GB2595665A - Improvements in or relating to organic material - Google Patents

Abstract

A synthetic surface-covering material comprising a pre-coated fabric, itself comprising a fabric layer and a pre-coat synthetic layer for bonding of the fabric, and a lower layer to which the fabric is bonded. The fabric may be low shrinkage, woven or non-woven, and may be polymeric. Additional layers such as non-slip, foamed, support, decorative, topcoat, wear and/or external protective layers may all be added. The pre-coated synthetic layer may comprise a polyester, preferable a vinyl acetate co-polymer, most preferably ethylene vinyl acetate. Also included are claims to the pre-coated fabric layer and to the method of preparing a synthetic covering by pre-coating a fabric layer prior to attaching to a lower synthetic layer.

Description

IMPROVEMENTS IN OR RELATING TO ORGANIC MATERIAL

The present invention relates to a synthetic surface covering and a method for its production.

There is a general desire to reduce the environmental impact of synthetic surface coverings which require the use of a lot of synthetic materials (typically plastics) in their manufacture. The synthetic materials are typically dense such that the synthetic surface coverings are heavy for a given thickness and so expensive to transport. Furthermore, care needs to be taken when handling them.

It is known to incorporate a fabric layer in synthetic floor coverings to improve adhesion to the subfloor, acoustic properties, and comfort under foot. A further advantage of including a fabric layer is that the weight of the synthetic floor covering for a given thickness is reduced, giving benefits in handling of the product, cost of raw materials and reduced weight (and hence fuel efficiency) of any vehicle in which the synthetic floor covering is installed.

Typically, there are two ways in which synthetic surface coverings are manufactured: laminating or coating methods. In a laminating method of manufacture, multiple layers or films of synthetic material are prepared and then fused together by the application of heat and pressure such as by calendering.

In a coating method of manufacture, layers of plasticized polymeric material are applied sequentially to build up a synthetic surface covering. It is known to incorporate a fabric layer into a surface covering manufactured by a coating method by applying a layer of plasticized polymeric material to it.

It is also known to adhere an additional fabric layer to a synthetic floor covering. Advantages include that the weight for a given thickness of the synthetic floor covering may be reduced further. However, there are problems including that the step of adhering the fabric layer to a synthetic floor covering is not straightforward to incorporate into the typical method of manufacture; that the fabric layer is not incorporated into the synthetic floor covering in the same way as its other layers; and that further costs are incurred for the additional layer and additional manufacturing steps.

A way of ameliorating these problems has been sought.

According to the invention there is provided a synthetic surface covering comprising a pre-coated fabric layer and one or more synthetic layers including a lower layer wherein the pre-coated fabric layer comprises a fabric layer and a pre-coated synthetic layer for bonding the fabric layer to the lower layer wherein the pre-coated synthetic layer has a pre-determined thickness.

According to the invention there is also provided a pre-coated fabric layer comprising a fabric layer and a pre-coated synthetic layer for bonding the fabric layer to a lower layer of a synthetic surface covering.

According to the invention there is further provided a method of preparing a synthetic surface covering according to the invention which method comprises the steps of: Providing a layer of fabric material; Coating the fabric material with a synthetic composition to form a pre-coated fabric layer; and Applying a lower layer of synthetic material to the pre-coated synthetic layer.

Advantages of the invention include that by using a pre-coated fabric layer, penetration of synthetic material from the lower layer into the fabric layer is prevented by the pre-coated synthetic layer. A problem that has been identified with using a fabric layer in a coating method of manufacture is that the degree of penetration of synthetic material into the fabric layer cannot be easily controlled. It is the thickness of the free fabric layer (which has not been penetrated by synthetic material) which provides the weight reduction for a given thickness of surface-covering material. By preventing penetration of synthetic material from the lower layer into the fabric layer and by selection of the thickness of the fabric layer and of the pre-coated layer, the weight reduction may be predicted and controlled. Furthermore, as the pre-coated synthetic layer has a pre-determined thickness, its relationship to the thickness of the lower synthetic layer may also be controlled in order to obtain an additional weight reduction. It has been found that a weight reduction of from 10, for example from 20, to 40wt%, for example to 30wt% may be obtained. Provision of a pre-coated synthetic layer on the fabric layer enables the pre-coated fabric layer to be incorporated into known manufacturing processes for the preparation of surface-covering materials as pre-coated synthetic layer provides a substrate to which other layers of synthetic material may easily be bonded. Further advantages of the pre-coated fabric layer include that it provides improved sound attenuation (by from 1 to 5 dB) and insulation (such that it is more comfortable to walk on bare foot) by minimising the degree of penetration of synthetic material into the fabric layer.

In some embodiments, the fabric layer has a lower surface which engages the surface to which the surface-covering material is to be applied. In some embodiments, the fabric layer may be a woven or non-woven fabric layer. In some embodiments, the fabric layer may be formed from one or more synthetic or natural fibres. Suitable examples of synthetic fibres include a fibreglass, carbon fibre, or polymeric fibre. Suitable examples of polymeric fibres include polyester (such as polyethylene terephthalate), vinylon fibre, high-density polyethylene fibre, and/or aramid fibre. Suitable examples of natural fibres include cotton and/or cellulose. In some embodiments, the fabric layer may be a brushed fabric layer such that it is a fleece fabric layer. It should be understood herein that a fleece fabric layer is a fabric layer which has a nap or pile to increase its thickness for a given weight.

In some embodiments, the fabric layer may be a low shrinkage fabric layer which does not shrink substantially on heating. Substantial shrinkage on heating is disadvantageous for the floor covering as it may change the shape of the floor covering comprising the fabric layer or cause the floor covering to curl. In some embodiments, the fabric layer may be a low shrinkage fabric layer which has a shrinkage in one or two dimensions (such as length, width or area) of less than 3%, for example less than 2% or 1% on heating. In some embodiments, the fabric layer may have an elongation capacity sufficient to allow the fabric layer to stretch during preparation of the surface-covering material; for example, the elongation capacity may be from 30% to 120% in one or two dimensions (such as length, width or area).

In some embodiments, the fabric layer may have a thickness sufficient to provide the desired weight reduction for the surface-covering. For example, the fabric layer may have a thickness of from 0.2mm, e.g. from 0.3mm, or from 0.4mm, or from 0.5mm to 5mm, e.g. to 4mm, or to 3mm, or to 2mm, or to 1.5mm. In some embodiments, the fabric layer may have a weight per square metre of from 50g, for example from 80g, e.g. from 90g, or from 100g to 500, e.g. to 450g, or to 400g, or to 300g.

In some embodiments, the pre-coated synthetic layer may have a pre-determined thickness which is less than 50% of the thickness of the fabric layer, such as a thickness which is less than 40%, 30%, 20%, 10% or 5% of the fabric layer. In some embodiments, the pre-coated synthetic layer may have a predetermined thickness of from about 10 lam, for example from 20 p.m, e.g. from 50 p.m, e.g. from 100 pm, e.g. from 200 pm to 500 pm, e.g. to 400 pm, e.g. to 300 pm, e.g. to 200 pm, e.g. to 150 jim, e.g. to 120 pm, or e.g. to 100 jim. In some embodiments, where the pre-coated synthetic layer has a substantial pre-determined thickness (for example from 200 pm to 500 pm), the thickness of the lower layer of synthetic material may be reduced. In some embodiments, the lower layer of synthetic material may be a partial lower layer of synthetic material having a less substantial thickness than a normal lower layer. Advantages of using a partial lower layer of synthetic material include that the weight saving benefits of the invention are increased even when the pre-coated synthetic layer has a substantial pre-determined thickness.

In some embodiments, the pre-coated synthetic layer may be formed from a suitable plastics material. In some embodiments, the pre-coated synthetic layer may be a laminated pre-coated synthetic layer. In some embodiments, a laminated pre-coated synthetic layer may be formed from a calendered plastics film, e.g. a calendered PVC film.

In some embodiments, the synthetic surface-covering material may be a material suitable for application to a substantially flat surface such as a wall, ceiling or floor (such that the material provides a covering for a sub-floor). In some embodiments, the synthetic surface-covering material may be provided in the form of a roll.

In some embodiments, the surface-covering material may be formed from one or more synthetic materials such as a plastics material such as a polymeric material. Suitable plastics materials include PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyolefin, a thermoplastic elastomer and/or polyacrylate.

In some embodiments, the synthetic composition used to coat the fabric material may be a plastics material such as a polymeric material. In some embodiments, the synthetic composition may comprise a polymer which is compatible with a polymer used to form the surface-covering material. In some embodiments, where a polar polymer such as PVC is used to form the surface-covering material, the synthetic composition may comprise a polymer having a suitable disperse strength and/or a polar group. Suitable plastics materials for use in the synthetic composition include PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyester copolymer such as polyethylene vinyl acetate, a polyolefin, a thermoplastic elastomer and/or polyacrylate.

In some embodiments, the surface-covering material may include one or more of the following layers: a foamed layer, a support layer, a decorative layer, a topcoat layer, a clear wear layer, and/or an external protective coating layer. In some embodiments, the surface-covering material may be a surface-covering material which includes a non-slip layer. In some embodiments, the lower layer of the surface-covering material may be a layer of synthetic material which is a layer of plastics material, a foamed layer of plastics material, a printing layer, or a decorative layer.

In some embodiments, the surface-covering material may include a support layer. In some embodiments, the support layer may be provided on an upper surface of the lower layer. In some embodiments, the support layer may be an optionally woven layer. In some embodiments, the support layer may be formed from fibreglass. In some embodiments, the support layer may be a scrim complex. In some embodiments, the support layer may have an impregnated layer of plastics material.

In some embodiments, the surface-covering material may include a decorative layer provided on an upper surface of the lower layer or of the support layer (if present). In some embodiments, the decorative layer may comprise a printing layer and a printed design layer. In some embodiments, the surface covering material may include a wear layer and optionally an external protective coating layer on an upper surface of the lower layer, of the support layer, or of the decorative layer.

In some embodiments, the printing layer may be suitable for receiving a printed design or having a printed design applied to it by a digital or gravure printer. In some embodiments, the printing layer may have a pigment which is suitable for providing a background to a printed design where such a pigment may have a similar or contrasting colour to one or more colours in the printed design, e.g. a white pigment. In some embodiments, the printing layer may be formed from a plastics material which may comprise, for example, one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyolefin, a thermoplastic elastomer and/or polyacrylate.

In some embodiments, the printed design layer may comprise a decoration applied by a printing process, for example offset lithography, flexography, digital printing, gravure, or screen printing. In some embodiments, the printed design layer may be a digitally printed design layer. In some embodiments, the printed design layer may comprise a latex-based ink.

In some embodiments, the decorative layer may be a layer having a decoration such as a pattern. In some embodiments, a decoration or pattern may comprise one or more decorative elements such as a decorative or coloured chip or particle which may be formed from an optionally coloured polymeric or inorganic material.

In some embodiments, the surface-covering material may include a topcoat layer. A topcoat layer may be used as an alternative to a decorative layer. In some embodiments, the topcoat layer may be pigmented. Benefits of including a pigmented topcoat layer include that where the surface-covering material includes a support layer, the pigmented topcoat layer prevents the support layer from being seen. In some embodiments, the topcoat layer may include one or more decorative elements. In some embodiments, the one or more decorative elements may be formed from glass, a ceramic material, an inorganic material (such as aluminium oxide or silicon carbide), and/or a plastics material (such as PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyolefin, a thermoplastic elastomer and/or polyacrylate). In some embodiments, each of the one or more decorative elements may be in the form of a chip having a visible flat surface, a bead or a sphere.

In some embodiments, the wear layer may comprise a clear plastics material including one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyolefin, a thermoplastic elastomer and/or polyacrylate.

In some embodiments, the non-slip layer may comprise one or more particles suitable for providing a non-slip surface. In some embodiments, the non-slip layer may be provided as part of the wear layer. In some embodiments, the particles of the non-slip layer may be at least partially embedded in the wear layer. In some embodiments, the surface-covering material may have a protective coating layer on an upper surface of the wear layer.

In some embodiments, the foamed layer may comprise a foamed plastics material capable of imparting a sound attenuation effect, for example an acoustic impact sound absorption of more than 10dB. In some embodiments, the acoustic impact sound absorption may be from 4dB, e.g. from 6dB, e.g. from 8dB, 10dB, e.g. from 12dB to 22dB, e.g. to 20dB, e.g. to 18dB, e.g. to 16dB. In some embodiments, the acoustic impact sound absorption may be 12dB, 14dB, 16dB, or 18dB. In some embodiments, the foamed plastics material may be mechanically foamed by incorporating one or more types of compressible plastic spheres. In some embodiments, the foamed plastics material may be chemically foamed by an exothermic or endothermic blowing agent. In some embodiments, the blowing agent may be an azodicarbonamide, modified azodicarbonamide" oxy-bis(benzenesuldonylhydrazide), 5-ohenyltetrazole" p-Toluylensulfonyl-sernicarbazid or p-Toluylensulfonylhycarbazide; for example, the blowing agent may be Hydrocerte (Ciariant) or ToarnazoH (Bergen International). In some embodiments, the foamed layer may comprise one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester and/or polyacrylate.

In some embodiments, the protective coating layer may comprise a cured polymer layer which seals the surface-covering material. In some embodiments, the protective coating layer includes a polyurethane, polyacrylate, urethane acrylate or a PVDF based composition.

In some embodiments, the surface-covering material may be embossed to provide a decorative finish and/or to improve the non-slip properties of the surface-covering material. In some embodiments, the non-slip layer comprises one or more particles suitable for providing a non-slip surface. In some embodiments, the particles may be at least partially embedded in the surface-covering material. In some embodiments, the particles may comprise one or more aggregate materials. In some embodiments, the particles may comprise one or more types of slip resistant particles such as a glass particle (e.g. a recycled glass bead), a silica particle, a silicon carbide particle, a polymeric particle (for example Nylon (Trademark)), a ceramic particle (e.g. porcelain) and/or an aluminium oxide particle. In some embodiments, the particles may be smooth particles. A smooth particle is a particle which has no angular protrusion or indentation, for example a particle which has no protrusion or indentation having an outward facing angle of about 900 or less. In some embodiments, the particles may be one or more of a smooth sphere, bead, and/or grain. The advantage of using a smooth particle in the surface-covering material according to the invention is that the cured coating is easier to clean as the coating lacks any angular surface in which a cleaning material (for example the fibres of a mop) may be caught.

In some embodiments, the step of applying the pre-coated layer to the fabric layer comprises applying a layer of a synthetic composition using lamination or a pre-metered coating technique. In some embodiments, the synthetic composition used to apply the pre-coated layer may be a hot melt coating composition. In some embodiments, suitable pre-metered coating techniques include slot die coating, direct coating, curtain coating, or tensioned web coating. As a skilled person would be aware, it is possible to select the thickness of the pre-coated layer by controlling factors such as the viscosity of the synthetic composition and the pressure. In some embodiments, the step of applying the pre-coated layer to the fabric layer comprises applying a layer of a synthetic composition by thermal lamination and/or by lamination using an adhesive (such as a hot-melt adhesive).

In some embodiments, the step of applying the lower layer may include gelling the lower layer. In some embodiments, the lower layer may be a printing layer and the method of the invention may include a step of applying a printed design layer to the lower layer. In some embodiments, the step of applying a printed design layer may use a roll to roll printing machine. In some embodiments, the printing machine may be a digital printing machine. In some embodiments, the step of applying the lower layer may comprise applying the pre-coated fabric layer to a lower layer of synthetic material such that the pre-coated synthetic layer contacts the lower layer and gelling the lower layer.

In some embodiments, the method may further comprise a step of applying a wear layer to an upper surface of the lower layer or of the printed design layer (for example to an upper surface of the decorative layer) to form an upper layer. In some embodiments, the method may further comprise a step of applying a protective coating layer to an upper surface of the lower layer or of the printed design layer (for example to an upper surface of the wear layer) to form an upper layer. In some embodiments, the method may further comprise a step of applying a non-slip layer to the upper layer (for example to an upper surface of the wear layer or of the protective coating layer).

The invention will now be described with reference to the following Figures of the accompanying drawings which are not intended to limit the scope of the invention in which: Figure 1 shows a schematic cross-section of a first embodiment of a surface-covering material according to the invention which incorporates the pre-coated fabric layer shown in Figure 4; Figure 2 shows a schematic cross-section of a second embodiment of a surface-covering material according to the invention which incorporates the pre-coated fabric layer shown in Figure 4; Figure 3 shows a schematic cross-section of a third embodiment of a surface-covering material according to the invention which incorporates the pre-coated fabric layer shown in Figure 4; and Figure 4 shows a schematic cross-section of a pre-coated fabric layer for use in the surface-covering material according to the invention.

The first embodiment of a surface-covering material according to the invention is indicated generally at 30 on Figure 1. Surface-covering material 30 comprises a pre-coated fabric layer 20 which comprises a fabric layer 22 and a pre-coated synthetic layer 24 on an upper surface of the fabric layer 22 such that the fabric layer 22 has a floor-engaging lower surface 23. Surface-covering material 30 further comprises a lower layer 32 in the form of a foam-forming plastics material comprising a plasticised PVC composition and an azodicarbonamide wherein the foamed PVC lower layer 32 is arranged on an upper surface of the pre-coated synthetic layer 24, a support layer 33 in the form of a non-woven glass fibre layer arranged on an upper surface of the lower layer 32, an impregnation layer formed of plastics material arranged on an upper surface of the support layer 33, a pigmented printing layer 37 formed from a pigmented plasticised PVC composition having a white pigment on an upper surface of the impregnation layer 35, a printed decorative layer 34 on an upper surface of the pigmented printing layer 37, a clear wear layer 36 on an upper surface of the decorative layer 34, and a polyacrylate protective coating layer 38 on an upper surface of the clear wear layer. The pre-coated synthetic layer 24 may comprise one or more of the following polymers: PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester and/or polyacrylate. The surface-covering material 30 is suitable for use as a covering material for a ceiling, wall, and/or floor. The protective coating layer 38 comprises a cured polymer layer.

The second embodiment of a surface-covering material according to the invention is indicated generally at 130 on Figure 2. Like features of the second embodiment to the first embodiment of the surface-covering material are identified by like reference numerals. Surface-covering material 130 comprises the layers of a surface-covering material 30 according to the first embodiment which are the pre-coated fabric layer 20, the lower layer 32 in the form of a foamed PVC layer, a support layer 33, an impregnation layer 35, a pigmented printing layer 37, a printed decorative layer 34, a wear layer 36, and a protective coating layer 38. In addition, the floor covering material 130 comprises a non-slip layer 40 applied to an upper surface of the protective coating layer 38. Non-slip layer 40 comprises one or more particles 42 suitable for providing a non-slip surface wherein such particles 42 are at least partially embedded in the wear layer 36. The particles 38 may comprise one or more types of slip resistant particles such as aluminium oxide, silicon carbide, quartz and/or glass. The surface-covering material 130 is suitable for use as a covering material for a floor as the non-slip surface is intended to reduce the risk of a person slipping when walking on the floor-covering material.

The printed decorative layer 34 may be applied by any known suitable printing technique such as digital printing or gravure printing on the pigmented printing layer 37. The pigmented printing layer 37 is formulated to be suitable for receiving the printed decorative layer 34.

Suitable polymers for use in the protective coating layer 38 include polyurethane, polyacrylate, urethane acrylate or a PVDF based composition. A suitable coating composition for forming protective coating layer 38 is a UV curable mixture containing from 20 to 30 parts by weight of oxybis(methy1-2,1-ethanediy1) diacrylate, from 10 to less than 20 parts by weight of 2-phenoxyethyl acrylate, from to less than 20 parts by weight of acrylate resin, from 2.5 to 5 parts by weight of (1-methyl-1,2-ethanediyObis[oxy(methy1-2,1-ethanediy1)] diacrylate, from 1 to 5 parts by weight of benzophenone and from 1 to 5 parts by weight of 1-6,hexanedioldiacrylate was prepared. The surface-covering material 30 is suitable for use as a covering material for a ceiling, wall, and/or floor.

The third embodiment of a surface-covering material according to the invention is indicated generally at 230 on Figure 3. Like features of the third embodiment to the first embodiment of the surface-covering material are identified by like reference numerals. Surface-covering material 230 is a simpler surface-covering which does not include an impregnation layer 35, a pigmented printing layer 37 and a printed decorative layer 34. Instead a pigmented topcoat layer 236 is provided directly on the support layer 33. Also, the lower layer 332 is not foamed. Surface-covering material 230 comprises a pre-coated fabric layer 20 which comprises a fabric layer 22 and a pre-coated synthetic layer 24 on an upper surface of the fabric layer 22 such that the fabric layer 22 has a floor-engaging lower surface 23. Surface-covering material 230 further comprises a lower layer 232 of synthetic material arranged on an upper surface of the pre-coated synthetic layer 24, a support layer 33 in the form of a scrim complex arranged on an upper surface of the lower layer 232, a pigmented topcoat layer 236 on an upper surface of the support layer 33, a polyacrylate protective coating layer 38 on an upper surface of the pigmented topcoat layer, and a non-slip layer 40 applied to an upper surface of the protective coating layer 38. The surface-covering material 230 is suitable for use as a covering material for a floor as the non-slip surface is intended to reduce the risk of a person slipping when walking on the floor-covering material 230.

The surface-covering material 30,130,230 may optionally be embossed. The surface-covering material 30,130,230 may be provided as a roll of surface-covering material or may optionally be cut up into tiles.

The fabric layer 22 used in the pre-coated fabric layer 20 is formed from a brushed fabric layer 22 having a thickness of from 0.5 to 1.5 mm and a weight of from 90-450g/m2 such that the pre-coated fabric layer 20 imparts a sound attenuation effect, for example an acoustic impact sound reduction of 12, 13, 14, 15, 16, 17, 18, 19, or 20dB.

A pre-coated fabric layer for use in the surface covering according to the invention is indicated generally at 20 on Figure 4. Pre-coated fabric layer 20 has a fabric layer 22 and a thin pre-coated synthetic layer 24 having a thickness of 100p.m. The fabric layer 22 is formed from a brushed polyester sheet such as a polyester fleece. The pre-coated synthetic layer 24 is formed from polyurethane. The pre-coated synthetic layer 24 is applied to the fabric layer 22 using a slot die coating head. In an alternative embodiment, the fabric layer 22 may be formed from glass-fibre, vinylon fibre, high-density polyethylene fibre, aramid fibre, carbon fibre, cellulose, and/or polyester fibre. In an alternative embodiment, the pre-coated synthetic layer 24 may be formed from a different polymeric material such as PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, a polyester copolymer such as polyethylene vinyl acetate, a polyolefin (e.g. polyethylene), a thermoplastic elastomer and/or polyacrylate. In an alternative embodiment, the pre-coated plastic layer may be applied using a hot melt coating.

The invention will now be illustrated with reference to the following Example which is not intended to limit the scope of the claimed invention.

EXAMPLE 1

The method of the invention was performed to prepare a surface covering 30 according to the first embodiment of the invention having a digitally printed decorative layer 34 by carrying out the following steps: a. coating a non-woven glass fibre support layer with an impregnation layer of plastics material and gelling (the coating) on a heated drum; b. Applying a printing layer formed from a pigmented plasticised PVC composition where the pigment is white; c. gelling the white printing layer on a heated drum; d. Winding the layered product on a jumbo roll; e. Loading the jumbo roll onto a roll-to-roll digital printer; f. Printing onto the surface of the white printing layer using digital printing to form a decorative layer having a digitally printed design; g. Curing and/or drying the printed ink with heat and/or radiation; h. Inverting the printed layered product; Applying a backing layer comprising a foam-forming plastics material comprising a plasticised PVC composition and an azodicarbonamide j. Applying the pre-coated fabric to the backing layer, such that the pre-coated side makes contact with the plasticised PVC composition k. Gelling the backing layer on a heated drum; Inverting the product; m. Applying a wear layer comprising a clear plastics material having a plasticised PVC composition; n. Gelling the wear layer in an oven to form a surface-covering material according to the first embodiment of the invention; o. Embossing the wear layer; p. Cooling the embossed surface-covering material according to the first embodiment of the invention; cl. Applying a polyacrylate protective coating layer and curing it to form a surface-covering material according to the second embodiment of the invention; r. Winding the product into a roll of the required length; and optionally s. Cutting the product into tiles.

To form a surface-covering material according to the second embodiment of the invention, the method of the invention may additionally include after step n: a step n1 of applying a layer of particulate material to the wear layer to form a non-slip layer.

EXAMPLE 2

The method of the invention was performed to prepare a surface covering 30 according to the first embodiment of the invention having a gravure printed decorative layer 34 by carrying out the following steps: a. coating a non-woven glass fibre support layer with an impregnation layer of plastics material and gelling (the coating) on a heated drum; b. Applying a printing layer formed from a pigmented plasticised PVC composition where the pigment is white; c. gelling the white printing layer on a heated drum; d. Printing onto the surface of the white printing layer using gravure printing to form a decorative layer; e. Drying the printed ink with heat; f. Inverting the printed layered product; g. Applying a backing layer comprising a foam-forming plastics material comprising a plasticised PVC composition and an azodicarbonamide h. Applying the pre-coated fabric to the backing layer, such that the pre-coated side makes contact with the plasticised PVC composition Gelling the backing layer on a heated drum; j. Inverting the printed layered product; k. Applying a wear layer comprising a clear plastics material having a plasticised PVC composition; Gelling the wear layer in an oven to form a surface-covering material according to the first embodiment of the invention; m. Embossing the wear layer; n. Cooling the embossed surface-covering material; a Applying a polyacrylate protective coating layer and curing it to form a surface-covering material according to the first embodiment of the invention; p. Winding the product into a roll of the required length; and optionally q. Cutting the product into tiles.

To form a surface-covering material according to the second embodiment of the invention, the method of Example 2 may additionally include after step I: a step 11 of applying aggregate material and/or decorative PVC chips to the wear layer to form a non-slip layer.

EXAMPLE 3

The method of the invention was performed to prepare a surface covering 230 according to the third embodiment of the invention by carrying out the following steps: a. Coating a scrim complex with a lower layer comprising a PVC plastisol; b. Applying the pre-coated fabric to the PVC plastisol, such that the pre-coated side comes into contact with the PVC plastisol; c. Gelling the plastisol in an oven; d. Inverting the product; e. Applying a pigmented topcoat layer comprising a PVC plastisol to the reverse side of the scrim complex; f. Applying aggregate material (e.g. silicon carbide, quartz) and/or decorative elements (such as PVC chips) to the upper surface of the top layer; g. Gelling the plastisol in an oven; h. Embossing of the surface of the top layer; Applying a polyacrylate protective coating layer and curing it to form a surface-covering material according to the third embodiment of the invention; J. Winding the product into a roll of the required length; and optionally k. Cutting the product into tiles.

Claims (17)

1. CLAIMS1. A synthetic surface-covering material comprising a pre-coated fabric layer and one or more synthetic layers including a lower layer wherein the pre-coated fabric layer comprises a fabric layer and a pre-coated synthetic layer for bonding the fabric layer to the lower layer.
2. 2. A surface-covering material as defined in Claim 1 wherein the fabric layer is a low shrinkage fabric layer which does not shrink substantially on heating.
3. 3. A surface-covering material as defined in Claim 1 or Claim 2 wherein the fabric layer has a shrinkage in one or two dimensions of less than 3%.
4. 4. A surface-covering material as defined in any one of the preceding Claims wherein the fabric layer has a thickness of from 0.2mm to 4mm.
5. S. A surface-covering material as defined in any one of the preceding Claims wherein the pre-coated synthetic layer has a thickness which is less than 50% of the thickness of the fabric layer.
6. 6. A surface-covering material as defined in any one of the preceding Claims wherein the pre-coated synthetic layer has a thickness of from 10 to 500 p.m.
7. 7. A surface-covering material as defined in any one of the preceding Claims wherein the fabric layer is formed from a woven or a non-woven fabric.
8. 8. A surface-covering material as defined in any one of the preceding Claims wherein the fabric layer is formed from polymeric fibres.
9. 9. A surface-covering material as defined in any one of the preceding Claims which includes one or more of the following layers: a foamed layer, a support layer, a decorative layer, a topcoat layer, a clear wear layer, and/or an external protective coating layer.
10. 10. A surface-covering material as defined in any one of the preceding Claims which is a floor-covering material which includes a non-slip layer.
11. 11. A surface-covering material as defined in any one of the preceding Claims wherein the lower layer is a layer of plastics material, a foamed layer, a printing layer, or a decorative layer.
12. 12. A surface-covering material as defined in any one of the preceding Claims wherein the pre-coated synthetic layer comprises a polyester; preferably the polyester is a vinyl acetate copolymer; preferably the polyester is ethylene vinyl acetate.
13. 13. A pre-coated fabric layer comprising a fabric layer and a pre-coated synthetic layer for bonding the fabric layer to a lower layer of a synthetic surface covering.
14. 14. A pre-coated fabric layer as defined in Claim 13 wherein the pre-coated synthetic layer comprises a polyester; preferably the polyester is a vinyl acetate copolymer; preferably the polyester is ethylene vinyl acetate.
15. 15. A method of preparing a synthetic surface covering as defined in any one of Claims 1 to 12 which method comprises the steps of: Providing a layer of fabric material; Coating the fabric material with a synthetic composition to form a pre-coated fabric layer; and Applying a lower layer of synthetic material to the pre-coated synthetic layer.
16. 16. A method as defined in Claim 15 wherein the step of applying the pre-coated layer to the fabric layer comprises applying a layer of a synthetic composition using a pre-metered coating technique.
17. 17. A method as defined in Claim 15 or Claim 16 wherein the synthetic composition used to apply the pre-coated layer is a hot melt coating composition or is a synthetic film for lamination.Amendments to the claims have been filed as allowsCLAIMS1. A synthetic surface-covering material comprising a pre-coated fabric layer and one or more synthetic layers including a lower layer wherein the pre-coated fabric layer comprises a fabric layer and a pre-coated synthetic layer for bonding the fabric layer to the lower layer; wherein the surface is a floor, wall, or ceiling; and wherein the one or more synthetic layers include a decorative layer and an external protective coating layer.2. A surface-covering material as defined in Claim 1 wherein the fabric layer is a low shrinkage fabric layer which does not shrink substantially on heating.3. A surface-covering material as defined in Claim 1 or Claim 2 wherein the fabric layer has a shrinkage in one or two dimensions of less than 3%.4. A surface-covering material as defined in any one of the preceding Claims wherein the fabric layer has a thickness of from 0.2mm to 4mm.5. A surface-covering material as defined in any one of the preceding Claims wherein the pre-coated synthetic layer has a thickness which is less than 50% of the thickness of the fabric layer.C\I 15 6. A surface-covering material as defined in any one of the preceding Claims wherein the pre-coated synthetic layer has a thickness of from 10 to 500 CD 7. A surface-covering material as defined in any one of the preceding Claims wherein the fabric CO layer is formed from a woven or a non-woven fabric.8. A surface-covering material as defined in any one of the preceding Claims wherein the fabric layer is formed from polymeric fibres.9. A surface-covering material as defined in any one of the preceding Claims which includes one or more of the following layers: a foamed layer, a support layer, a topcoat layer, and/or a clear wear layer.10. A surface-covering material as defined in any one of the preceding Claims which is a floor-covering material which includes a non-slip layer.11. A surface-covering material as defined in any one of the preceding Claims wherein the lower layer is a layer of plastics material, a foamed layer, a printing layer, or a decorative layer.12. A surface-covering material as defined in any one of the preceding Claims wherein the pre-coated synthetic layer comprises a polyester; preferably the polyester is a vinyl acetate copolymer; preferably the polyester is ethylene vinyl acetate.13. A method of preparing a synthetic surface covering as defined in any one of Claims 1 to 12 which method comprises the steps of: Providing a layer of fabric material; Coating the fabric material with a synthetic composition to form a pre-coated fabric layer; and Applying a lower layer of synthetic material to the pre-coated synthetic layer; Applying a decorative layer; and Applying an external protective coating layer; wherein the surface is a floor, wall, or ceiling.14. A method as defined in Claim 13 wherein the step of applying the pre-coated layer to the fabric layer comprises applying a layer of a synthetic composition using a pre-metered coating technique.15. A method as defined in Claim 13 or Claim 14 wherein the synthetic composition used to apply the pre-coated layer is a hot melt coating composition or is a synthetic film for lamination. C\ICO CO