WO2004006736A1 - Surface covering - Google Patents

Surface covering Download PDF

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Publication number
WO2004006736A1
WO2004006736A1 PCT/GB2003/003013 GB0303013W WO2004006736A1 WO 2004006736 A1 WO2004006736 A1 WO 2004006736A1 GB 0303013 W GB0303013 W GB 0303013W WO 2004006736 A1 WO2004006736 A1 WO 2004006736A1
Authority
WO
WIPO (PCT)
Prior art keywords
surface covering
covering according
fibres
base layer
backing
Prior art date
Application number
PCT/GB2003/003013
Other languages
French (fr)
Inventor
Pierre-Marie Bernard
John Lewin
Original Assignee
Bonar Floors 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 Bonar Floors Limited filed Critical Bonar Floors Limited
Priority to AU2003281160A priority Critical patent/AU2003281160A1/en
Publication of WO2004006736A1 publication Critical patent/WO2004006736A1/en

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • D06N2201/0272—Aromatic polyamide fibres
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/08—Inorganic fibres
    • D06N2201/082—Glass fibres
    • 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
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/06—Melt
    • 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
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/14—Corona, ionisation, electrical discharge
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/02—Properties of the materials having acoustical properties
    • D06N2209/025—Insulating, sound absorber
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/065—Insulating
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/067—Flame resistant, fire resistant
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/146—Soilproof, soil repellent
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/147—Stainproof, stain repellent
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1685—Wear resistance
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/06—Building materials
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/26—Vehicles, transportation
    • D06N2211/267—Aircraft

Definitions

  • the present invention relates to surface coverings and particularly but not exclusively to surface coverings, such as floorcoverings for aircraft.
  • the floor area of the passenger section at least, is covered to provide comfort for passengers.
  • Other floor areas such as those in sections used primarily by the crew of the aircraft may also be covered.
  • areas of internal walls of aircraft may desirably be covered with the same or similar material used to cover the floor areas.
  • Floorcoverings conventionally used in aircraft comprise carpeting having a traditional looped pile. Such carpeting suffers from a number disadvantages, including relatively poor durability and wear characteristics which often means in areas with high volumes of traffic, such as central aisles in passenger aeroplanes, frequent replacement is necessary. This presents considerable inconvenience and expense.
  • Floorcoverings contribute a not insignificant amount to the weight of an aircraft, and conventional carpeting can present a significant contribution to the total weight of an aircraft.
  • a surface covering comprising a fire resistant backing and a pile of unlooped fibres extending therefrom.
  • fire resistant relates to the properties of the surface covering material being such that it resists fire. It is also intended that fire resistance preferably imparts characteristics of fire retardance, as a function of the material in use. It is also a preferred characteristic that the surface covering emits relatively low levels of smoke, and that smoke emitted therefrom is of relatively low toxicity, when exposed to fire.
  • the fibres are generally straight and fixed at one end thereof to the backing.
  • the fibres may be fire resistant.
  • the fibres preferably extend generally perpendicularly from the plane of the backing.
  • the fibres may
  • the pile preferably forms a flocked surface on the backing.
  • the backing comprises a carrier substrate, which may comprise glass fibres, and may have a woven structure.
  • the backing preferably further comprises an adhesive layer to fix the fibres to one side of the carrier substrate.
  • the surface covering may further comprise a base layer which may act to provide cushioning characteristics for the surface covering and may further provide sound and/or thermal insulation properties.
  • the base layer is preferably flame resistant and may comprise needle felt or similar material.
  • the base layer may comprise polyaramide.
  • Adhesive such as a hot melt adhesive may be provided to attach the base layer to the carrier substrate, desirably on the opposite side thereof to the side on which the pile is provided. The adhesive may be fire resistant.
  • the surface covering is in the form of a sheet and is desirably flexible.
  • the thickness of the base layer is approximately equal to the depth of the pile.
  • the base layer has a thickness considerably greater than the thickness of the backing layer, and desirably in the order of between five and fifty times greater.
  • the base layer may have a thickness in the range l-5mm, and preferably about 2mm.
  • the depth of the pile is preferably in the range of 0.1-5mm, and desirably about 1.5-2mm.
  • the weight of the surface covering is preferably in the range 700-1200 g/m 2 .
  • the surface covering is a floorcovering.
  • a method of producing a surface covering comprising forming a pile of unlooped fibres on a fire resistant backing.
  • the pile may be formed using electrostatically charged fibres which are located on the backing under the influence of an electric field.
  • An adhesive which is preferably flame retardant, is provided to fix the fibres to a carrier substrate, which is preferably fire resistant.
  • the fibres may comprise substantially straight fibres of a chargeable material, such as nylon.
  • a base layer is provided on the, in use, underside of the backing, with the pile extending from the opposite side of the backing.
  • the base layer may comprise a fire retardant material, such as needle felt or similar material. This may be fixed to the underside of the backing by a suitable adhesive, such as a hot melt adhesive, which may be fire resistant.
  • a surface covering 10 comprising a fire resistant backing 12 and a pile 14 of unlooped fibres 16 extending therefrom.
  • the backing 12 includes a carrier substrate 18 comprising a fire resistant material such as woven glass fibre.
  • the backing also includes a layer of fire resistant adhesive 20 which extends over an upper surface 22 of the carrier substrate 18 to fix the fibres 16 to form the pile 14.
  • the fibres 16 comprise relatively short (about 2mm) generally straight strands of material, which is preferably relatively stain resistant and durable to wear. Preferably the fibres also show some fire resistant characteristics.
  • One end 24 of each fibre is located in the adhesive layer 20 and fixed thereby. Each fibre 16 extends generally perpendicularly from the general plane of the substrate 18, to form a generally flocked pile or surface.
  • the surface covering 10 can be used to provide a covering for surfaces such as floors and walls.
  • the fire resistant characteristics make the covering 10 suitable for use where such characteristics are necessary, or at least preferable, and where good wear and durability characteristics and resistance to soiling are preferred.
  • the above covering 10 could be improved by adding a base layer 26 to give the covering a more cushioned feel, which is particularly advantageous when the covering 10 is used as a floorcovering intended to be walked upon.
  • the base layer 26 is flame retardant, and a suitable material is needle felt, which comprises a generally random matrix of polyaramide fibres that have been “needled” in the direction generally through the plane of the material.
  • the base layer 26 is fixed to the other side of the carrier substrate 18 opposite to that to which the pile is fixed by a suitable hot melt adhesive 28, which is desirably fire resistant.
  • the material and thickness of the base layer 26 is chosen to provide suitable cushioning characteristics in the covering 10, and also in some applications to provide sound and/or thermal insulation characteristics either in addition, or as an alternative.
  • a suitable thickness of the base layer 26 has been found to be in the order of l-5mm, and preferably about 2mm.
  • the depth of the pile is preferably in the range of 0.1-5mm, and desirably about I.5-2mm. Within these ranges the weight of the surface covering 10 is approximately 700-1200 g/m 2 .
  • the thickness of the carrier substrate 18 is considerably less than that of the base layer 26, perhaps by an order of five to fifty times.
  • the covering can be used to cover any suitable surface, with particular application for floorcovering and wall and panel coverings in aircraft.
  • the structure of the surface covering 10 provides good fire resistant characteristics, which are essential in applications such as these.
  • the fire resistance is an inherent characteristic of the materials used in the manufacture of the surface covering 10, and can therefore be considered permanent, in that the characteristics are not vulnerable to wear and such like, which could be a problem for materials in which the resistance is added to the materials, for example by way of sprays or other surface coatings.
  • the weight of the covering 10 wherein the base layer 26 comprises needle felt of thickness in the order of 2mm and the pile depth is of similar magnitude has a weight of in the order of 900g/m 2 . This is considerably lighter than woven carpeting used in aircraft which has a weight of 1500-I700g/m 2 .
  • the present invention therefore provides a considerable weight saving over known carpeting which
  • the nature of the surface coating 10 and the structure of the pile 14 provides the surface covering with excellent durability characteristics and also relative ease of maintenance.
  • the straight nature of the fibres 16 helps the removal of dirt and other contaminants from the surface covering 10, when compared to conventional looped or woven carpets.
  • the inherent nature of materials used in the surface covering 10 give the covering 10 fire resistant characteristics. Such characteristics enables the material 10 to offer permanent fire retardant properties, in use. It is therefore intended that the covering 10 should show inherent resistance to fire and also help to retard the development or progression of a fire.
  • the invention also provides a method of producing a surface covering 10.
  • the method comprises forming a pile 14 of generally straight fibres 16 on a surface of a fire resistant backing 12, to form an unlooped pile.
  • the pile 14 of fibres 16 is produced by electrostatically charging the fibres 16 and then introducing the fibres 16 and the carrier substrate 18 bearing the adhesive 20 into a electrically charged region or chamber, so that the charged fibres are orientated and driven into the adhesive layer 20 to form the pile 14 under the influence of the electric field. As the adhesive hardens the fibres 16 are securely retained to form the flocked pile 14.
  • the base layer 26 may then be fixed to the other side of the carrier substrate 18 using suitable, hot melt adhesive, preferably of fire resistant character.
  • suitable, hot melt adhesive preferably of fire resistant character.
  • the base layer 26 may be fixed to the underside of the carrier substrate 18 prior to the formation of the pile 1.4 on the substrate 18.

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

Abstract

A surface covering (10) comprises a fire resistant backing (12) and a pile (14) of unlooped fibres (16) extending therefrom. The backing (12) includes a carrier substrate (18) such as woven glass fibre on which is attached a fire resistant base layer (26). A layer of fire resistant adhesive (20) is provided on the carrier substrate (18) to fix the fibres (16) to form the pile (14). The fibres (16) comprise relatively short fibres of durable stain resistant material.

Description

SURFACE COVERING
The present invention relates to surface coverings and particularly but not exclusively to surface coverings, such as floorcoverings for aircraft.
For aircraft such as passenger aircraft it is desirable that the floor area of the passenger section at least, is covered to provide comfort for passengers. Other floor areas, such as those in sections used primarily by the crew of the aircraft may also be covered. In some instances, areas of internal walls of aircraft may desirably be covered with the same or similar material used to cover the floor areas.
Floorcoverings conventionally used in aircraft comprise carpeting having a traditional looped pile. Such carpeting suffers from a number disadvantages, including relatively poor durability and wear characteristics which often means in areas with high volumes of traffic, such as central aisles in passenger aeroplanes, frequent replacement is necessary. This presents considerable inconvenience and expense. Floorcoverings contribute a not insignificant amount to the weight of an aircraft, and conventional carpeting can present a significant contribution to the total weight of an aircraft.
According to the present invention there is provided a surface covering comprising a fire resistant backing and a pile of unlooped fibres extending therefrom.
For the purpose of this specification, the term fire resistant relates to the properties of the surface covering material being such that it resists fire. It is also intended that fire resistance preferably imparts characteristics of fire retardance, as a function of the material in use. It is also a preferred characteristic that the surface covering emits relatively low levels of smoke, and that smoke emitted therefrom is of relatively low toxicity, when exposed to fire.
Preferably the fibres are generally straight and fixed at one end thereof to the backing. The fibres may be fire resistant. The fibres preferably extend generally perpendicularly from the plane of the backing. The fibres may
comprise nylon or other suitable generally stain resistant and durable material. The pile preferably forms a flocked surface on the backing.
Preferably the backing comprises a carrier substrate, which may comprise glass fibres, and may have a woven structure. The backing preferably further comprises an adhesive layer to fix the fibres to one side of the carrier substrate.
The surface covering may further comprise a base layer which may act to provide cushioning characteristics for the surface covering and may further provide sound and/or thermal insulation properties. The base layer is preferably flame resistant and may comprise needle felt or similar material. The base layer may comprise polyaramide. Adhesive such as a hot melt adhesive may be provided to attach the base layer to the carrier substrate, desirably on the opposite side thereof to the side on which the pile is provided. The adhesive may be fire resistant.
Preferably the surface covering is in the form of a sheet and is desirably flexible. Preferably the thickness of the base layer is approximately equal to the depth of the pile. Preferably the base layer has a thickness considerably greater than the thickness of the backing layer, and desirably in the order of between five and fifty times greater.
The base layer may have a thickness in the range l-5mm, and preferably about 2mm.
The depth of the pile is preferably in the range of 0.1-5mm, and desirably about 1.5-2mm.
The weight of the surface covering is preferably in the range 700-1200 g/m2.
Preferably the surface covering is a floorcovering.
According to a further aspect of the present invention there is provided a method of producing a surface covering, the method comprising forming a pile of unlooped fibres on a fire resistant backing.
The pile may be formed using electrostatically charged fibres which are located on the backing under the influence of an electric field. An adhesive, which is preferably flame retardant, is provided to fix the fibres to a carrier substrate, which is preferably fire resistant. The fibres may comprise substantially straight fibres of a chargeable material, such as nylon.
Preferably a base layer is provided on the, in use, underside of the backing, with the pile extending from the opposite side of the backing. The base layer may comprise a fire retardant material, such as needle felt or similar material. This may be fixed to the underside of the backing by a suitable adhesive, such as a hot melt adhesive, which may be fire resistant.
An embodiment of the present invention will now be described by way of example only, with reference to the accompanying drawing which shows a diagrammatic cross-section of an area of floorcovering according to the present invention.
Referring to the drawing there is provided a surface covering 10 comprising a fire resistant backing 12 and a pile 14 of unlooped fibres 16 extending therefrom.
In more detail, the backing 12 includes a carrier substrate 18 comprising a fire resistant material such as woven glass fibre. The backing also includes a layer of fire resistant adhesive 20 which extends over an upper surface 22 of the carrier substrate 18 to fix the fibres 16 to form the pile 14. The fibres 16 comprise relatively short (about 2mm) generally straight strands of material, which is preferably relatively stain resistant and durable to wear. Preferably the fibres also show some fire resistant characteristics. One end 24 of each fibre is located in the adhesive layer 20 and fixed thereby. Each fibre 16 extends generally perpendicularly from the general plane of the substrate 18, to form a generally flocked pile or surface.
In this form, the surface covering 10 can be used to provide a covering for surfaces such as floors and walls. The fire resistant characteristics make the covering 10 suitable for use where such characteristics are necessary, or at least preferable, and where good wear and durability characteristics and resistance to soiling are preferred.
It has been found however that for certain applications the above covering 10 could be improved by adding a base layer 26 to give the covering a more cushioned feel, which is particularly advantageous when the covering 10 is used as a floorcovering intended to be walked upon. The base layer 26 is flame retardant, and a suitable material is needle felt, which comprises a generally random matrix of polyaramide fibres that have been "needled" in the direction generally through the plane of the material.
The base layer 26 is fixed to the other side of the carrier substrate 18 opposite to that to which the pile is fixed by a suitable hot melt adhesive 28, which is desirably fire resistant.
The material and thickness of the base layer 26 is chosen to provide suitable cushioning characteristics in the covering 10, and also in some applications to provide sound and/or thermal insulation characteristics either in addition, or as an alternative.
A suitable thickness of the base layer 26 has been found to be in the order of l-5mm, and preferably about 2mm. The depth of the pile is preferably in the range of 0.1-5mm, and desirably about I.5-2mm. Within these ranges the weight of the surface covering 10 is approximately 700-1200 g/m2.
The thickness of the carrier substrate 18 is considerably less than that of the base layer 26, perhaps by an order of five to fifty times.
In use, the covering can be used to cover any suitable surface, with particular application for floorcovering and wall and panel coverings in aircraft. The structure of the surface covering 10 provides good fire resistant characteristics, which are essential in applications such as these. The fire resistance is an inherent characteristic of the materials used in the manufacture of the surface covering 10, and can therefore be considered permanent, in that the characteristics are not vulnerable to wear and such like, which could be a problem for materials in which the resistance is added to the materials, for example by way of sprays or other surface coatings. The weight of the covering 10 wherein the base layer 26 comprises needle felt of thickness in the order of 2mm and the pile depth is of similar magnitude has a weight of in the order of 900g/m2. This is considerably lighter than woven carpeting used in aircraft which has a weight of 1500-I700g/m2. The present invention therefore provides a considerable weight saving over known carpeting which
provides advantages, for example in fuel economy and potential for increases in passenger numbers in passenger aircraft.
The nature of the surface coating 10 and the structure of the pile 14 provides the surface covering with excellent durability characteristics and also relative ease of maintenance. The straight nature of the fibres 16 helps the removal of dirt and other contaminants from the surface covering 10, when compared to conventional looped or woven carpets.
The inherent nature of materials used in the surface covering 10 give the covering 10 fire resistant characteristics. Such characteristics enables the material 10 to offer permanent fire retardant properties, in use. It is therefore intended that the covering 10 should show inherent resistance to fire and also help to retard the development or progression of a fire.
The invention also provides a method of producing a surface covering 10. The method comprises forming a pile 14 of generally straight fibres 16 on a surface of a fire resistant backing 12, to form an unlooped pile.
The pile 14 of fibres 16 is produced by electrostatically charging the fibres 16 and then introducing the fibres 16 and the carrier substrate 18 bearing the adhesive 20 into a electrically charged region or chamber, so that the charged fibres are orientated and driven into the adhesive layer 20 to form the pile 14 under the influence of the electric field. As the adhesive hardens the fibres 16 are securely retained to form the flocked pile 14.
The base layer 26 may then be fixed to the other side of the carrier substrate 18 using suitable, hot melt adhesive, preferably of fire resistant character. As an alternative, the base layer 26 may be fixed to the underside of the carrier substrate 18 prior to the formation of the pile 1.4 on the substrate 18.
Various modifications may be made without departing from the spirit or scope of the present invention. For example, the fibres 16 have been illustrated
as being of equal length, although it is possible that unequal length fibres may be used.
Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims

1. A surface covering comprising a fire resistant backing and a pile of unlooped fibres extending therefrom.
2. A surface covering according to claim 1, in which the fibres are generally straight and fixed at one end thereof to the backing.
3. A surface covering according to any preceding claim, in which the fibres are fire resistant.
4. A surface covering according to any preceding claim, in which the fibres extend generally perpendicularly from the plane of the backing.
5. A surface covering according to any preceding claim, in which the fibres comprise nylon or other suitable generally stain resistant and durable material.
6. A surface covering according to any preceding claim, in which the pile preferably forms a flocked surface on the backing.
7. A surface covering according to any preceding claim, in which the backing comprises a carrier substrate.
8. A surface covering according to claim 7, in which the carrier substrate comprises glass fibres.
9. A surface covering according to claim 7 or claim 8, in which the carrier substrate has a woven structure.
10. A surface covering according to any of claims 7 to 9, in which the backing further comprises an adhesive layer to fix the fibres to one side of the carrier substrate.
11. A surface covering according to any preceding claim, in which the surface covering further comprises a base layer which acts to provide cushioning characteristics for the surface covering.
12. A surface covering according to claim 11, in which the base layer further provides sound and/or thermal insulation properties.
13. A surface covering according to claim 11 or 12, in which the base layer is flame resistant.
14. A surface covering according to any of claims 11 to 13, in which the base layer comprises needle felt or similar material.
15. A surface covering according to any of claims 11 to 14, in which the base layer comprises polyaramide.
16. A surface covering according to any of claims 11 to 15, in which adhesive attaches the base layer to the carrier substrate.
17. A surface covering according to claim 16, in which the adhesive is a hot melt adhesive.
18. A surface covering according to claim 16 or claim 17, in which the adhesive attaches the base layer on the opposite side of the carrier substrate to the side on which the pile is provided.
19. A surface covering according to any of claims 16 to 18, in which the adhesive is fire resistant.
20. A surface covering according to any preceding claim, in which the surface covering is in the form of a sheet.
21. A surface covering according to any preceding claim, in which the surface covering is flexible.
22. A surface covering according to any of claims 11 to 21, in which the thickness of the base layer is approximately equal to the depth of the pile.
23. A surface covering according to any of claims 11 to 22, in which the base layer has a thickness considerably greater than the thickness of the backing layer.
24. A surface covering according to claim 23, in which the base layer is in the order of between five and fifty times greater.
25. A surface covering according to any of claims 11 to 24, in which the base layer has a thickness in the range l-5mm.
26. A surface covering according to claim 25, in which the thickness of the base layer is about 2mm.
27. A surface covering according to any preceding claim, in which the depth of the pile is in the range of 0.1-5mm.
28. A surface covering according to claim 27, in which the depth of the pile is about 1.5 - 2 mm.
29. A surface covering according to any preceding claim, in which the weight of the surface covering is in the range 700-1200 g/m2.
30. A surface covering according to any preceding claim, in which the surface covering is a floorcovering.
31. A method of producing a surface covering, the method comprising forming a pile of unlooped fibres on a fire resistant backing.
32. A method according to claim 31, in which the pile is formed using electrostatically charged fibres which are located on the backing under the influence of an electric field.
33. A method according to claim 31 or claim 32, in which an adhesive is provided to fix the fibres to a carrier substrate.
34. A method according to claim 33, in which the adhesive used is flame retardant.
35. A method according to claim 33 or claim 34, in which the carrier substrate is fire resistant.
36. A method according to any of claims 31 to 35, in which the fibres used comprise substantially straight fibres of a chargeable material, such as nylon.
37. A method according to any of claims 31 to 36, in which a base layer is provided on the, in use, underside of the backing, with the pile extending from the opposite side of the backing.
38. A method according to claim 37, in which the base layer comprises a fire resistant material, such as needle felt or similar material.
39. A method according to claims 37 or claim 38, in which the base layer is fixed to the underside of the backing by a suitable adhesive.
40. A method according to claim 39, in which the adhesive used is fire resistant.
41. A surface covering substantially as hereinbefore described with reference to the accompanying drawings.
42. A method of producing a surface covering substantially as hereinbefore described with reference to the accompanying drawings.
43. Any novel subject matter or combination including novel subject matter disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims.
PCT/GB2003/003013 2002-07-17 2003-07-11 Surface covering WO2004006736A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003281160A AU2003281160A1 (en) 2002-07-17 2003-07-11 Surface covering

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0216615A GB2390807A (en) 2002-07-17 2002-07-17 Surface covering
GB0216615.5 2002-07-17

Publications (1)

Publication Number Publication Date
WO2004006736A1 true WO2004006736A1 (en) 2004-01-22

Family

ID=9940651

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2003/003013 WO2004006736A1 (en) 2002-07-17 2003-07-11 Surface covering

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AU (1) AU2003281160A1 (en)
GB (1) GB2390807A (en)
WO (1) WO2004006736A1 (en)

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US3666522A (en) * 1970-03-26 1972-05-30 Stephen George Flameproof fabric construction
US3968284A (en) * 1974-07-01 1976-07-06 Stephen George Breathable flame resistant fabric construction and method of making same
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WO1988005091A1 (en) * 1987-01-08 1988-07-14 Bonar & Flotex Limited Anti-static flocked material
EP0346762A2 (en) * 1988-06-14 1989-12-20 Toray Industries, Inc. Heat-resistant flock sheet
US5320890A (en) * 1993-06-23 1994-06-14 E. I. Du Pont De Nemours And Company Fire resistant fabrics with a flocked nylon surface
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GB1161078A (en) * 1965-12-14 1969-08-13 Pierre Delfour Improvements in or relating to Covering Materials, Notably for Floors and Walls.
US3666522A (en) * 1970-03-26 1972-05-30 Stephen George Flameproof fabric construction
US3968284A (en) * 1974-07-01 1976-07-06 Stephen George Breathable flame resistant fabric construction and method of making same
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WO1988005091A1 (en) * 1987-01-08 1988-07-14 Bonar & Flotex Limited Anti-static flocked material
EP0346762A2 (en) * 1988-06-14 1989-12-20 Toray Industries, Inc. Heat-resistant flock sheet
US5320890A (en) * 1993-06-23 1994-06-14 E. I. Du Pont De Nemours And Company Fire resistant fabrics with a flocked nylon surface
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Publication number Priority date Publication date Assignee Title
EP3409468A1 (en) * 2017-06-01 2018-12-05 Autoneum Management AG Aestetic floor covering system
WO2018219844A1 (en) * 2017-06-01 2018-12-06 Autoneum Management Ag Aesthetic floor covering system
CN110719844A (en) * 2017-06-01 2020-01-21 欧拓管理公司 Aesthetic floor covering system
JP2020522423A (en) * 2017-06-01 2020-07-30 オートニアム マネジメント アクチエンゲゼルシャフトＡｕｔｏｎｅｕｍ Ｍａｎａｇｅｍｅｎｔ ＡＧ Aesthetic floor cover material mechanism

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Publication number Publication date
GB2390807A (en) 2004-01-21
GB0216615D0 (en) 2002-08-28
AU2003281160A1 (en) 2004-02-02

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