EP3860844A1 - Pvc based, layered floor covering - Google Patents

Pvc based, layered floor covering

Info

Publication number
EP3860844A1
EP3860844A1 EP19772965.0A EP19772965A EP3860844A1 EP 3860844 A1 EP3860844 A1 EP 3860844A1 EP 19772965 A EP19772965 A EP 19772965A EP 3860844 A1 EP3860844 A1 EP 3860844A1
Authority
EP
European Patent Office
Prior art keywords
pvc
layer
textile product
accordance
floor covering
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.)
Pending
Application number
EP19772965.0A
Other languages
German (de)
French (fr)
Inventor
Frederik MARIJSSE
Kristof van Vlassenrode
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.)
Unilin BV
Original Assignee
Flooring Industries Ltd SARL
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 Flooring Industries Ltd SARL filed Critical Flooring Industries Ltd SARL
Publication of EP3860844A1 publication Critical patent/EP3860844A1/en
Pending legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/06—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/06—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
    • D06N3/08—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products with a finishing layer consisting of polyacrylates, polyamides or polyurethanes or polyester
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
    • D06N3/186—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials one of the layers is on one surface of the fibrous web and the other layer is on the other surface of the fibrous web
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0086—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing characterised by the cushion backing, e.g. foamed polyurethane
    • 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
    • E04F15/107—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 composed of several layers, e.g. sandwich panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
    • E04F15/20—Separately-laid insulating layers; Other additional insulating measures; Floating floors for sound insulation
    • E04F15/206—Layered panels for sound insulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0235—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/06—Building materials
    • D06N2211/066—Floor coverings
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2213/00—Others characteristics
    • D06N2213/02—All layers being of the same kind of material, e.g. all layers being of polyolefins, all layers being of polyesters
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2213/00—Others characteristics
    • D06N2213/06—Characteristics of the backing in carpets, rugs, synthetic lawn
    • D06N2213/063—Porous back coating or pre-coat
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
    • E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
    • E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise

Definitions

  • the invention relates to PVC-based, layered floor coverings, and methods for the production of such floor coverings.
  • PVC-based, layered floor coverings are already generally known.
  • the floor coverings known to date have a number of possible drawbacks.
  • the sound damping for continuous noise is not adequate, the floor coverings may possibly show a lasting imprint after point loading (for example by table or chair legs), and floor coverings that are not fully glued to the substrate tend to wrinkle if an object is slid over their surface. All of this is particularly the case if the floor covering is configured as a floor covering that is wall-to-wall, soft, and capable of being rolled up. These floor coverings should also remain flat after being unrolled, which is not always the case.
  • An object of the invention is to provide a PVC-based, layered floor covering that is capable of achieving a good compromise with respect to the above-mentioned drawbacks.
  • a PVC-based, layered floor covering comprising the following successive layers:
  • a decorative layer comprising a polymer layer
  • a wear layer comprising a transparent polymer layer
  • the first PVC layer has a thickness of more than 2.0 mm, consists of foamed PVC and provides the underside of the floor covering.
  • the thickness of the first layer is selected in the range of 2.0 mm to 3.5 mm, more preferably between 2.3 mm and 3.0 mm, for example between 2.4 mm and 2.6 mm .
  • the density of the first PVC layer can be in the range of 0.25 to 1.00 g/cm 3 .
  • the PVC of the first PVC layer preferably has a density of 0.30 to 0.80 g/cm 3 , such as 0.30 to 0.50 g/cm 3 .
  • the PVC of the first PVC layer is foamed.
  • a foamed layer refers to a layer that has hollow cavities, preferably in an amount such that the density of the material is reduced by at least 10%, and preferably even at least 25%, with respect to the weight of an equal volume of thermoplastic material without hollow cavities. Preferably, this is so-called closed cell foam.
  • a non-foamed layer refers to a layer without hollow cavities, or at least, however, with a maximum proportion of hollow cavities such that the density of the material is not reduced, or is reduced by not more than 10%, and preferably even by not more than 2%.
  • the PVC can be chemically or mechanically foamed.
  • the foamed layer is obtained at least by means of a mechanical foaming process.
  • a mechanical foaming process This means that cavities are formed in the layer in question by pressing out the thermoplastic material and replacing it with a gas (such as air), often under the influence of a mechanical action or by blowing in of a gas (such as air) under pressure.
  • the foamed layer is obtained at least by means of a chemical foaming process.
  • a gaseous reaction product for example, azodicarbonamide can be used.
  • this substance releases nitrogen gas that remains present in the foamed layer in the form of bubbles.
  • the foamed layer is obtained at least by means of fillers, wherein these fillers themselves comprise one or more cavities.
  • these fillers themselves comprise one or more cavities.
  • the PVC of the first PVC layer can be a soft PVC.
  • the soft PVC of the first PVC layer comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr.
  • the plasticizers can include, inter alia, esters of carboxylic acids (for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid), for example diisononylphthalate (DINP), dioctyl terephthalate (DOTP), di-isononyl-1 , 2-cyclohexane dicarboxylate (DINCH), esters of phosphoric acid, for example triaryl or trialkylaryl phosphates, for example tricresyl phosphate, chlorinated or non-chlorinated hydrocarbons, ethers, polyesters, polyglycols, sulfonamides, or combinations thereof.
  • esters of carboxylic acids for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid
  • DINP diisononylphthalate
  • DINP dioctyl terephthalate
  • DINCH
  • the PVC of the first PVC layer possibly also comprises fillers, such as glass fibers, calcium hydroxide (slaked lime), calcium carbonate and calcium hydrogencarbonate, and/or CaMg(CC>3)2, talc, or also lightweight fillers such as hollow microspheres (Expancel).
  • the PVC formulation of this PVC layer can comprise fillers to between 10 and 50 wt%, preferably between 15 and 45 wt%, for example between 20 and 45 wt%.
  • the above-mentioned percent by weight (wt%) is expressed as the weight of the filler with respect to the weight of the entire polymer formulation, in this case PVC, in which the filler is contained.
  • this PVC can comprise additives such as pigments and dyes, preservatives, antifungal agents, thermal stabilizers, UV stabilizers, blowing agents, viscosity regulators, and the like.
  • the PVC of the second PVC layer can be a soft PVC.
  • the soft PVC of the second PVC layer comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 30 to 60 phr. “Phr” stands for parts by weight of plasticizer per hundred parts by weight of PVC.
  • the plasticizers can include, inter alia, esters of carboxylic acids (for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid), for example diisononylphthalate (DINP), dioctyl terephthalate (DOTP), di-isononyl-1 , 2-cyclohexane dicarboxylate (DINCH), esters of phosphoric acid, for example triaryl or trialkylaryl phosphates, for example tricresyl phosphate, chlorinated or non-chlorinated hydrocarbons, ethers, polyesters, polyglycols, sulfonamides, or combinations thereof.
  • esters of carboxylic acids for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid
  • DINP diisononylphthalate
  • DINP dioctyl terephthalate
  • DINCH
  • the PVC of the second PVC layer possibly also comprises fillers, such as glass fibers, calcium hydroxide (slaked lime), calcium carbonate and calcium hydrogencarbonate, and/or CaMg(CC>3)2, talc, or also lightweight fillers such as hollow microspheres (Expancel).
  • the PVC formulation of this PVC layer can comprise fillers to between 10 and 60 wt%, preferably between 15 and 45 wt%, for example between 15 and 35 wt%.
  • the above-mentioned percent by weight (wt%) is expressed as the weight of the filler with respect to the weight of the entire polymer formulation, in this case PVC, in which the filler is contained.
  • this PVC can comprise additives such as pigments and dyes, preservatives, antifungal agents, thermal stabilizers, UV stabilizers, blowing agents, viscosity regulators, and the like.
  • the PVC of the second PVC layer can be unfoamed. In accordance with other embodiments, the PVC of the second PVC layer can be foamed.
  • the PVC of the second PVC layer preferably has a density of 0.30 to 0.80 g/cm 3 , such as 0.30 to 0.50 g/cm 3 .
  • the PVC of the second PVC layer can be foamed in accordance with the methods described above.
  • the foamed PVC of the second PVC layer can be foamed in a similar, identical or different manner compared to the foamed PVC of the first PVC layer.
  • the PVC of the second PVC layer can also be unfoamed, and then has a density of for example more than 1 g/cm 3 , for example between 1.2 and 1.9 g/cm 3 , such as 1.3 to 1.6 g/cm 3 .
  • the thickness of the second layer is selected in the range of 0.2 mm to 2 mm, more preferably between 0.3 mm and 1.2 mm, for example between 0.4 mm and 0.8 mm .
  • a layer of a first PVC permeated textile product is provided.
  • This first textile product is preferably a textile product comprising glass fibers, such as a glass fiber nonwoven or a glass fiber woven.
  • a glass fiber nonwoven is used, which preferably can have a surface weight of between 30 and 60 g/m 2 and a thickness of between 0.20 and 0.45 mm, for example between 0.25 and 0.45mm.
  • the first textile product can be partially impregnated with the PVC of the second PVC layer and partially impregnated with the PVC of the first PVC layer, so that first textile product is permeated with PVC.
  • the first textile product can be completely permeated, and therefore permeated, with the PVC of the first PVC layer.
  • the first textile product can be completely permeated, and therefore permeated, with the PVC of the second PVC layer.
  • the first textile product can be permeated with a PVC that is either identical to the PVC of the first PVC layer, identical to the PVC of the second PVC layer, or completely different from the PVCs used for the production of the first and second PVC layer.
  • the first PVC permeated textile product therefore comes into contact with the second PVC layer on a first side of the second PVC layer.
  • this first textile product is permeated by this second PVC layer.
  • this second PVC layer is brought into contact with a second textile product, which is a part of a layer of a second PVC permeated textile product.
  • This second textile product is preferably a textile product comprising glass fibers such as a glass fiber nonwoven or a glass fiber woven.
  • This second textile product can, but does not have to be, the same product as the first textile product.
  • a glass fiber nonwoven is used for this second textile product that preferably can have a surface weight of between 30 and 60 g/m 2 and a thickness of between 0.20 and 0.45 mm, for example between 0.25 and 0.45 mm.
  • the second textile product can be permeated with the PVC that is either identical to the PVC of the first PVC layer, identical to the PVC of the second PVC layer, or completely different from the PVCs used for the production of the first and second PVC layer.
  • the second textile product can be permeated with the PVC that is different from the PVC of the first and the second PVC layer.
  • a PVC is used for the permeation of the second textile product, more preferably a soft PVC.
  • a PVC with a density of for example more than 1 g/cm 3 is used, for example between 1.2 and 1.9 g/cm 3 , such as 1.3 to 1.6 g/cm 3 .
  • this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr.
  • the thickness of the layer of the second with PVC permeated textile product is between 0.3 and 0.4mm.
  • the second PVC permeated textile product therefore comes into contact with the second PVC layer on a first side of the PVC permeated textile product. On the second side of the second PVC permeated textile product, this second PVC permeated textile product is brought into contact with a decorative layer.
  • This decorative layer comprises a polymer layer, typically again PVC, which has the purpose of determining the final outer appearance of the floor covering.
  • a decorative pattern or motif can be applied to this polymer layer, for example with ink, such as waterproof inks.
  • this pattern or motif is not more than one uniform color other than the color of the polymer used.
  • the polymer is dyed in the mass.
  • a PVC is used for the provision of the decorative layer, more preferably soft PVC.
  • a PVC with a density of for example more than 1 g/cm 3 is used, for example between 1.2 and 1.9 g/cm 3 , such as 1.3 to 1.6 g/cm 3 .
  • this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr.
  • this PVC layer preferably comprises Ti02, preferably larger amounts of Ti02.
  • the polymer of the decorative layer can be PVC.
  • the polymer of the decorative layer can be foamed PVC.
  • the polymer of the decorative layer can be unfoamed PVC.
  • the thickness of the decorative layer is between the 0.1 and 0.6 mm, for example between 0.15 and 0.25 mm.
  • a wear layer is provided on the side opposite the side of the decorative layer that comes into contact with the second textile product permeated with PVC.
  • This wear layer comprises a transparent polymer layer, again preferably transparent PVC.
  • the polymer of the wear layer can be PVC.
  • a PVC with a density of for example more than 1 g/cm 3 is used, for example between 1.1 and 1.6 g/cm 3 , such as 1.15 to 1.35 g/cm 3 .
  • this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr.
  • this PVC layer is not filled, and therefore comprises no fillers.
  • the thickness of the wear layer is between 0.1 and 0.7 mm, for example between 0.35 and 0.55.
  • This lacquer is preferably a polyurethane (PU) lacquer, with a surface weight of preferably between 10 and 30 g/m 2 , and a thickness of between 10 and 30 pm.
  • PU polyurethane
  • the floor covering in accordance with this first aspect of the invention has a number of advantages.
  • the floor covering can be rolled up, i.e. can be provided on a roll, for example a roll 2 to 4 meters in width and for example up to 20 or 30 meters in length, but behaves as a flat surface once it is unrolled onto a flat substrate. It remains dimensionally stable and shows little or no wrinkle formation when objects, for example furniture, are slid over the surface, and this without gluing the floor covering to the substrate.
  • the floor covering also provides an improvement in contact sound insulation ALw of 20 dB: this is the sound damping for continuous sound.
  • the determination of improvement in the contact sound insulation ALw is measured in accordance with the standards NF EN ISO 10140-1 (2013), NF EN ISO 10140-3 (2013), NF EN ISO 10140- 4 (2013) and NF EN ISO 10140-5 (2013), supplemented by standard NF EN ISO 717/2 (2013) and annexes.
  • the resistance to point load is also adequate.
  • the floor covering can be between 2 and 4 meters wide and 20 to 30 meter long.
  • the floor covering can be provided in rolled-up form.
  • a method for producing a floor covering comprising the following successive steps:
  • the provision of a first PVC permeated textile product can comprise the following steps:
  • the application to the second side of the permeated textile product of a PVC can comprise the following steps:
  • step e can take place before step d.ii, wherein the PVC penetrates into the further textile product in order to permeate the further textile product.
  • the application to the further textile product of a layer of foamable or foamed PVC can comprise the following steps:
  • the method can comprise the following steps:
  • this plastisol brings about the second PVC layer of the floor covering in accordance with the first aspect of the invention.
  • the third PVC plastisol applied in step f.i after gelling, this plastisol brings about the first PVC layer of the floor covering in accordance with the first aspect of the invention.
  • a lacquer layer can be applied to the wear layer.
  • step e can take place before d.ii, and wherein the PVC plastisol of step d.i penetrates into the further textile product in order to permeate the further textile product.
  • the PVC plastisol can penetrate into the further textile product in order to permeate the textile product.
  • the pregelling takes place via a drying step, wherein the PVC plastisol is partially dried and is dried such that it is suitable for receiving the following layer.
  • Step a provides the PVC permeated second textile product of the floor covering in accordance with the first aspect of the invention.
  • the steps can take place by applying the PVC plastisol to one or both sides of the textile product. Using a doctor blade, the plastisol can be pressed into the textile product.
  • the polymer applied in step b provides the floor covering in accordance with the first aspect of the invention with a decorative layer.
  • a decorative pattern can be applied during step b.
  • the polymer applied in step c provides the floor covering in accordance with the first aspect of the invention with a wear layer.
  • the polymer of the decorative layer in step b, can be a PVC plastisol and wherein step b comprises the pregelling of this PVC plastisol.
  • the polymer of the decorative layer in step c, can be a PVC plastisol and wherein step c comprises the pregelling of this PVC plastisol.
  • the textile product impregnated with a first PVC material is provided by extrusion of the PVC material on or around the textile product.
  • the decorative layer and/or the wear layer can be applied by thermal lamination to the underlying layer, or the layer can be provided by extrusion of the corresponding PVC material onto the underlying layer.
  • the layer of a second PVC can be provided by thermally laminating one or more layers of the corresponding PVC onto the underlying layer, or the layer can be provided via extrusion of the corresponding PVC material onto the underlying layer.
  • the layer of a third, foamable or foamed PVC can be provided by thermally laminating one or more layers of the corresponding PVC onto the underlying layer, or the layer can be provided via extrusion of the corresponding PVC material onto the underlying layer.
  • the method in accordance with a second aspect of the invention can be used for producing a floor covering in accordance with the first aspect of the invention.
  • Fig. 1 is a schematic representation of a production process in accordance with the invention.
  • Fig. 2 is a schematic representation of a cross-section of a floor covering in accordance with the invention.
  • an object comprising the elements A and B is therefore not limited to an object that only comprises the elements A and B.
  • a method comprising the steps A and B is not limited to a method that only comprises the steps A and B.
  • Fig. 1 schematically shows a production method for producing a floor covering in accordance with the invention.
  • a first textile product for example a glass fiber nonwoven 1 10
  • a first station 120 for the application of a first PVC plastisol 122.
  • the plastisol is pressed into the nonwoven, so that a textile product 130 permeated with PVC plastisol is obtained.
  • the plastisol 122 is pregelled at a first drying station 140.
  • a PVC plastisol 152 is applied via a second station 150 in order to provide a decorative layer. Again with a doctor blade 154, the thickness of this layer of plastisol is set. The plastisol 152 is pregelled at a second drying station 160. After the application of a decorative pattern by means of a printing station 170, a transparent PVC plastisol 182 is then applied via a third station 180 in order to provide a wear layer. Again with a doctor blade 184, the thickness of this layer of plastisol is set. The plastisol 182 is pregelled at a third drying station 190.
  • the printing station can be a digital printer, but can just as well be a rotogravure cylinder for rotary printing. In the case of rotary printing, it is possible that the intermediate product is again turned before and after the printer in order to position the printing roll under the product to be printed.
  • the intermediate product is turned so that the second side of the textile product 130 permeated with plastisol is turned upward.
  • a further PVC plastisol layer 212 is then applied at a station 210. Again with a doctor blade 214, the thickness of this PVC plastisol layer is set.
  • This plastisol can optionally be a foamable plastisol.
  • a further textile product 11 1 is brought into contact with the wet PVC plastisol 212, and by means of a light pressure exerted for example by the roll 220, the PVC plastisol 212 partially impregnates the further textile product 1 11 , for example a glass fiber nonwoven.
  • the PVC plastisol 212 is pregelled.
  • a layer of a foamable PVC plastisol 242 is applied at station 240, wherein again the doctor blade 244 is to determine the thickness of the applied layer.
  • the plastisol 242 is first pregelled in an oven 250, and all of the layers of plastisol are then to be gelled in this oven. During this passage through the oven 250, all of the pregelled plastisols are to be further gelled, and the foamable plastisol or plastisols are to foam.
  • the pregelling of plastisol 242 and gelling of all of the layers of plastisol can also be carried out in one step and in one oven.
  • the product obtained is turned at turning station 260, after which a UV-hardened PU lacquer layer is applied by means of a lick roller 270 and is hardened with UV at station 280.
  • the floor covering 300 thus obtained can be rolled up at rolling-up station 290.
  • the product obtained 300 has a cross section as schematically shown in Fig. 2. As the representation is schematic, the thicknesses as shown are not metrically representative.
  • the PVC-based, layered floor covering comprises successive layers, specifically:
  • a second layer 1210 of PVC derived from PVC plastisol 212 a second layer 1210 of PVC derived from PVC plastisol 212; d. a layer of a textile product permeated with PVC 1 130, which comprises the textile product 110 that is permeated with PVC plastisol 122;
  • a decorative layer 1 150 comprising a polymer layer derived from the PVC plastisol 152 and the decorative pattern;
  • a wear layer 1180 comprising a transparent polymer layer derived from the PVC plastisol 182;
  • the PVC plastisol of PVC layer 1240 is a soft PVC with a density of 0.3 to 0.4 g/cm 3 . It comprises approximately 30 wt% of filler and 60 phr of plasticizer.
  • PVC plastisol of PVC layer 1210 is a soft PVC with a density of 1.3 to 1.4 g/cm 3 . It comprises approximately 20 wt% of filler and 40 phr of plasticizer.
  • the PVC of the PVC permeated textile product 1 130 is a soft PVC with a density of 1.5 to 1.6 g/cm 3 . It comprises approximately 40 wt% of filler and 60 phr of plasticizer.
  • the PVC of the decorative layer comprises soft PVC with a density of 1.5 to 1.6 g/cm 3 . It comprises approximately 40 wt% of filler and 60 phr of plasticizer.
  • the PVC of the wear layer comprises soft PVC with a density of 1.2 to 1.3 g/cm 3 . It comprises no filler and comprises 40 phr of plasticizer.
  • All of the PVCs are obtained by emulsion or (micro)suspension polymerization and have a K value of between 50 and 90.
  • Textile product 110 is a glass fiber nonwoven with a surface weight of 35 g/m 2 and a thickness of approximately 0.3 mm.
  • Textile product 11 1 is a glass fiber nonwoven with a surface weight of 50 g/m 2 and a thickness of approximately 0.4 mm.
  • PU lacquer is applied in an amount of 20 g/m 2 and a thickness of 20 pm. A 100% solid UV lacquer is used.
  • the ALw is 20 dB: this value represents the improvement in contact sound insulation by means of using the product.
  • the product like all products in accordance with the invention, has particularly favorable values in terms of expansion under the influence of temperature.
  • the above-mentioned product was subjected to a dilation test in accordance with EN ISO 23999.
  • a product identical to the above-mentioned product but with a glass fiber reinforcement was subjected to the test in a similar manner. For both the production direction and the direction perpendicular to the production direction, it was found that by using two glass fiber reinforcements, a reduction in expansion by 50% was obtained.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Textile Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)

Abstract

A PVC-based, layered floor covering, comprising the following successive layers: a. a first PVC layer; b. a layer of a first PVC permeated textile product; c. a second PVC layer; d. a layer of a second PVC permeated textile product; e. a decorative layer comprising a polymer layer; f. a wear layer comprising a transparent polymer layer; wherein the first PVC layer has a thickness of more than 2.0 mm, consists of foamed PVC and provides the underside of the floor covering.

Description

PVC- BASED, LAYERED FLOOR COVERING
Technical field
The invention relates to PVC-based, layered floor coverings, and methods for the production of such floor coverings.
Prior art
PVC-based, layered floor coverings are already generally known. The floor coverings known to date have a number of possible drawbacks. As is generally the case, the sound damping for continuous noise is not adequate, the floor coverings may possibly show a lasting imprint after point loading (for example by table or chair legs), and floor coverings that are not fully glued to the substrate tend to wrinkle if an object is slid over their surface. All of this is particularly the case if the floor covering is configured as a floor covering that is wall-to-wall, soft, and capable of being rolled up. These floor coverings should also remain flat after being unrolled, which is not always the case.
Summary of the invention
An object of the invention is to provide a PVC-based, layered floor covering that is capable of achieving a good compromise with respect to the above-mentioned drawbacks.
In accordance with a first aspect, a PVC-based, layered floor covering is provided, comprising the following successive layers:
a. a first PVC layer;
b. a layer of a first PVC permeated textile product;
c. a second PVC layer;
d. a layer of a second PVC permeated textile product;
e. a decorative layer comprising a polymer layer;
f. a wear layer comprising a transparent polymer layer;
wherein the first PVC layer has a thickness of more than 2.0 mm, consists of foamed PVC and provides the underside of the floor covering. Preferably, the thickness of the first layer is selected in the range of 2.0 mm to 3.5 mm, more preferably between 2.3 mm and 3.0 mm, for example between 2.4 mm and 2.6 mm .
In accordance with embodiments, the density of the first PVC layer can be in the range of 0.25 to 1.00 g/cm3. The PVC of the first PVC layer preferably has a density of 0.30 to 0.80 g/cm3, such as 0.30 to 0.50 g/cm3. The PVC of the first PVC layer is foamed. A foamed layer refers to a layer that has hollow cavities, preferably in an amount such that the density of the material is reduced by at least 10%, and preferably even at least 25%, with respect to the weight of an equal volume of thermoplastic material without hollow cavities. Preferably, this is so-called closed cell foam. A non-foamed layer refers to a layer without hollow cavities, or at least, however, with a maximum proportion of hollow cavities such that the density of the material is not reduced, or is reduced by not more than 10%, and preferably even by not more than 2%.
The PVC can be chemically or mechanically foamed.
In accordance with a first possibility, the foamed layer is obtained at least by means of a mechanical foaming process. This means that cavities are formed in the layer in question by pressing out the thermoplastic material and replacing it with a gas (such as air), often under the influence of a mechanical action or by blowing in of a gas (such as air) under pressure.
In accordance with a second possibility, the foamed layer is obtained at least by means of a chemical foaming process. This means that cavities are formed in the layer in question by means of a gaseous reaction product. For example, azodicarbonamide can be used. On heating, this substance releases nitrogen gas that remains present in the foamed layer in the form of bubbles.
In accordance with a third possibility, the foamed layer is obtained at least by means of fillers, wherein these fillers themselves comprise one or more cavities. For example, one can make use of the expanded state of the above-mentioned microspheres. More particularly, one can make use of the microspheres known from WO 2013/178561. Or it can be obtained by using expanded granules in a PVC-based layer. In accordance with embodiments, the PVC of the first PVC layer can be a soft PVC. Preferably, the soft PVC of the first PVC layer comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr. “Phr” stands for parts by weight of plasticizer per hundred parts by weight of PVC. The plasticizers can include, inter alia, esters of carboxylic acids (for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid), for example diisononylphthalate (DINP), dioctyl terephthalate (DOTP), di-isononyl-1 , 2-cyclohexane dicarboxylate (DINCH), esters of phosphoric acid, for example triaryl or trialkylaryl phosphates, for example tricresyl phosphate, chlorinated or non-chlorinated hydrocarbons, ethers, polyesters, polyglycols, sulfonamides, or combinations thereof.
The PVC of the first PVC layer possibly also comprises fillers, such as glass fibers, calcium hydroxide (slaked lime), calcium carbonate and calcium hydrogencarbonate, and/or CaMg(CC>3)2, talc, or also lightweight fillers such as hollow microspheres (Expancel). The PVC formulation of this PVC layer can comprise fillers to between 10 and 50 wt%, preferably between 15 and 45 wt%, for example between 20 and 45 wt%. The above-mentioned percent by weight (wt%) is expressed as the weight of the filler with respect to the weight of the entire polymer formulation, in this case PVC, in which the filler is contained.
Furthermore, this PVC can comprise additives such as pigments and dyes, preservatives, antifungal agents, thermal stabilizers, UV stabilizers, blowing agents, viscosity regulators, and the like.
In accordance with embodiments, the PVC of the second PVC layer can be a soft PVC. Preferably, the soft PVC of the second PVC layer comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 30 to 60 phr. “Phr” stands for parts by weight of plasticizer per hundred parts by weight of PVC. The plasticizers can include, inter alia, esters of carboxylic acids (for example esters of ortho- or terephthalic acid, trimellitic acid, benzoic acid and adipic acid), for example diisononylphthalate (DINP), dioctyl terephthalate (DOTP), di-isononyl-1 , 2-cyclohexane dicarboxylate (DINCH), esters of phosphoric acid, for example triaryl or trialkylaryl phosphates, for example tricresyl phosphate, chlorinated or non-chlorinated hydrocarbons, ethers, polyesters, polyglycols, sulfonamides, or combinations thereof. The PVC of the second PVC layer possibly also comprises fillers, such as glass fibers, calcium hydroxide (slaked lime), calcium carbonate and calcium hydrogencarbonate, and/or CaMg(CC>3)2, talc, or also lightweight fillers such as hollow microspheres (Expancel). The PVC formulation of this PVC layer can comprise fillers to between 10 and 60 wt%, preferably between 15 and 45 wt%, for example between 15 and 35 wt%. The above-mentioned percent by weight (wt%) is expressed as the weight of the filler with respect to the weight of the entire polymer formulation, in this case PVC, in which the filler is contained.
Furthermore, this PVC can comprise additives such as pigments and dyes, preservatives, antifungal agents, thermal stabilizers, UV stabilizers, blowing agents, viscosity regulators, and the like.
In accordance with certain embodiments, the PVC of the second PVC layer can be unfoamed. In accordance with other embodiments, the PVC of the second PVC layer can be foamed.
The PVC of the second PVC layer preferably has a density of 0.30 to 0.80 g/cm3, such as 0.30 to 0.50 g/cm3. The PVC of the second PVC layer can be foamed in accordance with the methods described above. The foamed PVC of the second PVC layer can be foamed in a similar, identical or different manner compared to the foamed PVC of the first PVC layer.
The PVC of the second PVC layer can also be unfoamed, and then has a density of for example more than 1 g/cm3, for example between 1.2 and 1.9 g/cm3, such as 1.3 to 1.6 g/cm3.
Preferably, the thickness of the second layer is selected in the range of 0.2 mm to 2 mm, more preferably between 0.3 mm and 1.2 mm, for example between 0.4 mm and 0.8 mm .
Between this first PVC layer and this second PVC layer, a layer of a first PVC permeated textile product is provided. This first textile product is preferably a textile product comprising glass fibers, such as a glass fiber nonwoven or a glass fiber woven. Preferably, a glass fiber nonwoven is used, which preferably can have a surface weight of between 30 and 60 g/m2 and a thickness of between 0.20 and 0.45 mm, for example between 0.25 and 0.45mm.
In accordance with embodiments, the first textile product can be partially impregnated with the PVC of the second PVC layer and partially impregnated with the PVC of the first PVC layer, so that first textile product is permeated with PVC.
In accordance with embodiments, the first textile product can be completely permeated, and therefore permeated, with the PVC of the first PVC layer.
In accordance with embodiments, the first textile product can be completely permeated, and therefore permeated, with the PVC of the second PVC layer.
This permeation can be achieved during the production process for producing a floor covering in accordance with the second aspect of the invention. In accordance with alternative embodiments, the first textile product can be permeated with a PVC that is either identical to the PVC of the first PVC layer, identical to the PVC of the second PVC layer, or completely different from the PVCs used for the production of the first and second PVC layer.
The first PVC permeated textile product therefore comes into contact with the second PVC layer on a first side of the second PVC layer. Optionally, this first textile product is permeated by this second PVC layer.
On the second, opposite side of the second PVC layer, this second PVC layer is brought into contact with a second textile product, which is a part of a layer of a second PVC permeated textile product.
This second textile product is preferably a textile product comprising glass fibers such as a glass fiber nonwoven or a glass fiber woven. This second textile product can, but does not have to be, the same product as the first textile product.
Preferably, a glass fiber nonwoven is used for this second textile product that preferably can have a surface weight of between 30 and 60 g/m2 and a thickness of between 0.20 and 0.45 mm, for example between 0.25 and 0.45 mm. In accordance with embodiments, the second textile product can be permeated with the PVC that is either identical to the PVC of the first PVC layer, identical to the PVC of the second PVC layer, or completely different from the PVCs used for the production of the first and second PVC layer.
In accordance with embodiments, the second textile product can be permeated with the PVC that is different from the PVC of the first and the second PVC layer.
Preferably, a PVC is used for the permeation of the second textile product, more preferably a soft PVC. Preferably, a PVC with a density of for example more than 1 g/cm3 is used, for example between 1.2 and 1.9 g/cm3, such as 1.3 to 1.6 g/cm3.
Preferably, this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr.
Preferably, the thickness of the layer of the second with PVC permeated textile product is between 0.3 and 0.4mm.
The second PVC permeated textile product therefore comes into contact with the second PVC layer on a first side of the PVC permeated textile product. On the second side of the second PVC permeated textile product, this second PVC permeated textile product is brought into contact with a decorative layer.
This decorative layer comprises a polymer layer, typically again PVC, which has the purpose of determining the final outer appearance of the floor covering. A decorative pattern or motif can be applied to this polymer layer, for example with ink, such as waterproof inks. Optionally, this pattern or motif is not more than one uniform color other than the color of the polymer used. In an alternative form, the polymer is dyed in the mass.
Preferably, a PVC is used for the provision of the decorative layer, more preferably soft PVC. Preferably, a PVC with a density of for example more than 1 g/cm3 is used, for example between 1.2 and 1.9 g/cm3, such as 1.3 to 1.6 g/cm3. Preferably, this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr. In order to make the layer opaque or white, this PVC layer preferably comprises Ti02, preferably larger amounts of Ti02.
In accordance with embodiments, the polymer of the decorative layer can be PVC.
In accordance with embodiments, the polymer of the decorative layer can be foamed PVC.
In accordance with embodiments, the polymer of the decorative layer can be unfoamed PVC.
Preferably, the thickness of the decorative layer is between the 0.1 and 0.6 mm, for example between 0.15 and 0.25 mm.
On the side opposite the side of the decorative layer that comes into contact with the second textile product permeated with PVC, a wear layer is provided.
This wear layer comprises a transparent polymer layer, again preferably transparent PVC.
In accordance with embodiments, the polymer of the wear layer can be PVC.
Preferably, a PVC with a density of for example more than 1 g/cm3 is used, for example between 1.1 and 1.6 g/cm3, such as 1.15 to 1.35 g/cm3.
Preferably, this soft PVC comprises plasticizers, in an amount of 15 to 100 phr, and preferably in an amount of 30 to 100 phr, for example 50 to 80 phr. Preferably, this PVC layer is not filled, and therefore comprises no fillers.
Preferably, the thickness of the wear layer is between 0.1 and 0.7 mm, for example between 0.35 and 0.55.
Possibly, on the wear layer, on the side that does not come into contact with the decorative layer, another lacquer layer can be applied. This lacquer is preferably a polyurethane (PU) lacquer, with a surface weight of preferably between 10 and 30 g/m2, and a thickness of between 10 and 30 pm.
The floor covering in accordance with this first aspect of the invention has a number of advantages. The floor covering can be rolled up, i.e. can be provided on a roll, for example a roll 2 to 4 meters in width and for example up to 20 or 30 meters in length, but behaves as a flat surface once it is unrolled onto a flat substrate. It remains dimensionally stable and shows little or no wrinkle formation when objects, for example furniture, are slid over the surface, and this without gluing the floor covering to the substrate. The floor covering also provides an improvement in contact sound insulation ALw of 20 dB: this is the sound damping for continuous sound. The determination of improvement in the contact sound insulation ALw is measured in accordance with the standards NF EN ISO 10140-1 (2013), NF EN ISO 10140-3 (2013), NF EN ISO 10140- 4 (2013) and NF EN ISO 10140-5 (2013), supplemented by standard NF EN ISO 717/2 (2013) and annexes. The resistance to point load is also adequate.
In accordance with embodiments, the floor covering can be between 2 and 4 meters wide and 20 to 30 meter long. The floor covering can be provided in rolled-up form.
In accordance with a second aspect of the invention, a method is provided for producing a floor covering. The method for producing a floor covering in accordance with the second aspect comprising the following successive steps:
a. the provision of a first PVC permeated textile product that corresponds to the second PVC permeated textile product of the floor covering in accordance with the first aspect of the invention;
b. the application, to a first side of the permeated textile product, of the polymer layer of the decorative layer;
c. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,
d. the application, to the second side of the permeated textile product, of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with the first aspect of the invention;
e. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first PVC permeated textile product of the floor covering in accordance with the first aspect of the invention;
f. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with the first aspect of the invention, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state.
In accordance with certain embodiments, the provision of a first PVC permeated textile product can comprise the following steps:
a.i.- the provision of a textile product;
a.ii.- the permeation of this textile product with a first PVC plastisol; a.iii.- the pregelling of the first PVC plastisol.
In accordance with certain embodiments, the application to the second side of the permeated textile product of a PVC can comprise the following steps:
d.i.- the application, to the second side of the permeated textile product, of a PVC plastisol;
d.ii.- the pregelling of this PVC plastisol.
In accordance with certain embodiments, step e can take place before step d.ii, wherein the PVC penetrates into the further textile product in order to permeate the further textile product.
In accordance with certain embodiments, the application to the further textile product of a layer of foamable or foamed PVC can comprise the following steps:
f.i.- the application to the further textile product of a layer of foamable or foamed PVC plastisol;
f.ii.- optionally, the pregelling of this PVC plastisol.
In accordance with certain embodiments, the method can comprise the following steps:
a. the provision of a first PVC material permeated textile product that corresponds to the second PVC permeated textile product of the floor covering in accordance with the first aspect of the invention, comprising i. the provision of a textile product;
ii. the impregnation of this textile product with a PVC plastisol; iii. the pregelling of the first PVC plastisol;
b. the application, to a first side of the impregnated textile product, of the polymer layer of the decorative layer;
c. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,
d. the application of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with the first aspect of the invention comprising
i. the application, to the second side of the impregnated textile product, of a PVC plastisol layer;
ii. the pregelling of this PVC plastisol;
e. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first PVC permeated textile product of the floor covering in accordance with the first aspect of the invention;
f. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with the first aspect of the invention, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state, comprising
i. the application to the further textile product of a layer of a foamable PVC plastisol, which is to have a thickness of more than 2 mm in a foamed and gelled state;
ii. optionally, the pregelling of this PVC plastisol;
g. the gelling of all PVC plastisols.
As a result of the second PVC plastisol applied in step d.i, after gelling, this plastisol brings about the second PVC layer of the floor covering in accordance with the first aspect of the invention. As a result of the third PVC plastisol applied in step f.i, after gelling, this plastisol brings about the first PVC layer of the floor covering in accordance with the first aspect of the invention.
In accordance with certain embodiments, after step g, a lacquer layer can be applied to the wear layer. In accordance with certain embodiments, step e can take place before d.ii, and wherein the PVC plastisol of step d.i penetrates into the further textile product in order to permeate the further textile product.
In accordance with certain embodiments, during step f, the PVC plastisol can penetrate into the further textile product in order to permeate the textile product.
The pregelling takes place via a drying step, wherein the PVC plastisol is partially dried and is dried such that it is suitable for receiving the following layer.
Step a provides the PVC permeated second textile product of the floor covering in accordance with the first aspect of the invention. In the case of steps a.i to a.iii, the steps can take place by applying the PVC plastisol to one or both sides of the textile product. Using a doctor blade, the plastisol can be pressed into the textile product.
The polymer applied in step b provides the floor covering in accordance with the first aspect of the invention with a decorative layer.
In accordance with certain embodiments, during step b, a decorative pattern can be applied.
The polymer applied in step c provides the floor covering in accordance with the first aspect of the invention with a wear layer.
In accordance with certain embodiments, in step b, the polymer of the decorative layer can be a PVC plastisol and wherein step b comprises the pregelling of this PVC plastisol.
In accordance with certain embodiments, in step c, the polymer of the decorative layer can be a PVC plastisol and wherein step c comprises the pregelling of this PVC plastisol.
In accordance with alternative embodiments, the textile product impregnated with a first PVC material is provided by extrusion of the PVC material on or around the textile product. In accordance with alternative embodiments, the decorative layer and/or the wear layer can be applied by thermal lamination to the underlying layer, or the layer can be provided by extrusion of the corresponding PVC material onto the underlying layer.
In accordance with still further embodiments, the layer of a second PVC can be provided by thermally laminating one or more layers of the corresponding PVC onto the underlying layer, or the layer can be provided via extrusion of the corresponding PVC material onto the underlying layer.
In accordance with still further embodiments, the layer of a third, foamable or foamed PVC can be provided by thermally laminating one or more layers of the corresponding PVC onto the underlying layer, or the layer can be provided via extrusion of the corresponding PVC material onto the underlying layer.
The method in accordance with a second aspect of the invention can be used for producing a floor covering in accordance with the first aspect of the invention.
The independent and dependent claims describe specific and preferred features of the embodiments of the invention. Features of the dependent claims can be combined with features of the independent and dependent claims, and this in any suitable manner that would be clear to a person skilled in the art.
The above-mentioned and other features, characteristics and advantages of the present invention are to be clarified by means of the following examples of embodiments, optionally in combination with the drawings.
The description of these examples of embodiments is given as a clarification, without intending to limit the scope of the invention. The reference numbers in the following description refer to the drawings. The same reference numbers in any different figures refer to identical or similar elements.
Brief description of the figures
In order to better demonstrate the features of the invention, several preferred embodiments are described below as examples that are not in any way limitative, with reference to the accompanying drawings, wherein: • Fig. 1 is a schematic representation of a production process in accordance with the invention.
• Fig. 2 is a schematic representation of a cross-section of a floor covering in accordance with the invention.
Description of examples of embodiments
The present invention is described below by means of specific embodiments.
It is to be noted that the term "comprising", as used in the claims, must not be interpreted in a limitative sense as being limited to the following elements, features and/or steps. The term "comprising" does not exclude the presence of other elements, features or steps.
The scope of the term "an object comprising the elements A and B" is therefore not limited to an object that only comprises the elements A and B. The scope of the term "a method comprising the steps A and B" is not limited to a method that only comprises the steps A and B.
In the sense of the present invention, these terms simply mean that the relevant elements or steps for the invention are the elements or steps A and B.
In the following specification, reference is made to "an embodiment” or "the embodiment". Such a reference means that a specific element or feature described by means of this embodiment is contained in at least this one embodiment.
However, the presence of the terms "in an embodiment" or "in embodiments" at various places in this description does not necessarily refer to the same embodiment, although it may refer to the same embodiment.
Furthermore, the characteristics or the features can be combined into one or more embodiments in any suitable manner that would be clear to the person skilled in the art.
Fig. 1 schematically shows a production method for producing a floor covering in accordance with the invention. A first textile product, for example a glass fiber nonwoven 1 10, is unrolled and supplied to a first station 120 for the application of a first PVC plastisol 122. By means of a doctor blade 124, the plastisol is pressed into the nonwoven, so that a textile product 130 permeated with PVC plastisol is obtained. The plastisol 122 is pregelled at a first drying station 140.
On a first side of the permeated textile product 130, a PVC plastisol 152 is applied via a second station 150 in order to provide a decorative layer. Again with a doctor blade 154, the thickness of this layer of plastisol is set. The plastisol 152 is pregelled at a second drying station 160. After the application of a decorative pattern by means of a printing station 170, a transparent PVC plastisol 182 is then applied via a third station 180 in order to provide a wear layer. Again with a doctor blade 184, the thickness of this layer of plastisol is set. The plastisol 182 is pregelled at a third drying station 190. The printing station can be a digital printer, but can just as well be a rotogravure cylinder for rotary printing. In the case of rotary printing, it is possible that the intermediate product is again turned before and after the printer in order to position the printing roll under the product to be printed.
At a turning station 200, the intermediate product is turned so that the second side of the textile product 130 permeated with plastisol is turned upward. On this side of the textile product 130 permeated with plastisol, a further PVC plastisol layer 212 is then applied at a station 210. Again with a doctor blade 214, the thickness of this PVC plastisol layer is set. This plastisol can optionally be a foamable plastisol.
A further textile product 11 1 is brought into contact with the wet PVC plastisol 212, and by means of a light pressure exerted for example by the roll 220, the PVC plastisol 212 partially impregnates the further textile product 1 11 , for example a glass fiber nonwoven.
At drying station 230, the PVC plastisol 212 is pregelled.
Subsequently, a layer of a foamable PVC plastisol 242 is applied at station 240, wherein again the doctor blade 244 is to determine the thickness of the applied layer. Subsequently, the plastisol 242 is first pregelled in an oven 250, and all of the layers of plastisol are then to be gelled in this oven. During this passage through the oven 250, all of the pregelled plastisols are to be further gelled, and the foamable plastisol or plastisols are to foam. The pregelling of plastisol 242 and gelling of all of the layers of plastisol can also be carried out in one step and in one oven.
Finally, the product obtained is turned at turning station 260, after which a UV-hardened PU lacquer layer is applied by means of a lick roller 270 and is hardened with UV at station 280.
The floor covering 300 thus obtained can be rolled up at rolling-up station 290.
The product obtained 300 has a cross section as schematically shown in Fig. 2. As the representation is schematic, the thicknesses as shown are not metrically representative.
The PVC-based, layered floor covering comprises successive layers, specifically:
a. a first PVC layer 1240 that is obtained at station 240;
b. A layer 1220 of a first textile product permeated with PVC, wherein the textile product is the textile product 1 1 1 that is permeated with the plastisol 212;
c. a second layer 1210 of PVC derived from PVC plastisol 212; d. a layer of a textile product permeated with PVC 1 130, which comprises the textile product 110 that is permeated with PVC plastisol 122;
e. a decorative layer 1 150 comprising a polymer layer derived from the PVC plastisol 152 and the decorative pattern;
f. a wear layer 1180 comprising a transparent polymer layer derived from the PVC plastisol 182;
g. the PU lacquer layer 1270.
The following layer thicknesses are applicable:
The PVC plastisol of PVC layer 1240 is a soft PVC with a density of 0.3 to 0.4 g/cm3. It comprises approximately 30 wt% of filler and 60 phr of plasticizer.
PVC plastisol of PVC layer 1210 is a soft PVC with a density of 1.3 to 1.4 g/cm3. It comprises approximately 20 wt% of filler and 40 phr of plasticizer.
The PVC of the PVC permeated textile product 1 130 is a soft PVC with a density of 1.5 to 1.6 g/cm3. It comprises approximately 40 wt% of filler and 60 phr of plasticizer.
The PVC of the decorative layer comprises soft PVC with a density of 1.5 to 1.6 g/cm3. It comprises approximately 40 wt% of filler and 60 phr of plasticizer.
The PVC of the wear layer comprises soft PVC with a density of 1.2 to 1.3 g/cm3. It comprises no filler and comprises 40 phr of plasticizer.
All of the PVCs are obtained by emulsion or (micro)suspension polymerization and have a K value of between 50 and 90.
Textile product 110 is a glass fiber nonwoven with a surface weight of 35 g/m2 and a thickness of approximately 0.3 mm.
Textile product 11 1 is a glass fiber nonwoven with a surface weight of 50 g/m2 and a thickness of approximately 0.4 mm.
PU lacquer is applied in an amount of 20 g/m2 and a thickness of 20 pm. A 100% solid UV lacquer is used.
The ALw is 20 dB: this value represents the improvement in contact sound insulation by means of using the product.
The product, like all products in accordance with the invention, has particularly favorable values in terms of expansion under the influence of temperature. The above-mentioned product was subjected to a dilation test in accordance with EN ISO 23999. A product identical to the above-mentioned product but with a glass fiber reinforcement was subjected to the test in a similar manner. For both the production direction and the direction perpendicular to the production direction, it was found that by using two glass fiber reinforcements, a reduction in expansion by 50% was obtained. It is clear that, although the embodiments and/or the materials for providing embodiments in accordance with the present invention are discussed, various amendments or modifications can be applied without deviating from the scope of this operating range and/or the spirit of this invention. The present invention is by no means limited to the embodiments described above, but can be realized in accordance with different variants without departing from the scope of the present invention.

Claims

Claims
1. A PVC-based, layered floor covering, comprising the following successive layers:
a. a first PVC layer;
b. a layer of a first PVC permeated textile product ;
c. a second PVC layer;
d. a layer of a second PVC permeated textile product ;
e. a decorative layer comprising a polymer layer;
f. a wear layer comprising a transparent polymer layer;
wherein the first PVC layer has a thickness of more than 2.0 mm, consists of foamed PVC and provides the underside of the floor covering.
2. A floor covering in accordance with claim 1 , wherein the density of the first PVC layer is in the range of 0.25 to 1.00 g/cm3.
3. A floor covering in accordance with claim 1 or 2, wherein the PVC of the first PVC layer is a soft PVC.
4. A floor covering in accordance with one of the preceding claims, wherein the PVC of the second PVC layer is a soft PVC.
5. A floor covering in accordance with one of the preceding claims, wherein the PVC of the second PVC layer is unfoamed.
6. A floor covering in accordance with one of claims 1 to 4, wherein the PVC of the second PVC layer is foamed.
7. A floor covering in accordance with one of the preceding claims, wherein the first textile product is partially impregnated with the PVC of the second PVC layer and the first textile product is partially impregnated with the PVC of the first PVC layer.
8. A floor covering in accordance with one of claims 1 to 6, wherein the first textile product is completely permeated with the PVC of the second PVC layer.
9. A floor covering in accordance with one of the preceding claims, wherein the second textile product is permeated with a PVC that is different from the PVC of the first and the second PVC layer.
10. A floor covering in accordance with one of the preceding claims, wherein the polymer of the decorative layer is PVC.
11. A floor covering in accordance with claim 10, wherein the polymer of the decorative layer is foamed PVC.
12. A floor covering in accordance with claim 10, wherein the polymer of the decorative layer is unfoamed PVC.
13. A floor covering in accordance with one of the preceding claims, wherein the polymer of the wear layer is PVC.
14. A floor covering in accordance with one of the preceding claims, wherein the floor covering is between 2 and 4 meters wide and 20 to 30 meters long.
15. A floor covering in accordance with one of the preceding claims, wherein the floor covering is provided in rolled-up form.
16. The method for producing a floor covering in accordance with one of the preceding claims, comprising the following successive steps:
g. the provision of a first PVC permeated textile product with that corresponds to the second textile PVC permeated product of the floor covering in accordance with one of the preceding claims;
h. the application, to a first side of the permeated textile product, of the polymer layer of the decorative layer;
i. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,
j. the application, to the second side of the permeated textile product, of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with one of the preceding claims; k. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first textile product impregnated with PVC of the floor covering in accordance with one of the preceding claims;
L. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with one of the preceding claims, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state.
17. The method in accordance with claim 16, wherein the provision of a textile product permeated with a first PVC comprises the following steps::
a.i.- the provision of a textile product;
a.ii.- the permeation of this textile product with a first PVC plastisol; a.iii.- the pregelling of the first PVC plastisol.
18. The method in accordance with one of claims 16 or 17, wherein the application to the second side of the permeated textile product of a PVC comprises the following steps:
d.i.- the application, to the second side of the permeated textile product, of a PVC plastisol;
d.ii.- the pregelling of this PVC plastisol.
19. The method in accordance with claim 18, wherein step e takes place before step d.ii, and wherein the PVC penetrates into the further textile product in order to permeate the further textile product.
20. The method in accordance with one of claims 16 to 19, wherein the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with one of the preceding claims comprises the following steps:
f.i.- the application to the further textile product of a layer of foamable or foamed PVC plastisol;
f.ii.- optionally, the pregelling of this PVC plastisol.
21. The method in accordance with claim 16, comprising the steps: a. the provision of a textile product impregnated with a first PVC material that corresponds to the second PVC permeated textile product of the floor covering in accordance with one of claims 1 to 15, comprising
i. the provision of a textile product;
ii. the impregnation of this textile product with a PVC plastisol; iii. the pregelling of the first PVC plastisol;
b. the application, to a first side of the impregnated textile product, of the polymer layer of the decorative layer;
c. the application, to the free side of the polymer layer of the decorative layer, of the polymer layer of the wear layer,
d. the application of a PVC layer that corresponds to the second PVC layer of the floor covering in accordance with one of claims 1 to 15, comprising i. the application, to the second side of the impregnated textile product, of a PVC plastisol layer;
ii. the pregelling of this PVC plastisol.
e. the application of a further textile product to this PVC layer, which textile product corresponds to the textile product of the first PVC permeated textile product of the floor covering in accordance with one of the preceding claims;
f. the application to the further textile product of a layer of foamable or foamed PVC that is to provide the first PVC layer of the floor covering in accordance with one of claims 1 to 15, which foamable or foamed PVC is to have a thickness of more than 2 mm in a foamed state, comprising i. the application to the further textile product of a layer of a foamable PVC plastisol, which is to have a thickness of more than 2 mm in a foamed and gelled state;
ii. optionally, the pregelling of this PVC plastisol;
g. the gelling of all PVC plastisols.
22. The method in accordance with one of claims 17 to 20, wherein after step g, a lacquer layer is applied to the wear layer.
23. The method in accordance with one of claims 18, 21 or 22, wherein step e takes place before step d.ii, and wherein the PVC plastisol of step d.i penetrates into the further textile product in order to permeate the further textile product.
24. The method in accordance with one of claims 20, 21 or 22, wherein during step f, the PVC plastisol penetrates into the further textile product in order to permeate the textile product.
25. The method in accordance with one of claims 16 to 24 wherein during step b, a decorative pattern is applied.
26. The method in accordance with one of claims 16 to 25, wherein in step b, the polymer of the decorative layer is a PVC plastisol and wherein step b comprises the pregelling of this PVC plastisol.
27. The method in accordance with one of claims 16 to 26, wherein in step c, the polymer of the decorative layer is a PVC plastisol and wherein step c comprises the pregelling of this PVC plastisol.
EP19772965.0A 2018-10-05 2019-10-01 Pvc based, layered floor covering Pending EP3860844A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BE20185685A BE1026681B1 (en) 2018-10-05 2018-10-05 PVC-based, layered floor covering
PCT/IB2019/058347 WO2020070646A1 (en) 2018-10-05 2019-10-01 Pvc based, layered floor covering

Publications (1)

Publication Number Publication Date
EP3860844A1 true EP3860844A1 (en) 2021-08-11

Family

ID=63878299

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19772965.0A Pending EP3860844A1 (en) 2018-10-05 2019-10-01 Pvc based, layered floor covering

Country Status (4)

Country Link
EP (1) EP3860844A1 (en)
BE (1) BE1026681B1 (en)
RU (1) RU2769858C1 (en)
WO (1) WO2020070646A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RS66851B1 (en) 2021-02-16 2025-06-30 Evonik Oxeno Gmbh & Co Kg Use of 1,4-bis(2-ethylhexyl) cyclohexane dicarboxylate as plasticizer in surface coatings

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2555404T3 (en) * 2011-02-01 2015-12-30 Ivc Nv Method of manufacturing a plate-shaped product and plate-shaped product manufactured by said method
WO2013178561A2 (en) * 2012-05-30 2013-12-05 Akzo Nobel Chemicals International B.V. Microspheres
JP6093961B2 (en) * 2013-05-16 2017-03-15 東リ株式会社 Floor structure and underlay sheet
KR101895635B1 (en) * 2013-07-11 2018-09-05 (주)엘지하우시스 Eco-friendly for elastic floor sheet and manufacturing method thereof
JP6776028B2 (en) * 2016-07-06 2020-10-28 東リ株式会社 Floor sheet

Also Published As

Publication number Publication date
BE1026681B1 (en) 2020-05-07
BE1026681A1 (en) 2020-04-30
RU2769858C1 (en) 2022-04-07
WO2020070646A1 (en) 2020-04-09

Similar Documents

Publication Publication Date Title
CN104945642B (en) Method for producing breathable film
US20210230883A1 (en) Co-foamable pvc plastisol composition and co-foamed pvc layer for floor covering
US11975523B2 (en) Floor panel and method for manufacturing a floor panel
US3485711A (en) Low-density web-like cushioning structure of cellular filamentary material
US4022943A (en) Sheet type covering material with metallic luster and process for making same
US20030108718A1 (en) Polyurethane coated resilient surface covering having improved fidelity of texture and process of manufacture
KR100884270B1 (en) Eco-friendly FIVE foam sheet and its manufacturing method
KR101816392B1 (en) Artificial leather for vehicle interior material and method for manufacturing the same
EP3864235A1 (en) Underlayment
CA1094439A (en) Embossed sheet type covering material
EP3860844A1 (en) Pvc based, layered floor covering
TWI825260B (en) Synthetic leather and method of forming a synthetic leather
WO2021116793A1 (en) Method for manufacturing a wall or floor covering
DE3728773A1 (en) METHOD FOR PRODUCING THREE-DIMENSIONAL PATTERNS OR COATINGS ON CARRIER SHEETS OF PAPER, TEXTILES AND / OR ON PLASTIC FILMS
JP2000211049A (en) Foam cosmetic material
CA1145910A (en) Flexible sheet-type covering material and process for making same
KR101277424B1 (en) Flooring using woven cloth made from fiber coated by resin
KR102037641B1 (en) Artificial leather and its manufacturing method
KR102057398B1 (en) Artificial leather and its manufacturing method
EP1496148B1 (en) Wallpaper for automobile and manufacturing method
CA1135127A (en) Process for sealing fiber web of open structure
KR20190030595A (en) The method of Artificial leather and the Artificial leather manufactred thereform
RU2793178C2 (en) Combined foamed polyvinyl chloride plastisol composition and combined foamed polyvinyl chloride layer for floor covering
WO2025238235A1 (en) Floor covering comprising recycled pvc and method for the manufacture of such covering
DE2622574A1 (en) Sound absorbing floor covering prodn. - from plasticised polyvinyl chloride by coating compact sheet with expandable compsn.

Legal Events

Date Code Title Description
STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: UNKNOWN

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

Free format text: STATUS: THE INTERNATIONAL PUBLICATION HAS BEEN MADE

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

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

Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE

17P Request for examination filed

Effective date: 20210312

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

DAV Request for validation of the european patent (deleted)
DAX Request for extension of the european patent (deleted)
STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: EXAMINATION IS IN PROGRESS

RAP1 Party data changed (applicant data changed or rights of an application transferred)

Owner name: UNILIN, BV

17Q First examination report despatched

Effective date: 20240429