WO2024042322A1 - Surface coverings and method of manufacture thereof - Google Patents

Surface coverings and method of manufacture thereof Download PDF

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Publication number
WO2024042322A1
WO2024042322A1 PCT/GB2023/052193 GB2023052193W WO2024042322A1 WO 2024042322 A1 WO2024042322 A1 WO 2024042322A1 GB 2023052193 W GB2023052193 W GB 2023052193W WO 2024042322 A1 WO2024042322 A1 WO 2024042322A1
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WO
WIPO (PCT)
Prior art keywords
layer
covering according
flexible covering
flexible
covering
Prior art date
Application number
PCT/GB2023/052193
Other languages
French (fr)
Original Assignee
Magnetic Surfaces Limited
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Filing date
Publication date
Application filed by Magnetic Surfaces Limited filed Critical Magnetic Surfaces Limited
Publication of WO2024042322A1 publication Critical patent/WO2024042322A1/en

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0002—Wallpaper or wall covering on textile basis
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0036—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by their backing, e.g. secondary backing, back-sizing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0052—Compounding ingredients, e.g. rigid elements
    • D06N7/0055—Particulate material such as cork, rubber particles, reclaimed resin particles, magnetic particles, metal particles, glass beads
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/08—Inorganic fibres
    • D06N2201/087—Carbon 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
    • D06N2205/10—Particulate form, e.g. powder, granule
    • 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
    • D06N2209/04—Properties of the materials having electrical or magnetic properties
    • D06N2209/045—Magnetic, paramagnetic
    • 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
    • D06N2209/1664—Releasability
    • 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
    • D06N2211/063—Wall coverings
    • 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
    • D06N2211/066—Floor coverings
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0042—Conductive or insulating layers; Antistatic layers; Flame-proof layers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • D06N7/0044—Sealing or barrier layers, e.g. against solvents, asphalt, plasticisers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06Q—DECORATING TEXTILES
    • D06Q1/00—Decorating textiles
    • D06Q1/10—Decorating textiles by treatment with, or fixation of, a particulate material, e.g. mica, glass beads

Definitions

  • the invention to which this application relates is to an improved form of surface covering and, in particular, flexible cladding of a type which is mounted on a structure such as a wall or other support structure.
  • Cladding In the construction industry it is known to use cladding to provide thermal insulation and a degree of weather resistance, as well as to improve the appearance of buildings, walls and other structures.
  • Cladding can be made of any of a wide range of materials, although conventionally, cladding for walls is typically formed of a rigid sheet material that may be single or multi layered.
  • cladding panels the rigid structure limits the performance and functionality of such a covering.
  • It is an aim of the present invention is to provide an improved form of covering which addresses the abovementioned problems.
  • a flexible covering for use in decorating substrates said covering including a fibrous backing layer to which is applied a decorative layer, said decorative layer including stone powder and a polymeric binder.
  • the fibre backing layer is flexible as is the decorative layer which binds to and/ or combines or mixes with the fibres in the backing layer.
  • the substrate typically includes surfaces, such as walls, floors and/or the like.
  • substrate can includes frames, joists, studwork and other building and support structures.
  • the stone powder includes powdered stone, rock, mineral rock, slate and marble. Further typically the stone powder includes powdered aggregates of minerals and mineraloid matter or material.
  • the decorative layer provides an outer surface or facing when the covering is mounted to a wall or support structure in use.
  • the backing layer provides an inner substrate or body for the covering.
  • the fibrous backing layer comprises and/or includes fibre-reinforced polymer.
  • the polymer is an epoxy, vinyl ester, polyester and/ or phenolic resin or plastics material.
  • the fibrous backing layer comprises or includes glass fibres. Further typically the fibrous backing layer comprises or includes fibre glass.
  • the mixture of stone powder and binder is applied onto a flexible glass fibre backing material.
  • the decorative layer is formed, moulded and/or texturised to create the desired finishes. Typically a slate or stone effect finish is achieved.
  • a fire retardant additive is included in the covering. Typically the fire retardant is included in the decorative layer, sealant and/or combination of the same. Further typically a fire rating additive is added into the mixture of stone powder and binder to improve the Fire Rating of the product.
  • a pigment composition and/or colour wash is added to the decorative layer.
  • a sealant or sealing layer is added to the outer surface of the decorative layer.
  • the sealant is a transparent polymer layer.
  • the covering includes a ferrous layer.
  • the ferrous layer is applied to the rear of back surface of the covering and/or fibre layer.
  • the ferrous layer comprises a coating or layer including iron and/or ferromagnetic material.
  • the iron and/ or ferromagnetic material enables the covering to be mounted and/ or positioned magnetically.
  • the ferrous layer comprises a ferromagnetic or ferrous paint and/ or a flexible magnetic sheet material.
  • the covering can be applied to a complimentary magnetic or ferrous layer on a wall or floor for example.
  • the covering includes a layer of insulation and/ or an insulating layer.
  • the insulating layer includes one or more aerogels.
  • the insulating layer comprises a layer of aerogel material.
  • the aerogel is a silica, carbon and/ or metal oxide aerogel.
  • the covering is changeable, interchangeable or replaceable without requiring fixings and/or fixing tools.
  • the covering can be fitted and/ or fixed in position without requiring glue or adhesive.
  • the covering is substantially flexible.
  • the covering can be mounted or fitted to curved surfaces. Further typically the covering can be fitted to points on an arc thereby forming a curved surface.
  • a conductive member or element receives an electrical current.
  • the conductive member or element is a resistive element that generates heat and/ or infra red radiation on receiving the electrical current.
  • the conductive member is a heating element or heating layer. Further typically at least part of the conductive member is embedded or included in the decorative layer. In one embodiment the conductive member is included as a separate or discreet heating layer.
  • the conductive member can be used as an electricity supply.
  • other devices can be powered and/ or charged using the electricity supplied to the conductive member.
  • a flexible material means suitable for use as a wall covering said flexible material means including at least two layers wherein one of the layers includes aerogel material.
  • a covering system comprising two or more layers including at least one outer decorative layer including crushed stone and binder and at least one insulation layer characterised in that the insulation layer includes at least one aerogel.
  • a method of applying a covering to a substate said covering including a fibrous backing layer to which is applied a decorative layer, said decorative laying including stone powder and a polymeric binder said method including the step of attaching said covering to a substrate.
  • a method of forming a covering including a fibrous backing layer and including the step of applying a decorative layer, said decorative laying including stone powder and a polymeric binder.
  • a covering material comprising at least a polymeric layer and decorative layer including stone powder and a binder.
  • the polymeric layer is an insulating layer. Further typically the polymeric layer is an acoustic insulating layer.
  • the polymer layer comprises polyethylene terephthalate (PET).
  • the system includes one or more magnetic layers.
  • the magnetic layers attach the other layers together and/ or the system to the substrate.
  • the substrate is a surface such as a wall, floor and/ or the like
  • Figure 1 illustrates a multi-layered covering in accordance with one embodiment of the invention.
  • FIGS. 2a-2d illustrate the attachment of a further a multi-layered covering system in accordance with an embodiment of the invention
  • the present invention proves changeable interior and exterior wall finishes that can be used in interior and exterior locations and is particularly suitable in wet rooms and bathrooms as an alternative to tiling. In other words it provides changeable floor and wall surfaces, furniture etc.
  • the covering is the use of stone powder.
  • the invention does not utilise a composite core.
  • the covering may include fire retardant compositions and insulation to reduce noise or thermal transfer.
  • magnetism can be incorporated to improve interchangeability, allowing a surface that can be reused or reapplied. Conventional coverings or surfaces are predominately glued or fixed.
  • the coverings are lightweight and easy to transport which reduces logistical and transport problems and improves the environmental properties. Furthermore, the system lends itself to fast installation, improving efficiency and reducing cost of the system and installation.
  • FIG la shows the make-up of a surface covering 2 in a specific example.
  • the essential features in this example are the textured stone surface 4 that comprised powdered stone formed into the appearance of solid stone when moulded with a binder.
  • the Stone Surface Texture layer 4 is, in this example bonded to a glass fibre backing 6 using adhesive 8.
  • a wash of colour and/ or waterproof sealer 10 may be applied to the outer surface of the Stone Surface Texture layer.
  • an insulating layer 12 (acoustic insulation in this example), may also be included before or after the magnetic or ferrous layer 14 is applied to assist in mounting the covering system either to a magnetic surface.
  • the magnetic surface can be another panel or ferrous painted surface and/ or the like.
  • Figure 2 shows a similar system in use.
  • Figure 2a shows a wall substrate 16 onto which is magnetically mounted a flexible panel 2’ that comprises moulded stone powder and binder that presents an attractive outer layer 4.
  • the outer layer 4 is bonded or includes a fibrous backing layer 6.
  • the panel 2’ includes a magnetic layer 14 so that the same can be removed from the wall, as shown in figure 2b, without the need of any tool or requiring any fixings or adhesives to be removed.
  • the aerogel insulating layer 12 is included between two magnetic sheets 18, 18’ as shown in figure 2c.
  • the wall substrate 20 in this example includes a layer of magnetic paint 22 that facilitates magnetic attachment of the system and the easy interchangeability.
  • the outer flexible panel 2’ can be reapplied or reattached by simply replacing the various layers.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Finishing Walls (AREA)

Abstract

A flexible covering and method of producing the same. The covering for use in decorating substrates and said covering including a fibrous backing layer to which is applied a decorative layer, said decorative layer including stone powder and a polymeric binder.

Description

Surface Coverings and Method of Manufacture Thereof
The invention to which this application relates is to an improved form of surface covering and, in particular, flexible cladding of a type which is mounted on a structure such as a wall or other support structure.
Although the following description refers exclusively to flexible coverings for walls the skilled person will appreciate that the present invention can be used in covering floors and other similar non-vertical structures and is not limited to indoor or outdoor wall coverings.
In the construction industry it is known to use cladding to provide thermal insulation and a degree of weather resistance, as well as to improve the appearance of buildings, walls and other structures. Cladding can be made of any of a wide range of materials, although conventionally, cladding for walls is typically formed of a rigid sheet material that may be single or multi layered. However, despite the availability of a range of different formations of cladding panels the rigid structure limits the performance and functionality of such a covering.
In addition, many decorative coverings used in commercial settings, for example wall coverings in restaurants may need to be changed relatively frequently and replacing conventional panels can be costly and time consuming.
It is an aim of the present invention is to provide an improved form of covering which addresses the abovementioned problems.
It is a further aim of the present invention to provide a method of manufacturing a covering that addresses the abovementioned problems.
It is a yet further aim of the present invention to provide a method of installing a covering that addresses the abovementioned problems.
In a first aspect of the invention, there is provided a flexible covering for use in decorating substrates, said covering including a fibrous backing layer to which is applied a decorative layer, said decorative layer including stone powder and a polymeric binder.
As such the fibre backing layer is flexible as is the decorative layer which binds to and/ or combines or mixes with the fibres in the backing layer.
Typically the substrate includes surfaces, such as walls, floors and/or the like. In addition substrate can includes frames, joists, studwork and other building and support structures.
Typically the stone powder includes powdered stone, rock, mineral rock, slate and marble. Further typically the stone powder includes powdered aggregates of minerals and mineraloid matter or material.
Typically the decorative layer provides an outer surface or facing when the covering is mounted to a wall or support structure in use. Further typically the backing layer provides an inner substrate or body for the covering.
In a preferred embodiment the fibrous backing layer comprises and/or includes fibre-reinforced polymer. Typically the include glass, carbon, aramid, and/ or basalt. Further typically the polymer is an epoxy, vinyl ester, polyester and/ or phenolic resin or plastics material.
In an embodiment of the invention the fibrous backing layer comprises or includes glass fibres. Further typically the fibrous backing layer comprises or includes fibre glass.
In one embodiment the mixture of stone powder and binder is applied onto a flexible glass fibre backing material.
In a preferred embodiment the decorative layer is formed, moulded and/or texturised to create the desired finishes. Typically a slate or stone effect finish is achieved. In a preferred embodiment a fire retardant additive is included in the covering. Typically the fire retardant is included in the decorative layer, sealant and/or combination of the same. Further typically a fire rating additive is added into the mixture of stone powder and binder to improve the Fire Rating of the product.
In one embodiment a pigment composition and/or colour wash is added to the decorative layer.
In one embodiment a sealant or sealing layer is added to the outer surface of the decorative layer. Typically the sealant is a transparent polymer layer.
In one embodiment the covering includes a ferrous layer. Typically the ferrous layer is applied to the rear of back surface of the covering and/or fibre layer. Further typically the ferrous layer comprises a coating or layer including iron and/or ferromagnetic material.
Typically the iron and/ or ferromagnetic material enables the covering to be mounted and/ or positioned magnetically.
Further typically the ferrous layer comprises a ferromagnetic or ferrous paint and/ or a flexible magnetic sheet material. As such the covering can be applied to a complimentary magnetic or ferrous layer on a wall or floor for example.
In one embodiment the covering includes a layer of insulation and/ or an insulating layer. Typically the insulating layer includes one or more aerogels. Further typically the insulating layer comprises a layer of aerogel material.
Typically the aerogel is a silica, carbon and/ or metal oxide aerogel.
In one embodiment the covering is changeable, interchangeable or replaceable without requiring fixings and/or fixing tools. Typically the covering can be fitted and/ or fixed in position without requiring glue or adhesive. In one embodiment the covering is substantially flexible. Typically the covering can be mounted or fitted to curved surfaces. Further typically the covering can be fitted to points on an arc thereby forming a curved surface.
In one embodiment of the invention there is provided a conductive member or element. Typically the conductive member or element receives an electrical current. Further typically the conductive member or element is a resistive element that generates heat and/ or infra red radiation on receiving the electrical current.
Typically the conductive member is a heating element or heating layer. Further typically at least part of the conductive member is embedded or included in the decorative layer. In one embodiment the conductive member is included as a separate or discreet heating layer.
In one embodiment the conductive member can be used as an electricity supply. Typically other devices can be powered and/ or charged using the electricity supplied to the conductive member.
In a second aspect of the invention there is provided a flexible material means suitable for use as a wall covering, said flexible material means including at least two layers wherein one of the layers includes aerogel material.
In a third aspect of the invention there is provided a covering system, said system comprising two or more layers including at least one outer decorative layer including crushed stone and binder and at least one insulation layer characterised in that the insulation layer includes at least one aerogel.
In a further aspect of the invention there is provided a method of applying a covering to a substate, said covering including a fibrous backing layer to which is applied a decorative layer, said decorative laying including stone powder and a polymeric binder said method including the step of attaching said covering to a substrate.
In a yet further aspect of the invention there is provided a method of forming a covering, said covering including a fibrous backing layer and including the step of applying a decorative layer, said decorative laying including stone powder and a polymeric binder.
In a yet further aspect of the invention there is provided a covering material comprising at least a polymeric layer and decorative layer including stone powder and a binder.
Typically the polymeric layer is an insulating layer. Further typically the polymeric layer is an acoustic insulating layer.
In one embodiment the polymer layer comprises polyethylene terephthalate (PET).
In one embodiment the system includes one or more magnetic layers. Typically the magnetic layers attach the other layers together and/ or the system to the substrate.
Further typically the substrate is a surface such as a wall, floor and/ or the like
Specific embodiments of the invention are now described with reference to the accompanying drawings wherein:
Figure 1 illustrates a multi-layered covering in accordance with one embodiment of the invention; and
Figures 2a-2d illustrate the attachment of a further a multi-layered covering system in accordance with an embodiment of the invention
The present invention proves changeable interior and exterior wall finishes that can be used in interior and exterior locations and is particularly suitable in wet rooms and bathrooms as an alternative to tiling. In other words it provides changeable floor and wall surfaces, furniture etc.
One of the unique features of the covering is the use of stone powder. The invention does not utilise a composite core. In addition the covering may include fire retardant compositions and insulation to reduce noise or thermal transfer. Also magnetism can be incorporated to improve interchangeability, allowing a surface that can be reused or reapplied. Conventional coverings or surfaces are predominately glued or fixed.
In addition the coverings are lightweight and easy to transport which reduces logistical and transport problems and improves the environmental properties. Furthermore, the system lends itself to fast installation, improving efficiency and reducing cost of the system and installation.
Turning to figure la which shows the make-up of a surface covering 2 in a specific example. The essential features in this example are the textured stone surface 4 that comprised powdered stone formed into the appearance of solid stone when moulded with a binder. The Stone Surface Texture layer 4 is, in this example bonded to a glass fibre backing 6 using adhesive 8.
Optionally a wash of colour and/ or waterproof sealer 10 may be applied to the outer surface of the Stone Surface Texture layer.
In addition, an insulating layer 12 (acoustic insulation in this example), may also be included before or after the magnetic or ferrous layer 14 is applied to assist in mounting the covering system either to a magnetic surface. The magnetic surface can be another panel or ferrous painted surface and/ or the like.
Figure 2 shows a similar system in use. Figure 2a shows a wall substrate 16 onto which is magnetically mounted a flexible panel 2’ that comprises moulded stone powder and binder that presents an attractive outer layer 4. The outer layer 4 is bonded or includes a fibrous backing layer 6. The panel 2’ includes a magnetic layer 14 so that the same can be removed from the wall, as shown in figure 2b, without the need of any tool or requiring any fixings or adhesives to be removed.
In this example, the aerogel insulating layer 12 is included between two magnetic sheets 18, 18’ as shown in figure 2c. The wall substrate 20 in this example includes a layer of magnetic paint 22 that facilitates magnetic attachment of the system and the easy interchangeability. As demonstrated in figure 2d the outer flexible panel 2’ can be reapplied or reattached by simply replacing the various layers.

Claims

Claims
1. A flexible covering for use in decorating substrates, said covering including a fibrous backing layer to which is applied a decorative layer, said decorative layer including stone powder and a polymeric binder.
2. A flexible covering according to claim 1 wherein the substrate includes surfaces, such as walls, floors and/ or the like.
3. A flexible covering according to claim 1 wherein the stone powder includes powdered stone, rock, mineral rock, slate and/ or marble.
4. A flexible covering according to claim 1 wherein the stone powder includes powdered aggregates of minerals and mineraloid matter or material.
5. A flexible covering according to claims 1-4 wherein the decorative layer provides an outer surface or facing when the covering is mounted to a wall or support structure in use.
6. A flexible covering according to claim 5 wherein the backing layer provides an inner substrate or body for the covering.
7. A flexible covering according to claims 1-6 wherein the fibrous backing layer comprises and/ or includes fibre-reinforced polymer.
8. A flexible covering according to claim 7 wherein the fibre includes glass, carbon, aramid, and/ or basalt.
9. A flexible covering according to claim 7 wherein the polymer is an epoxy, vinyl ester, polyester and/or phenolic resin or plastics material.
10. A flexible covering according to claims 8 or 9 wherein the fibrous backing layer comprises or includes glass fibres.
11. A flexible covering according to claim 10 wherein the mixture of stone powder and binder is applied onto a flexible glass fibre backing material.
12. A flexible covering according to any preceding claim wherein the decorative layer is formed, moulded and/ or texturised to create the desired finishes.
13. A flexible covering according to any preceding claim wherein a fire retardant additive is included in the covering.
14. A flexible covering according to any preceding claim wherein a pigment composition and/ or colour wash is added to the decorative layer.
15. A flexible covering according to any preceding claim wherein a sealant or sealing layer is added to the outer surface of the decorative layer
16. A flexible covering according to any preceding claim wherein the covering includes a ferrous layer.
17. A flexible covering according to claim 16 wherein the ferrous layer is applied to the rear of back surface of the covering and/ or fibre layer.
18. A flexible covering according to claim 17 wherein the ferrous layer comprises a coating or layer including iron and/or ferromagnetic material, that enables the covering to be mounted and/ or positioned magnetically.
19. A flexible covering according to claim 16 wherein the ferrous layer comprises a ferromagnetic or ferrous paint and/ or a flexible magnetic sheet material enabling the covering can be applied to a complimentary magnetic or ferrous layer on a wall or floor for example.
20. A flexible covering according to claims 1-19 wherein the covering includes a layer of insulation and/ or an insulating layer.
21. A flexible covering according to claim 20 wherein the insulating layer includes one or more aerogels.
22. A flexible covering according to claim 21 wherein the insulating layer comprises a layer of aerogel material.
23. A flexible covering according to claim 21 or 22 wherein the aerogel is a silica, carbon and/ or metal oxide aerogel.
24. A flexible covering according to claim 20 wherein the insulation includes limestone and/ or titanium dioxide particles.
25. A flexible covering according to claim 24 wherein the insulation includes microspheres or limestone and/ or titanium dioxide.
26. A method of forming a covering, said covering including a fibrous backing layer and including the step of applying a decorative layer, said decorative laying including stone powder and a polymeric binder.
PCT/GB2023/052193 2022-08-22 2023-08-22 Surface coverings and method of manufacture thereof WO2024042322A1 (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2259070A1 (en) * 1974-01-30 1975-08-22 Bozec Philippe Le Thermosetting resin-based compsns - for surfacing materials resembling natural marble
RU2503542C2 (en) * 2012-04-13 2014-01-10 Татьяна Александровна Усатова Finishing decorative-protective material and method of its production
CN104553091A (en) * 2014-12-26 2015-04-29 高俊丽 Aerogel composite board and preparation method thereof
US20160319553A1 (en) * 2015-03-27 2016-11-03 Golconda Holdings Llc System, method, and apparatus for magnetic surface coverings
US20210060910A1 (en) * 2018-02-22 2021-03-04 Alice ZANTEDESCHI Process for the manufacture of a membrane adapted for coupling to a fabric, and product so obtained

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2259070A1 (en) * 1974-01-30 1975-08-22 Bozec Philippe Le Thermosetting resin-based compsns - for surfacing materials resembling natural marble
RU2503542C2 (en) * 2012-04-13 2014-01-10 Татьяна Александровна Усатова Finishing decorative-protective material and method of its production
CN104553091A (en) * 2014-12-26 2015-04-29 高俊丽 Aerogel composite board and preparation method thereof
US20160319553A1 (en) * 2015-03-27 2016-11-03 Golconda Holdings Llc System, method, and apparatus for magnetic surface coverings
US20210060910A1 (en) * 2018-02-22 2021-03-04 Alice ZANTEDESCHI Process for the manufacture of a membrane adapted for coupling to a fabric, and product so obtained

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