln,e,w < 75 VS 75 ≤ _Ln,e,w < 85 D 85 ≤ L _n,e,w

In order to compare the shock absorption capacities of the panels according to the invention, references 1 and 3 are also compared with Example 1. The absorption test of shock (EN 14808 standard) is representative of the absorption of energy during a race for an athlete of 1.80m/80kg running a 100m in 10s. Table 7 Measurement 1 (%) Measurement 2 (%) Measure 3 (%) Mean (%) Ref-1 2.3 1.5 2 1.9 Ref-3 1.7 1.9 2.5 2 Example 1 4.6 5.1 4.5 4.7

The results presented in Table 7 show a marked improvement in shock absorption thanks to the panel according to the invention, the values being greater than 3%. Thus the panel makes it possible to limit the transmission of noise in the room where it is laid and also to improve the walking comfort of the floor covering obtained.

Claims (11)

1. A multilayer panel (1) for the production of a floor covering having sound-insulating properties, comprising successively a top layer (2) providing wear-resistance and decorative functions, a non-woven textile layer (3) comprising textile fibres and a back layer (4) comprising at least one non-flexible layer (4a) made from a thermoplastic material, the said layers (2, 3, 4) being bonded together to form the multilayer panel (1), the nonwoven textile layer (3) comprises at least one so-called free thickness in which the textile fibers are free and not impregnated, characterized in that the nonwoven textile layer (3) is constituted by the so-called free thickness bordered by two so-called bonding thicknesses with the top layer (2) and the back layer (4), the sum of the bonding thicknesses is less than or equal to the free thickness
2. Multilayer panel (1) according to claim 1, wherein the back layer (4) comprises at least one rigid layer (4b).
3. Multilayer panel (1) of claim 1, wherein the top layer (2) and the nonwoven textile layer (3) are bonded together by a first bonding layer (5a) impregnating less than 50% of the thickness of the nonwoven textile layer (3).
4. Multilayer panel (1) of claim 3, wherein the first bonding layer (5a) is a gelled plastisol layer.
5. Multilayer panel (1) of claim 3, wherein the first bonding layer (5a) is a hot melt adhesive.
6. Multilayer panel (1) of claim 1, wherein the back layer (4) and the nonwoven textile layer (3) are bonded together by a second bonding layer (5b) impregnating less than 45% of the thickness of the nonwoven textile layer (3).
7. Multilayer panel (1) of claim 6, wherein the second bonding layer (5b) is an adhesive.
8. Multilayer panel (1) according to claim 1, wherein the non-flexible layer (4a) is made from PVC.
9. Multilayer panel (1) according to claim 1, wherein the top layer (2) comprises a reinforcement (2d) embedded in the thickness of the top layer (2).
10. Multilayer panel (1) according to claim 1, wherein the back layer (4) comprises male-female means for connecting or assembling (6a, 6b) a plurality of panels to each other.
11. Multilayer panel (1) according to claim 1, wherein the back layer (4) comprises a damping underlayer (7) intended to be in contact with the floor.

Images