Sports floor in form of tiles or boards

Abstract

The invention relates to a sports floor in the form of tiles or planks, which is freely mounted and comprises a coupling device (6) coupled to an adjacent tile or plank. The floor according to the invention comprises, in order from top to bottom:-a surface layer (2) comprising at least one flexible layer (2a) having a thickness of between 0.3 mm and 1 mm and a compression modulus of between 10 MPa and 100 MPa; -a rigid intermediate layer (3) having a thickness of between 3.5 mm and 7 mm, a flexural modulus of between 1000 MPa and 10000 MPa, a compressive modulus of between 35 MPa and 300 MPa; -a shock-absorbing underlayer (5) having a thickness greater than 3 mm, typically between 3 mm and 10 mm, preferably between 5 mm and 10 mm, and having a compressive modulus between 0.5 MPa and 15 MPa.

Description

Technical Field

[0001] The invention relates to a multilayer structure for producing so-called "sports" floors for use in sports centres, gymnasiums, multifunctional gyms or similar facilities. Background Art

[0002] According to the EN 14808 standard, sports floors must ensure safety and protection for the user, especially in terms of shock absorption. So-called "point-elastic" sports floors must specifically comply with the NF EN 14904 standard issued in June 2006, which stipulates that the floor must absorb 25% of the shock measured according to the EN 14808 standard.

[0003] Typically, sports floors consist of a multi-layer structure comprising an upper wear layer, whose main functions are skid control, wear resistance, ease of cleaning and decorative appearance, bonded to a backing layer of polyvinyl chloride foam, typically with a density between 0.30 and 0.40 and a thickness between 4 and 9 mm, allowing it to absorb point impacts.

[0004] In actual use, however, this type of flooring is often installed in so-called multi-purpose gymnasiums that host non-sporting events that could degrade the flooring's quality.

[0005] In fact, the backing foam is subject to traffic, heavy loads or unforeseen impacts that can cause irreversible deformation and damage the floor. While sports flooring is excellent at absorbing point impacts, it is less effective in resisting the above-mentioned stresses.

[0006] Known patent WO2018 / 197543 solves the problem of the versatility of the venue by placing a polymer film between the surface layer of the floor and the polyvinyl chloride foam backing layer, which film has a stiffness greater than 100 N / mm and a Young's modulus greater than 1.5 GPa to limit the indentation phenomenon in the foam by better distributing the stress and reducing the shear effect on the foam cell walls, which corresponds to the vertical deformation of the punch penetration.

[0007] This type of sports flooring fully meets the requirements of users in terms of safety and protection. However, it has some inherent disadvantages, since the foam layer that allows the absorption of point impacts is designed to be glued to the floor.

[0008] This gluing installation technique is long and tedious and, when these floors are laid without gluing, can lead to problems with deformation, expansion, sliding or joint openings between the two floor structures, especially due to expansion / contraction when laying large areas.

[0009] Furthermore, this type of sports flooring is usually supplied in rolls, which adds logistical disadvantages, in particular due to the weight of the roll and the relatively large surface area for the intended application. Furthermore, laying this type of flooring is complex and requires a high level of expertise on the part of the installer.

[0010] Known patent EP1570143 describes a sports floor having a wooden layer covered with varnish and comprising a resilient foam layer made of thermoplastic. The floor comprises male / female assembly means at the edges, suitable for free installation.

[0011] Such a floor may comprise a supporting layer which may be made of, for example, MDF, HDF, plywood, particle board, wood, metal or plastic.

[0012] The patent combines different materials such as wood and plastic, making it difficult to manufacture and recycle. Although it is called sports flooring, its shock-absorbing properties are not disclosed.

[0013] Finally, patent EP1570143 does not provide any solution for limiting the expansion or contraction phenomena when laying flooring over large areas. Summary of the invention

[0014] One of the objects of the present invention is to overcome the problems of the prior art by providing a sports floor that can easily, temporarily or permanently, convert an existing room into a sports room capable of being "multifunctional", i.e. a room in which several sports (such as volleyball and handball) can be played, while still accommodating non-sporting events, without having to remove the floor.

[0015] Another object is to provide a floor that meets the requirements defined in the NF EN 14904 standard of June 2006 for shock absorption measured according to NF EN 14808, vertical deformation measured according to NF EN 14.809, indentation measured according to EN 1516 and impact resistance measured according to EN 1517.

[0016] Another object is to provide a floor covering that meets the requirements defined in the NF-EN ISO 11638 standard in terms of resistance to indentation measured according to NF-EN ISO 24343-1.

[0017] An object of the present invention is to provide a floor which exhibits shock-absorbing and anti-marking properties comparable to those of conventional sports floors of glue-mounted rolling form and floors for general construction.

[0018] For this purpose, a sports floor in the form of tiles or planks has been developed which can be freely installed and which comprises coupling means for coupling with adjacent tiles or planks.

[0019] According to the present invention, the floor comprises, from top to bottom, the following components which are combined together:

[0020] - a surface layer, preferably composed of several layers, but including at least one flexible layer having a thickness between 0.1 mm and 2 mm and a compression modulus between 10 MPa and 100 MPa;

[0021] - a rigid intermediate layer, contrary to the flexible nature of the above-mentioned layers, having a thickness between 3.5 mm and 7 mm and a flexural modulus between 1000 MPa and 10000 MPa, preferably between 1000 MPa and 8000 MPa, to allow free installation of the floor, since the intermediate layer should not be too flexible to facilitate handling of the floor, nor too rigid to still allow cutting; the compression modulus of said intermediate layer is between 35 MPa and 300 MPa; a very dimensionally stable rigid intermediate layer allows free installation, is resistant to indentation, impact, rolling, and at least partially realizes a coupling device between tiles or planks; a flexural modulus below 1000 MPa will reduce the resistance to indentation and may cause swelling in free installation, which is undesirable; a flexural modulus above 10000 MPa makes on-site cutting difficult and may cause whitening of the material on the cutting line; a flexural modulus below 8000 MPa is preferred to avoid cutting problems independent of the on-site temperature;

[0022] - A shock-absorbing bottom layer for shock absorption and anti-indentation, with a thickness greater than 3 mm, typically between 3 mm and 10 mm, preferably between 5 mm and 10 mm, and a compression modulus between 0.5 MPa and 15 MPa; the compression modulus should not be less than 0.5 MPa so as not to reduce the anti-indentation performance, nor should it be greater than 15 MPa so as not to significantly reduce the shock absorption performance.

[0023] In summary, the present invention provides a freely installable floor that allows an existing room to be easily and temporarily or permanently converted into a sports and multi-purpose room.

[0024] The combination of compression modulus and thickness of the surface layer, rigid middle layer and shock absorbing bottom layer contributes to good indentation resistance.

[0025] The combination of compression modulus and thickness of the shock absorbing bottom layer contributes to absorbing at least 25% of the impacts to meet the requirements of the NF EN 14904 standard issued in June 2006 measured according to NF EN 14808.

[0026] The basic features of the invention thus provide a good compromise between indentation resistance and shock absorption. It can also be installed on slightly deformed substrates without preparation, i.e. without a depression greater than 2 mm within 2 m.

[0027] Preferably, the flexible layer is made of polyvinyl chloride, polyethylene, polypropylene, thermoplastic polyurethane or linoleum.

[0028] In order to improve the shear resistance of the floor, the tensile modulus of the flexible layer is between 100 MPa and 1000 MPa.

[0029] The intermediate layer is preferably made of polyvinyl chloride, polyethylene or polypropylene. In order to improve the shear resistance of the floor, the tensile modulus of the intermediate layer is between 500MPa and 3000MPa. The tensile modulus is measured according to the CSTB 99030-01 technical document. The intermediate layer can be compact or foamed.

[0030] Depending on the compatibility of the materials, the intermediate layer is bonded to the base layer via an adhesive layer, for example a double-sided adhesive, a reactive polyurethane adhesive layer, a copolyester film (coPes) or a hot melt adhesive layer.

[0031] The middle layer preferably has a thickness between 4 kg / m 2 and 9.5kg / m 2 The surface quality between.

[0032] The shock-absorbing bottom layer is preferably made of foamed polyethylene, foamed PVC, foamed polyurethane, rubber or cork. The density of the bottom layer is preferably 90 kg / m 3 and 400kg / m 3 This characteristic improves the shock absorbing performance of the floor according to the invention.

[0033] The middle layer preferably has a thickness between 390 g / m 2 and 1300g / m 2 The surface quality between.

[0034] The shock-absorbing substrate preferably has an anti-slip coating on its surface facing the ground, for example a coating based on ethylene vinyl acetate.

[0035] The surface quality of the surface layer is preferably 100 g / m 2 and 3000g / m 2 Between, preferably between 100 and 800 g / m 2 The surface layer is preferably dense.

[0036] The coupling means of the floor according to the invention may be of suitable type, such as receiving grooves for connecting equipment, made in the shock-absorbing bottom or surface layer and in at least part of the thickness of the intermediate layer, as described in patent FR3128478, the content of which is incorporated by reference.

[0037] According to another embodiment, the coupling means are of male / female or hermaphroditic type as described in patents FR3024990, FR3090711, FR3089534, FR3105280, the contents of which are incorporated by reference, and are made complementarily on opposite or adjacent edges, at least in the thickness of the edges of the intermediate layer.

[0038] Preferably, in this embodiment, the bottom layer extends horizontally from one edge of the intermediate layer and is set back at a complementary adjacent or opposite edge (i.e. at an edge including complementary coupling means) to extend under the surface layer and intermediate layer of an adjacent floor panel to which the floor panel is coupled to limit mechanical stresses at the coupling means.

[0039] Regardless of the embodiment of the coupling device, the surface layer preferably has at least one beveled edge to limit the unevenness between the surface layers of two adjacent tiles. The beveled edge also forms a recess for thermal welding of the joint between two adjacent tiles using a welding wire. The welding wire is made of a material similar to or compatible with the composition of the surface layer and counteracts the effects of expansion between the two tiles.

[0040] The surface quality of the sports floor according to the present invention is preferably 5 kg / m 2 and 13.3kg / m 2 More preferably, between 7kg / m 2 Up to 9kg / m 2 between.

[0041] The thickness of the sports floor according to the invention is between 6.5 mm and 18 mm, preferably between 8 mm and 12 mm. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 is a cross-sectional view of a specific embodiment of a floor panel according to the present invention.

[0043] Figure 2 is with Figure 1 Similar views, which show another embodiment.

[0044] Figure 3 is a perspective view of a coupling device showing a shock absorbing bottom layer extending from the edges of the intermediate layer and the surface layer.

[0045] Figure 4 is with Figure 3 Similar cross-section.

[0046] Figure 5 is a perspective view of one embodiment including a seam placed between two adjacent tiles or planks.

[0047] Figure 6is a perspective view of one embodiment of a joint that may be placed between two adjacent tiles or planks.

[0048] Figure 7 is with Figure 5 Similar cross-section. DETAILED DESCRIPTION

[0049] refer to Figures 1 to 7 The present invention relates to a sports floor (1) in the form of tiles or planks, which can be freely installed and allows the temporary or permanent conversion of existing rooms into "multifunctional" rooms and gymnasiums, i.e. rooms where several sports can be played, such as volleyball, handball and where non-sporting events can be accommodated, while ensuring compliance with the requirements of the NF EN 14904 standard of June 2006 in terms of shock absorption, vertical deformation, indentation and impact resistance, as well as compliance with the requirements of the NF EN ISO 11638 standard measured according to NF EN ISO 24343-1 in terms of indentation resistance.

[0050] The floor (1) according to the invention provides the user with optimal protection from potential injuries caused by repeated impacts during sports practice.

[0051] The invention is particularly suitable for continuous free installation, where tiles or wooden panels are laid over large areas (especially over 100m 2 , even up to 1000m 2 ) is continuous and at the same time reduces the influence of expansion / contraction phenomena. The width and length of the tile or plank are usually between 50cm and 150cm, preferably between 50cm and 100cm.

[0052] The invention also aims to keep the total thickness of the sports floor 1 between 6.5 mm and 18 mm, preferably between 8 mm and 11 mm, while ensuring a total surface quality of 5 kg / m 2 and 13.3kg / m 2 between 7kg / m 2 Up to 9kg / m 2 These dimensions and weights ensure the portability and durability of the Floor 1.

[0053] The sports floor 1 is in the form of freely installed tiles or planks and comprises coupling means 6 for connecting adjacent tiles or planks.

[0054] The floor panel 1 comprises at least a surface layer 2, a rigid middle layer 3 and a shock-absorbing bottom layer 5 intended to come into contact with the ground, which are combined together in this order from top to bottom.

[0055] The surface layer 2 comprises at least one flexible layer 2a, its thickness is between 0.1mm and 2mm, compression modulus is between 10MPa and 100MPa, according to EN ISO 604 standard, measure with v=20mm / min, and tensile modulus is between 100MPa and 1000MPa, measure according to CSTB 99030-01 technical file.Described surface layer 2 is preferably tight (solid (compact)).The thickness of surface layer 2 is between 0.1 and 2mm, preferably between 1 and 2mm, helps to reduce impact force like this.

[0056] This layer can be made of various materials, such as PVC, particularly plasticized PVC, PE, PP, TPU or linoleum, by known processes such as calendering, coating, extrusion or pressing. It is designed to be sufficiently wear-resistant and as non-slip as possible. The surface layer 2 can be a single layer or a combination of a transparent flexible layer 2a and a decorative film 2b. It may be a traditional varnish. The thickness of the transparent flexible layer 2a is generally between 0.15 and 1.95mm, preferably between 1 and 1.95mm. The decorative film 2b can be printed by gravure printing or inkjet printing. For example, the transparent surface layer 2 contains 27% by weight of plasticizer, 70% by weight of PVC and 3% by weight of other additives.

[0057] The rigid intermediate layer 3 has a thickness between 3.5 mm and 7 mm, a flexural modulus between 1000 MPa and 10000 MPa, preferably between 1000 MPa and 8000 MPa, measured according to the NF EN ISO 178 standard, and preferably has a compression modulus between 35 MPa and 300 MPa, measured at v=20 mm / min according to the EN ISO 604 standard, and a tensile modulus between 500 MPa and 3000 MPa, measured according to the CSTB99030-01 technical document. This layer can be made of PVC, PE or PP, helps to absorb shocks and provides structural stability to the entire floor 1. This rigid intermediate layer 3 can be made by extrusion or calendaring. For example, it can be made of PVC with fillers and plasticized at less than 10% of the total weight of the layer, preferably less than 5% of the total weight of the layer.

[0058] The filler can be selected from calcium carbonate, chalk, kaolin, talc, silicon dioxide. The intermediate layer 3 can also contain at least one additive selected from the following group: heat stabilizer, desiccant, lubricant, processing aid, pigment, flame retardant.

[0059] The plasticizer can be selected from diisononyl phthalate (DINP), diisodecyl phthalate (DIDP), 2-ethylhexyl diphenyl phosphate (DPO), dioctyl terephthalate (DOTP), diisononyl 1,2-cyclohexanedicarboxylate (DINCH), benzoate family plasticizers, adipate family plasticizers, Perstorp and Plasticizers sold under the brand names, epoxidized soybean oil (ESO), epoxy stearate octyl (ESO), partially or fully bio-based plasticizers such as those sold by RoquettePharma exeID 37, sold by Jungbunzlauer International AG Series plasticizers or those sold by Danisco Plasticizers. Liquid plasticizers can be used alone or in combination.

[0060] For example, the rigid middle layer 3 may be made of a composition containing 55% filler, 43% PVC, 0.3% foaming agent and 2.7% other additives without adding plasticizer.

[0061] The shock-absorbing bottom layer 5 is designed to absorb most of the impact, reduce the impact force, and resist indentation. The thickness of this layer is greater than 3 mm, ideally between 3 mm and 10 mm, and the compression modulus measured at v=20 mm / min according to EN ISO 604 standard is between 0.5 MPa and 15 MPa. It can be made of foamed PE, foamed PVC, foamed PU, rubber or cork by extrusion or coating process, such as coating expanded PVC plastisol. Foaming can be achieved mechanically or using a foaming agent. Preferably, the bottom layer 5 has a closed-cell foam composition, more preferably, which is cross-linked. For example, the foam used contains 30% by weight of plasticizer, 8% by weight of filler, 57% by weight of polyvinyl chloride and 5% by weight of other additives.

[0062] According to a particular embodiment, the sports flooring 1 comprises an adhesive layer 4 , for example a double-sided adhesive, a reactive polyurethane adhesive layer, a copolyester film (coPes) or a hot melt adhesive layer, positioned to bond the intermediate layer 3 and the bottom layer 5 .

[0063] Furthermore, the floor 1 comprises coupling means 6 which may be receiving grooves for connecting equipment, as shown in patent FR3128478, machined from the surface layer 2, or preferably from the shock-absorbing bottom layer 5, in at least part of the thickness of the intermediate layer 3.

[0064] The connection device may have a joint seam 8 which is installed between tiles or wooden boards and improves the expansion resistance for installation areas of 100 square meters or more.

[0065] exist Figure 3 , 4 In the embodiments shown in FIGS. 5 and 7 , these coupling means 6 may be of male / female or hermaphroditic type, made at least in the thickness of the edges of the intermediate layer 3 and complementary on opposite or adjacent edges.

[0066] The coupling device 6 allows a plurality of tiles or planks to be connected together. Typically, the male / female coupling device 6 comprises a first machined profile (e.g., a tongue) machined on one edge and configured to couple with a complementary second machined profile (e.g., a groove) machined on the opposite or adjacent edge of the adjacent floorboards 1' or joint 8.

[0067] Regardless of the form of the coupling device 6, the surface layer 2a preferably has at least one beveled edge 7 to limit the unevenness between the surface layers of two adjacent tiles (1, 1'). The beveled edge 7 also forms a recess for thermally welding the joint between two adjacent tiles using a welding wire. The welding wire is made of a material similar or compatible with the composition of the surface layer and offsets the effects of expansion between the two tiles (1, 1', 1").

[0068] according to Figure 3 and Figure 4 , the bottom layer 5 extends horizontally from one edge of the intermediate layer 3 and is set back (set back) at the complementary adjacent or opposite edge so as to extend under the surface layer 2 and the intermediate layer 1 of the adjacent floorboard (1) coupled to the floorboard 1 to limit the mechanical stress at the coupling device. The extension value and the setback value are the same and are preferably between 10 mm and 50 mm, more preferably between 20 mm and 40 mm.

[0069] Once coupled, the coupling device 6 locks the displacement of the two tiles or planks in the vertical direction (ie perpendicular to the floor) and in the horizontal direction (ie parallel to the floor plane).

[0070] according to Figure 5 and Figure 7 The sports floor 1 is in the form of tiles or planks and can be freely installed, including male coupling devices 6 as described in patent FR3024990 on its four edges and allowing assembly with joints 8, the shape of which includes corresponding female assembly devices 6 as described in patent FR3024990. The bottom layer 5 is set back horizontally relative to the surface layer 2a and the intermediate layer 3 to form a space for installing the joint 8 between two adjacent floor panels (1, 1').

[0071] according to Figure 6 and Figure 7The outer shape of the joint 8 includes two-sided female assembly devices 6 as described in patent FR3024990. When assembling multiple tiles or wooden boards (1, 1', 1"), the surface of the tiles or wooden boards is flush with the upper surface 9 of the joint 8. The lower surface 10 of the joint 8 rests on the ground to ensure good assembly strength. The joint 8 can be made by extrusion or other processes. Its composition can be made of PVC, rubber, silicone, nitrile or other equivalent elastomers, and may also have metal reinforcements.

[0072] One embodiment of the invention was tested and measured as described in the following table. The structure of the layers that are combined together to form the floor is defined in the first column:

[0073] Table 1

[0074]

[0075] Among them: The bending modulus indicates the ease of installation, especially free installation. The compression modulus indicates the resistance to indentation. The tensile modulus indicates the shear resistance of the floor (1). The test and measurement results are shown in the following table:

[0076] Table 2

[0077]

Claims

1. A sports floor (1) in the form of tiles or planks, which is freely installed and comprises coupling means (6) for connecting to adjacent tiles or planks, characterised in that It includes, from top to bottom, bonded together: - a surface layer (2) comprising at least one flexible layer (2a) having a thickness between 0.1 mm and 2 mm and a compression modulus between 10 MPa and 100 MPa; - a rigid intermediate layer (3) having a thickness between 3.5 mm and 7 mm, a flexural modulus between 1000 MPa and 10000 MPa, and a compression modulus between 35 MPa and 300 MPa; - a shock-absorbing bottom layer (5) having a thickness greater than 3 mm, generally between 3 mm and 10 mm, preferably between 5 mm and 10 mm, and a compression modulus between 0.5 MPa and 15 MPa.

2. The sports floor (1) according to claim 1, characterized in that The tensile modulus of the flexible layer (2a) is between 100 MPa and 1000 MPa.

3. Sports floor (1) according to any one of the preceding claims, characterized in that The tensile modulus of the rigid intermediate layer (3) is between 500 MPa and 3000 MPa.

4. Sports floor (1) according to any one of the preceding claims, characterized in that The intermediate layer (3) is bonded to the bottom layer (5) via an adhesive layer (4), such as a double-sided adhesive, a reactive polyurethane adhesive layer, a copolyester film or a hot melt adhesive layer.

5. Sports floor (1) according to any one of the preceding claims, characterized in that The surface mass of the intermediate layer (3) is 4 kg / m 2 and 9.5kg / m 2 between.

6. Sports floor (1) according to any one of the preceding claims, characterized in that The density of the bottom layer (5) is 90 kg / m 3 and 400kg / m 3 between.

7. Sports floor (1) according to any one of the preceding claims, characterized in that The coupling device (6) is a receiving groove for a connecting device, and the coupling device (6) is processed in the shock-absorbing bottom layer (5), or in the surface layer (2) and in at least a part of the thickness of the intermediate layer (3).

8. Sports floor (1) according to any one of the preceding claims, characterized in that The coupling means (6) are of the male / female or hermaphroditic type, formed complementarily at least in the thickness of the edges of the intermediate layer (3) on opposite or adjacent edges.

9. The sports floor (1) according to claim 8, characterized in that The bottom layer (5) extends horizontally from one edge of the intermediate layer (3) and is arranged rearwardly at the complementary adjacent or opposite edge to extend below the surface layer (2) and the intermediate layer (3) of an adjacent floor panel (1) coupled to the floor panel (1).

10. Sports floor (1) according to any one of the preceding claims, characterized in that The surface quality of the sports floor (1) is 5 kg / m 2 and 13.3kg / m 2 Between, preferably between 7kg / m 2 Up to 9kg / m 2 between.

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