MULTI-LAYER FLOOR COVERING AND METHOD FOR THE MANUFACTURE OF THIS FLOOR COVERING

Description

2 environmentalandhealthconcernsassociatedwithPVCandplasticizers.Itisalsoan objectivetoprovideamultilayerfloorcoveringthateliminatesPVC,andoptionallyplasticizers, whereinthefloorcoveringhasoptimalmechanicalproperties,insulation,and / oracoustic properties. Itisalsoanobjectivetoprovideamethodforproductionofafloorcoveringthateliminatesthe5 useofPVC,andoptionallyplasticizers,butwhereintheexistingproductionplantsofcushion vinylfloorcoveringscanbeeasilyconvertedtoproductionplantsthatallowtheproductionof amultilayerfloorcoveringaccordingtotheinvention. SUMMARYOFTHEINVENTION10 Theinventionhasforitsobjecttoremedyortoreduceatleastoneofthedrawbacksofthe priorart,oratleastprovideausefulalternativetopriorart.Theobjectisachievedthrough features,whicharespecifiedinthedescriptionbelowandintheclaimsthatfollow. Theinventionisdefinedbytheindependentpatentclaims.Thedependentclaimsdefine advantageousembodimentsoftheinvention.15 TheinventorshavedevelopedamultilayerfloorcoveringthateliminatestheuseofPVCand optionallyalsotheuseofplasticizers.Specifically,themultilayerfloorcoveringcomprisesin thefollowingorderatleastabackinglayer,acoatinglayerbasedonapolymer-in-water dispersionandawearlayer.Preferredforthepresentinventionisthatthebackinglayer,the coatinglayer,andthewearlayerareeachessentiallyfreeofPVChomopolymersandPVC20 copolymersandthattheselayerseachcompriseathermoplasticpolymerwhereinsaid thermoplasticpolymerineachlayerisofthesamefamilyofthermoplasticpolymers.Also preferredisthatthebackinglayerhasanairpermeabilityofatleast500l / m2 / smeasuredat 200PascalaccordingtoISO9237,suchthattheafterapplicationofthecoatinglayer,which isbasedonapolymer-in-waterdispersion,sufficientwaterfromthecoatinglayercan25 evaporatethroughthebackinglayer.Insomepreferredembodiments,themultilayerfloor coveringisessentiallyfreeofPVChomopolymersandPVCcopolymers.Insomepreferred embodiments,thebackinglayer,thecoatinglayer,andthewearlayerareeachessentially freeofanypolymerotherthanthethermoplasticpolymer.Assuch,amultilayerfloorcovering iscreatedwhereinonlyonefamilyofthermoplasticpolymerispresentinthebackinglayer,30 thecoatinglayer,andthewearlayer.Morepreferably,themultilayerfloorcoveringis essentiallyfreeofanypolymerotherthanthethermoplasticpolymer.Furtherpreferred,isthat themultilayerfloorcoveringasdisclosedhereinhasabendingstiffnessofatmost800N.mm, preferablyasmeasuredbythebendingstiffnesstestdisclosedherein,morepreferablybya modifiedbendingtestaccordingtoISO5628asdisclosedherein.Assuch,eveninthe35 BE2024 / 5874 3 absenceofPVCandoptionallyalsointheabsenceofplasticizers,aflexiblefloorcovering productiscreated.Theinventorshavealsodevelopedaproductionmethodtoproduceamultilayerfloorcovering asdisclosedherein,whereinawearlayerisprovidedwhereafteracoatinglayerbasedona polymer-in-waterdispersionisappliedonthewearlayerfollowedbyapplyingabackinglayer5 onthecoatinglayer,whereinthebackinglayerisconfiguredtooverliethecoatinglayersuch thatthebackinglayercontactsthecoatinglayer. Anotheraspectprovidesaproductionmethodtoproduceamultilayerfloorcoveringas disclosedherein,whereinabackinglayerisprovidedwhereafteracoatinglayerbasedona polymer-in-waterdispersionisappliedonthebackinglayerfollowedbyapplyingawearlayer10 onthecoatinglayer,whereinthewearlayerisconfiguredtooverliethecoatinglayersuchthat thewearinglayercontactsthecoatinglayer. Theadvantageoftheproductionmethodsdisclosedhereinisthattheyeliminatetheuseof PVC,andoptionallyalsotheuseofplasticizers.Thepresentinventionprovidesacost-competitiveanddurablemultilayerfloorcovering15 equivalenttoaplasticizedheterogenousvinylfloorcoveringbutwithoutusingPVCand / or plasticizers.Themultilayerfloorcoveringofthepresentinventionthusachievesthedesirable propertiesofdurability,flexibility,andaestheticappealwithouttheenvironmentalandhealth drawbacksassociatedwithPVC.Inparticular,thefloorcoveringofthepresentinventionis characterizedinthatitcomprisesatleastawearlayer,acoatinglayer,andabackinglayer20 thatareallessentiallyfreeofPVCandoptionallyessentiallyfreeofplasticizersandwherein thefloorcoveringstillprovidesthenecessarymechanicalandscratchresistanceproperties. Insomeembodiments,themultilayerfloorcoveringhasabendingstiffnessofatmost800 N.mm,preferablyasmeasuredaccordingtothebendingstiffnesstestdisclosedherein,more preferablyasmeasuredaccordingtoamodifiedbendingstiffnesstestaccordingtoISO562825 asdisclosedherein,evenintheabsenceofPVCand / orplasticizers.Alsoprovidedisamethodtoproduceamultilayerfloorcoveringthatcomprisesawearlayer, acoatinglayer,andabackinglayerthatareallessentiallyfreeofPVCandoptionally essentiallyfreeofplasticizers. Finally,themultilayerfloorcoveringoftheinventionprovidesbenefitstorecyclingandtake-30 backofusedflooringssinceitcanbepartofexistingrecyclingprocessesofthermoplastic polymers,suchaspolypropylene(PP)orpolyethyleneterephthalate(PET). Inafirstaspect,theinventionrelatestoamultilayerfloorcoveringcomprising,infollowing order,atleastabackinglayer,acoatinglayerbasedonapolymer-in-water-dispersion,anda BE2024 / 5874 4 wearlayer,whereinthebackinglayer,thecoatinglayer,andthewearlayereachcomprisea thermoplasticpolymerwhereinsaidthermoplasticpolymerineachlayerisofthesamefamily ofthermoplasticpolymersandwhereinthebackinglayer,thecoatinglayer,andthewearlayer areessentiallyfreeofpolyvinyl(PVC)homopolymersandPVCcopolymers.Thebackinglayer isfurthercharacterizedinthatithasanairpermeabilityofatleast500l / m2 / smeasuredat2005 PascalaccordingtoISO9237. Insomepreferredembodiments,thebackinglayer,thecoatinglayer,andthewearlayerare eachessentiallyfreeofanypolymerotherthanthethermoplasticpolymerthatisofthesame familyofthermoplasticpolymers.. Insomepreferredembodiments,themultilayerfloorcoveringisessentiallyfreeofanypolymer10 otherthanthethermoplasticpolymerthatisofthesamefamilyofthermoplasticpolymers. Insomepreferredembodiments,thethermoplasticpolymerisapolymerofthefamilyof polyolefins,polystyrenes,polyesters,orpolyamides;morepreferablyofthefamilyof polyolefins,polystyrenesorpolyamides.Insomefurtherpreferredembodiments,the thermoplasticpolymerisselectedfromthegroupconsistingofpolypropylene(PP),15 polyethylene(PE),ethylene-propylenecopolymer,ethylene-butenecopolymer,ethylene- octenecopolymer,butadiene-propylenecopolymer,ethylenevinylacetate(EVA),ethylene methylacetate(EMA),polystyrene(PS),styrene-propylenecopolymer,polyethylene terephthalate(PET),co-PET,polyethyleneterephthalateglycol(PETG),polybutylene terephthalate(PBT),polylacticacid(PLA),polycaprolactone(PCL),polyamide,andco-20 polyamide.Insomeembodiments,thethermoplasticpolymerisselectedfrompolyethylene (PE),polypropylene(PP),ethylene-propylenecopolymer,ethylene-butenecopolymer, ethylene-octenecopolymer,polyethyleneterephthalateglycol,polybutyleneterephthalate, polyethyleneterephthalate(PET),andco-PET.Preferably,thethermoplasticpolymerisa thermoplasticpolymerofthefamilyofpolyolefinsorpolyesters,suchasPP,orPET,orco-25 PET.Insomeembodiments,thebackinglayer,thecoatinglayer,andthewearlayereach compriseapolyolefinorapolyester. Insomeembodiments,thethermoplasticpolymerisarecycledthermoplasticpolymer. Themultilayerfloorcoveringoftheinventionispreferablycharacterizedinthatatleastthe backinglayer,thecoatinglayerandthewearlayerareessentiallyfreeofPVC.Insome30 preferredembodiments,themultilayerfloorcoveringisessentiallyfreeofPVC. Insomeembodiments,themultilayerfloorcoveringispreferablycharacterizedinthatatleast thebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofplasticizers.In somepreferredembodiments,themultilayerfloorcoveringisessentiallyfreeofplasticizers. BE2024 / 5874 5 Insomeembodiments,themultilayerfloorcoveringischaracterizedinthatatleastthebacking layer,thecoatinglayerandthewearlayerareessentiallyfreeofPVCandessentiallyfreeof plasticizers.Insomepreferredembodiments,themultilayerfloorcoveringisessentiallyfree ofPVCandessentiallyfreeofplasticizers.Insomeembodiments,thebackinglayerisanon-wovenbackinglayer;preferablyanon-5 woventextilebackinglayer. Insomeembodiments,thebackinglayerisawovenbackinglayer;preferablyawoventextile backinglayer. Insomeembodiments,thebackinglayercomprisesanadditionallayerofglassfibretissue. Inordertoallowsufficientwaterevaporationfromthecoatinglayeritisparticularlypreferred10 thatthebackinglayerhasahighrateofairpermeability.Insomepreferredembodiments,the airpermeabilityofthebackinglayerisatleast500l / m2 / s,preferablyatleast750l / m2 / s,more preferablyatleast1000l / m2 / s,evenmorepreferablyatleast1250l / m2 / s,measuredat200 PascalaccordingtoISO9237. Insomeembodiments,themultilayerfloorcoveringhasabendingstiffnessofatmost800.015 N.mmasmeasuredusingthebendingstiffnesstestdisclosedherein,inparticularas measuredusingamodifiedbendingstiffnesstestaccordingtoISO5628whereinthebending angleissetat30°asdisclosedherein.Insomefurtherembodiments,themultilayerfloor coveringhasabendingstiffnessofatmost600.0N.mm,preferablyatmost450N.mm,more preferablyatmost350N.mm,asmeasuredusingthebendingstiffnesstestdisclosedherein,20 inparticularasmeasuredusingamodifiedbendingstiffnesstestaccordingtoISO5628 whereinthebendingangleissetat30°. Insomeembodiments,themultilayerfloorcoveringhasabendingstiffnessofatleast5.0 N.mmasmeasuredusingthebendingstiffnesstestdisclosedherein,inparticularas measuredusingamodifiedbendingstiffnesstestaccordingtoISO5628whereinthebending25 angleissetat30°asdisclosedherein.Insomefurtherembodiments,themultilayerfloor coveringhasabendingstiffnessofatleast100.0N.mm,preferablyatleast150.0N.mm,more preferablyatleast180.0N.mm,asmeasuredusingthebendingstiffnesstestdisclosedherein, inparticularasmeasuredusingamodifiedbendingstiffnesstestaccordingtoISO5628 whereinthebendingangleissetat30°.30 Insomeembodiments,themultilayerfloorcoveringhasabendingstiffnessofatleast5.0 N.mmandatmost800.0N.mmasmeasuredusingtothebendingstiffnesstestdisclosed herein.Preferably,thebendingstiffnessisofatleast100.0N.mmandatmost600.0N.mm, morepreferablyofatleast150N.mmandatmost450N.mm;evenmorepreferablyofatleast BE2024 / 5874 6 180N.mmtoatmost350N.mm,asmeasuredusingtothebendingstiffnesstestdisclosed herein,inparticularasmeasuredusingamodifiedbendingstiffnesstestaccordingtoISO 5628whereinthebendingangleissetat30°.Insomeembodiments,themultilayerfloorcoveringfurthercomprisesareinforcementlayer andanadditionalcoatinglayer(orsecondcoatinglayer)basedonapolymer-in-water5 dispersion,whereinsaidreinforcementlayerandadditional(orsecond)coatinglayerare locatedinbetweenthecoatinglayerandthebackinglayer,withtheadditionalcoatinglayer beingincontactwiththebackinglayerandthereinforcementlayerbeingincontactwiththe coatinglayer,andwhereintheadditional(orsecond)coatinglayercomprisesthesame thermoplasticpolymerasthebackinglayer,thecoatinglayerandthewearlayerandwherein10 theadditional(orsecond)coatinglayerisessentiallyfreeofpolyvinylchloride(PVC) homopolymersandPVCcopolymers.Evenmorepreferably,theadditional(orsecond)coating layerisessentiallyfreeofplasticizers. Thefloorcoveringoftheinventionpreferablycomprisesacoatinglayerbasedonapolymer- in-waterdispersionthatisappliedtothebackinglayer.Insomeembodiments,thefloor15 coveringcomprisesonlyonecoatinglayerbasedonapolymer-in-waterdispersion.Insome embodiments,thefloorcoveringcomprisesa(first)coatinglayerbasedonapolymer-in-water dispersionandanadditional(orsecond)coatinglayerbasedonapolymer-in-waterdispersion. Insomeembodiments,andwhenacoatinglayerandanadditionalcoatinglayerarepresent, thebackinglayer,thecoatinglayer,theadditionalcoatinglayer,andthewearlayereach20 compriseathermoplasticpolymerthatisofthesamefamilyofthermoplasticpolymers.In somefurtherembodiments,thebackinglayer,thecoatinglayer,theadditionalcoatinglayer, andthewearlayerareessentiallyfreeofanypolymerotherthanthethermoplasticpolymer. Insomepreferredembodiments,thepolymer-in-waterdispersionofthecoatinglayerandthe additionalcoatinglayerhasasolidcontentofatleast10.0wt%;preferablyatleast30.0wt%;25 morepreferablyatleast50.0wt%,oratleast65.0wt%;evenmorepreferablyatleast68.0 wt%. Insomeembodiments,thesolidcontentinthecoatinglayerisdeterminedbyallsolid componentspresentinthepolymer-in-waterdispersion.Insomeembodiments,thesolid contentisdeterminedbythepolymerofthecoatinglayerandbyanyadditivesthatarepresent30 inthepolymer-in-waterdispersion.Insomeembodiments,thesolidcontentinthecoating layerisdeterminedbythepolymerofthecoatinglayer,oneormorefillerspresentinthe coatinglayer,andanyothersolidcomponentspresentinthepolymer-in-waterdispersion.In someembodiments,thesolidcontentinthecoatinglayerisdeterminedonlybythepolymer ofthecoatinglayer.35 BE2024 / 5874 7 Insomeembodiments,thecoatinglayerand / oradditionalcoatinglayerisafoamedcoating layer. Insomeembodiments,thecoatinglayerand / oradditionalcoatinglayerisanon-foamed coatinglayer.Insomeembodiments,thewearlayercomprisesonethermoplasticpolymer,suchasone5 polymerselectedfromthegroupconsistingofpolypropylene(PP),polyethylene(PE), ethylene-propylenecopolymer,ethylene-butenecopolymer,ethylene-octenecopolymer, ethylenevinylacetate(EVA),ethylenemethylacetate(EMA),polystyrene(PS),styrene- propylenecopolymer,polyethyleneterephthalate(PET),co-PET,polyethyleneterephthalate glycol(PETG),polybutyleneterephthalate(PBT),polylacticacid(PLA),polycaprolactone10 (PCL),polyamide,andco-polyamide.Insomeembodiments,thewearlayercomprisesa thermoplasticpolymerofthefamilyofpolyolefinsorpolyestersandnootherpolymers.Insome embodiments,thewearlayerisamono-polymermaterialwearlayerwhereinonlyonetypeof thermoplasticpolymerispresent. Insomepreferredembodiments,thewearlayercomprisesaprintpatterndepositedonthe15 surfaceofthewearlayeronthesideofthecoatinglayer.Insomeembodiments,thewear layercomprisesaprintpatterndepositedonthesurfaceofthewearlayer.Insome embodiments,suchprintpatternisdepositedonthesurfaceofthewearlayerduringthe productionprocessofthefloorcovering.Inotherembodiments,suchprintpatternisdeposited onthesurfaceofthewearlayerpriortoproductionofthefloorcoveringandthewearlayeris20 providedwithaprintedpattern. Insomeembodiments,thewearlayerisanembossedwearlayer;suchasathermally embossedwearlayer,acoldembossedwearlayer,oranembossedwearlayergenerated throughacastingprocess. Insomeembodiments,themultilayerfloorcoveringfurthercomprisesalacquerlayerthatis25 locatedonthewearlayer;preferablywhereinthelacquercomprisespolyurethane, polyacrylate,oramixturethereof. Insomeembodiments,thelacquerlayerisessentiallyfreeofPVChomopolymersandPVC copolymers.Insomeembodiments,thelacquerlayerisessentiallyfreeofplasticizers. Insomeembodiments,themultilayerfloorcoveringisessentiallyfreeofPVChomopolymers30 andPVCcopolymers.Insomeembodiments,themultilayerfloorcoveringisessentiallyfree ofplasticizers.Anotheraspectprovidesamethodtoproduceamultilayerfloorcovering;preferablyamethod toproduceamultilayerfloorcoveringaccordingtoanyoftheembodimentsdescribedherein. BE2024 / 5874 8 Insomeembodiments,themethodcomprisesthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer; and, c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayerisconfigured5 tooverliethecoatinglayersuchthatthebackinglayercontactsthecoatinglayer; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerwhereinsaidthermoplasticpolymerineachlayerisofthesamefamilyof thermoplasticpolymers; whereinthebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVC10 homopolymersandPVCcopolymers;and whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s,measuredat200 PascalaccordingtoISO9237.Insomeembodiments,thebackinglayer,thecoatinglayerand thewearlayerareessentiallyfreeofplasticizers.Insomefurtherembodiment,themethodcomprisesastepb1)whereinafterstepb)a15 reinforcementlayerisappliedonthecoatinglayerandwhereinanadditionalcoatinglayer basedonapolymer-in-waterdispersionisappliedonthereinforcementlayer,andwhereinin stepc)thebackinglayerisappliedontheadditionalcoatinglayer,whereinthebackinglayer isconfiguredtooverlietheadditionalcoatinglayersuchthatthebackinglayercontactsthe additionalcoatinglayer.20 Insomeembodiments,themethoddisclosedhereincomprisesthestepsof: a)providingabackinglayerthathasanairpermeabilityofatleast500l / m2 / s,measured at200PascalaccordingtoISO9237; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthebackinglayer; and25 c)applyingawearlayeronthecoatinglayer,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthewearlayercontactsthecoatinglayer; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerwhereinsaidthermoplasticpolymerineachlayerisofthesamefamilyof thermoplasticpolymers;and30 whereinthebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVC homopolymersandPVCcopolymers. Insomeembodiments,thebackinglayer,thecoatinglayerandthewearlayerareessentially freeofplasticizers.Insomefurtherembodiments,saidmethodcomprisesastepa1)whereinafterstepa)an35 additionalcoatinglayerbasedonapolymer-in-waterdispersionisappliedonthebackinglayer BE2024 / 5874 9 andwhereinareinforcementlayerisappliedontheadditionalcoatinglayerandwhereinin stepb)thecoatinglayerisappliedonthereinforcementlayer. Insomeembodiments,themethodfurthercomprisesastepd)thatcomprisesheatingthefloor coveringtoatemperatureofatleast70.0°Ctoatmostatemperaturethatis20.0°Cabovethe meltingtemperatureofthethermoplasticpolymerinthemultilayerfloorcovering,thereby5 allowingthecoatinglayertofusewiththewearlayerandthebackinglayer.Insomefurther embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmostatemperaturethatis10.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering.Insomefurtherpreferredembodiments,stepd) comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmost270°C;10 preferablyatleast80.0°Ctoatmost250°C;morepreferablyatleast80.0°Ctoatmost200°C; evenmorepreferablyatleast80°Ctoatmost180°C,oratleast80°Ctoatmost165°C,orat least85°Ctoatmost160°C,oratleast85°Ctoatmost155°C. Insomeembodiments,thewearlayerisapreprintedwearlayerwhereinthewearlayer comprisesaprintpatterndepositedonthesurfaceofthewearlayerthatisonthesideofthe15 coatinglayer.Insomeembodiments,thewearlayerisapreprintedwearlayerwhereinthe wearlayercomprisesaprintpatterndepositedonthesurfaceofthewearlayerthatisonthe oppositesideofthecoatinglayer. Insomeembodiments,andpriortostepa)orstepc),aprintpatternisdepositedonthesurface ofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments,andpriorto20 stepa)orstepc),aprintpatternisdepositedonthesurfaceofthewearlayerthatisonthe oppositesideofthecoatinglayer. Insomeembodiments,themethodfurthercomprisesastepe)thatcomprisesembossingof thewearlayer.Insomeembodiments,thewearlayeristhermallyembossed;morepreferably whereintheembossingisperformedbyinfraredheatingofthefloorcoveringfollowedbycold25 pressingofastructureintothewearlayer.Insomeembodiments,thewearlayeriscold embossed. Insomeembodiments,themethodfurthercomprisesastepf)thatcomprisesapplyinga lacquerlayeronthewearlayer;preferablywhereinthelacquerlayercomprisespolyurethane, polyacrylate,oramixturethereof.30 Insomeembodiments,themethodisforthemanufactureofamultilayerfloorcoveringthatis essentiallyfreeofPVChomopolymersandPVCcopolymers.Insomefurtherembodiments, themethodisforthemanufactureofamultilayerfloorcoveringthatisessentiallyfreeof plasticizers.Insomefurtherembodiments,themethodisforthemanufactureofamultilayer floorcoveringthathasabendingstiffnessofatmost800N.mm,preferablyasmeasured35 BE2024 / 5874 10 usingtothebendingstiffnesstestdisclosedherein,morepreferablyasmeasuredusinga modifiedbendingstiffnesstestaccordingtoISO5628whereinthebendingangleissetat30°.Anotheraspectprovidesamultilayerfloorcoveringmanufacturedbythemethodasdisclosed herein. 5 DETAILEDDESCRIPTIONOFTHEFIGURES Inthefollowingisdescribedexamplesofpreferredembodimentsillustratedinthe accompanyingdrawings,wherein: FIG.1illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),acoatinglayer(3),andawearlayer(4).10 FIG.2Illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),acoatinglayer(3),aprintpattern(5), andawearlayer(4). FIG.3illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),acoatinglayer(3),aprintpattern(5),a15 wearlayer(4),andalacquerlayer(6). FIG.4illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),anadditionalcoatinglayer(7),a reinforcementlayer(8),acoatinglayer(3),aprintpattern(5)andawearlayer(4).FIG.5illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention.20 Thefloorcovering(1)comprisesabackinglayer(2),anadditionalcoatinglayer(7),a reinforcementlayer(8),acoatinglayer(3)andawearlayer(4). FIG.6illustratesaschematicrepresentationofamethodforthemanufactureofamultilayer floorcoveringaccordingtoanembodimentoftheinvention.Afirstcoatinglayer(3a)and, optionally,asecondcoatinglayer(3b),areappliedonawearlayer(4)withaprintpattern(5),25 followedbytheapplicationofabackinglayer(2)onthecoatinglayer,therebyforminga multilayerfloorcoveringaccordingtoanembodimentoftheinvention. FIG.7illustratesamethodforthemanufactureofamultilayerfloorcoveringaccordingtoan embodimentoftheinvention.Inafirststep,awearlayer(4)withaprintpattern(5)isprovided woundedonaroll(11).Thewearlayer(4)iscoatedwithacoatinglayer(3)basedona30 polymer-in-waterdispersion.Thecoatingisappliedatthecoatingstationusingacoatingknife (12).Next,abackinglayer(2)isappliedonthecoatinglayer,whereinthebackinglayeris configuredtooverliethecoatinglayer(3)suchthatthebackinglayer(2)contactsthecoating layer(3).Asshowninthefigure,thebackinglayer(2)canbeprovidedonaroll(13)and guidedtoaniproll(14).Afterapplicationofthebackinglayer(2)onthecoatinglayer(3),the35 BE2024 / 5874 11 floorcoveringislaminatedandheatedinanair-heatedoven(15)toallowthelayerstofuse witheachother. Anypositionalindicationsrefertothepositionshowninthefigures.Inthefigures,sameor correspondingelementsareindicatedbysamereferencenumerals.Forclarityreasons,some elementsmayinsomeofthefiguresbewithoutreferencenumerals.Apersonskilledinthe5 artwillunderstandthatthefiguresarejustprincipaldrawings.Therelativeproportionsof individualelementsmayalsobedistorted. DETAILEDDESCRIPTIONOFTHEINVENTION Whendescribingtheinvention,thetermsusedaretobeconstruedinaccordancewiththe10 followingdefinitions,unlessthecontextdictatesotherwise.Asusedherein,thesingularforms"a”,"an",and"the"includebothsingularandpluralreferents unlessthecontextclearlydictatesotherwise.Bywayofexample,"aresin"meansoneresin ormorethanoneresin. Theterms"comprising","comprises"and"comprisedof"asusedhereinaresynonymouswith15 "including","includes"or"containing","contains",andareinclusiveoropen-endedanddonot excludeadditional,non-recitedmembers,elements,ormethodsteps.Itwillbeappreciated thattheterms"comprising","comprises"and"comprisedof"asusedhereincomprisethe terms"consistingof","consists"and"consistsof". Asusedherein,theterm“infollowingorder”,referstoaspecificorderofdifferentlayersofthe20 floorcoveringdisclosedherein.Theterm“infollowingorder”doesnotexcludethatany additionallayerscanbepresentinbetweenthelistedlayers. Therecitationofnumericalrangesbyendpointsincludesallintegernumbersand,where appropriate,fractionssubsumedwithinthatrange(e.g.,1to5caninclude1,2,3,4when referringto,forexample,anumberofelements,andcanalsoinclude1.5,2,2.75and3.80,25 whenreferringto,forexample,measurements).Therecitationofendpointsalsoincludesthe endpointvaluesthemselves(e.g.,from1.0to5.0includesboth1.0and5.0).Anynumerical rangerecitedhereinisintendedtoincludeallsub-rangessubsumedtherein. Allreferencescitedinthepresentspecificationareherebyincorporatedbyreferenceintheir entirety.Inparticular,theteachingsofallreferenceshereinspecificallyreferredtoare30 incorporatedbyreference. Referencethroughoutthisspecificationto“oneembodiment”or“anembodiment”meansthat aparticularfeature,structure,orcharacteristicdescribedinconnectionwiththeembodiment isincludedinatleastoneembodimentofthepresentinvention.Thus,appearancesofthe phrases“inoneembodiment”or“inanembodiment”invariousplacesthroughoutthis35 specificationarenotnecessarilyallreferringtothesameembodiment,butmay.Furthermore, BE2024 / 5874 12 theparticularfeatures,structuresorcharacteristicsmaybecombinedinanysuitablemanner, aswouldbeapparenttoapersonskilledintheartfromthisdisclosure,inoneormore embodiments.Furthermore,whilesomeembodimentsdescribedhereinincludesome,butnot otherfeaturesincludedinotherembodiments,combinationsoffeaturesofdifferent embodimentsaremeanttobewithinthescopeoftheinvention,andformdifferent5 embodiments,aswouldbeunderstoodbythoseintheart. Unlessdefinedotherwise,percentagesarepercentagesbyweight,basedonthetotalweight ofthecompositionorarticlereferredto.Forexample,aplastisolcompositioncomprising 50.0%filler,refersto50.0wt%fillerbasedonthetotalweightoftheplastisolcomposition.On theotherhand,afloorcoveringcomprising50.0%filler,refersto50.0wt%fillerbasedonthe10 totalweightofthefloorcovering,includingalllayers. Thetermsdescribedabove,andothersusedinthespecificationarewellunderstoodtothose skilledintheart. Preferredstatements(features)andembodiments,resins,articles,methods,andusesofthis inventionaresethereinbelow.Eachstatementandembodimentoftheinventionsodefined15 maybecombinedwithanyotherstatementand / orembodimentunlessclearlyindicatedtothe contrary.Inparticular,anyfeatureindicatedasbeingpreferredoradvantageousmaybe combinedwithanyotherfeatureorfeaturesorstatementsindicatedasbeingpreferredor advantageous. Theindependentanddependentclaimssetoutparticularandpreferredfeaturesofthe20 invention.Featuresfromthedependentclaimsmaybecombinedwithfeaturesofthe independentorotherdependentclaimsasappropriate. Thepresentinventionwillnowbefurtherdescribed.Inthefollowingpassages,different aspectsoftheinventionaredefinedinmoredetail.Eachaspectsodefinedmaybecombined withanyotheraspectoraspectsunlessclearlyindicatedtothecontrary.Inparticular,any25 featureindicatedasbeingpreferredoradvantageousmaybecombinedwithanyotherfeature orfeaturesindicatedasbeingpreferredoradvantageous.Inafirstaspect,theinventionrelatestoamultilayerfloorcoveringcomprisinginfollowing order:abackinglayer,acoatinglayerbasedonapolymer-in-waterdispersion,andawear30 layer,whereinthebackinglayer,thecoatinglayer,andthewearlayereachcomprisea thermoplasticpolymerwhereinsaidthermoplasticpolymerineachlayerisofthesamefamily ofthermoplasticpolymers;whereinthebackinglayer,thecoatinglayerandthewearlayerare essentiallyfreeofPVChomopolymersandPVCcopolymers,andwhereinthebackinglayer hasanairpermeabilityofatleast500l / m2 / s,measuredat200PascalaccordingtoISO9237.35 Preferably,thebackinglayer,thecoatinglayerandthewearlayerarefreeofPVC homopolymersandPVCcopolymers. BE2024 / 5874 13 Insomepreferredembodiments,thebackinglayer,thecoatinglayer,andthewearlayerare essentiallyfreeofanypolymerotherthanthethermoplasticpolymerthatispresentinsaid layers.Preferably,thebackinglayer,thecoatinglayerandthewearlayerarefreeofany polymerotherthanthethermoplasticpolymer.Insomepreferredembodiments,thebacking layer,thecoatinglayer,andthewearlayeronlycomprisethethermoplasticpolymerasa5 polymer.Insomepreferredembodiments,thethermoplasticpolymerinthebackinglayer,the coatinglayerandthewearlayerisidentical. Insomepreferredembodiments,thefloorcoveringasdisclosedhereinisessentiallyfreeof PVChomopolymersandPVCcopolymers;preferablyfreeofPVChomopolymersandPVC copolymers.Insomeembodiments,themultilayerfloorcoveringisessentiallyfreeofany10 polymerotherthantheidenticalpolymer;preferablyfreeofanypolymerotherthanthe identicalpolymer.Insomeembodiments,themultilayerfloorcoveringthuscomprisesonly onetypeofthermoplasticpolymer. Insomepreferredembodiments,thebackinglayer,thecoatinglayerandthewearlayerare15 essentiallyfreeofplasticizers.Insomeembodiments,thebackinglayer,thecoatinglayerand thewearlayerarethusessentiallyfreeofPVChomopolymers,PVCcopolymersand plasticizers.Insomeembodiments,thebackinglayer,thecoatinglayerandthewearlayerare freeofplasticizers.Insomeembodiments,thebackinglayer,thecoatinglayerandthewear layerarethusfreeofPVChomopolymers,PVCcopolymersandplasticizers.20 Insomepreferredembodiments,thefloorcoveringasdisclosedhereinisessentiallyfreeof plasticizers.Insomeembodiments,thefloorcoveringasdisclosedhereinisthusessentially freeofPVChomopolymers,PVCcopolymersandplasticizers.Insomeembodiments,thefloor coveringasdisclosedhereinisfreeofplasticizers.Insomeembodiments,thefloorcovering asdisclosedhereinisthusfreeofPVChomopolymers,PVCcopolymersandplasticizers.25 Asusedherein,theterm“essentiallyfreeof”ofasubstanceorcompoundmeansthatthe substanceorcompoundisonlypresentintraceamountsthatdonotaffecttheoverall propertiesorperformanceoftheproduct.Forexample,essentiallyfreeofPVCoressentially freeofPVChomopolymersandPVCcopolymersmeansthatPVChomopolymersandPVC copolymersareonlypresentintraceamounts.Or,essentiallyfreeofanypolymerotherthan30 thethermoplasticpolymerofthesamefamilymeansthatotherpolymersthanthe thermoplasticpolymersfromthatspecificfamilyareonlypresentintraceamounts.Insome embodiments,essentiallyfreeofPVChomopolymersandPVCcopolymersmeansthatat most5.0wt%PVChomopolymers,atmost5.0wt%PVCcopolymers,oratmost5.0wt%ofa combinationofPVChomopolymersandPVCcopolymersarepresentinalayerorinthefloor35 coveringasdisclosedherein.Insomefurtherembodiments,essentiallyfreeofPVC homopolymersandPVCcopolymersmeansthatatmost1.0wt%,preferablyatmost0.50 BE2024 / 5874 14 wt%,orpreferablyatmost0.10wt%;morepreferablyatmost0.050wt%;evenmore preferablyatmost0.01wt%PVChomopolymers;atmost1.0wt%,preferablyatmost0.50 wt%,orpreferablyatmost0.10wt%;morepreferablyatmost0.050wt%;evenmore preferablyatmost0.010wt%PVCcopolymers;oratmost1.0wt%,preferably0.50wt%,or preferablyatmost0.10wt%;morepreferablyatmost0.050wt%;evenmorepreferablyat5 most0.010wt%ofacombinationofPVChomopolymersandPVCcopolymersarepresentin alayerorinthefloorcoveringasdisclosedherein. Insomeembodiments,essentiallyfreeofanypolymerotherthanthethermoplasticpolymer ofthesamefamilymeansthatatmost5.0wt%ofanypolymerotherthanthethermoplastic polymerofthesamefamilyispresentinalayerorinthefloorcoveringasdisclosedherein.In10 somefurtherembodiments,essentiallyfreeofanypolymerotherthantheidentical thermoplasticpolymermeansthatatmost1.0wt%,preferablyatmost0.50wt%,orpreferably atmost0.10wt%;morepreferablyatmost0.050wt%;evenmorepreferablyatmost0.010 wt%ofanypolymerotherthantheidenticalthermoplasticpolymerispresentinalayerorin thefloorcoveringasdisclosedherein.15 Insomeembodiments,essentiallyfreeofplasticizersmeansthatplasticizersareonlypresent intraceamounts.Insomeembodiments,essentiallyfreeofplasticizersmeansthatatmost 5.0wt%plasticizer,oratmost5.0wt%ofacombinationofoneormoreplasticizersarepresent inalayerorinthefloorcoveringasdisclosedherein.Insomefurtherembodiments,essentially freeofplasticizersmeansthatatmost1.0wt%,preferablyatmost0.50wt%,preferablyat20 most0.10wt%;morepreferablyatmost0.050wt%;evenmorepreferablyatmost0.010wt% ofaplasticizerorthatatmost1.0wt%,preferablyatmost0.50wt%,orpreferablyatmost0.10 wt%;morepreferablyatmost0.050wt%;evenmorepreferablyatmost0.010wt%ofa combinationofplasticizers;arepresentinalayerorinthefloorcoveringasdisclosedherein. Withtheterm“plasticizer”asusedherein,acompoundismeantthattypicallycanincrease25 thefluidityorplasticityofamaterial,typicalapolymer.Theplasticizercanbeanyconventional plasticizerknownintheart.Forexample,theplasticizermaybeaphthalicdiester(alsoknown as“phthalates),suchasdiisonylphthalate,diallylphthalate,di-2-ethylhexylphthalate,dioctyl phthalate,anddiisodecylphthalate. 30 Insomepreferredembodiments,thebackinglayer,thecoatinglayer,andthewearlayerare freeofPVChomopolymersandPVCcopolymers.Insomepreferredembodiments,the backinglayer,thecoatinglayer,andthewearlayerdonotcompriseanyotherpolymerthan thethermoplasticpolymerthatisofthesamefamilyofthermoplasticpolymers.Assuch,only onetypeofpolymerfamilyispresentinthebackinglayer,thewearlayer,andthecoatinglayer35 whichimprovestherecyclingcapacityofthefloorcovering.Thebackinglayer,thecoating layer,andthewearlayermaythuscompriseonlythethermoplasticpolymerasapolymer. BE2024 / 5874 15 Insomeembodiments,thefloorcoveringasdisclosedhereinisfreeofPVChomopolymers andPVCcopolymers.Insomeembodiments,themultilayerfloorcoveringisfreeofany polymerotherthanthethermoplasticpolymerthatisofthesamefamilyofthermoplastic polymers.Themultilayerfloorcoveringasdisclosedmaythusnotcompriseanyotherpolymer thanthethermoplasticpolymerthatisofthesamefamilyofthermoplasticpolymers.Assuch,5 onlyonetypeofthermoplasticpolymerfamilymaybepresentinthefloorcoveringasdisclosed herein.Insomefurtherpreferredembodiments,thebackinglayer,thecoatinglayer,andthewear layerarefreeofplasticizers.Insomefurtherembodiments,thebackinglayer,thecoating layer,andthewearlayerdonotcompriseanytypeofplasticizer.10 Insomefurtherpreferredembodiments,thefloorcoveringasdisclosedhereinisfreeof plasticizers.Themultilayerfloorcoveringasdisclosedmaythusnotcompriseanytypeof plasticizer. Asusedherein,theterm“freeof”asubstanceorcompoundmeansthatsaidsubstanceor compoundisnotpresentintheproduct.Thisimpliesacompleteabsenceofthesubstanceor15 compoundintheproduct,whereanalyticaltechniquesormethodswouldnotdetectthe presenceofthesubstanceorcompoundwithinthelimitsofdetection.Forexample,theterm “freeofPVC”,or“freeofPVChomopolymersandPVCcopolymers”meansthatnoPVC,in particularnoPVChomopolymersandPVCcopolymers,arepresentinthelayersorproduct asdisclosedherein.Or,freeofanypolymerotherthantheidenticalpolymermeansthatother20 polymersthantheidenticalpolymerarenotpresentinthelayersorproductasdisclosed herein.Or,freeofanyplasticizer,meansthatnoplasticizerispresentinthelayersorproduct asdisclosedherein. Thefloorcoveringofthepresentinventionisthuspreferablycharacterizedinthatthebacking25 layer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVChomopolymersand PVCcopolymerbutthateachofthesethreelayerscomprisesathermoplasticpolymer, whereinsaidthermoplasticpolymerineachofthelayersisofthesamefamilyofthermoplastic polymers.Insomepreferredembodiments,thewholemultilayerfloorcoveringisessentially freeofPVChomopolymersandPVCcopolymers.30 Insomepreferredembodiments,thebackinglayer,thecoatinglayer,andthewearlayerare freeofPVChomopolymersandPVCcopolymerbuteachofthesethreelayerscomprisesa thermoplasticpolymerthatisofthesamefamilyofthermoplasticpolymers.Insomepreferred embodiments,thewholemultilayerfloorcoveringisfreeofPVChomopolymersandPVC copolymers.35 BE2024 / 5874 16 Asusedherein,theterm“thermoplasticpolymer”referstoapolymerthatbecomespliableor mouldableuponheatingandsolidifiesuponcooling.Thermoplasticpolymersare characterizedbytheirabilitytosoftenwhenexposedtoheatandtohardenwhencooled. Thethermoplasticpolymerinthebackinglayer,thecoatinglayer,andthewearlayerofthe floorcoveringdescribedhereincanbeanythermoplasticpolymerexceptaPVChomopolymer5 andPVCcopolymer.Insomeembodiments,athermoplasticpolymercanalsobepresentin anyoftheotherlayersofthefloorcovering. Thewearlayer,coatinglayerandbackinglayerofthefloorcoveringdisclosedhereinthus eachcompriseathermoplasticpolymer,whereinsaidthermoplasticpolymerineachofthe10 layersbelongstothesamefamilyofthermoplasticpolymers. Asusedherein,theterm“familyofthermoplasticpolymers”referstothedifferentfamiliesof thermoplasticpolymersthatareavailable.Thedifferentfamiliesofthermoplasticpolymers includepolyolefins,vinylpolymers,polystyrenes,acrylics,polyamides,polyesters, polycarbonates,acetalpolymers,fluoropolymers,polyurethanesandpolyimides.Thewording15 “samefamilyofthermoplasticpolymers”referstoasinglefamilyofthermoplasticpolymers.Assuch,thethermoplasticpolymerpresentineachofthewearlayer,coatinglayerand backinglayerisathermoplasticpolymerthatbelongstothesamefamilyofpolymersbutcan stillbeadifferenttypeofpolymerwithinthatsamefamilyoracopolymerofdifferentpolymers withinthatsamefamily.20 Insomepreferredembodiments,thethermoplasticpolymerinthewearlayer,thecoatinglayer andthebackinglayerofthefloorcoveringasdisclosedhereinisidenticalineachlayer.In somefurtherpreferredembodiments,thethermoplasticpolymerinthewearlayer,thecoating layer,thebackinglayerandanyadditionallayerpresentinthefloorcoveringasdisclosed hereinisidentical.25 Insomeembodiments,thethermoplasticpolymerisapolymerselectedfromthefamilyof polyolefins,polystyrenes,polyamides,orpolyesters;preferablyfromthefamilyof thermoplasticpolymersselectedfrompolyolefins,polyestersorpolyamides. Insomeembodiments,thethermoplasticpolymerfamilyisthefamilyofpolyolefins.Insome embodiments,thethermoplasticpolymerfamilyisthefamilyofpolystyrenes.Insome30 embodiments,thethermoplasticpolymerfamilyisthefamilyofpolyamides.Insome embodiments,thethermoplasticpolymerfamilyisthefamilyofpolyesters. Asusedherein,afamilyofthermoplasticpolymersisagroupofthermoplasticpolymersthat shareacommonchemicalstructure,synthesispathwayorothercharacteristics.Inpreferred BE2024 / 5874 17 embodiments,memberswithinafamilyofpolymersarederivedfromthesametypeof monomerorcloselyrelatedmonomers.Insomefurtherembodiments,thethermoplasticpolymerisselectedfromthegroupconsisting ofpolyethylene(PE),polypropylene(PP),polybutene(PB),polyisobutylene(PIB),ethylene vinylacetate(EVA),ethylene-propylenecopolymer,ethylene-butenecopolymer,ethylene-5 octenecopolymer,butadiene-propylenecopolymer,styrene-butadienecopolymer,styrene- propylenecopolymer,styrene-acrylonitrilecopolymer,styrene-methylmethacrylate copolymer,polycaprolactam,polyhexamethyleneadipamide,polyamide11,polyamide12, polyethyleneterephthalate(PET),co-PET,polyethyleneterephthalateglycol(PETG), polybutyleneterephthalate(PBT),polyethylenenaphthalate(PEN),polylacticacid(PLA),and10 polycaprolactone(PCL).Morepreferably,thethermoplasticpolymerisselectedfromthe groupconsistingofpolyethylene(PE),polypropylene(PP),ethylene-propylenecopolymer, ethylene-butenecopolymer,ethylene-octenecopolymer,polyethyleneterephthalateglycol, polybutyleneterephthalate,polyethyleneterephthalate(PET),andco-PET.Insomeembodiments,thethermoplasticpolymerisapolymerofthefamilyofpolyolefins.As15 usedherein,polyolefinsaretobeunderstoodasanyhomo-orcopolymermadefrom monomerssuchasethyleneorpropylenebyapolymerisationprocessintoalinearor branchedconfigurationresultinginlow-densityorhigh-densitypolymerstructureorany structureinbetweenlow-densityorhigh-density.Polyolefincopolymerscanberandom copolymers,blockpolymers,alternatingcopolymers,graftcopolymers,orgradient20 copolymers.Polyolefinscanalsoincludeamixtureofhomopolymersandcopolymers.Insome preferredembodiments,thethermoplasticpolymerisselectedfromthegroupconsistingof polypropylene(PP),polyethylene(PE),polypropylene(PP),polybutene(PB),polyisobutylene (PIB),butadiene-propylenecopolymer,ethylene-propylenecopolymer,ethylene-butene copolymer,orethylene-octenecopolymer.Preferably,thethermoplasticpolymerisPP,25 ethylene-propylenecopolymer,ethylene-butenecopolymer,orethylene-octenecopolymer. Morepreferably,thethermoplasticpolymerisPP.Insomeembodiments,thethermoplasticpolymerisethylenevinylacetate(EVA)orethylene methylacetate(EMA). Insomeembodiments,thethermoplasticpolymerisapolymerofthefamilyofpolystyrenes.30 Insomepreferredembodiments,thethermoplasticpolymerisselectedfromthegroup consistingofstyrene-butadienecopolymer,styrene-propylenecopolymer,styrene-acrylonitrile copolymer,styrene-methylmethacrylatecopolymer. Insomeembodiments,thethermoplasticpolymerisapolymerofthefamilyofpolyamides.In somepreferredembodiments,thethermoplasticpolymerisselectedfromthegroupconsisting35 BE2024 / 5874 18 ofpolycaprolactam(nylon6),polyhexamethyleneadipamide(nylon6,6),polyamide11(nylon 11),andpolyamide12(nylon12). Insomeembodiments,thethermoplasticpolymerisapolymerofthefamilyofpolyesters (PES).Polyester(PES)referstoacategoryofpolymersthatarecombinationsofdiacidsand diolsandcontainesterlinkagesineveryrepeatunitoftheirmainchain.Combinationsof5 differentdiacidsanddiolsresultindifferenttypesofpolyesters.Typically,polyestersconsisting ofonlyonetypeofdiacidanddiolarecalledpolyesterwhereaspolyestersconsistingof multipletypesofdiacidand / ordiolarecalledcoPET.Polyethyleneterephthalate(PET),which isacombinationofdiacidterephthalicacid(ordimethylterephthalate)anddiolethyleneglycol, isaspecifictypeofpolyesterincludedinthisfamily.Insomepreferredembodiments,the10 thermoplasticpolymerisselectedfromthegroupconsistingofpolyethyleneterephthalate (PET),co-PET,polyethyleneterephthalateglycol(PETG),polybutyleneterephthalate(PBT), polyethylenenaphthalate(PEN),polylacticacid(PLA),polycaprolactone(PCL).Insomemore preferredembodiments,thethermoplasticpolymerisPEToraco-PET. Thethermoplasticpolymerspresentinthewearlayer,coatinglayerandbackinglayerarepart15 ofthesamefamilyofthermoplasticpolymersbuttheycanstillbedifferentineachlayer.For example,thethermoplasticpolymerineachofthelayers,preferablyinthewholefloor covering,maybelongtothefamilyofpolyolefins,butthethermoplasticpolymerinthewear layercanbepolypropylene(PP),whereasthethermoplasticpolymerinthecoatinglayerand backinglayerispolyethylene(PE).Or,thethermoplasticpolymercanbeapolypropylene(PP),20 withatype1PPpresentinonelayerandatype2PPpresentinanotherlayer.Forexample, thethermoplasticpolymercanbeaPP,butstillincludebothatype1PPandatype2PP. Hence,inthemultilayerfloorcoveringaccordingtotheinvention,thebackinglayercan compriseonetypeofapolymerofthesamefamily,e.g.type1PP,whereasthecoatinglayer and / orthewearlayercancompriseanothertypeofthepolymerofthesamefamily,e.g.type25 2PP. Somethermoplasticpolymersindeedcomprisedifferenttypesofpolymersthatstillbelongto thesamefamily.Forexample,PPisapolymerfamilycomprisingdifferenttypescategorized basedontheirstructureandproperties.Type1PP,alsoknownasPPhomopolymer,isthe mostbasicformofPPmadefrompolymerizingonlypropylenemonomers.Type2PP,also30 knownasPPcopolymer,isproducedbythecopolymerizationofpropyleneandethylene monomers(typicallylessthan6%).Type3PP,alsoknownasPPimpactpolymerorblock copolymerpolypropylene,ismadebypolymerizingPPwithahigherpercentageofethylene (upto15%).Type4PP,alsoknownasexpandedPP,isafoamformofPPproducedby heatingandmelting,therebyexpanding,PPbeads.Type5PP,alsoknownasPPterpolymer,35 isproducedbypolymerizationofthreemonomerspropylene,ethyleneandathirdmonomer BE2024 / 5874 19 suchasbuteneorhexene.Type6PP,alsoknownashighmeltstrengthPP,isproducedby incorporatingaspecificamountoflongchainbranchingintothePPpolymerchainduringthe polymerizationprocess.Asaresult,amodifiedPPwithenhancedmeltstrengthandelasticity iscreated. Insomepreferredembodiments,theidenticalpolymercanbeselectedfromthegroup5 consistingoftype1PP,type2PP,andtype3PP.Assuch,inamultilayerfloorcovering accordingtoanembodimentoftheinvention,thebackinglayer,thecoatinglayer,andthe wearlayermaycompriseatype1PP,atype2PP,atype2PP,oramixturethereof. Insomeembodiments,thethermoplasticpolymercanbeamixtureoftwoormore thermoplasticpolymersthatbelongtothesamefamilyofthermoplasticpolymers.Insome10 embodiments,thethermoplasticpolymercanbeacopolymeroftwothermoplasticpolymers thatbelongtothesamefamilyofthermoplasticpolymers. Insomeembodiments,thethermoplasticpolymerisamixtureoftwoormorepolyolefins,such asforexampleamixtureofPPandPE.Insomeembodiments,thethermoplasticpolymeris acopolymer,suchasethylene-propylenecopolymer,ethylene-butenecopolymer,orethylene-15 octenecopolymer. Thethermoplasticpolymerasusedhereincanbeavirginthermoplasticpolymer,arecycled thermoplasticpolymer,oramixturethereof.Insomeembodimentsthethermoplasticpolymer isarecycledthermoplasticpolymer.Asusedherein,“recycled”thermoplasticpolymerrefers toathermoplasticpolymerthatispreparedbyprocessingpolymerwasteproducts,suchas20 thermoplasticpolymersderivedfromdomesticwaste,householdwaste,orendoflifeproducts waste.Insomeembodiments,theoriginoftherecycledthermoplasticpolymerispost- industrialwaste,pre-consumerwaste(beforeorafterinstallation),post-consumerwaste, flooringwaste,wastefromcablesorwindowprofiles.Insomeembodiments,washingand grindingoperationscanbeusedforprocessingpost-consumeritemsintorecycled25 thermoplasticpolymerstobeusedintheproductormethodoftheinvention. Thebackinglayer,thecoatinglayer,andthewearlayerofthefloorcoveringasdescribed hereinwillthuscompriseonlythermoplasticpolymersthatbelongtothesamefamily.Insome preferredembodiments,thefloorcoveringasdescribedhereincomprisesonlythermoplastic polymersthatbelongtothesamefamily.30 Alsopreferablefortheinventionisthatthebackinglayer,thecoatinglayer,andthewearlayer areessentiallyfreeofPVC,inparticularessentiallyfreeofPVChomopolymersandPVC copolymers,moreinparticularfreeofPVChomopolymersandPVCcopolymers. BE2024 / 5874 20 Insomefurtherembodiments,alsootherlayers,ifpresent,ofthefloorcoveringareessentially freeofPVChomopolymersandPVCcopolymers,inparticularfreeofPVChomopolymersand PVCcopolymers. Instillsomefurtherpreferredembodiments,themultilayerfloorcoveringisessentiallyfreeof PVChomopolymersandPVCcopolymers,inparticularfreeofPVChomopolymersandPVC5 copolymers. TheabsenceofPVCinatleastthebackinglayer,thecoatinglayer,andthewearlayer,and preferablyinthecompletefloorcovering,thuseliminatestheenvironmentalandhealth concernsassociatedwithPVC. Furtherpreferredisthatthebackinglayer,thecoatinglayer,andthewearlayerareessentially10 freeofplasticizers,moreinparticularfreeofplasticizers.Insomefurtherembodiments,alsootherlayers,ifpresent,ofthefloorcoveringareessentially freeofplasticizers,inparticularfreeofplasticizers. Instillsomefurtherpreferredembodiments,themultilayerfloorcoveringisessentiallyfreeof plasticizers,inparticularfreeofplasticizers.15 Theabsenceofplasticizers,inadditiontotheabsenceofPVC,inatleastthebackinglayer, thecoatinglayer,andthewearlayer,andpreferablyinthecompletefloorcovering,also eliminatestheenvironmentalandhealthconcernsassociatedwithplasticizers. AdvantageouslyandevenintheabsenceofPVC,andoptionallyalsointheabsenceof plasticizers,thefloorcoveringdisclosedhereinstillcomprisesgoodbendingproperties,as20 reflectedbythebendingstiffness,andthusaflexiblefloorcoveringisstillprovided. Insomeembodiments,themultilayerfloorcoveringhasabendingstiffnessofatmost800.0 N.mmasmeasuredaccordingtothebendingstiffnesstestdisclosedherein,inparticularas measuredusingamodifiedbendingstiffnesstestaccordingtoISO5628.Assuch,the multilayerfloorcoveringisaflexiblefloorcovering.Insomepreferredembodiments,the25 multilayerfloorcoveringhasabendingstiffnessofatmost600N.mm,preferablyatmost450 N.mm,morepreferablyatmost350N.mm,asmeasuredaccordingtothebendingstiffness testdisclosedherein,inparticularasmeasuredusingamodifiedbendingstiffnesstest accordingtoISO5628. Insomeembodiments,themultilayerfloorcoveringhasabendingstiffnessofatleast5.030 N.mmasmeasuredaccordingtothebendingstiffnesstestdisclosedherein.Insomepreferred embodiments,themultilayerfloorcoveringhasabendingstiffnessofatleast100.0N.mm, preferablyatleast150.0N.mm,morepreferablyatleast180.0N.mm,asmeasuredaccording BE2024 / 5874 21 tothebendingstiffnesstestdisclosedherein,inparticularasmeasuredusingamodified bendingstiffnesstestaccordingtoISO5628. Insomeembodiments,themultilayerfloorcoveringhasabendingstiffnessofatleast5.0 N.mmandatmost800N.mmasmeasuredaccordingtothebendingstiffnesstestdisclosed herein.Preferably,thebendingstiffnessisofatleast100.0N.mmandatmost600N.mm,5 morepreferablyofatleast150.0N.mmtoatmost450N.mm,evenmorepreferablyatleast 180.0N.mmtoatmost350.0N.mm,asmeasuredaccordingtothebendingstiffnesstest disclosedherein. Theterm“bendingstiffness”asusedhereinisdefinedastheforce(inNewton.millimeter, N.mm;orsimilarlyinmilliNewton.meter,mN.m)thatisrequiredtobendarectangulartest10 piecetoaspecifiedangle(forexampleanangleof30°),whenthetestpieceisfixedatone endandtheforceisappliedtoitsfreeend. Insomeembodiments,thebendingstiffnesstestasdisclosedhereinisamodifiedbending stiffnesstestbasedonthebendingstiffnesstestaccordingtoISO5628.Thebendingstiffness testaccordingtoISO5628isabendingstiffnesstestforpaperandboard.Inthepresent15 application,forapplicationinthefieldoffloorcoveringproductsasdisclosedherein,the bendingstiffnesstesthasbeenslightlymodified.Inparticular,thebendingstiffnesstestas disclosedhereinisaccordingtoISO5628butthemeasurementofthebendingstiffnessis performedatanangleof30°.Insomeembodiments,thebendingstiffnessasdisclosedherein isthusmeasuredusingamodifiedbendingtestaccordingtoISO5628whereinthebending20 angleissetat30°.Thus,insomeembodiments,thebendingforceFthatneedstobeapplied toreachabendingangleof30°forasampleofaparticularsizeisthendeterminedusinga BendingTestersystemandthebendingstiffnesscanbecalculatedbasedonFormula(I). Insomeembodiments,bendingstiffness(Sb)iscalculatedusingthefollowingFormula(I):25 Sb=(60xFxL2) / (πxaxw)(FormulaI) wherein Sb=bendingstiffness(N.mm) F=bendingforce(N) L=samplelength(mm)30 a=bendingangle(°) w=samplewidth(mm) BE2024 / 5874 22 Forexample,thebendingstiffnesstestcanbeperformedusingaBendingTesteravailablein thepriorart,andwhereinatestsampleisplacedinaclamp,suchasforexampleaL&W BendingTester. Themultilayerfloorcoveringdescribedhereincomprisesabackinglayeronwhichacoating5 isapplied.Themultilayerfloorcoveringasdisclosedhereincomprisesabackinglayerthatis essentiallyfreeofPVC,inparticularessentiallyfreeofPVChomopolymersandPVC copolymers;morepreferablyfreeofPVChomopolymersandPVCcopolymers.Thebacking layerstillcomprisesathermoplasticpolymer,athermoplasticpolymerthatisofthesame familyofthermoplasticpolymersasthepolymerpresentinthecoatinglayerandthewear10 layer,butsaidpolymerisnotPVC.Thethermoplasticpolymerinthebackinglayerispreferably athermoplasticpolymerselectedfromthegroupconsistingofpolyolefins(includingolefin copolymers),polystyrenes,polyamides(includingco-polyamides),andpolyesters(including co-polyesters). Thebackinglayerasusedhereincanbeanymaterialaslongastheairpermeabilityofthe15 materialishighenoughtoallowheatpenetrationintothebackinglayersothatevaporationof waterafterapplicationofthecoatinglayerbasedonapolymer-in-watercanoccur.Thus,inordertoallowsufficientwaterevaporationfromthecoatinglayeritisparticularly preferredthatthebackinglayerhasahighairpermeabilitysuchthatwaterfromthepolymer- in-waterdispersionofthecoatingcanbeeasilyevaporatedafterapplicationofthecoatingon20 thebackinglayer.Theairpermeabilityofthebackinglayeristhereofatleast500l / m2 / sat200 Pascal,measuredaccordingtoISO9237.Inpreferredembodiments,theairpermeabilityof thebackinglayerisatleast750l / m2 / soratleast1000l / m2 / s,morepreferablyatleast1250 l / m2 / s,at200Pascal,measuredaccordingtoISO9237. Insomeembodiments,thebackinglayerhasawetstrength(alsoreferredtoaswettensile25 strength)ofatleast30.0%,preferablyatleast40.0%,morepreferablyatleast50.0%and evenmorepreferablyatleast60.0%,ofthebreakingstrengthatthetemperatureatwhichthe floorcoveringisheatedduringmanufacture.Insomeembodiments,thewetstrengthis measuredaccordingtoISO1421:2017(section8.1). Insomeembodiments,thebackinglayercomprisesatleast80.0wt%,preferablyatleast85.030 wt%,morepreferablyatleast90.0wt%,ofthethermoplasticpolymer,basedonthetotal weightofthebackinglayer.Insomepreferredembodiments,thebackinglayercomprisesat least95.0wt%ofthethermoplasticpolymer,suchasforexample95.0wt%;96.0wt%,97.0 wt%,98wt%,99wt%oreven100wt%,ofthethermoplasticpolymer,basedonthetotalweight ofthebackinglayer.35 BE2024 / 5874 23 Insomeembodiments,thebackinglayeronlycomprisesonethermoplasticpolymer,suchas onepolymerselectedfrompolypropylene(PP),polyethylene(PE),polybutene(PB), polyisobutylene(PIB),ethylenevinylacetate(EVA),butadiene-propylenecopolymer, ethylene-propylenecopolymer,ethylene-butenecopolymer,ethylene-octenecopolymer, styrene-butadienecopolymer,styrene-propylenecopolymer,styrene-acrylonitrilecopolymer,5 styrene-methylmethacrylatecopolymer,polycaprolactam(nylon6),polyhexamethylene adipamide(nylon6,6),polyamide11(nylon11),polyamide12(nylon12),polyethylene terephthalate(PET),co-PET,polyethyleneterephthalateglycol(PETG),polybutylene terephthalate(PBT),polyethylenenaphthalate(PEN),polylacticacid(PLA),and polycaprolactone(PCL),andnootherpolymersarepresentinthebackinglayer.Insome10 embodiments,thebackingcomprisesonlyPP,PEethylene-propylenecopolymer,ethylene- butenecopolymer,ethylene-octenecopolymer,PET,orco-PET,andnootherpolymers.In someembodiments,thebackinglayeristhusamono-orco-polymermaterialbackinglayer whereinonlyonetypeofthermoplasticpolymerispresent. Theterm“backinglayer”,“backingsheet”,or“backingfilm”referstoalayerthatmaybeused15 asabacking. Insomeembodiments,thebackinglayerisatextilelayer,suchasawovenornon-woven layerincludingafelt,afibrouslayerwhereinthefibrecanbeanaturalfibre,suchasjuteor flaw,oramineralfibresuchasglassfiber. Assuedherein,theterms“fiber”or“fibre”and“filament”refertofilamentousmaterialthatcan20 beusedinyarnfabricandnon-woventextilefabrication. Theterm“non-woven”whichcanbeusedwiththepresentinventionmaybestaplenon-woven madebyprovidingcutfibersofafewcentimeterslength,puttingtheseintobales,placingon aconveyerbeltanddispersed,e.g.spreadinauniformwebbyawetlaid,airlaid,or carding / crosslappingprocess.25 Insomeembodiments,thebackinglayercomprisesaglassfiberlayer.Afterall,thepresence ofaglassfiberlayerwillnotaffecttherecyclingabilityofthethermoplasticpolymermaterial inthebackinglayeraslongasthecontentofthefiberglassinthebackinglayerisbelow40 g / m2. Insomeembodiments,thebackinglayerisanon-wovenbackinglayer;preferablyanon-30 woventextilebackinglayeroranon-wovenpolyesterlayer,suchasneedlefeltorcontinuous web.Thebackinglayermaycompriseadditionalsublayersasabackprint.Asusedhereinthe term“non-woven”referstoasheetoffibres,continuousfilaments,orchoppedyarnsofany natureororigin,thathavebeenformedintoawebofanymeans,andbondedtogetherbyany means,withtheexceptionofweavingorknitting.Compositestructuremaybeconsiderednon-35 BE2024 / 5874 24 wovenprovidedtheirmassisconstitutedofatleast50%ofnon-wovenaspertotheabove definition,orifthenon-wovencomponentplaysarelevantrole. Thenon-wovenbackinglayerasusedhereincanbeaspun-laidnon-wovenbackinglayer,a spunbondednon-wovenbackinglayer,aneedle-feltnon-wovenbackinglayer,oranairlaid non-wovenbackinglayer.5 Insomeembodiments,thebackinglayerisawovenbackinglayer. Insomeembodiments,andinparticularwhenareinforcementlayercomprisingglassfiber tissueispresent,anadditionalcoatinglayerisappliedonthebackinglayer.Theadditional coatinglayerisbasedonapolymer-in-waterdispersioncomprisingathermoplasticpolymer thatisofthesamefamilyofthermoplasticpolymersasthepolymerofthewearlayer,coating10 layerandbackinglayer.Insomepreferredembodiments,thepolymerintheadditionalcoating layerisidenticaltothepolymerinthecoatinglayer. Thebackinglayermayfurthercompriseafoamedlayer,forinstanceforimprovingacoustics orprovidingthermalinsulation. Thebackinglayerasusedhereincanbeanymaterialaslongastheairpermeabilityofthe15 materialishighenoughtoallowheatpenetrationintothebackinglayersothatevaporationof waterafterapplicationofthecoatinglayercanoccur.Thus,inordertoallowsufficientwaterevaporationfromthecoatinglayeritisparticularly preferredthatthebackinglayerhasahighairpermeabilitysuchthatwaterfromthepolymer- in-waterdispersionofthecoatingcanbeeasilyevaporatedafterapplicationofthecoatingon20 thebackinglayer.Insomepreferredembodiments,theairpermeabilityofthebackinglayeris atleast750l / m2 / soratleast1000l / m2 / s,morepreferablyatleast1250l / m2 / s,at200Pascal, measuredaccordingtoISO9237. Insomeembodiments,thebackinglayerhasanareaweightofatleast50.0g / m2andatmost 3000.0g / m2;preferablyofatleast80.0g / m2toatmost2000.0g / m2,morepreferablyofat25 least85.0g / m2toatmost1000.0g / m2,orofatleast100.0g / m2toatmost700.0g / m2,as measuredaccordingtoISOEN29073-1. Asusedherein,theareaweightofalayer,suchasthebackinglayer,referstothemassper unitareaofthematerialandistypicallyexpresseding / m2accordingtoISOEN29073-1. 30 Thefloorcoveringoftheinventionpreferablycomprisesacoatinglayerbasedonapolymer- in-waterdispersionthatisappliedtothebackinglayer.BE2024 / 5874 25 Insomeembodiments,thefloorcoveringdisclosedhereincomprisesanadditionalcoating layer,alsoreferredtoasasecondcoatinglayer.Saidadditionalcoatinglayerisalsobased onapolymer-in-waterdispersion. Asusedherein,apolymer-in-waterdispersionisacolloidalsysteminwhichpolymerparticles aredispersedinwater.5 Insomeembodiments,thecoatinglayerand / oradditionalcoatinglayerisonlyasinglecoating layerbasedonapolymer-in-waterdispersion. Insomeembodiments,thecoatinglayerand / oradditionalcoatinglayermaycompriseafirst coatinglayerbasedonapolymer-in-waterdispersionandasecondcoatinglayerbasedona polymer-in-waterdispersion.10 Insomeembodiments,thecoatinglayerand / oradditionalcoatinglayermaycompriseafirst coatinglayerandasecondcoatinglayerthataredistinguishable.Insomeembodiments,the coatinglayerand / oradditionalcoatinglayermaycompriseafirstcoatinglayerandasecond coatinglayerthatareindistinguishable.Whenacoatinglayerandanadditionalcoatinglayerarepresentinthefloorcovering,both15 thecoatinglayerandtheadditionalcoatinglayerareeachbasedonapolymer-in-water dispersion.Whenanadditionalcoatinglayerispresentinthefloorcovering,theadditional coatinglayerisalsobasedonapolymer-in-waterdispersion. Insomeembodiments,thecoatinglayerandtheadditionalcoatinglayerareidentical.Insome embodiments,thecoatinglayerandtheadditionalcoatinglayeraredifferentandbasedona20 differentpolymer-inwaterdispersionbutwhereinthethermoplasticpolymerinthecoating layerandadditionalcoatinglayerisofthesamefamilyofthermoplasticpolymers.Insome embodiments,thepolymer-in-waterdispersionofthecoatinglayerandoftheadditional coatinglayerhasthesamecomposition.Insomeembodiments,thepolymer-in-water dispersionofthecoatinglayerandoftheadditionalcoatinglayerhasadifferentcomposition25 butthecoatinglayerandtheadditionalcoatinglayerstillcompriseathermoplasticpolymer thatisofthesamefamilyofthermoplasticpolymers.Insomeembodiments,thepolymer-in-waterdispersionofthecoatinglayerandtheadditional coatinglayerhasthesamecomposition.Insomeembodiments,thepolymer-in-water dispersionofthecoatinglayerandtheadditionalcoatinglayerhasadifferentcompositionbut30 thecoatinglayerandtheadditionalcoatinglayercompriseathermoplasticpolymerthatisof thesamefamilyofthermoplasticpolymers. Insomeembodiments,andwhenanadditionalcoatinglayerispresent,thebackinglayer,the coatinglayer,theadditionalcoatinglayerandthewearlayereachcompriseathermoplastic BE2024 / 5874 26 polymerthatisofthesamefamilyofpolymersorcopolymers,preferablyanidentical thermoplasticpolymer.Insomeembodiments,thebackinglayer,thecoatinglayer,the additionalcoatinglayer,andthewearlayerareessentiallyfreeofanypolymerotherthanthe thermoplasticpolymer.Instillsomefurtherembodiments,thebackinglayer,thecoatinglayer, theadditionalcoatinglayer,andthewearlayerarefreeofanypolymerotherthanthe5 thermoplasticpolymer.Insomeembodiments,thecoatinglayer,andoptionallytheadditionalcoatinglayer,comprises onethermoplasticpolymer,preferablyonepolymerthatisofthefamilyofpolyolefins(including olefincopolymers),polystyrenes,polyamides(includingco-polyamides),andpolyesters (includingco-polyesters),morepreferablyselectedfromthegroupconsistingofpolypropylene10 (PP),polyethylene(PE),polybutene(PB),polyisobutylene(PIB),ethylenevinylacetate(EVA), butadiene-propylenecopolymer,ethylene-propylenecopolymer,ethylene-butenecopolymer, styrene-butadienecopolymer,styrene-propylenecopolymer,styrene-acrylonitrilecopolymer, styrene-methylmethacrylatecopolymer,polycaprolactam(nylon6),polyhexamethylene adipamide(nylon6,6),polyamide11(nylon11),polyamide12(nylon12),polyethylene15 terephthalate(PET),co-PET,polyethyleneterephthalateglycol(PETG),polybutylene terephthalate(PBT),polyethylenenaphthalate(PEN),polylacticacid(PLA),and polycaprolactone(PCL),andnootherpolymersarepresentinthecoatinglayer.Insome embodiments,thecoatinglayer,andoptionallytheadditionalcoatinglayer,comprisesonly PP,PE,co-PET,ethylene-propylenecopolymer,ethylene-butenecopolymer,ethylene-octene20 copolymer,orPETandnootherpolymers.Insomeembodiments,thecoatinglayer,and optionallytheadditionalcoatinglayer,isthusamono-polymerorco-polymermaterialcoating layerwhereinonlyonetypeofthermoplasticpolymerfamilyispresent,preferablywhereinonly onetypeofthermoplasticpolymerispresent. 25 Insomeembodiments,thepolymer-in-waterdispersionofthecoatinglayer,andoptionallythe additionalcoatinglayer,comprisesatleast10.0wt%thermoplasticpolymerbasedonthetotal weightofthepolymer-in-waterdispersion.Insomeembodiments,thepolymer-in-water dispersioncomprisesatmost90.0wt%thermoplasticpolymerbasedonthetotalweightofthe polymer-in-waterdispersion.Insomeembodimentsthepolymer-in-waterdispersion30 comprisesatleast20.0wt%andatmost90.0wt%ofthethermoplasticpolymer,preferablyat least20.0wt%andatmost80.0wt%,morepreferablyatleast25.0wt%andatmost80.0 wt%,oratleast30.0wt%andatmost75.0wt%,suchasforexample35.0wt%or55.0wt%, ofthethermoplasticpolymerbasedonthetotalweightofthepolymer-in-waterdispersion. BE2024 / 5874 27 Insomeembodiments,theamountofpolymerinthepolymer-in-waterdispersionofthecoating layerandtheadditionalcoatinglayeristhesame.Insomeembodiments,theamountof polymerinthepolymer-in-waterdispersionofthecoatinglayerandtheadditionalcoatinglayer isdifferent. Insomeembodiments,theamountofpolymerinthepolymer-in-waterdispersionofthefirst5 coatinglayerandthesecondcoatinglayeristhesame.Insomeembodiments,theamountof polymerinthepolymer-in-waterdispersionofthefirstcoatinglayerandthesecondcoating layerisdifferent. Itshouldbeunderstoodthatafterapplicationofthecoatinglayer,thelargemajorityofthe waterinthepolymer-in-waterdispersionwillevaporate,suchthatthewatercontentinthe10 coatinglayerwillfinallybebelow10.0wt%;preferablybelow5.0wt%.Insomeembodiments,thepolymer-in-waterdispersioncomprisesathermoplasticpolymer andoneormoreadditives,suchasinorganicfillers.Preferably,theinorganicfillersare selectedfromthegroupconsistingoftalcum,calciumcarbonate,chalk,wollastonite,mica,or acombinationthereof.Insomeembodiments,thefilleriscalciumcarbonate.Insomefurther15 embodiments,whenthethermoplasticpolymerinthecoatinglayerisapolyolefin,thefilleris calciumcarbonate.Insomeembodiments,thecoatinglayerthuscomprisesofapolyolefin andcalciumcarbonate. Insomeembodiments,thepolymer-in-waterdispersionfurthercomprisesathickener,a dispersant,afoamingagent,anadhesionpromoter,awettingagent,acolorantorapigment,20 oramixturethereof. Insomepreferredembodiments,thepolymer-in-waterdispersionmayfurthercompriseone ormorecolorantsorpigments.Asaresult,thecoatinglayercancompriseaspecificcolor,a specificdesign,oravariegatedpattern.Insomeembodiments,andwhenthecoatinglayer comprisesoneormorecolorantsorpigments,itwillnotbenecessarytoapplyaspecificprint25 patterntothesurfaceofthewearlayer.Insomeembodiments,thecoatinglayercomprisesa variegatedpattern.Asusedhereinavariegatedpatternreferstoairregularpattern,suchas apatternintheformofdifferentflames,whereinsaidirregularpatterniscreatedbythe presenceofnon-uniformdispersedpigmentinthecoatinglayer. Insomeembodiments,thepolymer-in-waterdispersioncomprisesatleast0.5wt%ofoneor30 moreadditives,suchasinorganicfillers,basedonthetotalweightofthepolymer-in-water dispersion.Insomeembodiments,thepolymer-in-waterdispersioncomprisesatmost45.0 wt%ofoneormoreadditives,suchasoneormoreinorganicfillers,basedonthetotalweight ofthepolymer-in-waterdispersion.Insomeembodimentsthepolymer-in-waterdispersion comprisesatleast0.5wt%andatmost45.0wt%ofoneormoreadditives,suchasinorganic35 BE2024 / 5874 28 fillers,preferablyatleast1.0wt%andatmost45.0wt%,morepreferablyatleast1.0wt%and atmost40.0wt%,ofoneormoreadditives,suchasinorganicfillers,basedonthetotalweight ofthepolymer-in-waterdispersion. Insomepreferredembodiments,thepolymer-in-waterdispersionofthecoatinglayer,and / or theadditionalcoatinglayerhasasolidcontentofatleast10.0wt%;preferablyatleast30.05 wt%;morepreferablyatleast50.0wt%oratleast60.0wt%;evenmorepreferablyatleast 68.0wt%,basedonthetotalweightofthepolymer-in-waterdispersion.Insomepreferred embodiments,thepolymer-in-waterdispersionhasasolidcontentofatmost75.0wt%; preferablyatmost73.0wt%;morepreferablyatmost72.0wt%,basedonthetotalweightof thepolymer-in-waterdispersion.10 Insomeembodiments,thesolidcontentinthepolymer-in-waterdispersionisdeterminedby thepolymerinthepolymer-in-waterdispersion.Insomeembodiments,thesolidcontentinthe polymer-in-waterdispersionisdeterminedbythepolymer,oneormorefillers,andanyother solidmaterialpresentinthedispersion. Insomeembodiments,thecoatinglayerand / ortheadditionalcoatinglayerisafoamedcoating15 layer.Insomeembodiments,thefoamedcoatinglayerisamechanicallyfoamedcoatinglayer. Amechanicalfoam,asusedherein,meansanyfoamobtainedbymechanicalmeans,for examplebyagitation,whipping,frothing,gasinjection,i.e.withouttheactivationofachemical blowingagent.Abenefitofthemechanicalfoamofapolymer-in-waterdispersionisthatthe20 airintroducedinthepolymer-in-waterdispersionofthecoatinglayerdoesnotcomplicatethe subsequentprocessessignificantly.Compressedairinjectedinthefrothingmachine preferablyshouldnotcontainmoisture,whichisusuallythecasesincethiscompressedairis normallydried.However,alimitedamountofwatercanbebeneficial.Watercanhelpinthe processofchemicalfoamingduetosteamformation.Theamountofwaterwhichcanbe25 addedis0.1-1.5%,preferably0.3-1.0%,ideally0.5wt%ofthetotalcomposition.Addinga limitedamountofwatercanimprovetheimpregnationandsaturationoftheporouslayerand canassistinthecreationofthebackinglayerifthisisrequired.Insomeembodiments,thecoatinglayerand / ortheadditionalcoatinglayerischemically foamed,andthepolymer-in-waterdispersioncomprisesafoamingagent;preferablyafoaming30 agent.Asusedherein,theterms“foamingagent”and“blowingagent”maybeused interchangeably,andrefertoachemicalsubstanceormixturethatiscapableofgenerating gas,typicallycarbondioxide,nitrogen,orwatervapor,withinapolymermatrixorother material,resultingintheformationofacellularstructure.Thiscellularstructure,alsoreferred toasfoam,reducesthedensityofthematerialandprovidesdesirablepropertiessuchas35 BE2024 / 5874 29 thermalandacousticinsulation,cushioning,andimpactresistance.Thefoamingagentis preferablyactivatedheat.Insomeembodiments,thefoamingagentisselectedfromthegroupcomprising: azodicarbonamide(AZO),4,4-oxy-bis(benzenesulfonylhydrazide)(OBSH),P-toluenesulfonyl- hydrazide(TSH),P-toluenesulfonylsemicarbazide(PTSS),dinitrosopentamethylenetetramine5 (DNPT),sodiumbicarbonate,5-phenyltetrazole(PT),oranycombinationsthereof;preferably thefoamingagentisAZO. Insomeembodiments,thecoatinglayerand / oradditionalcoatinglayerisanon-foamed coatinglayer.Insomeembodiments,thecoatinglayerdoesnotcompriseafoamingagent. Insomeembodiments,theareaweightofthecoatinglayerand / ortheadditionalcoatinglayer10 isatleast50.0g / m2andatmost1500.0g / m2;preferablyatleast100.0g / m2andatmost 1000.0g / m2;morepreferablyatleast200.0g / m2andatmost600.0g / m2,preferablyas measuredaccordingtoISOEN29073-1. Insomeembodiments,themultilayerfloorcoveringfurthercomprisesareinforcementlayer. Insomepreferredembodiments,thereinforcementlayerisanon-wovenlayer.Preferably,the15 reinforcementlayermaycompriseglassfibretissue,mineralparticles,cellulosefibres,PET, oramixturethereof.Forexample,thereinforcementlayermaycomprisepaperorcellulose fibres,orglassfibretissue,oramixtureofpaperfibresandglassfibretissue.Insome embodiments,thereinforcementlayerisaglassfibretissuelayer.Insomeembodiments,the reinforcementlayerisaPETlayer.Whenareinforcementlayerispresent,anadditional20 coatinglayerispresentinthemultilayerfloorcovering.Thereinforcementlayerandthe additionalcoatinglayerarelocatedinbetweenthecoatinglayerandthebackinglayerwith theadditionalcoatinglayerbeingincontactwiththebackinglayerandthereinforcementlayer beingincontactwiththecoatinglayer. Insomeembodiments,thereinforcementlayerhasawetstrength(alsoreferredtoaswet25 tensilestrength)ofatleast30.0%,preferablyatleast40.0%,morepreferablyatleast50.0% andevenmorepreferablyatleast60.0%,ofthebreakingstrengthatthetemperatureatwhich thefloorcoveringisheatedduringmanufacture.Insomeembodiments,thewetstrengthis measuredaccordingtoISO1421:2017(section8.1). 30 Thefloorcoveringoftheinventionpreferablycomprisesawearlayerthatisappliedabovethe coatinglayer,saidwearlayeralsocomprisingthethermoplasticpolymerthatisofthesame familyofthermoplasticpolymersasthepolymerofthecoatinglayerandbackinglayerand beingessentiallyfreeofPVC,inparticularessentiallyfreeofPVChomopolymersandPVC BE2024 / 5874 30 copolymers.Insomefurtherembodiments,thewearlayerisfreeofPVC,inparticularfreeof PVChomopolymersandPVCcopolymers. Thewearlayerstillcomprisesathermoplasticpolymer,inparticularathermoplasticpolymer thatisofthesamefamilyofthermoplasticpolymerspresentinthecoatinglayerandthe backinglayer,butsaidpolymerisnotPVC.Thethermoplasticpolymerinthewearlayeris5 preferablyofthefamilyofpolyolefins(includingolefincopolymers),polystyrenes,polyamides (includingco-polyamides),andpolyesters(includingco-polyesters),morepreferablyselected fromthegroupconsistingofpolypropylene(PP),polyethylene(PE),polybutene(PB), polyisobutylene(PIB),ethylenevinylacetate(EVA),butadiene-propylenecopolymer, ethylene-propylenecopolymer,ethylene-butenecopolymer,ethylene-octenecopolymer,10 styrene-butadienecopolymer,styrene-propylenecopolymer,styrene-acrylonitrilecopolymer, styrene-methylmethacrylatecopolymer,polycaprolactam(nylon6),polyhexamethylene adipamide(nylon6,6),polyamide11(nylon11),polyamide12(nylon12),polyethylene terephthalate(PET),co-PET,polyethyleneterephthalateglycol(PETG),polybutylene terephthalate(PBT),polyethylenenaphthalate(PEN),polylacticacid(PLA),and15 polycaprolactone(PCL).Insomefurtherpreferredembodiments,thepolymerinthewearlayer isPP,PE,ethylene-propylenecopolymer,ethylene-butenecopolymer,PETorco-PET.Insomeembodiments,thewearlayercomprisesonlyonethermoplasticpolymer,suchasone polymerselectedfrompolypropylene(PP),polyethylene(PE),polybutene(PB), polyisobutylene(PIB),ethylenevinylacetate(EVA),butadiene-propylenecopolymer,20 ethylene-propylenecopolymer,ethylene-butenecopolymer,ethylene-octenecopolymer, styrene-butadienecopolymer,styrene-propylenecopolymer,styrene-acrylonitrilecopolymer, styrene-methylmethacrylatecopolymer,polycaprolactam(nylon6),polyhexamethylene adipamide(nylon6,6),polyamide11(nylon11),polyamide12(nylon12),polyethylene terephthalate(PET),polyethyleneterephthalateglycol(PETG),polybutyleneterephthalate25 (PBT),polyethylenenaphthalate(PEN),polylacticacid(PLA),andpolycaprolactone(PCL), andnootherpolymersarepresentinthecoatinglayer.Insomeembodiments,thewearlayer comprisesonlyPP,PE,ethylene-propylenecopolymer,ethylene-butenecopolymer,PETor co-PET,andnootherpolymers.Insomeembodiments,thewearlayeristhusamono-polymer orco-polymermaterialwearlayerwhereinonlyonetypeofthermoplasticpolymerispresent.30 Insomeembodiments,thewearlayercomprisesatleast80.0wt%,preferablyatleast85.0 wt%,morepreferablyatleast90.0wt%,ofthethermoplasticpolymer,basedonthetotal weightofthewearlayer.Insomepreferredembodiments,thewearlayercomprisesatleast 95.0wt%ofthethermoplasticpolymer,suchasforexample95.0wt%;96.0wt%,97.0wt%, 98wt%,99wt%oreven100wt%,ofthethermoplasticpolymer,basedonthetotalweightof35 thewearlayer. BE2024 / 5874 31 Insomeembodiments,theareaweightofthewearlayerisatleast50.0g / m2andatmost 500.0g / m2;preferablyatleast50.0g / m2andatmost200.0g / m2;morepreferablyatleast70.0 g / m2andatmost100.0g / m2,preferablyasmeasuredaccordingtoISOEN29073-1. Insomeembodiments,thewearlayercomprisesaprintpatterndepositedonthesurfaceof thewearlayeronthesideofthecoatinglayer.Thus,insomeembodiments,theprintpattern5 ispresentinbetweenthecoatinglayerandthewearlayer.Theprintpatterncanbeprintedwithprintinginks,e.g.byrotogravure,flexographicordigital printing,onthewearlayer.Insomeembodiments,theprintpatternisadigitallyprintedpattern. Insomeembodiments,theprintpatternisarotogravureprintedpattern. Whenchoosingasuitablematerialforthewearlayer,hightransparencyandlackofowncolour10 arepreferredfeatures.Suchawearlayerallowstoprotectthecoatinglayerfromwearingout. Lackofwearlayercolourisimportanttoobtainadesignwithoutanycolourdeviationsandto allowtheprintpatterntobevisible. Inapreferredembodiment,thewearlayerisatransparentlayer.Preferably,thewearlayeris completelyclearandalsodoesnotshowanyyellowingover-time.15 Insomeembodiments,thewearlayerisanembossedwearlayer;suchasathermally embossedwearlayer,acoldembossedwearlayer,oranembossedwearlayergenerated throughacastingprocess.Insomefurtherembodiments,thewearlayerisanembossedwear layergeneratedthroughacastingprocess,morespecificthewearlayermaybemadefrom castingadispersiononacarrier,optionallypre-embossed.Upondryingandcuringofthe20 dispersion,awearlayerisobtainedwhichcanbeusedinanyoftheembodimentsdisclosed herein. Insomeembodiments,themultilayerfloorcoveringcomprisesalacquerlayerthatislocated onthewearlayer.Insomeembodiments,thelacquerlayeristhusappliedontoorabovethe25 wearlayer. Thelacquerlayermaybeseenasanadditionallayerthatenhancesscratchresistance,stain resistance,UVresistancesand / orreducesglossinthefinalfloorcoveringproduct. Thelacquerlayermaybeapolyurethaneoranacrylicpolymericlayer. Insomepreferredembodiments,thelacquerlayercomprisespolyurethane,polyacrylate,ora30 mixturethereof. Insomeembodiments,thelacquerlayeriswater-freeorsolvent-free,andtheliquidmonomers presentinthelacquerlayerarecurvedviaUVcuringtoformasolidifiedlacquerlayer. BE2024 / 5874 32 Insomeembodiments,thelacquerlayerisawater-basedorsolvent-basedlayer.Incasesuch awater-basedorsolvent-basedlacquerlayerispresent,thewaterorsolventpresentinthe lacquerlayerwillbeevaporatedduringorpriortocuringofthelacquerlayer.Insomeembodiments,thelacquerlayerisessentiallyfreeofPVC,inparticularessentially freeofPVChomopolymersandPVCcopolymers;morepreferablyfreeofPVChomopolymers5 andPVCcopolymers. Themultilayerfloorcoveringasdisclosedhereiniscompliantwithanyofthefollowing standards(non-limitativelist):ENISO24346(totalthickness),ENIS23997(totalweight),EN ISO23999(dimensionalstabilityandcurling),ENISO24343-1(residualindentation),DIN10 51130(slipresistance),ENISO9237(airpermeability),ENISO432(tearstrength),ENISO 527(tensilestrength),ENISO24345(delaminationstrength),ENISO23999(dimensional stabilityandcurling). Themultilayerfloorcoveringasdisclosedhereinthusprovidesafloorcoveringwhereinthe useofPVCiseliminated,butwithoptimalmechanicalproperties,aswellasimproved15 insulationand / oracousticproperties. Insomeembodiments,themultilayerfloorcoveringasdisclosedhereinisanembossed multilayerfloorcovering.Theterm“embossing”or“embossed”asusedhereinisknownintheartandbasedonthe principlethataportionofthesurfacematerialisshapedintostructuresbothvisibleandnon-20 visibletothehumaneye.“Mechanicalembossing”asusedhereinisknownintheartand basedontheprinciplethataportionofthesurfaceofmaterialisshapedbymeansofaso- calledembossingmould. Insomepreferredembodiments,atleastthewearlayerisembossed,preferablymechanically embossed.Insomepreferredembodiments,thewearlayerandthelacquerlayerare25 embossed,inparticularwhereinthereliefpatternisappliedtoboththeselayers.Insomeother embodiments,thebackinglayer,thecoatinglayer,thewearlayer,andoptionallythelacquer layer,areembossed;preferablymechanicallyembossed. Afurtheraspectprovidesamethodtoproduceormanufactureamultilayerfloorcoveringas30 disclosedherein.Inanembodiment,themethodpreferablycomprisesthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer; BE2024 / 5874 33 c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayerisconfigured tooverliethecoatinglayersuchthatthebackinglayercontactsthecoatinglayer; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerthatisofthesamefamilyofthermoplasticpolymers, whereinthebackinglayer,thecoatinglayer,thewearlayerareessentiallyfreeofPVC5 homopolymersandPVCpolymers,and whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / smeasuredat200Pascal accordingtoISO9237, therebyformingamultilayerfloorcoveringaccordingtoanyoftheembodimentsasdisclosed herein.10 Insomefurtherembodiments,thebackinglayer,thecoatinglayerandthewearlayerare essentiallyfreeofplasticizers.Insomefurtherembodiments,themethodcomprisesastepb1)whereinafterstepb)a reinforcementlayerisappliedonthecoatinglayerandwhereinanadditionalcoatinglayer basedonapolymer-in-waterdispersionisappliedonthereinforcementlayer,andwhereinin15 stepc)thebackinglayerisappliedontheadditionalcoatinglayer,whereinthebackinglayer isconfiguredtooverlietheadditionalcoatinglayersuchthatthebackinglayercontactsthe additionalcoatinglayer.Inanotherembodiment,themethodpreferablycomprisesthestepsof:20 a)providingabackinglayerwithanairpermeabilityofatleast500l / m2 / smeasuredat 200PascalaccordingtoISO9237; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthebackinglayer; c)applyingawearlayeronthecoatinglayer,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthewearlayercontactsthecoatinglayer;25 whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerthatisofthesamefamilyofthermoplasticpolymers,andwhereinthebackinglayer, thecoatinglayer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVC polymers,therebyformingamultilayerfloorcoveringaccordingtoanyoftheembodimentsas disclosedherein.30 Insomefurtherembodiments,thebackinglayer,thecoatinglayerandthewearlayerare essentiallyfreeofplasticizers.Insomefurtherembodiments,themethodcomprisesastepa1)whereinafterstepa)an additionalcoatinglayerbasedonapolymer-in-waterdispersionisappliedonthebackinglayer BE2024 / 5874 34 andwhereinareinforcementlayerisappliedontheadditionalcoatinglayerandwhereinin stepb)thecoatinglayerisappliedonthereinforcementlayer. Typicalforthemethodasdisclosedhereinisthecombinationofthelaminationofalllayers togetherinoneproductionline.5 Insomeembodiments,thewearlayerisprovidedonarollandisdirectedtowardsafirstknife usingarollcoatingstation. Insomeembodiments,thewearlayerasprovidedinstepa)orc)ofthemethoddisclosed hereinisapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited10 onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer. Insomeembodiments,themethodcomprisesanadditionalsteppriortostepa)orstepc) whereinaprintpatternisdepositedtothesurfaceofthewearlayeronthesideofthecoating layer. Printingcancompriseprintinginksappliedbyrotogravure,flexographicordigitalprinting.15 Theseareconvenientprintingtechniques. Insomeembodiments,thecoatinglayerisappliedatacoatingstationinstepb). Insomeembodiments,stepb)comprisestheapplicationofonlyonecoatinglayerbasedon apolymer-in-waterdispersiononthewearlayer. Insomeembodiments,stepb)comprisestheapplicationofafirstcoatinglayerbasedona20 polymer-in-waterdispersiononthewearlayer,followedbytheapplicationofasecondcoating layerbasedonapolymer-in-waterdispersiononthefirstcoatinglayer.Insaidembodiments, thecoatinglayerthuscomprisesafirstandasecondcoatinglayer. Byapplyingafirstandasecondcoatinglayer,thefirstcoatinglayercanbeformulatedfor optimaladhesiontothewearlayer,whereasthesecondcoatinglayercanbeformulatedfor25 optimaladhesiontothefirstcoatinglayerbutalsotoobtainahigherfillerloading.Also,both thefirstandthesecondcoatinglayercancontributetotheoverallstiffness,thicknessand dimensionalstabilityoftheflooringproduct. Insomeembodiments,thefirstcoatinglayerisnotfoamedwhereasthesecondcoatinglayer isafoamedcoatinglayer.Insomeembodiments,thesecondcoatinglayerisnotfoamed30 whereasthefirstcoatinglayerisafoamedcoatinglayer.Insomeembodiments,boththefirst andsecondcoatinglayerarefoamed.Furthermore,theuseofaseparatesecondcoating layermayalsocontributetoanincreasedoverallperformanceofthefloorcoveringby improvingtheresidualindentation,thedelaminationstrength,andthetearstrength. BE2024 / 5874 35 Insomeembodiments,thebackinglayerisappliedonthecoatinglayerinstepc)suchthat thebackinglayerislaminatedtothecoatinglayer. Insomeembodiments,thebackinglayerisprovidedinstepa)andthewearlayerisapplied onthecoatinglayerinstepc)suchthatthewearlayerislaminatedtothecoatinglayer. Insomeembodiments,thebackinglayercanbeprovidedwoundedonaroll;preferablyona5 rollthathasacorecomprisingcardboard.Insomeembodiments,thebackinglayerandthe rollcanbemountedinanunwindingmachineandfurtherthreadedtoaroller.Insomefurther embodiments,pressureisputonthebackinglayertoremoveanyairpresentinbetweenthe backinglayerandthecoatinglayer,therebyensuringagoodbondbetweenthebackinglayer andthecoatinglayer.10 Insomeembodiments,themethodfurthercomprisesastepd)thatcomprisesheatingthefloor coveringtoatemperatureofatleast70.0°Ctoatmostatemperaturethatis20.0°Cabovethe meltingtemperatureofthethermoplasticpolymerinthemultilayerfloorcovering,thereby allowingthecoatinglayertofusewiththewearlayerandthebackinglayer.Insomefurther embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C15 toatmostatemperaturethatis10.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering.Insomefurtherpreferredembodiments,stepd) comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmost270°C; preferablyatleast80.0°Ctoatmost250°C;morepreferablyatleast80.0°Ctoatmost200°C; evenmorepreferablyatleast80°Ctoatmost180°C,oratleast80°Ctoatmost165°C,orat20 least85°Ctoatmost160°C,oratleast85°Ctoatmost155°C.Insomeembodiments,step d)isperformedinathermalairdryer.Insaiddryingstep,thebackinglayerisontopsuchthat anywaterpresentinthecoatinglayercanevaporatemoreefficiently. Insomeembodiments,themethodasdisclosedhereinfurthercomprisesastepe)that comprisesembossingofthemultilayercoveringthatisformed.Inaparticularembodiment,25 themethodcomprisesembossingofthewearlayer. Insomeembodiments,theembossingisthermalembossing;preferablywhereinthe embossingisperformedbyinfraredheatingofthefloorcoveringfollowedbycoldpressingof astructureintothewearlayer.Asaresult,thestructurewillbefrozenintothewearlayer. Insomeembodiments,theembossingiscoldembossing.30 Insomeembodiment,theembossingismechanicalembossing. Insomeembodiments,thewearlayerthatisprovidedinstepa)isapre-embossedwearlayer andhencenoembossingstepe)needstobeapplied.BE2024 / 5874 36 Insomeembodiments,themethodasdisclosedhereinfurthercomprisesastepf)that comprisesapplyingalacquerlayeronthewearlayer.Preferablysaidlacquerlayercomprises polyurethane,polyacrylate,oramixturethereof. Inaparticularembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,5 saidmethodcomprisingthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer; c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayeris configuredtooverliethecoatinglayersuchthatthebackinglayercontactsthe10 coatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic15 polymerthatisofthesamefamilyofthermoplasticpolymers; whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / smeasuredat200Pascal accordingtoISO9237,and whereinthebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVC homopolymersandPVCcopolymers.20 Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers.Insomefurtherembodiments,thebackinglayer,the coatinglayerandthewearlayerareessentiallyfreeofplasticizers. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof25 thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270°C;preferablyatleast80.0°Ctoatmost250°C;morepreferablyatleast80.0°C toatmost200°C;evenmorepreferablyatleast80°Ctoatmost180°C,oratleast80°Ctoat most165°C,oratleast85°Ctoatmost160°C,oratleast85°Ctoatmost155°C.30 Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof: a)providingawearlayer,anddepositionofaprintpatterntothesurfaceofthewear layerthatisonthesideofthecoatinglayer;35 BE2024 / 5874 37 b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer; c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayeris configuredtooverliethecoatinglayersuchthatthebackinglayercontactsthe coatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta5 temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerthatisofthesamefamilyofthermoplasticpolymers; whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / sasmeasuredat20010 PascalaccordingtoISO9237,and whereinthebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVC homopolymersandPVCcopolymers. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof15 thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270°C;preferablyatleast80.0°Ctoatmost250°C;morepreferablyatleast80.0°C toatmost200°C;evenmorepreferablyatleast80°Ctoatmost180°C,oratleast80°Ctoat most165°C,oratleast85°Ctoatmost160°C,oratleast85°Ctoatmost155°C.20 Preferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers. Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfree fromplasticizers. 25 Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer; c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayeris30 configuredtooverliethecoatinglayersuchthatthebackinglayercontactsthe coatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering;35 BE2024 / 5874 38 e)embossingofthewearlayer;preferablythermallyembossingofthewearlayer; morepreferablywhereintheembossingisperformedbyinfraredheatingofthe floorcoveringfollowedbycoldpressingofastructureintothewearlayer; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerthatisofthesamefamilyofthermoplasticpolymers,whereinthebackinglayerhas5 anairpermeabilityofatleast500l / m2 / smeasuredat200PascalaccordingtoISO923,and whereinthebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVC homopolymersandPVCcopolymers.Morepreferably,thebackinglayer,thecoatinglayer, andthewearlayerarefreeofPVChomopolymersandPVCcopolymers.Insome embodiments,thewearlayerasprovidedinstepa)isapreprintedwearlayerwhereinthe10 wearlayercomprisesaprintpatterndepositedonthesurfaceofthewearlayerthatisonthe sideofthecoatinglayer.Insomeembodiments,themethodcomprisesanadditionalstepprior tostepa)whereinaprintpatternisdepositedtothesurfaceofthewearlayeronthesideof thecoatinglayer.Insomeembodiments,thecoatinglayercomprisesoneormorecolorants orpigments.15 Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast20 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80°Ctoatmost180.0°C,oratleast 80°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoatmost 155.0°C.Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said25 methodcomprisingthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer; c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayeris configuredtooverliethecoatinglayersuchthatthebackinglayercontactsthe30 coatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering; BE2024 / 5874 39 e)embossingofthewearlayer;preferablythermallyembossingofthewearlayer; morepreferablywhereintheembossingisperformedbyinfraredheatingofthe floorcoveringfollowedbycoldpressingofastructureintothewearlayer; f)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer comprisespolyurethane,polyacrylate,oramixturethereof;5 whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayer,thecoatinglayer,andthewearlayerare essentiallyfreeofPVChomopolymersandPVCcopolymers,andwhereinthebackinglayer hasanairpermeabilityofatleast500l / m2 / smeasuredat200PascalaccordingtoISO9237. Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC10 homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin stepa)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments, themethodcomprisesanadditionalsteppriortostepa)whereinaprintpatternisdeposited tothesurfaceofthewearlayeronthesideofthecoatinglayer.15 Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast20 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80°Ctoatmost180.0°C,oratleast 80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoatmost 155.0°C.Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said25 methodcomprisingthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer; c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayeris configuredtooverliethecoatinglayersuchthatthebackinglayercontactsthe30 coatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering; e)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer35 comprisespolyurethane,polyacrylate,oramixturethereof; BE2024 / 5874 40 whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s measuredat200PascalaccordingtoISO9237,andwhereinthebackinglayer,thecoating layer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVCcopolymers.Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC5 homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin stepa)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments, themethodcomprisesanadditionalsteppriortostepa)whereinaprintpatternisdeposited tothesurfaceofthewearlayeronthesideofthecoatinglayer.10 Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast15 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80°Ctoatmost180.0°C,oratleast 80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoatmost 155.0°C.Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said20 methodcomprisingthestepsof: a)providingcombinedlayerthatcomprisesalacquerlayer,aprintpattern,andawear layer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthecombined layer;25 c)applyingabackinglayeronthecoatinglayer,whereinthebackinglayeris configuredtooverliethecoatinglayersuchthatthebackinglayercontactsthe coatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic30 polymerinthemultilayerfloorcovering; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s measuredat200PascalaccordingtoISO9237,andwhereinthebackinglayer,thecoating layer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVCcopolymers.35 BE2024 / 5874 41 Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred5 embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C.10 Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer;15 b1)applyingareinforcementlayeronthecoatinglayer,followedbyapplyingan additionalcoatinglayerbasedonapolymer-in-waterdispersiononthereinforcement layer; c)applyingabackinglayerontheadditionalcoatinglayer,whereinthebackinglayer isconfiguredtooverlietheadditionalcoatinglayersuchthatthebackinglayer20 contactstheadditionalcoatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering; e)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer25 comprisespolyurethane,polyacrylate,oramixturethereof; whereinthebackinglayer,thecoatinglayer,theadditionalcoatinglayerandthewearlayer eachcompriseanidenticalthermoplasticpolymer;whereinthebackinglayerhasanair permeabilityofatleast500l / m2 / smeasuredat200PascalaccordingtoISO9237,andwherein thebackinglayer,thecoatinglayer,theadditionalcoatingandthewearlayerareessentially30 freeofPVChomopolymersandPVCcopolymers.Morepreferably,thebackinglayer,the coatinglayer,theadditionalcoatinglayerandthewearlayerarefreeofPVChomopolymers andPVCcopolymers.Insomeembodiments,thewearlayerasprovidedinstepa)isa preprintedwearlayerwhereinthewearlayercomprisesaprintpatterndepositedonthe surfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments,the35 BE2024 / 5874 42 methodcomprisesanadditionalsteppriortostepa)whereinaprintpatternisdepositedto thesurfaceofthewearlayeronthesideofthecoatinglayer. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred5 embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C.10 Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof: a)providingawearlayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthewearlayer;15 b1)applyingareinforcementlayeronthecoatinglayer,followedbyapplyingan additionalcoatinglayerbasedonapolymer-in-waterdispersiononthereinforcement layer; c)applyingabackinglayerontheadditionalcoatinglayer,whereinthebackinglayer isconfiguredtooverlietheadditionalcoatinglayersuchthatthebackinglayer20 contactstheadditionalcoatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering; e)embossingofthewearlayer;preferablythermallyembossingofthewearlayer;25 morepreferablywhereintheembossingisperformedbyinfraredheatingofthe floorcoveringfollowedbycoldpressingofastructureintothewearlayer; f)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer comprisespolyurethane,polyacrylate,oramixturethereof; whereinthebackinglayer,thecoatinglayer,theadditionalcoatinglayerandthewearlayer30 eachcompriseanidenticalthermoplasticpolymer;whereinthebackinglayerhasanair permeabilityofatleast500l / m2 / smeasuredat200PascalaccordingtoISO9237,andwherein thebackinglayer,thecoatinglayer,theadditionalcoatinglayerandthewearlayerare essentiallyfreeofPVChomopolymersandPVCcopolymers.Morepreferably,thebacking layer,thecoatinglayer,theadditionalcoatinglayerandthewearlayerarefreeofPVC35 homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin BE2024 / 5874 43 stepa)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments, themethodcomprisesanadditionalsteppriortostepa)whereinaprintpatternisdeposited tothesurfaceofthewearlayeronthesideofthecoatinglayer. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature5 ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat10 least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C.Inaparticularembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided, saidmethodcomprisingthestepsof:15 a)providingabackinglayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthebacking layer; c)applyingawearlayeronthecoatinglayer,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthewearlayercontactsthecoatinglayer,20 d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmosta temperaturethatis20.0°Cabovethemeltingtemperatureofthethermoplastic polymerinthemultilayerfloorcovering; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerthatisofthesamefamilyofthermoplasticpolymers;whereinthebackinglayerhas25 anairpermeabilityofatleast500l / m2 / smeasuredat200PascalaccordingtoISO9237,and whereinthebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVC homopolymersandPVCcopolymers. Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers.30 Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast35 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat BE2024 / 5874 44 least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C. Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof: a)providingabackinglayer;5 b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthebackinglayer; c)applyingapre-printedwearlayeronthecoatinglayer,whereinthewearlayeris configuredtooverliethecoatinglayersuchthatthewearlayercontactsthecoating layer; d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmostatemperature10 thatis20.0°Cabovethemeltingtemperatureofthethermoplasticpolymerinthe multilayerfloorcovering; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseathermoplastic polymerthatisofthesamefamilyofthermoplasticpolymers;whereinthebackinglayerhas anairpermeabilityofatleast500l / m2 / smeasuredat200PascalaccordingtoISO9237,and15 whereinthebackinglayer,thecoatinglayer,andthewearlayerareessentiallyfreeofPVC homopolymersandPVCcopolymers. Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature20 ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat25 least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C. Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof:30 a)providingabackinglayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthebackinglayer; c)applyingawearlayeronthecoatinglayer,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthebackinglayercontactsthecoatinglayer, BE2024 / 5874 45 d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmostatemperature thatis20.0°Cabovethemeltingtemperatureofthethermoplasticpolymerinthe multilayerfloorcovering; e)embossingofthewearlayer;preferablythermallyembossingofthewearlayer;more preferablywhereintheembossingisperformedbyinfraredheatingofthefloorcovering5 followedbycoldpressingofastructureintothewearlayer; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s measuredat200PascalaccordingtoISO9237,andwhereinthebackinglayer,thecoating layer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVCcopolymers.10 Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin stepc)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments, themethodcomprisesanadditionalsteppriortostepc)whereinaprintpatternisdeposited15 tothesurfaceofthewearlayeronthesideofthecoatinglayer. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C20 toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C.Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said25 methodcomprisingthestepsof: a)providingabackinglayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthebackinglayer; c)applyingawearlayeronthecoatinglayer,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthewearlayercontactsthecoatinglayer,30 d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmostatemperature thatis20.0°Cabovethemeltingtemperatureofthethermoplasticpolymerinthe multilayerfloorcovering; e)embossingofthewearlayer;preferablythermallyembossingofthewearlayer;more preferablywhereintheembossingisperformedbyinfraredheatingofthefloorcovering35 followedbycoldpressingofastructureintothewearlayer; BE2024 / 5874 46 f)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer comprisespolyurethane,polyacrylate,oramixturethereof; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s measuredat200PascalaccordingtoISO9237,andwhereinthebackinglayer,thecoating5 layer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVCcopolymers. Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin stepa)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments,10 themethodcomprisesanadditionalsteppriortostepc)whereinaprintpatternisdeposited tothesurfaceofthewearlayeronthesideofthecoatinglayer. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred15 embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C.20 Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof: a)providingabackinglayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthebackinglayer;25 c)applyingawearlayeronthecoatinglayer,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthewearlayercontactsthecoatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmostatemperature thatis20.0°Cabovethemeltingtemperatureofthethermoplasticpolymerinthe multilayerfloorcovering;30 e)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer comprisespolyurethane,polyacrylate,oramixturethereof; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s measuredat200PascalaccordingtoISO9237,andwhereinthebackinglayer,thecoating35 layer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVCcopolymers.BE2024 / 5874 47 Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin stepa)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments, themethodcomprisesanadditionalsteppriortostepc)whereinaprintpatternisdeposited5 tothesurfaceofthewearlayeronthesideofthecoatinglayer. Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C10 toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C. Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said15 methodcomprisingthestepsof: a)providingabackinglayer; a1)applyinganadditionalcoatinglayerbasedonapolymer-in-waterdispersiononthe backinglayerfollowedbyapplyingareinforcementlayerontheadditionalcoatinglayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthereinforcement20 layer; c)applyingawearlayeronthecoatinglayer,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthewearlayercontactsthecoatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmostatemperature thatis20.0°Cabovethemeltingtemperatureofthethermoplasticpolymerinthe25 multilayerfloorcovering; e)embossingofthewearlayer;preferablythermallyembossingofthewearlayer;more preferablywhereintheembossingisperformedbyinfraredheatingofthefloorcovering followedbycoldpressingofastructureintothewearlayer; f)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer30 comprisespolyurethane,polyacrylate,oramixturethereof; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s measuredat200PascalaccordingtoISO9237,andwhereinthebackinglayer,thecoating layer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVCcopolymers.35 Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC BE2024 / 5874 48 homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin stepa)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments, themethodcomprisesanadditionalsteppriortostepc)whereinaprintpatternisdeposited tothesurfaceofthewearlayeronthesideofthecoatinglayer.5 Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast10 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C.Inanotherembodiment,amethodtoproduceamultilayerfloorcoveringisthusprovided,said methodcomprisingthestepsof:15 a)providingabackinglayer; a1)applyinganadditionalcoatinglayerbasedonapolymer-in-waterdispersiononthe backinglayer,followedbyapplyingareinforcementlayerontheadditionalcoatinglayer; b)applyingacoatinglayerbasedonapolymer-in-waterdispersiononthereinforcement layer;20 c)applyingawearlayeronthecoatinglayero,whereinthewearlayerisconfiguredto overliethecoatinglayersuchthatthewearlayercontactsthecoatinglayer, d)heatingthefloorcoveringtoatemperatureofatleast70.0°Ctoatmostatemperature thatis20.0°Cabovethemeltingtemperatureofthethermoplasticpolymerinthe multilayerfloorcovering;25 e)applyingalacquerlayeronthewearlayer;preferablywhereinthelacquerlayer comprisespolyurethane,polyacrylate,oramixturethereof; whereinthebackinglayer,thecoatinglayer,andthewearlayereachcompriseanidentical thermoplasticpolymer;whereinthebackinglayerhasanairpermeabilityofatleast500l / m2 / s measuredat200PascalaccordingtoISO9237,andwhereinthebackinglayer,thecoating30 layer,andthewearlayerareessentiallyfreeofPVChomopolymersandPVCcopolymers. Morepreferably,thebackinglayer,thecoatinglayer,andthewearlayerarefreeofPVC homopolymersandPVCcopolymers.Insomeembodiments,thewearlayerasprovidedin stepa)isapreprintedwearlayerwhereinthewearlayercomprisesaprintpatterndeposited onthesurfaceofthewearlayerthatisonthesideofthecoatinglayer.Insomeembodiments,35 BE2024 / 5874 49 themethodcomprisesanadditionalsteppriortostepc)whereinaprintpatternisdeposited tothesurfaceofthewearlayeronthesideofthecoatinglayer.Insomefurtherembodiments,stepd)comprisesheatingthefloorcoveringtoatemperature ofatleast70.0°Ctoatmostatemperaturethatis10.0°Cabovethemeltingtemperatureof thethermoplasticpolymerinthemultilayerfloorcovering.Insomefurtherpreferred5 embodiments,stepd)comprisesheatingthefloorcoveringtoatemperatureofatleast70.0°C toatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyatleast 80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,orat least80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Ctoat most155.0°C.10 Itwillbeappreciatedthatinthepresentinventioninsomeembodiments,thelayersare assembledupsidedown,contrarytotraditionalassembly.Thecoatinglayercanbeappliedto thewearlayer,whichhasbeenplacedupside-down.Thebackinglayercanbeplacedontop ofthecoatinglayer.Thisresultsinsomeembodimentsinafinalproductthathasbeen15 assembledupside-down,contrarytotraditionalmethodswherebythecoatinglayerisapplied ontothebackinglayerinstead.Thepresentinventionalsorelatestoaproductionlineforperformingthemethodasdisclosed herein,and(preferred)embodimentsthereof.Aproductionlinepreferablycomprisesaseries20 ofmachinesinstalledoneafteranotherinthedesiredorder,andpreferablycomprisesoneor more,preferablyall,ofthefollowingunits: -adeviceforunwindingandcontrollingthetensionofthewearlayer; -acoatingstationtoapplythecoatinglayer; -adeviceforunwindingofabackinglayer;25 -anovenforfinalheattreatment;and / or, -awindingstationforfinishedfloorcovering. Optionally,embossingstationsandbackprintunitsmaybeinstalledandusedduring production.AnexemplaryproductionlineisprovidedinFigure6.30 Alsooptionally,alacqueringstationmaybeinstalledandusedduringproduction.The lacqueringstationcanbewater-based,UV-basedorsolvent-based.Itwillbeunderstoodthat, dependingonthetypeoflacquerapplied,thelacqueringstationmayhavedifferentcuring equipment,suchasUVlacqueringwillbedonewithUVlight,whereaswater-basedlacquering willbedonewithaheatedoven.35 BE2024 / 5874 50 Preferably,atthebeginning,arollofwearlayerwithaprintpatternmaybeinstalledinan unwindingmachineandattachedtoatemporarymaterialtotighteninalineinthedirectionof webtravel,suchthatthewearlayerwillreachthecoatingstationupside-down. Oncethewearlayerreachesthecoatingstation,thecoatinglayerisappliedonthewearlayer. Asthewearlayermovesforward,thepolymer-in-waterdispersionisequallydistributedforthe5 wholewidthofthewearlayertherebyformingthecoatinglayer.Thecoatingstationasused hereincanbeanysuitablecoatingstation,suchasaknife-over-rollstation,aknife-over-table station,adirectspreadcoatingstation,akiss-rollcoatingstationorasprayingstation.For example,adoctorblade,arollingknifeoranyotherapplicationsystemmaydistributethe polymer-in-waterdispersionequallyforthewholewidthofthewearlayertherebyformingthe10 coatinglayer.Adoctorbladewillalsoallowthewatertoevaporateafterthecoatingstepand toallowfusionofthethermoplasticpolymerinthedifferentlayers,inparticularinthecoating layer,thebackinglayerandwearlayer. Subsequently,anunwindingstationmaystarttodropthebackinglayerontothewearlayer withthecoatinglayeralreadyapplied.15 Whenalllayersoffloorcoveringareapplied,aheatingstepisappliedonthefloorcovering, preferablyatatemperatureofatleast70.0°Candatmostatemperaturethatis20.0°Cabove themeltingtemperatureofthethermoplasticpolymerinthemultilayerfloorcovering,thereby allowingthedifferentlayerstofusewitheachother.Insomefurtherembodiments,heating canbeperformedatatemperatureofatleast70.0°Ctoatmostatemperaturethatis10.0°C20 abovethemeltingtemperatureofthethermoplasticpolymerinthemultilayerfloorcovering.In somefurtherpreferredembodiments,heatingcanbeperformedatatemperatureofatleast 70.0°Ctoatmost270.0°C;preferablyatleast80.0°Ctoatmost250.0°C;morepreferablyat least80.0°Ctoatmost200.0°C;evenmorepreferablyatleast80.0°Ctoatmost180.0°C,or atleast80.0°Ctoatmost165.0°C,oratleast85.0°Ctoatmost160.0°C,oratleast85.0°Cto25 atmost155.0°C. Afterwards,thefloorcoveringmaybecooleddown. Attheendoftheproductionline,optionallyembossingcanbeappliedonthefloorcovering. Thepresentinventionhastheadvantagethatnochangesareneeded:standardtechnology30 maybeusedtoproducefloorcoveringthatisessentiallyfreeofPVC.Thepresentinvention usesthewearlayertoapplythecoatinglayerupon,contrarytocommonpractice.Thisupside- downassemblyallowsforsimpleconstructionandproperadhesion,evenwithoutPVC.The presentinventionhasfoundthatthismethodallowstoobtaina100%PVC-freestructure, BE2024 / 5874 51 usingexistingmachinery,whileavoidingtheuseofglassfibreandhardtemperatureregimes. Thepresentmethodalsoallowstoachieveanimprovedscratchresistance.Inanotheraspect,anapparatusorproductionlineformanufacturingamultilayerfloorcovering asdisclosedhereinisprovided,whereintheapparatusorproductionlineisconfiguredfor performingamethodasdescribedhereinand(preferred)embodimentsthereof.(Preferred)5 embodimentsofthemethodsasdescribedhereinarealso(preferred)embodimentsofan apparatusorproductionlineasdescribedherein,andviceversa. Theapparatusorproductionlinepreferablycomprisesarollconfiguredforprovidingawear layer.Theapparatusorproductionlinefurtherpreferablycomprisesacoatingstation,suchas acoatingstationusingacoatingknife,toapplythecoatinglayertothewearlayer.The10 apparatusorproductionlinemayfurthercomprisearolltoapplythebackinglayeronthe coatinglayer,morepreferablyalsoaniprollisprovidedtoguidethebackinglayer.The apparatusorproductionlinepreferablycomprisesaguidingsystemtoalaminationpoint.The apparatusorproductionlinepreferablycomprisesalaminationstation,preferablyconfigured tolaminatethelayersatthelaminationpoint.Thelaminationstationmayalsocontrolthe15 tensionandpressureonthebackinglayertherebyensuringagoodadhesionwithoutcreases orbubblesbetweenthedifferentlayers.Theapparatusorproductionlinepreferablycomprises anoven,preferablyanair-heatedoven,toallowheatingofthefloorcoveringthereby laminatingandfusingthedifferentlayerstoeachother.Insomeembodiments,theproduction lineorapparatusmayfurthercompriseacoolingstationtoallowcoolingdownofthefloor20 covering.Insomepreferredembodiments,theapparatusorproductionlinefurthercomprises anembossingstationtoembossthefloorcovering.Insomeembodiments,saidembossing stationisaninfraredheatingembossingstation. EXAMPLES25 Thefollowingexamplesservetomerelyillustratetheinventionandshouldnotbeconstrued aslimitingitsscopeinanyway.Whiletheinventionhasbeenshowninonlysomeofitsforms, itshouldbeapparenttothoseskilledintheartthatitisnotsolimited,butissusceptibleto variouschangesandmodificationswithoutdepartingfromthescopeoftheinvention. FIG.1illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention.30 Thefloorcovering(1)comprisesabackinglayer(2),acoatinglayer(3),andawearlayer(4). FIG.2Illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),acoatinglayer(3),aprintpattern(5), andawearlayer(4). BE2024 / 5874 52 FIG.3illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),acoatinglayer(3),aprintpattern(5),a wearlayer(4),andalacquerlayer(6). FIG.4illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),anadditionalcoatinglayer(7),a5 reinforcementlayer(8),acoatinglayer(3),aprintpattern(5)andawearlayer(4). FIG.5illustratesamultilayerfloorcovering(1)accordingtoanembodimentoftheinvention. Thefloorcovering(1)comprisesabackinglayer(2),anadditionalcoatinglayer(7),a reinforcementlayer(8),acoatinglayer(3)andawearlayer(4).Insomeembodiments,the wearlayercanalreadycompriseaprintpattern.10 FIG.6illustratesaschematicrepresentationofamethodforthemanufactureofamultilayer floorcoveringaccordingtoanembodimentoftheinvention.Afirstcoatinglayer(3a)and, optionally,asecondcoatinglayer(3b),areappliedonawearlayer(4)withaprintpattern(5), followedbytheapplicationofabackinglayer(2)onthecoatinglayer,therebyforminga multilayerfloorcoveringaccordingtoanembodimentoftheinvention.15 FIG.7illustratesamethodforthemanufactureofamultilayerfloorcoveringaccordingtoan embodimentoftheinvention.Inafirststep,awearlayer(4)isprovidedwoundedonaroll (11).Thewearlayer(4)comprisesaprintpattern(5)depositedonthesurfaceofthewear layerthatisonthesideofthecoatinglayer.Inafurtherstep,thewearlayer(4)iscoatedwith acoatinglayer(3)basedonapolymer-in-waterdispersion.Thecoatingisappliedatthe20 coatingstationusingacoatingknife(12).Inafurtherstep,abackinglayer(2)isappliedon thecoatinglayer,whereinthebackinglayerisconfiguredtooverliethecoatinglayer(3)such thatthebackinglayer(2)contactsthecoatinglayer(3).Asshowninth.