EP3927911A1

EP3927911A1 - Floor covering element

Info

Publication number: EP3927911A1
Application number: EP19874768.5A
Authority: EP
Inventors: Martina GRÜNEWALD
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-02-18
Filing date: 2019-11-14
Publication date: 2021-12-29
Also published as: WO2020168368A1; AT521612A4; AT521612B1; US20220104647A1

Abstract

The invention relates to a floor covering element comprising an insulation layer (1) facing the floor when laid, a backing layer (2) of canvas, provided on the insulation layer (1) and connected to said insulation layer (1), at least the upper face of the backing layer (2) being coated with a primer (3a), wherein: a printed layer (4) for at least partially optically designing the floor covering is applied to the primer (3a) on the upper face; and a transparent sealing coat (5) is provided on the printed layer (4), the surface structure of the sealing coat (5) being predetermined by the backing layer (2) of canvas and having a surface roughness (Sa) of at least 7.5 µm, in particular at least 8.0 µm, preferably at least 9.4 µm.

Description

Flooring element

The invention relates to a printed, multilayer floor covering element.

Floor covering elements are used, among other things, to achieve heat and footfall sound absorption, to protect the floor from signs of use, and to enable individual interior design. In order to create a warm, homely atmosphere, the haptic properties of the flooring element are also important, since smooth surfaces appear cold and rough materials are easily perceived as scratchy. The flooring element should have a non-slip surface and be as easy to clean as possible. At the end of the product life, a flooring element should be reusable or recyclable in order to avoid creating large amounts of waste that has to be disposed of.

A wide variety of floor covering elements such as carpets or floor mats are known from the prior art. On the one hand, carpets made of fiber materials with piles and loops of different fleas, e.g. "Oriental carpets", or flat-woven carpets such as "Fleckerl carpets". These have good insulating properties and create a warm atmosphere. However, they get dirty quickly and are difficult to clean, as they can usually only be cleaned locally by laborious dabbing or, due to their material composition, have to be taken for professional cleaning, which is associated with a high expenditure of time and money.

On the other hand, floor coverings made of vinyl, PVC and linoleum that can be freely placed or laid flat are known. Such floor coverings, which can be wiped off with a damp cloth, are severely restricted in terms of their individual design options due to the installation process. Known functional mats with a multi-layer structure also do not meet the need for a combination of high-quality functional, aesthetic and haptic properties and can hardly or not at all be recycled due to their material and assembly properties.

DE 202015004860 U1 shows, for example, a doormat with an adhesive layer to be glued to a floor, a design element and an anti-slip surface element, the anti-slip effect being achieved by lamination or embossing. Such surfaces tend to become soiled with long-term use. The surface element severely restricts individual design freedom, since the design element is not clearly visible, but rather because of the lamination or embossing the color quality is impaired and the boundaries are only indistinctly recognizable. Furthermore, the haptic properties are not suitable for creating a warm atmosphere and there is no insulation effect whatsoever.

Known floor covering elements can therefore not meet all the requirements placed on them.

The object of the invention is therefore to provide a floor covering element which has heat and impact sound absorption, is slip-resistant, easy to clean, in particular can be wiped off with a damp cloth, and which can be individually designed and has a pleasant feel.

According to the invention, the object is achieved by a floor covering element comprising an insulating layer facing the floor when in use, a carrier layer made of canvas arranged on the insulating layer and connected to the insulating layer, the carrier layer being coated with a primer at least on the top, with at least the top primer partially a print layer for the optical design of the floor covering element is applied, and a transparent seal is arranged on the print layer, the surface structure of the seal being predetermined by the carrier layer made of canvas and a surface roughness (Sa) of at least 7.5 gm, in particular at least 8 .0 gm, preferably at least 9.4 pm.

The structure according to the invention enables the requirements that are placed on a floor covering to be met. On the one hand, the insulation layer offers heat and footfall sound absorption. In addition, it can be prevented that the canvas is deformed through use or unevenness and crumbs that get under the floor covering element and that such deformations with further load cause damage to the seal.

The primer protects the canvas from moisture damage, such as deformation. The primer also enables a sharp print image that is visible through the transparent seal. This allows the flooring element to be designed individually. The seal is water and dirt repellent and enables easy cleaning, as the flooring element can be wiped off with a damp cloth. The surface roughness given by the canvas affects cleaning Not. In addition, a non-slip surface can be provided that has pleasant haptic properties.

The structure according to the invention also enables the floor covering element to be rolled up and in this way to be easy to transport without impairing functionality. This enables particularly flexible use.

Canvas is a tightly woven fabric made of strong yarn and is made from natural fibers such as vegetable fibers, preferably cotton, flanf, linen, banana fibers, or mineral fibers, preferably silicate glass fibers. Fabrics made from various natural fibers can also be used.

The canvas can also be made of mixed fabrics or mixed fibers with polyesters, polyacrylonitrile, etc.

Pure natural fiber fabrics are preferred because of the better adhesion of the primer and for reasons of sustainability.

Canvas is produced in different weaves, e.g. in plain weave, half-panama weave, panama weave, or ripstop. Each of these bonds is suitable for the invention and implies the desired surface roughness.

The perception threshold for haptic properties is around 1 pm, which means that surface structures can be perceived up to this small size. The surface roughness can be determined as Sa value, the arithmetic mean of the heights of the selected area being determined by light microscopic measurement. The surface roughness (Sa) is determined according to ISO 25178, e.g. using an Alicona Infinitive Focus Microscope (IFM). The surface roughness according to the invention is felt to be particularly pleasant.

Advantageous configurations result from the following features:

It can be provided that the floor covering element has a thickness between 2 mm and 7 mm, in particular between 2 mm and 5 mm, preferably between 2.5 mm and 4.5 mm. Due to the small thickness, the floor covering element can be used particularly flexibly, since it can also be used in the door area without hindering the opening or closing of a door. The floor covering element is therefore suitable both as a surface covering and as an exposed limited floor support. For example, the floor covering element can be used as a table pad or desk mat become. Thanks to its small thickness, it is particularly easy to transport without impairing stability.

In order to obtain particularly good slip resistance, it can be provided that the carrier layer made of canvas with a square meter weight between 350 g / m ² and 850 g / m ² , in particular between 450 g / m ² and 800 g / m ² , preferably between 500 g / m ² and 750 g / m ² . In addition or instead, the carrier layer made of canvas can have a thickness of at least 0.6 mm, in particular of at least 0.7 mm, preferably of at least 0.8 mm. This enables a stable floor covering element with particularly good slip resistance and pleasant haptic properties to be provided.

In order to prevent the carrier layer from being deformed as a result of the action of moisture, the carrier layer can be coated on both sides with the primer or an underside primer can be applied to the underside of the carrier layer facing the insulating layer. The primer on the underside also improves the connection between the carrier layer and the insulation layer, since with a carrier layer coated on both sides the carrier layer is connected to the insulation layer via the primer on the underside. The primer on the underside prevents the bonding agent from penetrating deeply into the canvas carrier layer, so that the insulation layer can be completely detached from the carrier layer by pulling it apart. This is particularly advantageous, since different materials can usually only be recycled separately and thus further use or recycling is possible at the end of the product life, while known floor covering elements often have to be disposed of.

It is particularly suitable if the primer consists of acrylic gesso. In addition or instead, it can be provided that the primer is designed as a coating comprising calcium carbonate and acrylic polymer, and in particular titanium white pigments. On the one hand, such a primer can protect the carrier layer made of canvas from moisture, while the surface roughness is only slightly impaired. The primer is also particularly suitable for the adhesion of the printing layer or, if necessary, also for connecting to the insulation layer. Furthermore, a particularly clear and sharp print image can be created on the primer.

A particularly resistant and stable floor covering element can be obtained if the seal consists of parquet lacquer. Additionally or alternatively can it can be provided that the seal is designed as a coating comprising polyurethane-acrylate copolymer and / or a polyurethane and / or a polyacrylate. This gives the flooring element a particularly waterproof, dirt-repellent and easy-to-clean surface that can be cleaned by wiping or vacuuming, for example. In addition, a particularly suitable hardness can be achieved to avoid scratches, while at the same time good flexibility can be obtained in order to prevent the floor covering element from being damaged by cracks when it is rolled up. Such a seal is easy to repair or replace even if it is damaged.

The same effect can be achieved by sealing with hard wax oil based on natural waxes or oils such as sunflower oil, soybean oil, safflower oil, carnauba and candelilla wax, which can be mixed with siccatives and water-repellent additives. This sealing has the further advantage that a floor covering element made of natural materials can be provided.

The seal can preferably have a thickness of 80 gm to 100 gm. As a result, the surface roughness specified by the canvas is retained, while at the same time, depending on the area of application, the ÖNORM C 2354 A, B or C (moderate, heavy or particularly heavy use) load classes can be met.

The seal in particular has a surface roughness (Sa) of up to 14 μm, preferably up to 11 μm. This surface roughness allows a particularly good anti-slip effect, with easy cleaning and good stability. In addition, the surface roughness is felt to be particularly pleasant and non-scratchy.

In order to simplify the use of the floor covering element for living rooms, in particular also for children's rooms, it can be provided that the seal is saliva-proof and acid-resistant.

A particularly clear and sharp print image can be obtained if the print layer consists of a latex ink. Additionally or instead it can be provided that the printing layer is designed as a coating comprising latex and pigments, and in particular a styrene-acrylate copolymer. These inks are very lightfast and abrasion resistant. In this way, it can be avoided that ink collects in the depressions of the surface structure. On the one hand, the surface roughness is retained particularly well, and even drying can be achieved be achieved. The ink is also odorless and harmless to health. The printing layer can preferably be applied using the digital printing process, so that the individual design is particularly simple and efficient, since a known and widespread technology can be used.

In order to obtain a particularly stable floor covering element, it can be provided that the insulation layer has a height of 2 mm - 5 mm. On the one hand, this thickness enables great flexibility, while at the same time good heat and footfall sound absorption can be achieved. In particular, it can be provided that the insulating layer consists of a, preferably natural, felt, in particular with a hardness of M3 to F3 (DIN 61200). A flame-retardant effect can be achieved through natural felts, especially with wool mixed in. In addition, such felts have particularly good insulating properties. This effect is reinforced by the special hardness. In addition, uneven floors are evened out particularly well and wrinkles can be avoided during use. In this way, the load on the seal can be reduced and the durability of the floor covering element can be improved.

In order to further increase the durability of the floor covering element, it can be provided that the insulating layer is glued to the carrier layer, preferably flat. In the case of a carrier layer coated on both sides, the carrier layer is glued to the insulation layer via the primer on the underside. The gluing can prevent moisture from penetrating into the floor covering element. This also makes the flooring element particularly stable. The surface roughness of the carrier layer serves as a mechanical anchor, the mountains of which when subjected to mechanical pressure from above, e.g. By walking on the floor covering element, placed objects or furniture, by pressing on the adhesive surface underneath, the stability of the connection is increased, since loosening of the connection by diametrically shifting the layers by means of mechanical force due to the mountains "sunk" into the gummed adhesive due to drying is prevented can.

Additionally or alternatively, it can be provided that the insulation layer can be completely separated from the carrier layer, so that further use or recycling at the end of the product life is simplified. If the carpet is to be returned to the material cycle, the insulation layer and the carrier layer can be separated manually by pulling them apart. Adhesive residues remain on the insulation layer. This can be used, for example, as a sealing material. The The carrier layer can, for example, be reused with a new insulation layer, or, for example, also be sanded off and resealed. Then, for example, it can be used as a table top, or combined with a new insulation layer, as a heat-insulating wall hanging. At the end of the product's life, the carrier layer can be fed to thermal recycling.

Good adhesion with good separability at the same time can be obtained if an adhesive is applied for the connection between the insulating layer and the carrier layer or the primer on the underside, comprising

- rubber and

a stabilizer, in particular ammonia, preferably 0.1 wt.% - 0.5 wt.% ammonia, and

a crosslinking system, in particular a fatty acid, preferably lauric acid, and / or a metal oxide, preferably zinc oxide, and / or a thiuram disulfide, preferably tetramethylthiuram disulfide.

The same effect can be achieved if an adhesive comprising natural rubber, rosin-glycerol ester, linseed oil, casein, xanthan and thiazoles is applied to connect the insulation layer and the carrier layer or the primer on the underside.

This special bonding makes it possible to provide a stable floor covering element that is easy to recycle.

It is also possible to combine the insulating and carrier layers or the insulating layer and the primer on the underside using a reactive hot-melt adhesive, for example made of polyurethane. This also provides a stable connection that enables the carrier layer and insulation layer to be separated at the end of the product life.

A particularly advantageous embodiment of the invention is shown by way of example with reference to the drawing without restricting the general inventive concept.

Fig. 1 shows the structure of an exemplary floor covering element according to the invention.

In Fig. 1, a flooring element is shown, with an insulating layer 1, which faces the floor when in use. In the embodiment shown, the insulating layer 1 is made of a wool felt. Alternatively, for example, a woolen Polyester mixture (e.g. 30% wool, 70% polyester) can be used. The insulation layer 1 is connected to a carrier layer 2 made of canvas.

In the embodiment shown, the insulation layer 1 is connected to the carrier layer 2 by an adhesive 6, the adhesive provided being liquid latex, i.e. an aqueous dispersion of rubber with approx. 0.2% ammonia and a mixture of lauric acid, thiram and zinc oxide. Alternatively, a pasty adhesive, e.g. based on natural rubber milk can be used. Another type of bonding is also possible, e.g. through adhesive tapes.

In the embodiment shown, the canvas is made of untreated cotton yarn that is woven in a plain weave. This has a particularly advantageous surface roughness and is particularly easy to coat with the primer. In principle, any other canvas can also be used as carrier layer 1, e.g. canvas of thicker quality with more than 1 mm thickness (e.g. # 6 number duck or # 4 number duck), of a consistently dense but coarser weave structure, and / or higher weight (e.g. 610 g / m ² or 710 g / m ² ). Cotton-polyester mixtures (e.g. 80% cotton, 20% polyester) or the like can also be used. be used.

In the embodiment shown, the carrier layer 2 is coated on both sides with a primer 3a, 3b. The carrier layer 2 therefore has a primer 3b on the underside facing the insulating layer 1 and an opposite primer 3a on the top. The primer 3a, 3b comprises calcium carbonate and acrylic polymer and titanium dioxide. In the embodiment shown, the primed carrier layer 1 has a weight of 619 g / m ² . In another embodiment, when using thicker canvas, for example # 8 can have a weight of 740 g / m ² or # 6 has a weight of 820 g / m ² .

In the embodiment shown, a printing layer 4 is arranged on the top-side primer 3 a facing away from the insulating layer 1. In the embodiment shown, the printing layer 4 is arranged over the entire area on the top-side primer 3a and is formed by a latex ink.

The printing layer 4 is completely covered by a transparent seal 5. In the embodiment shown, the seal 5 is composed of a polyurethane-acrylate copolymer-based composition. In another embodiment, the Seal 5 is also based on a composition comprising polyurethane or a composition comprising polyacrylate.

The surface structure of the seal 5 is predetermined by the carrier layer 2 made of canvas. In the embodiment shown, the seal 5 has a surface roughness (Sa) of 9.4 μm.

An exemplary method for producing one according to the invention

Flooring element is shown below:

First, untreated canvas is coated as a carrier layer 2 with a primer, preferably on both sides, which forms the primer 3a, 3b. A printing layer 4 is applied to one side of the primed carrier layer 2, for example with a latex ink in a digital printing process. A seal 5 is applied over the entire surface of the printing layer 4. The carrier layer 2 is connected to the insulating layer 1, an adhesive 6, preferably flat, being applied to the insulating layer 1 and the carrier layer 2 being arranged so that the seal 5 is arranged on the side facing away from the insulating layer 1. The application of the adhesive 6 between the insulation layer 1 and the carrier layer 2 is independent of the other process steps and can take place at any time.

The following can be done in detail:

A carrier layer 2 made of canvas is used for a floor covering element according to the invention, the canvas used being made of cotton yarn woven in a plain weave and having a weight of 514 g / m ² and a thickness of 0.8 mm.

Using a calender, the canvas is coated three times over with acrylic gesso on both sides. A conventional acid-free primer with calcium carbonate (CaC0 ₃ ), acrylic polymer (medium latex) and titanium white is used. The carrier layer 2 coated with the primer 3a, 3b has a weight of 610 g / m ² , a thickness of 0.83 mm and a mean surface roughness Sa (ISO 25178) of 10.4 μm on both sides.

The coated carrier layer 2 is printed with a decorative motif on one side, on the later upper side, by means of known latex digital printing technology. Inks are used that are available under the trade name HP 881 Latex Inks. These form a flat printing layer 4, which is arranged on the top-side primer 3a. A wool felt layer 2 mm thick (according to DIN 61206), 30 g / ccm density (according to DIN 61200) and 600 g / m ² weight (according to DIN 61200) and M5 hardness (according to DIN 61200) is provided as the insulation layer 1. An adhesive 6 is applied to one side of the insulating layer 1.

The adhesive 6 used is a product available under the trade name AURO floor covering adhesive No. 382, which is applied over the entire surface using a short hair roller or a toothed spatula (Fine A3). After a maximum drying time of 20 minutes at a room temperature of 22 ° C. and an average air humidity of 50%, the unprinted underside of the prepared carrier layer 2 is arranged on the insulating layer 1. The primer 3b on the underside is arranged on the adhesive surface and the insulating layer 1 is connected to the carrier layer 2 in this way, the layers being glued together using a calender under 3-4 bar roller pressure. The carrier layer 2 is arranged in such a way that the printing layer 4 is arranged on the top side facing away from the insulating layer 1.

The upper side with the printing layer 4 is sealed for better durability, a clear parquet lacquer being used as the seal 5, which is available under the trade name ADLER 42140 ff. The seal 5 is painted in three layers with a short hair roller to a total dry film thickness of 80-100 μm. 300 g / m ^{2 of} parquet varnish are used for the first layer and 200 g / m ² for each of the following layers. Between the individual layers there is an intermediate drying time of at least 30 minutes at a room temperature of 22 ° C and a humidity of 50%.

After applying twice, intermediate sanding with 400 grit sandpaper is possible. Alternatively, the seal 5 can be applied using airless or airmix syringes (0.28-0.33 mm nozzle, 100-120 bar / 1-2 bar, approx. 30 s) or compressed air syringes (1st , 8 mm nozzle, 3-4 bar, approx. 20 s) in a painting chamber or as a core element of an enclosed, automated painting system. The seal 5 can, for example, also be applied before the bonding to the insulating layer 1.

After a final drying time of eight days, the flooring element is waterproof, abrasion-resistant (ÖNORM C 2354 Category C, very heavy-duty use) and sealed against sweat and saliva in accordance with ÖNORM S 1555 and DIN 53160. The flooring element has an average surface roughness of 9.4 μm and a total thickness of 3000 μm. The flooring element can be cut to the desired dimensions.

The edges can be designed individually (e.g. hem seam, bias tape, fold, warp seam, end seam, or trimmed flush with the room). For example, the edges can be trimmed with a tricot stitch or triple zigzag stitch. For example, a particularly robust industrial sewing thread made of polytetrafluoroethylene (PTFE), color-coordinated with the decor, can be used (1400 denier / 1556 dtex, needle size: NM 100-120, thread size: approx. 35-40NM, nominal maximum tensile strength 4448 cN / ~ 4.5kg, thread diameter: 0.35mm).

A modified process sequence is also possible, e.g. the edges are designed before painting. E.g. First the insulation layer 1 is connected to the primed carrier layer 2, then the printing, the cutting and the edge design are carried out and only then is the sealing 5.

The floor covering element according to the invention is durable, can be used flexibly, slip-resistant, has a pleasant feel and good heat and footfall sound absorption, it is easy to clean and can be designed individually.

Claims

Patent claims:

1. Floor covering element comprising an insulating layer (1) facing the floor when in use, a carrier layer (2) made of canvas, arranged on the insulating layer (1) and connected to the insulating layer (1), the carrier layer (2) having at least one on the top Primer (3a) is coated, with a printing layer (4) for the optical design of the floor covering element being applied at least partially to the top-side primer (3a), and with a transparent seal (5) being arranged on the printing layer (4), the surface structure the seal (5) is predetermined by the carrier layer (2) made of canvas and has a surface roughness (Sa) of at least 7.5 gm, in particular at least 8.0 gm, preferably at least 9.4 μm.

2. Floor covering element according to claim 1, characterized in that the floor covering element has a thickness between 2 mm and 7 mm, in particular between 2 mm and 5 mm, preferably between 2.5 mm and 4.5 mm.

3. Floor covering element according to one of claims 1 or 2, characterized in that the carrier layer (2) made of canvas with a weight per square meter between 350 g / m ² and 850 g / m ² , in particular between 450 g / m ² and 800 g / m ² , preferably between 500 g / m ² and 750 g / m ² , and / or that the carrier layer (2) consists of canvas with a thickness of at least 0.6 mm, in particular of at least 0.7 mm, preferably of at least 0.8 mm.

4. Floor covering element according to one of claims 1 to 3, characterized in that the carrier layer (2) is coated on both sides with the primer (3a, 3b) or that on the underside of the carrier layer (2) facing the insulating layer (1) underside primer (3b) is applied.

5. Floor covering element according to one of claims 1 to 4, characterized in that the primer (3a, 3b) consists of acrylic gesso, and / or that the primer (3a, 3b) as a coating comprising calcium carbonate and acrylic polymer, and in particular titanium white Pigments.

6. Floor covering element according to one of claims 1 to 5, characterized in that the seal (5) consists of, in particular clear, parquet lacquer, and / or that the seal (5) is designed as a coating comprising polyurethane-acrylate copolymer and / or a polyurethane and / or a polyacrylate.

7. Floor covering element according to one of claims 1 to 5, characterized in that the seal (5) comprises natural hard wax oils, in particular based on sunflower oil, soybean oil, safflower oil, carnauba and / or candelilla wax, which is preferably provided that the seal contains siccative and / or water-repellent additives.

8. Floor covering element according to one of claims 1 to 7, characterized in that the printing layer (4) consists of a latex ink and / or that the printing layer (4) is designed as a coating comprising latex and pigments, and in particular a styrene-acrylate copolymer is.

9. Floor covering element according to one of claims 1 to 8, characterized in that the insulation layer (1) has a height of 2 mm to 5 mm, it being provided in particular that the insulation layer (1) consists of a, preferably natural, felt, especially with a hardness of M3 to F3 (DIN 61200).

10. Floor covering element according to one of claims 1 to 9, characterized in that the insulating layer (1) is glued to the carrier layer (2) or the primer (3b) on the underside, preferably flat, and / or that the insulating layer (1 ) is completely separable from the carrier layer (2) or the underside primer (3b).

1 1. Floor covering element according to one of claims 1 to 10, characterized in that for the connection between the insulating layer (1) and the carrier layer (2) or between the insulating layer (1) and the underside primer (3b), an adhesive (6) is applied, comprising

- natural rubber

- rosin glycerol ester,

- Linseed oil,

- casein,

- xanthan and

- thiazoles

or comprehensive

- rubber and a stabilizer, in particular ammonia, preferably 0.1 wt.% - 0.5 wt.% ammonia, and

12. Floor covering element according to one of claims 1 to 10, characterized in that for the connection between the insulating layer (1) and the carrier layer (2) or between the insulating layer (1) and the underside primer (3b), as an adhesive (6) reactive hot melt adhesive, in particular based on polyurethane, is applied.

13. Floor covering element according to one of claims 1 to 12, characterized in that the carrier layer (2) made of canvas made of natural fibers,

in particular vegetable fibers, preferably cotton, hemp, linen, banana fibers, and / or in particular mineral fibers, preferably silicate glass fibers.

14. Floor covering element according to one of claims 1 to 12, characterized in that the carrier layer (2) consists of canvas made of mixed fibers and / or mixed fabrics comprising natural fibers and artificial fibers, in particular with proportions of polyesters and / or polyacrylonitrile.