WO2003100162A2 - Revetement de sol - Google Patents

Revetement de sol Download PDF

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Publication number
WO2003100162A2
WO2003100162A2 PCT/GB2003/002252 GB0302252W WO03100162A2 WO 2003100162 A2 WO2003100162 A2 WO 2003100162A2 GB 0302252 W GB0302252 W GB 0302252W WO 03100162 A2 WO03100162 A2 WO 03100162A2
Authority
WO
WIPO (PCT)
Prior art keywords
plastics material
layer
floor covering
support
ionomer
Prior art date
Application number
PCT/GB2003/002252
Other languages
English (en)
Other versions
WO2003100162A3 (fr
Inventor
Barry Peter Hall
Original Assignee
Altro Limited
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 Altro Limited filed Critical Altro Limited
Priority to AU2003232347A priority Critical patent/AU2003232347A1/en
Publication of WO2003100162A2 publication Critical patent/WO2003100162A2/fr
Publication of WO2003100162A3 publication Critical patent/WO2003100162A3/fr

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Classifications

    • 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
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0052—Compounding ingredients, e.g. rigid elements
    • D06N7/0055—Particulate material such as cork, rubber particles, reclaimed resin particles, magnetic particles, metal particles, glass beads
    • 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
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0057—Layers obtained by sintering or glueing the granules together

Definitions

  • the present invention provides a new slip resistant floor covering which is stain resistant and a method for manufacturing the floor covering.
  • a floor covering is generally manufactured having a roughened surface which can be created by embossing its surface and/or by the addition of particulate material to the main component of the floor covering during manufacture.
  • the roughened surface of the flooring increases the risk of dirt being trapped on the surface.
  • the dirt depending on its nature, can be compatible with components of the flooring resulting in absorption of the dirt into the surface giving rise to a stain.
  • a non- laminated plastics floor covering including a first layer of plastics material having an upper surface and a first particulate material embedded in the layer of plastics material and exposed at the upper surface to provide slip resistance, wherein the layer of plastics material is substantially free from a plasticiser.
  • the invention therefore provides a floor covering with enhanced slip resistance having improved stain resistance without affecting the effectiveness of the life of non-slip properties which are achieved by including the particulate material.
  • the floor covering according to the invention is non-laminated which generally means that it is not formed from separate layers of plastics material which have been laminated together. Problems with floor coverings manufactured in this way include de-lamination of the layers and retention of the particulate material. It has been found that when a floor covering is formed from laminated layers there is a problem with sufficiently embedding the particulate material in the layers so that the floor covering is slip resistant.
  • a method of making a slip-resistant floor covering including the steps of:- applying a layer of a plastics material which is substantially free from a plasticiser; applying a first particulate material; melting or curing the plastics material.
  • the method according to the second aspect of the invention is preferably a method of making a floor covering according to the invention.
  • the layer of plastics material may be applied to a belt from which the floor covering made by the method can be removed, e.g. an optionally glass filled PTFE belt support.
  • the first layer may be applied to a support.
  • the support generally has an upper surface and a lower surface. Where the first layer is applied to the support, it is applied to the upper surface.
  • the lower surface of the support is optionally coated with a second layer of plastics material before or after the method of the invention is performed.
  • the floor covering according to the invention consists essentially of a support having an upper surface and a lower surface wherein on the upper surface of the support there is a first layer of plastics material having an upper surface and a first particulate material embedded in the first layer of plastics material and exposed at the upper surface of the plastics material to provide slip resistance and on the lower surface of the support there is optionally a second layer of plastics material.
  • the method also includes the step of applying the layer of plastics material which is substantially free from a plasticiser in two or more stages such that the composition and/or properties of the plastics material in the layer can be varied.
  • the layer of plastics material may therefore have a lower part applied in a first stage and upper part(s) applied in a second or subsequent stage.
  • the plastics material used to form the upper part may optionally have better wear resistance, greater scratch resistance and/or improved surface hardness than the plastics material applied in the first stage.
  • the method of the invention preferably includes one or more steps of cohering the layer of plastics material after application of one stage and before a further stage is applied to reduce scattering of the plastics material and mixing between the different parts.
  • the cohering step generally involves partially sintering the particles of the plastics material (e.g. with heat and/or radiation). This is in order to prevent the powder being blown off the layer of plastics material on entering the oven.
  • the cohering step preferably involves the application of heat and/or infrared radiation.
  • the plastics material is optionally cooled after the cohering step and before the application of a further stage.
  • the plastics material applied in the method of the invention includes an ionomer and/or a foaming agent.
  • the plastics material applied in the second or subsequent stage includes an ionomer.
  • the plastics material applied in the first stage preferably includes a foaming agent such that the lower part of the layer of plastics material is flexible.
  • the first particulate material preferably penetrates the lower part of the layer which is useful as it means that the particulate material is more securely embedded in the floor covering.
  • An ionomer is a copolymer of an olefin monomer and a polymerisable carboxylic acid monomer (e.g. acrylic acid or methacrylic acid) which has been at least partially neutralised by a metal cation such as sodium, lithium, zinc or magnesium.
  • a metal cation such as sodium, lithium, zinc or magnesium.
  • the bivalent metal ions reversibly cross-link adjacent carboxylate groups and therefore modify the properties of the polymer or copolymer.
  • Different methods for the preparation of ionomers are described in European patent application EP-A-0 847 406.
  • a method of making a floor covering including a layer of plastics material wherein a portion of the plastics material includes an ionomer which method includes the steps of applying at least a part of a layer of plastics material including a copolymer of an olefin monomer and a polymerisable carboxylic acid monomer; applying a compound including a metal cation to the surface of the part of the layer of plastics material; curing the plastics material such that the metal cation at least partially neutralises the carboxylic acid monomer.
  • the advantage of the method according to the third aspect of the invention is that the portion of the plastics material which includes an ionomer can be carefully controlled. Including an ionomer in a floor covering is advantageous because it increases the wear resistance.
  • the particulate material included in the floor covering according to the invention provides wear resistance but for some applications, for example where the floor covering may be subjected to heavy traffic, it may be desirable to improve the wear resistance by including an ionomer.
  • inclusion of an ionomer also increases the stiffness of a floor covering. This is a potential problem because it is important for a floor covering to be flexible especially as it is normally supplied in a roll.
  • the advantage of increased wear resistance at that surface is obtained without the disadvantage of increased stiffness throughout that part of the layer which would normally occur if the plastics material applied included a pre-formed ionomer.
  • the portion of the layer of plastics material which includes an ionomer is an upper portion of the layer, more preferably it is the upper surface of the layer.
  • the said compound is applied by sprinkling, spraying or spreading.
  • the method of the third aspect of the invention may optionally be included as steps of the method according to the second aspect of the invention.
  • the compound including a metal cation is preferably a salt of a metal cation or, more preferably, a base or metal oxide.
  • Bases which are suitable for use as the said compound are those which are strong enough to neutralise the carboxylic acid groups of the monomer. Examples of bases include NaOH, KOH, Mg(OH) 2 , Ca(OH) 2 or Zn(OH) 2 . Examples of metal oxides include MgO, CaO, ZnO, K 2 O.
  • Suitable salts include silicates such as Na 2 SiO 3 , carbonates such as Na 2 CO 3 , CaCO 3 , borates (such as sodium borate, potassium borate etc), and/or phosphates.
  • a suitable foaming agent is an azodicarbonamide or a gas filled microsphere such as that marketed under the name Expancel by Akzo Nobel.
  • the plastics material preferably further includes additives commonly used in the art such as a UN stabiliser system, a biocide, a dry flow aid such as fumed silica, and/or a static dissipator.
  • additives commonly used in the art such as a UN stabiliser system, a biocide, a dry flow aid such as fumed silica, and/or a static dissipator.
  • the plastics material used in the invention is preferably substantially free from PNC. More preferably, the plastics material used in the invention is a thermoplastic polymer and/or a thermoplastic elastomer. More preferably it is a thermoplastic polymer, particularly a thermoplastic polymer such as EVA (an ethylene vinyl acetate copolymer), a polyethylene-acrylic acid copolymer, a terpolymer (e.g. of ethylene/alkyl acrylate/maleic anhydride), and/or a copolymer of ethylene and methacrylic acid (e.g. that sold under the brand name ⁇ ucrel by Du Pont) .
  • EVA an ethylene vinyl acetate copolymer
  • a polyethylene-acrylic acid copolymer e.g. of ethylene/alkyl acrylate/maleic anhydride
  • terpolymer e.g. of ethylene/alkyl acrylate/maleic anhydride
  • thermoplastic elastomers examples include: styrene triblock copolymers (e.g. polystyrene polybutadiene polystyrene block copolymers or polystyrene polyisoprene polystyrene block copolymers), blends of thermoplastic elastomers and thermoplastic polymers (e.g.
  • thermoplastic polyurethanes polyyester or polyether based
  • thermoplastic copolyesters thermoplastic copolyesters
  • the plastics material applied in the first stage preferably includes a second particulate material dispersed therein to further improve the non-slip properties of the flooring covering and/or to enhance the hardness and/or the wear resistance of the flooring covering during the life of the product.
  • the floor covering may optionally contain decorative elements such as a pigment, pigmented particles (e.g. pigmented silicon carbide particles), optionally coloured or transparent silica chips and/or fine particles, and/or optionally coloured plastics chips.
  • decorative elements such as a pigment, pigmented particles (e.g. pigmented silicon carbide particles), optionally coloured or transparent silica chips and/or fine particles, and/or optionally coloured plastics chips.
  • the plastics chips are formed from the plastics material used to form the floor covering.
  • the floor covering preferably includes a support, especially a reinforcing support; the support is preferably a glass fibre reinforced non-woven support.
  • the support generally has an upper and a lower surface.
  • the first layer of plastics material is applied to the upper surface of the support; a second layer of plastics material is optionally applied to the lower surface of the support.
  • the first and/or second particulate material is preferably a grit; more preferably it is one or more of a number of types of hard particles including silicon carbide, a silica (e.g. quartz, a coloured or natural sand or a flint) , aluminium oxide and/or emery.
  • the melting or curing step will normally involve the application of heat e.g. by forced air convection optionally with the application of infra red radiation.
  • the method preferably includes a step of cohering the plastics material.
  • the plastics material is preferably cohered by the application of infra red heat. This step is advantageous as it alleviates the problem of 'craters' being formed on the upper surface of the plastics material when the first particulate material is applied.
  • the first particulate material is optionally applied in a manner such that its kinetic energy on impact with the plastics material is minimised, e.g. by applying the first particulate material through a sieve arranged close to the upper surface of the plastics material.
  • the plastics material has not been sintered prior to application of the surface grits, then it should preferably be sintered before it is melted or cured.
  • the plastics material is preferably sintered by the application of infra red heat. This step is particularly useful when a convection oven is used in the curing step. This is because there can be strong air-flows in a convection oven which can potentially blow the plastics material around the oven, particularly when the plastics material is applied in powder form.
  • the method optionally includes the steps of embossing the floor covering, cooling the floor covering and/or winding it up and trimming it to length.
  • the plastics material is preferably applied in the form of a powder, granules or pellets; more preferably in the form of a powder. Preferably it is applied to the desired thickness using knife over roller or knife over air.
  • the plastics material is optionally a thermoplastic plastics material, for example a thermoplastic elastomer.
  • the floor covering material is embossed.
  • Figure 1 shows a production line suitable for use in the method of manufacturing according to the invention.
  • Figure 2 shows a schematic cross-sectional view of a floor covering according to the invention.
  • Figure 1 shows a schematic cross-sectional view of key elements of a production line 1.
  • the line 1 has a belt 9 which runs from roller 13 past roller 17 in direction 15.
  • the belt 9 is in the form of a glass re-inforced closed mesh PTFE filled material.
  • a scrim 10 is provided on belt 9.
  • the scrim 10 is in the form of a non- woven glass fibre support for the floor covering.
  • the scrim 10 is optionally coated with plastics material, particularly on its reverse side.
  • the scrim 10 may be provided in the form of a glass fibre crenette over a cellulose/polyester non- woven support.
  • dispensers 3a, 3b, 3c There are three dispensers 3a, 3b, 3c arranged sequentially near the start of production line 1. Each dispenser 3a, 3b, 3c has a receptacle for plastics material 5a, 5b, 5c and a doctor blade 7a, 7b, 7c.
  • the production line 1 also includes an infra-red heater 19, a scatter head for grits 21 , a second infra-red heater 23, a curing oven 11 and a patterned emboss roller 14 over a smooth rubber nip roller 16.
  • the receptacles 5a, 5b of the first two dispensers 3a, 3b are filled with plastics material.
  • Dispenser 3a supplies a layer of the first plastics material onto the belt which is levelled to a first height by doctor blade 7a.
  • Dispenser 3b supplies a layer of a second plastics material onto the first plastics material. The layer of a second plastics material is levelled to a second height by doctor blade 7b.
  • the two layers of plastics material are then cohered by the application of infra-red radiation to the upper surface of the second plastics material by infra-red heater 19.
  • a particulate material in the form of grits is then applied to the cohered upper surface of the second plastics material by scatter head 21.
  • the combination of layers of plastics material and particulate material is then sintered by the application of further infra-red radiation by infra-red heater 21 before being cured in the oven 11 to form a floor covering which is then nipped between an embossing roller 14 and a rubber roller 16 before being cut to length and rolled up.
  • the receptacles 5a, 5b of the first two dispensers 3a, 3b are filled with plastics material.
  • Dispenser 3 a supplies a layer of a first plastics material onto the belt which is levelled to a first height by doctor blade 7a.
  • the layer of plastics material is then cohered by the application of infra-red radiation to its upper surface by infra-red heater 19.
  • the coated scrim thus formed is cooled and then put through the production line a second time.
  • Dispenser 3b supplies a layer of a second plastics material onto the first layer of plastics material.
  • the layer of the second plastics material is levelled to a second height by doctor blade 7b.
  • the second layer of plastics material is then cohered by the application of infra-red radiation to the upper surface of the second plastics material by infra-red heater 19.
  • a particulate material in the form of grits is then applied to the cohered upper surface of the second plastics material by scatter head 21.
  • the combination of layers of plastics material and particulate material is then sintered by the application of further infra-red radiation by infra-red heater 21 before being cured in the oven 11 to form a floor covering which is then nipped between an embossing roller 14 and a rubber roller 16 before being cut to length and rolled up.
  • FIG. 2 A schematic cross-section of a floor covering 31 according to the invention is shown in Figure 2.
  • Floor covering 31 includes a base portion 35, an upper portion 37 and a support 53.
  • Particulate material 41 in the upper portion 37 penetrates the base portion 35 and is proud of the upper surface of the upper portion 37.
  • Particulate material 43 is also in the upper portion 37 and is substantially smaller than particulate material 41.
  • Particulate material 43 is also proud of the upper surface of the upper portion 37.
  • Nucrel 925 and 960 are copolymers of ethylene and methacrylic acid supplied by DuPont. Surlyn 9910 is an ionomer also supplied by DuPont. ON320 is a grade of aluminium trihydrate supplied by OMYA. Irganox 1010, Tinuvin 770 and Tinuvin 328 are antioxidants supplied by Ciba Geigy. Expancel DU120 are microspheres (containing isopentane) supplied by Akzo Nobel. EXAMPLE 2
  • the ingredients of formulation A were weighed and blended by being tumbled together.
  • the blend was extruded in a Werner and Pfleiderer extruder (model number ZSK 70) with the feed zone temperature set at 160°C, and the barrel/die set at 200°C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 40 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -150°C.
  • the mill was maintained at -150°C during grinding. 99% of the resulting powder was of a size below 250 ⁇ m.
  • the resultant powder was blended by tumble mixing with 0.2% aluminium oxide C supplied by Degussa corporation.
  • the resultant powder was then spread coated on to a scrim to a thickness of 5 mm by knife over roller.
  • the scrim was a 2 m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '3x3' 68 tex glass crennette moving at a rate of 5 m/minute. Particles of coloured quartz of a size in the range 0.7 - 1.2 mm were then scattered on to the surface of the powder at a rate of 100 g/m 2 .
  • the coated scrim was then passed under a 50 kW medium wave infra red heater (height 10 cm above the coated scrim; width 2.5 m; length 1 m) . The power output was adjusted in order to partially sinter the powder.
  • formulation B The ingredients of formulation B were weighed and blended by being tumbled together.
  • the blend was extruded in a Werner and Pfleiderer extruder (model number ZSK 70) with the feed zone temperature set at 160°C, the barrel set at 190°C and the die at 200°C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 40 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -120° C.
  • the mill was maintained at -120°C during grinding. 99% of the resulting powder was of a size below 400 ⁇ m.
  • the resultant powder was then applied on to a scrim to a thickness of 2 mm by using knife over roller.
  • the scrim was a 2 m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '4x4' 34 tex glass crennette moving at a rate of 3 m/minute.
  • the coated scrim was then passed under a 50 kW medium wave infra red heater (height 10 cm above the coated scrim; width 2.5 m; length 1 m) .
  • the power output was adjusted in order to partially sinter the powder.
  • Particles of quartz of a size in the range 0.4-0.8 mm were then scattered on to the surface of the powder at a rate of 100 gnr 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 195°C for 2.5 minutes before being embossed and cooled.
  • the scrim was then further coated with powder of formulation A (made as described in Example 2).
  • Formulation A was spread on to the resulting scrim to an additional thickness of 3 mm by knife over roller. This time the powder of formulation A had been pre-blended by tumbling with 10% (w/w) aluminium oxide (Washington Mills) size F40 (FEPA Standard 42- GB-1984) and 5% (w/w) Activox B (zinc oxide) supplied by Elementis Specialities.
  • the coated scrim was then passed under a 50 kW medium wave infra red heater (height 10 cm above the coated scrim; width 2.5 m; length 1 m) . The power output was adjusted in order to partially sinter the powder.
  • Particles of coloured quartz of a size in the range 0.4-0.8 mm were then scattered on to the surface of the powder at a rate of 100 gnr 2 .
  • Particles of silicon carbide size F40 (FEPA Standard 42-GB- 1984) were then scattered on to the surface at a rate of 100 g m 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 200 °C for 2.5 minutes before being embossed, cooled and wound up for subsequent trimming to size.
  • the ingredients of formulation C were weighed and blended by being tumbled together.
  • the blend was extruded in a Werner and Pfleiderer extruder (model number ZSK 70) with the feed zone temperature set at 160° C, and the barrel/die set at 200°C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 40 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -150° C.
  • the mill was maintained at -150°C during grinding. 99% of the resulting powder was of a size below 400 ⁇ m.
  • the resultant powder was then spread coated on to a scrim to a thickness of 5 mm by knife over roller.
  • the scrim was a 0.5 m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '3x3' 34 tex glass crennette moving at a rate of 1 m/minute. Particles of coloured quartz of a size in the range 0.7-1.2 mm were then scattered on to the surface of the powder at a rate of 100 g/m 2 .
  • the scrim was then passed under a 4 kW medium wave infra red heater (height 5 cm above the coated scrim; width 0.6m; length 0.4m). The power output was adjusted in order to partially sinter the powder.
  • Particles of silicon carbide size F40 (FEPA Standard 42-GB-1984) were then scattered on to the surface at a rate of 100 gnr 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 190°C for 3 minutes before being embossed, cooled and wound up for subsequent trimming to size.
  • formulation A The ingredients of formulation A were weighed and blended by being tumbled together.
  • the blend was extruded in a Werner and Pfleiderer extruder (model number ZSK 70) with the feed zone temperature set at 160°C, and the barrel/die set at 200° C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 40 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -150°C.
  • the mill was maintained at -150°C during grinding. 99% of the resulting powder was of a size below 250 ⁇ m.
  • the resultant powder was then applied on to a scrim to a thickness of 5mm by using a Cavistat 91 Pulverstreuaggregat conventional powder scatter head (manufactured by Cavitec) .
  • the scrim was a 0.5 m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '4x4' 34 tex glass crennette moving at a rate of 1 m/minute.
  • the scrim was then passed under a 4 kW medium wave infra red heater (height 5cm above the coated scrim; width 0.6m; length 0.4m). The power output was adjusted in order to partially sinter the powder.
  • Particles of quartz of a size in the range 0.4-0.8mm were then scattered on to the surface of the powder at a rate of 100 g m 2 .
  • Particles of silicon carbide size F40 (FEPA Standard 42-GB-1984) were then scattered on to the surface at a rate of 100 gnr 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 195°C for 3 minutes before being embossed and cooled.
  • Desmopan is a polyurethane supplied by Bayer.
  • Arnitel is a polyetherester supplied by DSM.
  • Pebax is a polyetheramide supplied by Atofina.
  • Alcryn is an olefinic type TPE supplied by DuPont.
  • ON320 is aluminium trihydrate supplied by OMYA.
  • Blue BLP is a phthalocyanine blue pigment supplied by Ciba Pigments.
  • the ingredients of formulation D were weighed and blended by being tumbled together.
  • the blend was extruded in an extruder with a single screw with L:D ratio of 20 and a compression ratio of 1:3, maintaining the melt temperature in the region of 180-200 °C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 80 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -120°C.
  • the mill was maintained at -120 °C during grinding. 99% of the resulting powder was of a size below 400 ⁇ m.
  • the resultant powder was then applied on to a scrim to a thickness of 5mm by using a Cavistat 91 Pulverstreuaggregat conventional powder scatter head (manufactured by Cavitec) .
  • the scrim was a 0.5m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '4x4' 34 tex glass crennette moving at a rate of 1 m/minute.
  • the coated scrim was then passed under a 4 kW medium wave infra red heater (height 5cm above the coated scrim; width 0.6m; length 0.4m). The power output was adjusted in order to partially sinter the powder.
  • Particles of quartz of a size in the range 0.4-0.8mm were then scattered on to the surface of the powder at a rate of 100 gnr 2 .
  • Particles of silicon carbide size F40 (FEPA Standard 42-GB-1984) were then scattered on to the surface at a rate of 100 gnr 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 200 °C for 3 minutes before being embossed and cooled.
  • the ingredients of formulation E were weighed and blended by being tumbled together.
  • the blend was extruded in an extruder with a single screw with L:D ratio of 20 and a compression ratio of 1 :3, maintaining the melt temperature in the region of 180-200°C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 60 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -140° C.
  • the mill was maintained at -140 °C during grinding. 99% of the resulting powder was of a size below 400 ⁇ m.
  • the resultant powder was then applied on to a scrim to a thickness of 5mm by using a Cavistat 91 Pulverstreuaggregat conventional powder scatter head (manufactured by Cavitec) .
  • the scrim was a 0.5m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '4x4' 34 tex glass crennette moving at a rate of 1 m/minute.
  • the scrim was then passed under a 4 kW medium wave infra red heater (height 5cm above the coated scrim; width 0.6m; length 0.4m). The power output was adjusted in order to partially sinter the powder.
  • Particles of quartz of a size in the range 0.4-0.8mm were then scattered on to the surface of the powder at a rate of lOOgnr 2 .
  • Particles of silicon carbide size F40 (FEPA Standard 42-GB-1984) were then scattered on to the surface at a rate of lOOgnr 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 200 °C for 3 minutes before being embossed and cooled.
  • the ingredients of formulation F were weighed and blended by being tumbled together.
  • the blend was extruded in an extruder with a single screw with L:D ratio of 20 and a compression ratio of 1 :3, maintaining the melt temperature in the region of 180-200 °C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 80 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -120° C.
  • the mill was maintained at -120°C during grinding. 99% of the resulting powder was of a size below 400 ⁇ m.
  • the resultant powder was then applied on to a scrim to a thickness of 5mm by using a Cavistat 91 Pulverstreuaggregat conventional powder scatter head (manufactured by Cavitec) .
  • the scrim was a 0.5m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '4x4' 34 tex glass crennette moving at a rate of 1 m/minute.
  • the scrim was then passed under a 4 kW medium wave infra red heater (height 5cm above the coated scrim; width 0.6m; length 0.4m) .
  • the power output was adjusted in order to partially sinter the powder.
  • Particles of quartz of a size in the range 0.4-0.8 mm were then scattered on to the surface of the powder at a rate of 100 gnr 2 .
  • Particles of silicon carbide size F40 (FEPA Standard 42-GB-1984) were then scattered on to the surface at a rate of 100 gm 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 200 °C for 3 minutes before being embossed and cooled.
  • the ingredients of formulation G were weighed and blended by being tumbled together.
  • the blend was extruded in an extruder with a single screw with L:D ratio of 20 and a compression ratio of 2.5:1, maintaining the melt temperature in the region of 180-200° C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 50 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -150°C.
  • the mill was maintained at -150°C during grinding. 99% of the resulting powder was of a size below 400 ⁇ m.
  • the resultant powder was then applied on to a scrim to a thickness of 5 mm by using a Cavistat 91 Pulverstreuaggregat conventional powder scatter head (manufactured by Cavitec).
  • the scrim was a 0.5 m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '4x4' 34 tex glass crennette moving at a rate of 1 m/minute.
  • the scrim was then passed under a 4 kW medium wave infra red heater (height 5 cm above the coated scrim; width 0.6m; length 0.4m). The power output was adjusted in order to partially sinter the powder.
  • Particles of quartz of a size in the range 0.4-0.8 mm were then scattered on to the surface of the powder at a rate of 100 gnr 2 .
  • Particles of silicon carbide size F40 (FEPA Standard 42-GB-1984) were then scattered on to the surface at a rate of 100 g nr 2 .
  • the coated scrim was then passed in to a convection oven where it was exposed to a temperature of 200 °C for 3 minutes before being embossed and cooled.
  • formulation B The ingredients of formulation B were weighed and blended by being tumbled together.
  • the blend was extruded in a Werner and Pfleiderer extruder (model number ZSK 70) with the feed zone temperature set at 160°C, the barrel set at 190°C and the die at 200°C.
  • the extrudate was water cooled and pelletized.
  • the pellets were dried in a vacuum drier at 40 °C and then cryogenically ground in an Alpine pin disc mill using a single pass and no intermediate sieving screen.
  • the temperature of the material prior to its introduction in to the mill was -120°C.
  • the mill was maintained at -120°C during grinding. 99% of the resulting powder was of a size below 400 ⁇ m.
  • the resultant powder of formulation B was then applied on to a scrim to a thickness of 3 mm by using knife over roller.
  • the scrim was a 2m width cellulose/polyester support (Dexter 555:030) reinforced with a Kirson '4x4' 34 tex glass crennette moving at a rate of 3 m/minute.
  • An additional powder layer C (made as per example 4 for formulation A) was then spread on to the first powder layer at an additional thickness of 2 mm using knife over roller. Particles of quartz of a size in the range 0.4- 0.8 mm were then scattered on to the surface of the powder at a rate of 100 g/m 2 .
  • the coated scrim was then passed under a 50 kW medium wave infra red heater (height 10 cm above the coated scrim; width 2.5 m; length 1 m) .
  • the power output was adjusted in order to partially sinter the powder.
  • the scrim was then passed in to a convection oven where it was exposed to a temperature of 195 °C for 2.5 minutes before being embossed and cooled and wound up for subsequent trimming to size.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un revêtement de sol en plastique présentant une résistance au glissement accrue et une résistance aux taches améliorée sans réduction de la durée de vie efficace des propriétés antidérapantes. Ce revêtement de sol n'est pas stratifié et comprend une première couche de matière plastique présentant une surface supérieure ainsi qu'une première matière particulaire intégrée dans cette couche de matière plastique et découverte au niveau de cette surface supérieure de sorte à lui conférer une résistance au glissement, ladite couche de matière plastique étant sensiblement exempte de plastifiant.
PCT/GB2003/002252 2002-05-24 2003-05-23 Revetement de sol WO2003100162A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003232347A AU2003232347A1 (en) 2002-05-24 2003-05-23 Floor covering

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0211998.0 2002-05-24
GB0211998A GB0211998D0 (en) 2002-05-24 2002-05-24 Floor covering

Publications (2)

Publication Number Publication Date
WO2003100162A2 true WO2003100162A2 (fr) 2003-12-04
WO2003100162A3 WO2003100162A3 (fr) 2004-03-18

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Family Applications (1)

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PCT/GB2003/002252 WO2003100162A2 (fr) 2002-05-24 2003-05-23 Revetement de sol

Country Status (3)

Country Link
AU (1) AU2003232347A1 (fr)
GB (1) GB0211998D0 (fr)
WO (1) WO2003100162A2 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1512720A1 (fr) * 2003-08-28 2005-03-09 Congoleum Corporation Revêtement de sol exempt de PVC et son procédé de fabrication
DE102006034646A1 (de) * 2006-07-24 2008-01-31 Carl Freudenberg Kg Bodenbelag
WO2008029105A2 (fr) * 2006-09-04 2008-03-13 Altro Limited Revêtement de sol amélioré
US20140290171A1 (en) * 2010-12-08 2014-10-02 Bruno Paul Louis Vermeulen Method of Manufacturing a Panel Including a Wear Resistant Layer, and a Panel
EP2995661A1 (fr) * 2014-09-11 2016-03-16 Deflecto, LLC Revêtement à double usage
CN107139558A (zh) * 2017-04-01 2017-09-08 杭州捷尔思阻燃化工有限公司 一种低voc无卤阻燃耐磨地板革及其制备工艺

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USD817105S1 (en) 2015-01-28 2018-05-08 Deflecto, LLC Organizer with receptacles

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WO1995007178A1 (fr) * 1993-09-10 1995-03-16 Sommer S.A. Produits composites servant de revetement de sols ou de murs ou d'habillage interieur dans le secteur automobile et procedes pour leur fabrication
DE4427085A1 (de) * 1994-07-30 1996-02-01 Tarkett Pegulan Gmbh Herstellung von PVC- und weichmacherfreien Laufschichten bzw. Deckschichten für Boden- und Wandbeläge
WO1997009358A1 (fr) * 1995-09-01 1997-03-13 Sommer Revetements Luxembourg S.A. Procede de preparation d'ionomeres en poudre et leur utilisation comme couche de protection de produits de revetement de sols et de murs
US5787655A (en) * 1992-09-11 1998-08-04 Saylor, Jr.; Edward T. Slip-resistant cover system and method for making same
WO2000022225A1 (fr) * 1998-10-09 2000-04-20 Polyflor Limited Materiau de revetement pour sols et procede de fabrication correspondant
WO2000042274A1 (fr) * 1999-01-13 2000-07-20 Altro Limited Revetement de sol resistant aux taches
WO2001064997A1 (fr) * 2000-02-29 2001-09-07 Gerflor Procede pour la realisation d'un revetement de sol antiderapant et nouveau type de revetement ainsi realise

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5787655A (en) * 1992-09-11 1998-08-04 Saylor, Jr.; Edward T. Slip-resistant cover system and method for making same
WO1995007178A1 (fr) * 1993-09-10 1995-03-16 Sommer S.A. Produits composites servant de revetement de sols ou de murs ou d'habillage interieur dans le secteur automobile et procedes pour leur fabrication
DE4427085A1 (de) * 1994-07-30 1996-02-01 Tarkett Pegulan Gmbh Herstellung von PVC- und weichmacherfreien Laufschichten bzw. Deckschichten für Boden- und Wandbeläge
WO1997009358A1 (fr) * 1995-09-01 1997-03-13 Sommer Revetements Luxembourg S.A. Procede de preparation d'ionomeres en poudre et leur utilisation comme couche de protection de produits de revetement de sols et de murs
WO2000022225A1 (fr) * 1998-10-09 2000-04-20 Polyflor Limited Materiau de revetement pour sols et procede de fabrication correspondant
WO2000042274A1 (fr) * 1999-01-13 2000-07-20 Altro Limited Revetement de sol resistant aux taches
WO2001064997A1 (fr) * 2000-02-29 2001-09-07 Gerflor Procede pour la realisation d'un revetement de sol antiderapant et nouveau type de revetement ainsi realise

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1512720A1 (fr) * 2003-08-28 2005-03-09 Congoleum Corporation Revêtement de sol exempt de PVC et son procédé de fabrication
US7175904B2 (en) 2003-08-28 2007-02-13 Congoleum Corporation Non-vinyl flooring and method for making same
US7517422B2 (en) 2003-08-28 2009-04-14 Congoleum Corporation Non-vinyl flooring and method for making same
EP1884607A2 (fr) 2006-07-24 2008-02-06 Carl Freudenberg KG Revêtement de sol
DE102006034646A1 (de) * 2006-07-24 2008-01-31 Carl Freudenberg Kg Bodenbelag
KR100914809B1 (ko) 2006-07-24 2009-09-02 노라 시스템즈 게엠베하 바닥재
EP1884607A3 (fr) * 2006-07-24 2010-02-10 Nora Systems GmbH Revêtement de sol
WO2008029105A2 (fr) * 2006-09-04 2008-03-13 Altro Limited Revêtement de sol amélioré
WO2008029105A3 (fr) * 2006-09-04 2008-06-26 Altro Ltd Revêtement de sol amélioré
GB2462167A (en) * 2006-09-04 2010-02-03 Altro Ltd Slip-resistant floor covering including clear coated particles
US20100297394A1 (en) * 2006-09-04 2010-11-25 Peace Richard Floor Covering
GB2462167B (en) * 2006-09-04 2011-03-09 Altro Ltd Improved floor covering
US20140290171A1 (en) * 2010-12-08 2014-10-02 Bruno Paul Louis Vermeulen Method of Manufacturing a Panel Including a Wear Resistant Layer, and a Panel
EP2995661A1 (fr) * 2014-09-11 2016-03-16 Deflecto, LLC Revêtement à double usage
CN107139558A (zh) * 2017-04-01 2017-09-08 杭州捷尔思阻燃化工有限公司 一种低voc无卤阻燃耐磨地板革及其制备工艺

Also Published As

Publication number Publication date
GB0211998D0 (en) 2002-07-03
AU2003232347A1 (en) 2003-12-12
WO2003100162A3 (fr) 2004-03-18

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