WO2021122195A1 - Composite de revêtement de sol - Google Patents
Composite de revêtement de sol Download PDFInfo
- Publication number
- WO2021122195A1 WO2021122195A1 PCT/EP2020/085209 EP2020085209W WO2021122195A1 WO 2021122195 A1 WO2021122195 A1 WO 2021122195A1 EP 2020085209 W EP2020085209 W EP 2020085209W WO 2021122195 A1 WO2021122195 A1 WO 2021122195A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- flooring
- cell walls
- core structure
- folded core
- composite
- Prior art date
Links
- 238000009408 flooring Methods 0.000 title claims abstract description 122
- 239000002131 composite material Substances 0.000 title claims abstract description 69
- 210000002421 cell wall Anatomy 0.000 claims abstract description 87
- 210000004027 cell Anatomy 0.000 claims abstract description 65
- 229920003023 plastic Polymers 0.000 claims abstract description 6
- 239000004033 plastic Substances 0.000 claims abstract description 6
- 229920001169 thermoplastic Polymers 0.000 claims description 88
- 239000000835 fiber Substances 0.000 claims description 87
- 239000004416 thermosoftening plastic Substances 0.000 claims description 73
- 239000000463 material Substances 0.000 claims description 70
- 239000004744 fabric Substances 0.000 claims description 42
- 238000009732 tufting Methods 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 8
- 239000004747 spunlaid nonwoven Substances 0.000 claims description 6
- 239000004750 melt-blown nonwoven Substances 0.000 claims description 5
- 239000000919 ceramic Substances 0.000 claims description 2
- 239000007799 cork Substances 0.000 claims description 2
- 239000004800 polyvinyl chloride Substances 0.000 claims description 2
- 239000002023 wood Substances 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 73
- -1 polyethylene Polymers 0.000 description 68
- 229920000642 polymer Polymers 0.000 description 35
- 239000004753 textile Substances 0.000 description 34
- 229920000139 polyethylene terephthalate Polymers 0.000 description 28
- 239000005020 polyethylene terephthalate Substances 0.000 description 28
- 229920002037 poly(vinyl butyral) polymer Polymers 0.000 description 26
- 239000004743 Polypropylene Substances 0.000 description 24
- 229920001155 polypropylene Polymers 0.000 description 24
- 239000004696 Poly ether ether ketone Substances 0.000 description 22
- 239000004698 Polyethylene Substances 0.000 description 22
- 229920001643 poly(ether ketone) Polymers 0.000 description 22
- 229920001652 poly(etherketoneketone) Polymers 0.000 description 22
- 229920001707 polybutylene terephthalate Polymers 0.000 description 22
- 229920002530 polyetherether ketone Polymers 0.000 description 22
- 229920000573 polyethylene Polymers 0.000 description 22
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 22
- 229920001577 copolymer Polymers 0.000 description 12
- 229920002292 Nylon 6 Polymers 0.000 description 11
- 229920002302 Nylon 6,6 Polymers 0.000 description 11
- 239000004952 Polyamide Substances 0.000 description 11
- 239000004721 Polyphenylene oxide Substances 0.000 description 11
- 239000000203 mixture Substances 0.000 description 11
- 229920002647 polyamide Polymers 0.000 description 11
- 229920000515 polycarbonate Polymers 0.000 description 11
- 239000004417 polycarbonate Substances 0.000 description 11
- 229920000728 polyester Polymers 0.000 description 11
- 229920000570 polyether Polymers 0.000 description 11
- 229920000098 polyolefin Polymers 0.000 description 11
- 239000011800 void material Substances 0.000 description 11
- 238000010438 heat treatment Methods 0.000 description 9
- 239000000126 substance Substances 0.000 description 9
- 238000001816 cooling Methods 0.000 description 7
- 238000002844 melting Methods 0.000 description 7
- 230000008018 melting Effects 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 239000002245 particle Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 230000001747 exhibiting effect Effects 0.000 description 4
- 238000005452 bending Methods 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000012792 core layer Substances 0.000 description 3
- 239000000945 filler Substances 0.000 description 3
- 239000004575 stone Substances 0.000 description 3
- 238000003856 thermoforming Methods 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- 235000012222 talc Nutrition 0.000 description 2
- 229920008790 Amorphous Polyethylene terephthalate Polymers 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000000417 fungicide Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000009940 knitting Methods 0.000 description 1
- 239000011133 lead Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002557 mineral fiber Substances 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 210000001316 polygonal cell Anatomy 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- 235000012773 waffles Nutrition 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/02—Bending or folding
- B29C53/04—Bending or folding of plates or sheets
- B29C53/06—Forming folding lines by pressing or scoring
- B29C53/063—Forming folding lines by pressing or scoring combined with folding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/02—Bending or folding
- B29C53/04—Bending or folding of plates or sheets
- B29C53/06—Forming folding lines by pressing or scoring
- B29C53/063—Forming folding lines by pressing or scoring combined with folding
- B29C53/066—Forming folding lines by pressing or scoring combined with folding and joining the sides of the folding line, e.g. "Abkantschweissen"
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- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/0089—Producing honeycomb structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D3/00—Making articles of cellular structure, e.g. insulating board
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-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
- E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
- E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/185—Underlayers in the form of studded or ribbed plates
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/18—Separately-laid insulating layers; Other additional insulating measures; Floating floors
- E04F15/186—Underlayers covered with a mesh or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/732—Floor coverings
- B29L2031/7322—Carpets
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- 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
- B32B2274/00—Thermoplastic elastomer material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
- B32B2307/734—Dimensional stability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
- B32B2471/02—Carpets
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F2290/00—Specially adapted covering, lining or flooring elements not otherwise provided for
- E04F2290/04—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire
- E04F2290/041—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise
- E04F2290/043—Specially adapted covering, lining or flooring elements not otherwise provided for for insulation or surface protection, e.g. against noise, impact or fire against noise with a bottom layer for sound insulation
Definitions
- the invention pertains to a flooring composite, such as a carpet tile, a broadloom carpet, and an artificial turf comprising such a flooring composite, a method manufacturing such a flooring composite.
- carpets In house-holds and public buildings such as hotels, offices, hospitals and shops, broadloom carpets and carpet tiles can be found as flooring. Thereby, next to aesthetic requirements, carpets have to fulfill several requirements such as dimensional stability, resiliency, good/warm feel when walking over with naked feet and sound insulation in view of e.g. a reduction of impact sound or a reduction of reflecting sound.
- Carpets can also be used in automotive, ships such as cruises and ferries aircrafts and trains. In these applications, and in particular in buildings, e.g. houses, the carpets have to fulfill further requirements such as low weight and sound insulation.
- heavy layers are used as these heavy layers can improve the stability of the broadloom carpets and carpet tiles.
- Typical heavy layers are bitumen or polymeric layers which are added to the backside of broadloom carpets and carpet tiles. Further, such heavy layers support the broadloom carpet and carpet tiles when laid on a ground such that moving of a laid broadloom carpet and carpet tiles can be eliminated or at least reduced.
- heavy layers have disadvantages in transport or handling during installation. Further, when carpets are used in automotive, planes or trains, it is desired that the broadloom carpet and the carpet tiles are lightweight as possible.
- JP 2013220648 A discloses a folding-type honeycomb structure having high rigidity, which may be used as a vehicle floor panel, wherein cell halves are provided with an additional adhesive or welded together to ensure that the cell halves are firmly fixated to each other to provide rigidity.
- the object of the invention is to provide a flooring composite which is lightweight, has sound insulating properties, a good dimensional stability and which may be Tollable at the same time. Further, the flooring composite shall be more suitable for recycling.
- a flooring composite comprising a flooring surface and a folded core structure, wherein the flooring surface comprises a flooring face surface and a flooring back surface, and wherein the folded core structure is located adjacent to the flooring back surface, characterized in that said folded core structure is provided from an uncut flat body, by plastic deformation perpendicular to the plane of the uncut flat body such that three-dimensional structures comprising half cell walls and connection areas are formed, wherein the half cell walls are at an angle a to each other to provide a relaxed honeycomb structure or adjoin one another in the form of a honeycomb cell to provide a half-closed honeycomb structure, wherein the adjoining cell walls of neighboring half cell walls are free of bonding to each other at the main surfaces of the cell walls.
- the relaxed honeycomb structure and the half-closed honeycomb structure are formed by pushing the three-dimensional structures towards each other at predefined folding lines.
- the folded core structure can be a half-closed honeycomb structure, such as for example disclosed by WO 2006/053407 A1.
- This half-closed honeycomb structure can be provided from an uncut flat body, which can be composed of a thermoplastic polymer or thermoplastic elastomeric polymer, by plastic deformation perpendicular to the plane of the material such that three-dimensional (3D) structures and connection areas are formed, i.e. half cell walls and small connection areas are formed (Fig. 3). Subsequently, the 3D-structures are pushed towards each other at predefined folding lines to form cells having cell walls adjoining one another in the form of a honeycomb cell.
- the term “adjoining” means that the cell walls are in contact to each other, but the most of the adjoining cell walls can be free of bonding. Solely at one edge of the cell walls, the adjoining cell walls are connected to each other. The one edge of the cell walls is located in a first main surface of the folded core structure or in a second main surface of the folded core structure.
- the first main surface is established by parts of the folded core structure, which are extending the most above the plane of the x- and y- direction
- the second main surface is established by parts of the uncut flat body, which are extending the most below the plane of the x- and y-direction.
- the uncut flat body has to be understood as a thin body, which is a one pieced body, i.e. which does not consist of multiple parts connected to each other to provide the extension of the uncut flat body in x- and y- direction.
- the uncut flat body consists of solely one body and is free of any connections, e.g. seams, glued portions or welded portions.
- the term “provided from an uncut flat body” is understood to mean that the flat body is not cut to enable folding of the deformed sheet into a core having a three-dimensional structure.
- the uncut flat body may however be cut to provide a certain width and/or length of the uncut flat body before the uncut flat body is plastically deformed.
- the core having a three-dimensional structure is formed from an uncut flat body.
- the honeycomb cells comprised in the half-closed honeycomb structure and in the relaxed honeycomb structure are polygonal cells with a number n of walls.
- the number n is at least 3 and goes in principle to infinite, which is circular.
- the number n has an even value, more preferably n has the value of 4, 6 or 8, and most preferably n has the value of 6.
- the number n of walls of the honeycomb cells refers to the number of walls of two half cell walls which are at an angle a to one another.
- the formed honeycomb cells are closed by the connection areas at one end of the honeycomb cell, such that the honeycomb structure is water and/or gas impermeable over its entire extension and the void volumes on one side of the folded core structure are not connected to void volumes on the other side of the folded core structure.
- the formed honeycomb cells exhibit holes in the connection areas or are open at both ends, such that the void volumes on one side of the folded core structure are connected with the void volumes of the other side of the folded core structure.
- the folded core structure can also be a relaxed honeycomb structure.
- This relaxed honeycomb structure is produced in the same manner as the half-closed honeycomb structure with the exception that the folding of the plastically deformed uncut flat body is stopped before the half cell walls meet together to form the half- closed honeycomb structure.
- the half cell walls are at an angle a to each other.
- the angle a in the relaxed honeycomb structure is of at most 110°, preferably of at most 100°, more preferably of at most 90° even more preferably of at most 85°, and most preferably of at most 80°.
- the angle a in the relaxed honeycomb structure is of at least 1 °, preferably of at least 25°, more preferably of at least 45°, and most preferably of at least 60°.
- the angle a in the relaxed honeycomb structure is up to 110°, preferably between 1 ° and 100°, more preferably between 25° and 90°, even more preferably between 40° and 85°, and most preferably between 60° and 80°.
- the plastically deformed uncut flat body also comprises 3D-structures and connection areas such that the relaxed honeycomb structure can also be water impermeable and the void volumes on one side of the folded core structure are not connected void volumes on the other side of the folded core structure.
- a flooring composite comprising a half closed honeycomb structure or a relaxed honeycomb structure has an improved, or at least sufficient, dimensional stability, in terms of reduced dishing and doming, and/or improved, or at least sufficient, stretching and compression resistance, at least in the machine direction and cross machine direction.
- a folded core structure can be used instead of heavy layers in broadloom carpets and carpet tiles, thus, the flooring composite is lightweight in view of common flooring composites.
- the flooring composite can be rolled up.
- the flooring composite comprising a half closed honeycomb structure or a relaxed honeycomb structure can be produced more efficiently as compared to the folding- type honeycomb structure of JP 2013220648 A, as the flooring composite does not require an additional adhesive or welding to ensure that the cell halves are firmly fixated to each other.
- machine direction is understood to be the direction of production, as it is the largest dimension of the flooring composite, which can also be synonymously called x-direction.
- cross machine direction is the second largest dimension of the flooring composite, which is in plane with the machine direction and perpendicular to the machine direction, which can be synonymously called y-direction.
- y-direction is the third largest dimension of the flooring composite, which is the z-direction.
- the relaxed honeycomb structure comprises half cells having a diameter dhaif of 0.5 mm to 30 mm, preferably of 1 to 20 mm, and more preferably of 1 to 15 mm, even more preferably of 1 to 10 mm, and most preferably of 1.5 to 5 mm.
- the relaxed honeycomb structure is not fully folded, such that the connection area of a honeycomb cell comprises a kink.
- the diameter of the half cells dhaif of the relaxed honeycomb structure is determined by measuring the distance between the kink and the cell wall of the half cell of the relaxed honeycomb structure in the plane of the connection area, which is oriented parallel to the kink, wherein the distance is measured perpendicular to the kink and perpendicular to the parallel oriented honeycomb cell wall.
- the diameters dhaif of both half cells which share the same connection area having a kink, have to be summed up (Fig. 3 and 6).
- the honeycomb cells comprised in the relaxed honeycomb structure have a diameter of 1 mm to 60 mm, preferably of 2 to 40 mm, and more preferably of 2 to 30 mm, even more preferably of 2 to 20 mm, and most preferably of 3 to 10 mm.
- the half cells of the relaxed honeycomb structure have a height h of 1 mm to 60 mm, preferably of 2 mm to 20 mm, and more preferably of 3 to 15 mm, and most preferably of 3 to 10 mm.
- the half cells of the half-closed honeycomb structure have a height h of 1 mm to 60 mm, preferably of 2 mm to 20 mm, and more preferably of 3 to 15 mm, and most preferably of 3 to 10 mm.
- the method of determining the height of the half cells of the half-closed honeycomb structure is also applicable to the half cells of the relaxed honeycomb structure.
- the distance, i.e. the diameter and the height of the honeycomb cells are indicated by dashed lines in Figures 3, 5 and 6.
- the honeycomb cells comprised in the half-closed honeycomb structure or the relaxed honeycomb structure have a diameter of 1 mm to 60 mm, preferably of 2 to 40 mm, and more preferably of 2 to 30 mm, even more preferably of 2 to 20 mm, and most preferably of 3 to 10 mm and/or the honeycomb cells have a height of 1 mm to 60 mm, preferably of 2 mm to 30 mm, and more preferably of 3 to 20 mm, and most preferably of 3 to 10 mm.
- the folded core structure is a half-closed honeycomb structure.
- the advantage of a folded core structure which is a half-closed honeycomb structure, is that the folded core structure has an improved dimensional stability, at least in z-direction in view of flooring without a folded core structure, as the half cell walls are directed perpendicular to the plane of the folded core structure.
- a folded core structure could comprise adjoining cell walls of neighboring half cell walls in the half-closed honeycomb structure, which are bonded to each other (Fig. 1, 104a-d). Thereby, bonded to each other has to be understood that the adjoining cell walls of neighboring half cells are connected at least at two edges of each cell wall.
- the adjoining cell walls could be bonded to each other by any suitable method such as mechanical bonding, chemical bonding and/or thermal bonding.
- the adjoining cell walls could be bonded chemically and/or thermally.
- the folded core structure would have an improved dimensional stability in any direction as stretching and/or contraction of the folded core structure is eliminated or at least reduced.
- the bonding between the adjoining cell walls also improves the dimensional stability in z-direction as due to the bonded cell walls, the folded core structure is fixed in its folding.
- the folded core structure would also exhibit an improved bending stiffness and resistance against shear forces.
- a folded core structure wherein the half cell walls are bonded to each other e.g. over the full surfaces of the adjoining cell walls, requires more complex processing as compared to the folded core structure comprised in the flooring composite.
- a folded core structure wherein the half cell walls are bonded to each other do not enable that the flooring composite can be rolled up.
- the folded core structure comprises a thermoplastic polymer material or thermoplastic elastomeric polymeric material.
- the folded core structure comprises a thermoplastic elastomeric polymeric material
- the folded core structure has an improved resiliency.
- a broadloom carpet and/or a carpet tile comprising the folded core structure comprising a thermoplastic elastomeric polymeric material may have an improved dampening character, such that walking of a person on the broadloom carpet and/or carpet tile has a comfortable feeling.
- thermoplastic polymeric material is preferably selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2- furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers blends and combinations thereof.
- polyolefins in particular polyethylene (PE) or polypropylene (PP)
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- PBT polybutylene terephthalate
- PBT polyet
- the thermoplastic polymeric material of the folded core structure comprises a multi-layered laminate.
- the thermoplastic polymeric material of the multi-layered laminate is selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2- furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and blends thereof.
- PE polyethylene
- PP polypropylene
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- PBT poly
- Such a laminate can comprise a copolymer and homopolymer of e.g. polyethylene terephthalate.
- a multi-layered laminate can be a PET-GAG, wherein the laminate comprise glycol modified polyethylene terephthalate (PET-G) and amorphous polyethylene terephthalate (PET-A).
- the multi-layered laminate is a three-layered laminate comprising a core layer a first sheath layer and a second sheath layer.
- the layers are oriented co-planar to each other, and second sheath layer is located co-planar at one side of the core layer, which is facing away from the first sheath layer.
- the core layer has a melting temperature higher than the melting temperature of the first sheath layer and/ the second sheath layer.
- the melting temperature is at least 5°C, preferably 10°C, more preferably 15°C and most preferably 20°C higher than the melting temperature of the first sheath layer and/or the second sheath layer.
- the three-layered laminate can be one of the combinations e.g. PP/PET/PP, PA/PET/PA, PVB/PA/PVB, PVB/PET/PVB or PET- GAG.
- thermoplastic polymeric material and the thermoplastic elastomeric polymeric material of the folded core structure can comprise suitable additives such as flame retardants, antioxidants, fungicides, plasticizer and/or filler materials.
- the filler materials are particles such as talcum and grinded stone hard particles.
- the filler material has a weight of at least 10 wt.-%, preferably of at least 20 wt.-%, more preferably of at least 30 wt.-%, and most preferably of at least 40 wt.-% in view of the weight of the folded core structure.
- the folded core structure comprises an improved hardness and heat distortion temperature.
- the folded core structure is water impermeable and the void volumes on one side of the folded core structure are not connected to void volumes on the other side of the folded core structure.
- the folded core structure can be water impermeable, the folded core structure can be used as a water barrier.
- the flooring composite can also be used at locations having high humidity and/or on moist grounds.
- the void volumes in at least one side of the folded core structure is filled with a substrate.
- the substrate is a heated fluid or solid particles.
- the heated fluid can be a heated thermoplastic polymeric material or a heated thermoplastic elastomeric polymeric material.
- the solid particles can talcum or grinded stone hard particles.
- the filling of the void volumes can be increased the weight of the flooring composite, if necessary, which could improve the grip of the flooring composite on the ground.
- the folded core structure comprises heating means, cooling means, lighting, data sensing, data transferring, cables and/or further electrical component such as smart home components.
- the heating means can be wires, spot or films of conductive component.
- the conductive component can comprise any suitable conductive metal such as copper, iron, aluminum, lead, zinc, tin, nickel, chromium, platinum, palladium, silver, gold, and any alloy or combination thereof.
- the heating means can heat the folded core structure, respectively the flooring composite, by conducting electricity through the conductive material or by infrared irradiation of the conductive material.
- Heating means can also be small tubes which a heated medium can flow through, such as in an underfloor heating.
- the cooling means can be tubes comprising a cooling fluid. Thereby, the cooling tubes may be connected to a cooling aggregate.
- the heating means, cooling means, and/or cables are preferably located in the folded core structure.
- the heating means, cooling means, and/or cables are located in the void volumes in the relaxed honeycomb structure or in channels provided in the folded core structure.
- Channels in the folded core structure can be provided, at least in a half-closed honeycomb structure, by comprising rows of honeycomb cells having a smaller height compared to honeycomb cells having a larger height next to the honeycomb cells having the smaller height.
- the folded core structure comprises a first main surface and a second main surface and comprises a skin layer on at least one of the main surfaces of the folded core structure.
- the skin layer on at least one of the main surfaces of the folded core structure may further improve the dimensional stability and/or rigidity of the flooring composite, which is particularly advantageous when the flooring composite is a carpet tile.
- the skin layer can restrict movement of the half cell walls without requiring providing an additional adhesive or welding to ensure that the cell halves are firmly fixated to each other to provide rigidity.
- the first main surface and the second main surface of the folded core structure are preferably parallel to each other, wherein the first main surface of the folded core structure is on the side of the folded core structure facing the flooring surface and the second main surface of the folded core structure is on the side of the folded core structure facing away from the flooring surface.
- the skin layer can be bonded to the folded core structure chemically, thermally and/or mechanically.
- the skin layer on at least one of the main surfaces of the folded core structure can improve the dimensional stability at least in the plane of the skin layer, i.e. in machine direction and cross machine direction. It is also possible that the skin layer also improves the dimensional stability in z- direction as due to the bonded skin layer, the folded core structure is fixed in its folding.
- the skin layer can be a two-dimensional (2D) layer and may consists of a material selected from a group comprising a woven, a nonwoven such as a spunbonded or spun laid nonwoven, a melt blown nonwoven, a carded nonwoven, a needle- punched nonwoven, an air laid nonwoven, a hydroentangled nonwoven, and a wet laid nonwoven, a knitted fabric, a net, a scrim, a two-dimensional mat of extruded entangled filaments, a consolidated layer of unidirectional fibers, a continuous film, a discontinuous film, a paper, or any combination thereof.
- 2D two-dimensional
- nonwoven has to be understood as according to the EDANA (European Disposables and Nonwovens Association) and ISO 9092:
- a nonwoven is an engineered fibrous assembly, primarily planar, which has been given a designed level of structural integrity by physical and/or chemical means, excluding weaving, knitting or paper making.
- the continuous film and/or the discontinuous films can be provided by coating e.g. a thermoplastic polymeric material and/or a thermoplastic elastomeric polymeric material.
- the woven, nonwovens, scrims, nets, unidirectional fibers or knitted fabric of the skin layer may comprise mineral fibers, such as for example glass, basalt or rockwool fibers, and/or fibers composed of thermoplastic polymeric material or thermoplastic elastomeric polymeric material.
- the fibers may have any cross-sectional shape, including round, trilobal, multi-- lobal or rectangular, the latter exhibiting a width and a height wherein the width may be considerably larger than the height, so that the fiber in this embodiment is a tape.
- the fibers comprised in the skin layer are composed of a thermoplastic polymeric material or a thermoplastic elastomeric polymeric material.
- the fibers comprised in the skin layer can be monofilaments, multifilament yarns, mono-component fibers, two types of mono-component fibers and/or multicomponent fibers, in particular bicomponent fibers.
- the bicomponent fibers may be of a side-by-side model, concentric or eccentric core/sheath model or islands-in-the-sea model.
- the mono-component fibers comprised in the skin layer comprise of a thermoplastic polymeric material or a thermoplastic elastomeric polymeric material.
- the mono-component fibers comprised in the skin layer are composed of a thermoplastic polymer selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2-furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- a thermoplastic polymer selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET
- the fibers comprised in the skin layer are bicomponent fibers of the core/sheath model.
- the core and the sheath of the bicomponent fibers comprised in the skin layer comprise a thermoplastic polymer and/or a thermoplastic elastomeric polymer.
- the bicomponent fibers can combine the properties of a certain tensile strength of the core of the bicomponent fibers as well as a certain bonding strength between the fibers. This is possible if the thermoplastic polymeric material or thermoplastic elastomeric polymeric material of the sheath has a lower melting temperature than the core. Thus, the sheath can be at least partially melted, such that bicomponent fibers can be adhered together by the sheath and comprising at the same time the non-deteriorated properties of the core.
- any suitable thermoplastic polymer and/or thermoplastic elastomeric polymer can be used.
- the polymer of the sheath has a melting temperature which is lower than the melting temperature of the polymer of the core.
- the core of the bicomponent fibers comprises a thermoplastic polymeric material or a thermoplastic elastomeric polymeric material.
- the core of the bicomponent fibers is composed of a thermoplastic polymeric material selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2-furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- PE polyethylene
- PP polypropylene
- polyesters in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT)
- the sheath of the bicomponent fibers comprises a thermoplastic polymeric material or a thermoplastic elastomeric polymeric material.
- the sheath of the bicomponent fibers is composed of a thermoplastic polymeric material selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2-furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- PE polyethylene
- PP polypropylene
- polyesters in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (P
- the fibers comprised in the skin layer are filaments or staple fibers.
- the fibers comprised in the skin layer are filaments.
- the fibers comprised in the skin layer are filaments
- the dimensional stability of the textile fabric, at least in plane of the skin layer is improved due to the fact that forces affecting on the skin layer can be distributed along the whole length of the filaments and thus over an enlarged area of the skin layer.
- the fibers comprised in the skin layer of the skin layer are bonded at their crossing points. This will improve the aforementioned effect.
- the bonding of the fibers comprised in the skin layer can be chemical bonding, mechanical bonding and/or thermal bonding.
- the bonding of the fibers comprised in the skin layer is a chemical bonding and/or thermal bonding.
- the skin layer comprises monofilaments, multifilament yarns, mono-component fibers, two types of mono-component fibers and/or multicomponent fibers, in particular bicomponent fibers.
- the skin layer comprises two-types of mono-component fibers
- one type of the two-types of mono-component fibers can be for stability reasons and the other type for bonding reasons.
- the flooring surface is a carpet such as a tufted carpet, woven carpet or needlefelt carpet, a laminate, LVT laminate, natural flooring such as cork or wood, PVC flooring, and/or ceramic tiles.
- the flooring surface comprises a primary carpet backing, and tufting yarns tufted into the primary backing.
- the flooring surface comprising a primary carpet backing and tufting yarns tufted into the primary backing can be used directly, without any further layers, in the flooring composite.
- the tufting yarns are cut pile yarns and/or loop pile yarns.
- the primary carpet backing comprises at least a textile fabric.
- the textile fabric may comprise fibers and is preferably a woven, a knitted fabric, a nonwoven such as a spun-laid nonwoven, a carded nonwoven, a needle-punched nonwoven, an air-laid nonwoven, a hydroentangled nonwoven, and a wet-laid nonwoven, a melt blown nonwoven, a layer of unidirectional fibers, a net, a scrim, a two-dimensional entangled mat of extruded filaments, or any combination thereof.
- the term “spun-laid nonwoven”, has to be understood that the nonwoven is manufactured by extruding the fibers from a spinneret and subsequently laying down on a conveyor belt as a web of filaments and subsequently bonding the web to form a nonwoven layer of fibers, or by a two- step process wherein filaments are spun and wound on bobbins, preferably in the form of multifilament yarns, followed by the steps of unwinding the multifilament yarns and laying the filaments down on a conveyor belt as a web of filaments and bonding the web to form a nonwoven layer of fibers.
- the fibers may have any cross-sectional shape, including round, trilobal, multi- lobal or rectangular, the latter exhibiting a width and a height wherein the width may be considerably larger than the height, so that the fiber in this embodiment is a tape.
- the fibers of the textile fabric can be filaments or staple fibers.
- the fibers of the textile fabric of the primary carpet backing are filaments.
- the fibers of the textile fabric of the primary carpet backing are filaments
- the dimensional stability of the textile fabric, at least in plane of the textile fabric is improved due to the fact that forces affecting on the textile fabric can be distributed along the whole length of the filaments and thus over an enlarged area of the textile fabric.
- the fibers comprised in the textile fabric of the primary carpet backing are bonded at their crossing points. This will further improve the dimensional stability of the textile fabric.
- the bonding of the fibers the textile fabric of the primary carpet backing can be chemical bonding, mechanical bonding and/or thermal bonding.
- the bonding of the fibers the textile fabric of the primary carpet backing is a chemical bonding and/or thermal bonding.
- the textile fabric of the primary carpet backing comprises monofilaments, multifilament yarns, mono-component fibers, two types of mono-component fibers and/or multicomponent fibers, in particular bicomponent fibers.
- the textile fabric of the primary carpet backing comprises two-types of mono-component fibers, one type of the two types of mono-component fibers can be for stability reasons and the other type for bonding reasons.
- the fibers of the textile fabric of the primary carpet backing comprise a thermoplastic polymeric material or a thermoplastic elastomeric polymeric material.
- the thermoplastic polymeric material is selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2-furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- PE polyethylene
- PP polypropylene
- PET polyethylene terephthalate
- PTT polytrimethylene
- a precoat and/or a polymer coat can be added, preferably between the flooring back surface and the folded core structure, to the flooring surface comprises a primary carpet backing, and tufting yarns tufted into the primary backing.
- the precoat and/or the polymer coat may have the advantage that the tufting yarns tufted into the primary carpet backing are fixated. Further, the precoat and/or polymer coat may be used as a bonding agent to bond the tufted primary carpet backing onto the folded core structure.
- the flooring surface comprises a secondary carpet backing, preferably between the primary carpet backing and the folded core structure.
- the dimensional stability of the flooring surface can be improved and/or the secondary carpet backing can be used as a bonding layer which bonds the tufted primary carpet backing onto the folded core structure. It is believed that at the same time the secondary backing can improve the tuft lock of the tufting yarns in the primary carpet backing by bonding the tufting yarns.
- the secondary carpet backing comprises at least a textile fabric.
- the textile fabric may comprise fibers and is preferably a woven, a knitted fabric, a nonwoven such as a spun-laid nonwoven, a carded nonwoven, a needle-punched nonwoven, an air-laid nonwoven, a hydroentangled nonwoven, and a wet-laid nonwoven, a melt blown nonwoven, a layer of unidirectional fibers, a net, a scrim, a two-dimensional entangled mat of extruded filaments, or any combination thereof.
- the fibers may have any cross-sectional shape, including round, trilobal, multi- lobal or rectangular, the latter exhibiting a width and a height wherein the width may be considerably larger than the height, so that the fiber in this embodiment is a tape.
- the fibers of the textile fabric can be filaments or staple fibers.
- the fibers of the textile fabric of the secondary carpet backing are filaments.
- the fibers of the textile fabric of the secondary carpet backing are filaments
- the dimensional stability of the textile fabric, at least in plane of the textile fabric is improved due to the fact that forces affecting on the textile fabric can be distributed along the whole length of the filaments and thus over an enlarged area of the textile fabric.
- the fibers comprised in the textile fabric of the secondary carpet backing are bonded at their crossing points. This will improve the aforementioned effect.
- the bonding of the fibers the textile fabric of the secondary carpet backing can be chemical bonding, mechanical bonding and/or thermal bonding.
- the bonding of the fibers the textile fabric of the secondary carpet backing is a chemical bonding and/or thermal bonding.
- the textile fabric of the secondary carpet backing comprises monofilaments, multifilament yarns, mono-component fibers, two types of mono-component fibers and/or multicomponent fibers, in particular bicomponent fibers.
- the textile fabric of the secondary carpet backing comprises two-types of mono-component fibers, one type of the two types of mono-component fibers can be for stability reasons and the other type for bonding reasons and/or shaping capability.
- the fibers of the textile fabric of the secondary carpet backing comprise a thermoplastic polymeric material or a thermoplastic elastomeric polymeric material.
- the thermoplastic polymeric material is selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2-furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- PE polyethylene
- PP polypropylene
- PET polyethylene terephthalate
- PTT polytrimethylene
- the flooring composite may comprise at least one additional layer on the second main surface of the folded core structure.
- the at least one additional layer can be a two- dimensional (2D) layer and may consist of a material selected from a group comprising a woven, a nonwoven such as a spunbonded or spun laid nonwoven, a melt blown nonwoven, a carded nonwoven, a needle-punched nonwoven, an air laid nonwoven, a hydroentangled nonwoven, and a wet laid nonwoven, a knitted fabric, a net, a scrim, a two-dimensional mat of extruded entangled filaments, a consolidated layer of unidirectional fibers, a continuous film, a discontinuous film, or a combination thereof.
- the at least one additional layer is a carded nonwoven.
- a carded nonwoven used as additional layer improves the acoustic properties of the flooring composite.
- the at least one additional layer may also be a three-dimensional (3D) layer and may consist of a material selected from a group comprising a three-dimensional nonwoven, a foam, a three-dimensional structured mat of extruded filaments, a further folded core structure, knitted spacer fabrics, woven spacer fabrics, corrugated sheets, dimple drain materials, a ridged surface material or a combination thereof.
- the three-dimensional nonwoven can be provided from a two-dimensional nonwoven by three-dimensional shaping the nonwoven by e.g. thermoforming. The thermoforming can be performed by heated profiled rolls.
- the nonwoven comprises bicomponent fibers, such as core sheath type bicomponent fibers, and the nonwoven is thermoformed by heated profiled rolls, the sheath of the bicomponent fiber, which is melted by the heated rolls, is responsible for retaining the three-dimensional shape.
- bicomponent fibers such as core sheath type bicomponent fibers
- the fibers may have any cross-sectional shape, including round, trilobal, multi- lobal or rectangular, the latter exhibiting a width and a height wherein the width may be considerably larger than the height, so that the fiber in this embodiment is a tape.
- the filaments of the three-dimensional structured mat of extruded entangled filaments are extruded polymeric filaments.
- a three-dimensional structured mat of extruded entangled filaments may be provided by any suitable process.
- the three-dimensional structured mat of extruded entangled filaments is provided by extruding polymeric filaments and collecting the extruded filaments into a three-dimensional structure by allowing the filaments to bend, to entangle and to come into contact with each other, preferably in a still molten state. Bending and entangling of the extruded filaments are preferably initiated by collecting the filaments onto a profiled surface, which defines the structure of the three-dimensional structured mat of extruded entangled filaments.
- the surface on which the filaments are collected is profiled such that the three- dimensional structured mat of filaments is shaped into a three-dimensional form which comprises hills and valleys, hemispheres, positive and/or negative cuspates, cups and/or waffles, pyramids, U-grooves, V-grooves, cones and/or cylinders capped with a hemisphere.
- the at least one additional layer is laminate of at least one three-dimensional layer and at least one two-dimensional layer.
- all parts of the flooring composite e.g. the folded core structure, the flooring surface comprising tufting yarns tufted into the primary carpet backing, the secondary carpet backing and the at least one additional layer, comprise a thermoplastic polymer or a thermoplastic elastomeric polymer.
- the thermoplastic polymeric material is selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2- furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- polyolefins in particular polyethylene (PE) or polypropylene (PP)
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- PBT polybutylene terephthalate
- PBT polyetylene
- All parts of the flooring composite can be composed of different polymers, but preferably all parts of the flooring composite are composed of one thermoplastic polymer or one thermoplastic elastomeric polymer or of a single polymer family.
- at least the primary carpet backing, the secondary carpet backing, the tufting yarns and/or the skin layer comprised in the flooring composite are composed of one thermoplastic polymer or one thermoplastic elastomeric polymer or of a single polymer family.
- a polymer family has to be understood that the polymers of one family are composed of at least 50 % of the same monomeric units.
- all parts of the flooring composite are composed of thermoplastic polymers or thermoplastic elastomeric polymers, which are constituted of at least 50 %, preferably of at least 60 %, more preferably of at least 70 %, even more preferably of at least 80 %, even more preferably of at least 90 %, even more preferably of at least 95 %, and most preferably of 100 % of the same monomeric units.
- the flooring composite can be easily recycled after its lifetime.
- the at least one additional layer is an underfloor heating and/or a drainage layer.
- the object is also solved by a method of manufacturing a flooring composite by providing a folded core structure and a flooring surface located adjacent to a flooring back surface of the flooring surface, characterized in that the said folded core structure is formed from an uncut flat body, by plastic deformation perpendicular to the plane of the uncut flat body such that three-dimensional structures comprising half cell walls and connection areas are formed, wherein the half cell walls are at an angle a to each other to provide a relaxed honeycomb structure or adjoin one another in the form of a honeycomb cell to provide a half- closed honeycomb structure, wherein the adjoining cell walls of neighboring half cell walls are free of bonding to each other at the main surfaces of the cell walls.
- the method comprises the step of pushing the three-dimensional structures towards each other at predefined folding lines to form the relaxed honeycomb structure or the half-closed honeycomb structure.
- the aforementioned embodiments regarding the flooring composite are also applicable to the method of manufacturing the flooring composite.
- the object of the present invention is also solved by a carpet tile comprising the flooring composite according to any of the aforementioned embodiments.
- the folded core structure comprised in the carpet tile is a half-closed honeycomb structure.
- comprising a half-closed honeycomb structure as folded core structure in the carpet tile improves the dimensional stability of the carpet tile, at least in machine direction and cross machine direction of the comprised folded core structure.
- the carpet tile also exhibits an improved bending stiffness, which will increase the flatness i.e. avoidance of dishing and doming of a flooring, and shear and dynamic loads.
- the compression strength of the folded core structure is improved, such that the carpet tile is able to carry large weight loads, which can occur by using the carpet tile as flooring.
- the flooring composite can be rolled up.
- the method of manufacturing the flooring composite enables to manufacture the half closed honeycomb structure or the relaxed honeycomb structure efficiently as compared to the folding-type honeycomb structure of JP 2013220648 A, as the method of manufacturing the flooring composite does not require an additional adhesive or welding to ensure that the cell halves are firmly fixated to each other.
- a folded core structure comprised in a carpet tile, could comprise adjoining cell walls of neighboring half cell walls, which are bonded to each other (e.g. Fig. 1 , 104a-d).
- the adjoining cell walls would be bonded together, the folded core structure, respectively the carpet tile comprising the folded core structure would have an excellent dimensional stability as the folded core structure is fixed in its fully folded state.
- the folded core structure is not able or at least the ability is reduced to be stretched or compressed in any direction, and the resistance against shear forces would be improved.
- the adjoining cell walls of neighboring half cell walls could be bonded thermally, chemically, and/or mechanically.
- the bonding could be a chemical bonding and/or a thermal bonding.
- a folded core structure wherein the half cell walls are bonded to each other e.g. over the full surfaces of the adjoining cell walls, requires more complex processing as compared to the folded core structure comprised in the flooring composite.
- a folded core structure wherein the half cell walls are bonded to each other, e.g. over the full surfaces of the adjoining cell walls do not enable that the flooring composite can be rolled up.
- the carpet tile comprises connecting means such that at least two carpet tiles can be mechanically connected to each other.
- Such connecting means can be any suitable connecting means such as a nut and bold connecting assembly or any kind of form-fit connection.
- Form-fit connections are commonly known and are used e.g. for click laminate.
- a first part of a form-fit connection which may comprise a projection (male part)
- a second part of a form-fit connection which may comprise an indentation (female part).
- Both parts of a form-fit connection can be put together to build up a connection between, e.g. two carpet tiles, and can be easily released.
- This connection and disconnection can be performed multiple times, such that a carpet tile comprising such connecting means can be used at different locations several times without loss of dimensional stability and having at the same time a very easy handling.
- the connecting means comprise a thermoplastic polymeric material or a thermoplastic elastomeric polymeric material.
- the thermoplastic polymeric material is selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2-furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- PE polyethylene
- PP polypropylene
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- PBT poly
- the connecting means can be attached additionally to the carpet tile and bonded to the carpet tile by any suitable bonding technique.
- the connecting means are provided from the thermoplastic polymeric material or thermoplastic elastomeric polymeric material of the carpet tile.
- the connecting means can be provided from the thermoplastic polymeric material or thermoplastic elastomeric polymeric material of the carpet tile by a thermoforming process.
- all parts of the carpet tile e.g. the folded core structure, the flooring surface comprising tufting yarns tufted into the primary carpet backing, the secondary carpet backing, the at least one additional layer and the connecting means, comprise a thermoplastic polymer or a thermoplastic elastomeric polymer.
- the thermoplastic polymeric material is selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2-furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- polyolefins in particular polyethylene (PE) or polypropylene (PP)
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- PBT polybutylene terephthalate
- PBT polyetylene
- All parts of the carpet tile can be composed of different polymers, preferably all parts of the carpet tile are composed of one thermoplastic polymeric material or one thermoplastic elastomeric polymeric material or all parts of the carpet tile are composed of polymers of the same polymer family.
- at least the primary carpet backing, the secondary carpet backing, the tufting yarns and/or the skin layer comprised in the carpet tile are composed of one thermoplastic polymer or one thermoplastic elastomeric polymer or of a single polymer family.
- all parts of the carpet tile are composed of thermoplastic polymeric material or thermoplastic elastomeric polymeric material, which comprise of at least 50 %, preferably of at least 60 %, more preferably of at least 70 %, even more preferably of at least 80 %, even more preferably of at least 90 %, even more preferably of at least 95 %, and most preferably of 100 % of the same monomeric units.
- the carpet tile can be easily recycled after its lifetime.
- the object can also be solved by a broadloom carpet comprising the flooring composite according to any of the aforementioned embodiments.
- the broadloom carpet comprises folded core structure, which is a relaxed honeycomb structure or a half-closed honeycomb structure, in which adjoining cell walls of neighboring half cell walls are free of bonding to each other at the main surfaces of the cell walls.
- the relaxed honeycomb structure or half-closed honeycomb structure in which adjoining cell walls of neighboring half cell walls are free of bonding to each other at the main surfaces of the cell walls, provide a certain degree of flexibility such that the broadloom carpet can be rolled up and is easily transportable.
- the broadloom carpet comprises a folded core structure which is a relaxed honeycomb structure.
- all parts of the broadloom carpet e.g. the folded core structure, the flooring surface comprising tufting yarns tufted into the primary carpet backing, the secondary carpet backing and the at least one additional layer, comprise a thermoplastic polymer or a thermoplastic elastomeric polymer.
- the thermoplastic polymeric material is selected from a group consisting of polyolefins, in particular polyethylene (PE) or polypropylene (PP), polyesters, in particular polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT) or polyetylene-1 ,2- furandicaboxylate (PEF), polyamides, in particular polyamide 6 (PA6) or polyamide 6,6 (PA6,6), polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyvinyl butyral (PVB), polycarbonate (PC), polyether, polyetheresters, copolymers and mixtures thereof.
- polyolefins in particular polyethylene (PE) or polypropylene (PP)
- PET polyethylene terephthalate
- PTT polytrimethylene terephthalate
- PBT polybutylene terephthalate
- PBT polyetylene
- All parts of the broadloom carpet can be composed of different polymers, preferably all parts of the broadloom carpet are composed of one thermoplastic polymeric material or one thermoplastic elastomeric polymeric material or all parts of the carpet tile are composed of polymers of the same polymer family.
- At least the primary carpet backing, the secondary carpet backing, the tufting yarns and/or the skin layer comprised in the broadloom carpet are composed of one thermoplastic polymer or one thermoplastic elastomeric polymer or of a single polymer family.
- all parts of the broadloom carpet are composed of thermoplastic polymers or thermoplastic elastomeric polymers, which comprise of at least 50 %, preferably of at least 60 %, more preferably of at least 70 %, even more preferably of at least 80 %, even more preferably of at least 90 %, even more preferably of at least 95 %, and most preferably of 100 % of the same monomeric units.
- all parts of the broadloom carpet are composed of one thermoplastic polymeric material or one thermoplastic elastomeric polymeric material or all parts of the carpet tile are composed of polymers of the same polymer family, the broadloom carpet can be easily recycled after its lifetime.
- the object is also solved by an artificial turf comprising a flooring composite according to any of the aforementioned embodiments.
- the flooring composite respectively the carpet tile, the broadloom carpet and/or the artificial turf comprising such a flooring composite can be used in flat applications such as flooring, but also in non-flat application such as staircase covering or molded application such as interior of automotive, trains, aircrafts.
- Figure 1 Schematic cross section of a flooring composite
- Figure 2 Schematic cross section of a flooring composite
- Figure 3 Schematic perspective view of a part of a relaxed honeycomb structure
- Figure 4 Schematic cross-sectional view of a relaxed honeycomb structure.
- Figure 5 Schematic top view of a honeycomb cell.
- Figure 6 Schematic perspective view of a part of a honeycomb cell of a relaxed honeycomb structure.
- Figure 7 Schematic cross-sectional view of a fully folded honeycomb cell of a honeycomb structure.
- Figure 1 shows a part of a cross section of a flooring composite 100 comprising a flooring surface 101 with tufting yarns 101a tufted into the primary carpet backing 101b and a folded core structure 102.
- the folded core structure 102 is a half- closed honeycomb structure comprising honeycomb cells 103, which are delimited by cell walls.
- the half-closed honeycomb structure 102 has neighboring honeycomb cells which have adjoining cell walls 104a and 104b which are in contact to each other.
- 104a and 104b indicates these adjoining cell walls for a first row of honeycomb cells
- the dashed lines indicated by 104c and 104d shows adjoining cell walls of a neighboring row of honeycomb cells in cross machine direction.
- the honeycomb cells 103 of the half-closed honeycomb structure 102 comprises on one side of each honeycomb cell a connection area 105a or 105b, which closes the honeycomb cells on one side either on the side facing the flooring surface 101 or on the side facing away from the flooring surface 101.
- the connection area 105a is the connection area for the first row of honeycomb cells, which is on the side of the half-closed honeycomb structure 102 facing the flooring surface 101
- the connection area 105b is the connection area of the neighboring row of honeycomb cells in cross machine direction, which is on the side of the half-closed honeycomb structure 102 facing away from the flooring surface 101.
- Figure 2 shows a part of a cross section of a flooring composite 200 comprising a flooring surface 201 with tufting yarns 201a tufted into the primary carpet backing 201b and a folded core structure 202.
- the folded core structure is a relaxed honeycomb structure, wherein the folding of the plastically deformed uncut flat body is stopped before two half cells 203 meet together.
- the relaxed honeycomb structure 202 is preferably in contact with the flooring surface 201 by the edges 203a, and preferably in contact with the ground (or optionally with any further layer; both not shown) by the edges 203b.
- Figure 3 shows a part of a relaxed honeycomb structure 300 half cells 306 having a height h and a half diameter dhaif. Also, the relaxed honeycomb structure 300 comprises kinks 307 and connection areas 305a. The machine direction MD and cross machine direction CD are indicated by arrows.
- Figure 4 shows a cross sectional view of a relaxed honeycomb structure 402, which has an angle a between two in machine direction consecutive half cells 409 and 410. Thereby, the two half honeycomb cells are folded such that an angle a is established by the corner points 408a-c and 408d-f.
- the machine direction MD and cross machine direction CD are indicated by arrows.
- FIG. 5 shows a schematic top view of a honeycomb cell 500.
- the diameter d is the perpendicular distance between two parts 511a of two consecutive half cell walls of the honeycomb structure in machine direction, which are oriented parallel to each other.
- the machine direction MD and cross machine direction CD are indicated by arrows.
- Figure 6 shows a schematic perspective view of a part of a honeycomb cell of a relaxed honeycomb structure 600 comprising a kink 607 and a cell wall of the half cells of the relaxed honeycomb structure 611 , which is oriented parallel to the kink 607.
- the diameter of the honeycomb cells of the relaxed honeycomb structure is determined by measuring the diameter dhaif between the kink 607 and the cell wall of the half-cell of the relaxed honeycomb structure 611 , which is perpendicular to the kink 607 and perpendicular to the plane of the cell wall 611 , and sum up the diameters dhaif of two half cells, which share the same kink 607.
- the partially dashed lines 612 indicates a half-cell of the relaxed honeycomb structure.
- the machine direction MD and cross machine direction CD are indicated by arrows.
- Figure 7 shows a schematic cross-sectional view of a fully folded honeycomb cell of a honeycomb structure 700 comprising a connection area 705 and honeycomb cell walls 711.
- the height of the fully folded honeycomb cell 700 is measured as the perpendicular distance between the plane of connection area 705 and the end of the honeycomb walls 711.
- the machine direction MD and cross machine direction CD are indicated by arrows.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Textile Engineering (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Laminated Bodies (AREA)
Abstract
Un composite (100, 200) de revêtement de sol comprenant une surface (101, 201) de revêtement de sol et une structure de noyau pliée (102, 202), la surface (101, 201) de revêtement de sol comprenant une surface de face de revêtement de sol et une surface arrière de revêtement de sol, et la structure de noyau pliée (102, 202) étant située adjacente à la surface arrière de revêtement de sol, caractérisé en ce que ladite structure de noyau pliée (102, 202) est formée à partir d'un corps plat non coupé, par déformation plastique perpendiculaire au plan du corps plat non coupé de telle sorte que des structures tridimensionnelles comprenant des parois de demi-cellule (409, 410) et des zones de liaison (305a) sont formées, les parois de demi-cellule (409, 410) sont à un angle α l'une par rapport à l'autre pour fournir une structure en nid d'abeilles relâchée (202) ou se rejoignent sous la forme d'une cellule en nid d'abeilles pour former une structure en nid d'abeilles semi-fermée (102), les parois de cellule adjacentes des parois de demi-cellule voisines n'étant pas liées l'une à l'autre au niveau des surfaces principales des parois de cellule.
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PCT/EP2020/085209 WO2021122195A1 (fr) | 2019-12-18 | 2020-12-09 | Composite de revêtement de sol |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2023111955A1 (fr) | 2021-12-16 | 2023-06-22 | 3M Innovative Properties Company | Articles comprenant un espaceur et articles comprenant un film découpé et procédés de fabrication et d'utilisation des articles |
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WO2006053407A1 (fr) | 2004-11-19 | 2006-05-26 | K.U.Leuven Research & Development | Structure alvéolaire thermoplastique semi-fermée, son procédé de fabrication et le matériel pour la produire |
JP2013220648A (ja) | 2012-04-19 | 2013-10-28 | Honda Motor Co Ltd | 折畳式ハニカム構造体および折畳式ハニカム構造体の製造方法 |
EP1620254B1 (fr) | 2003-05-05 | 2017-10-11 | North Carolina State University | Structures tridimensionnelles moulees en profondeur aux proprietes ameliorees |
US20190352845A1 (en) * | 2018-05-17 | 2019-11-21 | Columbia Insurance Company | Carpet compositions having laminated film backings and methods for making same |
-
2020
- 2020-12-09 WO PCT/EP2020/085209 patent/WO2021122195A1/fr active Application Filing
Patent Citations (4)
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EP1620254B1 (fr) | 2003-05-05 | 2017-10-11 | North Carolina State University | Structures tridimensionnelles moulees en profondeur aux proprietes ameliorees |
WO2006053407A1 (fr) | 2004-11-19 | 2006-05-26 | K.U.Leuven Research & Development | Structure alvéolaire thermoplastique semi-fermée, son procédé de fabrication et le matériel pour la produire |
JP2013220648A (ja) | 2012-04-19 | 2013-10-28 | Honda Motor Co Ltd | 折畳式ハニカム構造体および折畳式ハニカム構造体の製造方法 |
US20190352845A1 (en) * | 2018-05-17 | 2019-11-21 | Columbia Insurance Company | Carpet compositions having laminated film backings and methods for making same |
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WO2023111955A1 (fr) | 2021-12-16 | 2023-06-22 | 3M Innovative Properties Company | Articles comprenant un espaceur et articles comprenant un film découpé et procédés de fabrication et d'utilisation des articles |
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