Method of manufacturing a floor or wall covering and related covering

Abstract

The invention relates to a method for manufacturing a floor or wall covering comprising at least one base layer (2) made of a polymeric material and having an upper surface (2a) having a predetermined relief pattern and a lower surface (2b), the method comprising at least the following steps: a) advancing the base layer (2); b) controlling the numerically controlled deposition device to deposit a fluid adhesive material (4a, 4b) on the upper surface (2a) of the base layer (2) according to a predetermined relief pattern; c) depositing material particles (3a, 3b) on the fluid adhesive material (4a, 4b); d) crosslinking the deposited fluid adhesive material (4a, 4b) to connect the material particles (3a, 3b) to the base layer (2) and form a predetermined relief pattern.

Description

Technical Field

[0001] The present invention relates to the technical field of floor and wall coverings made of polymeric materials and methods for their manufacture. The present invention more particularly relates to a method for manufacturing polyvinyl chloride or similar coverings, and more particularly to a covering having at least one layer with a relief surface. Background Art

[0002] In the field of floor or wall coverings, slabs, slats or rolls comprising at least one layer of plastic material (such as a plastic material obtained from polyvinyl chloride (PVC)) are well known. Known methods for manufacturing such floor coverings generally include a first step: depositing a first layer of plastic material granules on a support, and then melting and pressing this layer by means of a double-belt flat press or through the passage between two rollers of a calender in order to bond the granules and obtain a decorative floor covering layer. The floor or wall covering may also include a decorative layer in the form of a printed film protected by a transparent or translucent layer, the decorative layer being provided on the upper part of the floor covering.

[0003] These floor coverings thus have a mimicked, even realistic, decoration. In order to improve the visual and tactile performance of these coverings or to provide them with anti-slip properties, there are methods for granulating the upper surface of these coverings. These methods make it possible to provide the covering with a predetermined relief pattern. Mechanical granulation methods use, for example, a roller having protrusions or cavities according to a predetermined pattern and capable of applying an imprint of such a relief pattern to the covering surface by cold pressing or hot pressing. There are also other methods by adding materials, such as the method described in patent EP2108524, which comprises applying a superimposed varnish layer on the panel surface by inkjet printing to form a relief.

[0004] However, these different methods for obtaining a relief are not satisfactory in terms of flexibility, long cylinder changeover time and high cost, or the depth of the relief obtained, or even wear resistance. On the other hand, the mechanical granulation process using a granulating roller is difficult to superimpose in a marked manner on a printed decoration and to repeat quickly. In fact, the relief pattern cannot be longer than the developed length of the cylinder, which is generally less than 3 meters. Summary of the Invention

[0005] One of the aims of the present invention is to overcome the drawbacks of the prior art, in particular by proposing a method for manufacturing a floor or wall covering comprising at least one base layer made of a polymeric material, the base layer comprising an upper surface and a lower surface, the upper surface comprising a predetermined relief pattern that is easy to adjust, has no length limitation, and is capable of having a considerable depth.

[0006] A second object of the present invention is to provide a method for manufacturing a floor or wall covering, the floor or wall covering having a base layer with a decorative pattern, the decorative pattern being located in the thickness of the base layer or on a printed film, and the pattern being predefined; and a second relief pattern, the second relief pattern being predefined and preferably marked at the location of the decorative pattern.

[0007] To this end, a method for manufacturing a floor or wall covering is developed, the floor or wall covering comprising at least one base layer made of a polymeric material and comprising an upper surface and a lower surface, the base layer comprising a predefined relief pattern, the method comprising at least the following steps:

[0008] a) Advancing the base layer;

[0009] b) Controlling a numerically controlled deposition device to deposit a fluid adhesive material on the upper surface of the base layer according to the predefined relief pattern;

[0010] c) Depositing material particles on the fluid adhesive material;

[0011] d) Crosslinking the deposited fluid adhesive material to attach the material particles to the base layer and form the predefined relief pattern.

[0012] Thus, the method enables a relief to be obtained on the upper surface of the base layer, the relief being obtained by a combination of the predefined relief pattern obtained by the distribution of the material particles and the crosslinked fluid adhesive material.

[0013] Advantageously, the steps of depositing the fluid adhesive material and depositing the particles can be repeated to obtain a more complex relief pattern.

[0014] A support is generally used to support and advance the base layer. The support is only used to obtain the floor or wall covering and is then separated from the covering. The support may include, for example, a continuous conveyor belt, such as a metal belt, or a transfer paper, such as a paper coated with a silicone resin layer on the face for receiving the base layer, or a textile that does not adhere to the base layer material.

[0015] The base layer is made of a polymeric material and may be in the form of a single-layer or multi-layer structure. The lower surface of the base layer may optionally be subsequently bonded to other layers to form a heterogeneous floor covering and provide the covering with, for example, other damping, resistance or acoustic properties. In particular, the base layer may be obtained from PVC and may be manufactured, for example, by calendering, coating then gelling, by pressing or also by flat die extrusion, the layer being in the form of a sheet having smooth upper and lower surfaces.

[0016] A numerically controlled deposition device capable of depositing a fluid adhesive material may in particular be a digital inkjet printing device and process, which enables droplets of the fluid adhesive material to be deposited on the upper surface of a substrate according to a predefined relief pattern and according to coordinates obtained from a digital file representing the relief pattern.

[0017] Alternatively, a numerically controlled deposition device capable of depositing a fluid adhesive material may be any device comprising at least one adhesive material reservoir and at least one deposition nozzle in communication with the reservoir, for depositing the fluid adhesive material according to coordinates obtained from a digital file representing the relief pattern. The fluid adhesive material is advantageously deposited, ejected or sprayed in the form of droplets having a volume of from 1 picoliter to 1 milliliter. The fluid adhesive material may in particular be a varnish (especially an acrylic- or polyurethane-based varnish), a liquid adhesive, a plastisol.

[0018] After the fluid adhesive material has been deposited, the step of depositing material particles on the fluid adhesive material may be carried out batchwise or in a controlled manner using any known device, such as a hopper, a sprayer or other deposition device. After the deposition step, a step of removing the particles that have not been deposited on the adhesive material and remain free may be considered, in particular by suction or blowing, so as not to degrade the final visual appearance of the coating.

[0019] Alternatively, step c) comprises controlling the numerically controlled deposition device to deposit the material particles on the fluid adhesive material according to a predefined relief pattern. This alternative makes it possible to limit the amount of particles to be deposited and to avoid the step of removing the particles that have not adhered to the adhesive material. In fact, despite the removal step, the particles may still contaminate the desired relief pattern by remaining in an undesired position.

[0020] Polymeric materials that can be used in the composition of the material particles for the substrate and deposition to form a relief pattern are, for example, polyvinyl chloride (PVC), polyvinyl butyral (PVB), PLA or polylactic acid, thermoplastic polyurethane (TPU), polypropylene (PP), polymethyl methacrylate (PMMA), cellulose derivatives, elastomers, alone or in a mixture. The material particles deposited to form the relief pattern may also comprise at least one mineral filler, natural filler or synthetic filler.

[0021] The material particles deposited to form the relief pattern may also comprise at least one plasticizer. They may be colored, transparent or translucent.

[0022] The material particles deposited to form the relief pattern may be from recycled molds.

[0023] The material particles deposited to form the relief pattern can have a spherical and / or oval shape to improve the fluidity and fineness of the pattern, as well as its repeatability. In fact, particles with a rough shape (e.g., particles obtained by grinding post-consumer products or other products) do not flow uniformly and can cause variability during the deposition step. In particular, spherical and / or oval particles can be obtained through well-known extrusion processes through a die with underwater blade cutting. Advantageously, the material particles deposited to form the pattern are particles made of a polymeric material such as PVC, polypropylene, polyethylene, PMMA, linoleum, thermosetting materials, individually or in a mixture, or particles made of a non-polymeric material such as corundum, glass, natural mineral particles such as mica, quartz, basalt, etc.

[0024] Advantageously, the particles are granules with a particle size of 0.5 mm to 10 mm, or powders with a particle size of 2 μm to less than 500 μm, preferably 20 μm to 250 μm. The particles can also include a mixture of granules and powders. Since a variety of particles can be used in the method according to the present invention, a relief with a significant depth of several millimeters and a very fine resolution of up to several micrometers can be obtained.

[0025] The material particles deposited to form the relief pattern can also be in the form of a PVC dry blend, or in the form of granules obtained from a gel polymer material such as PVC. The material particles deposited to form the pattern can be in the form of colored granules, each granule containing one or more colors.

[0026] A variety of methods can partially or completely crosslink the deposited fluid adhesive material to connect the material particles to the substrate and form a predetermined relief pattern. In particular, a known method is drying, which enables the evaporation of the liquid part of the adhesive material without causing deformation of the substrate. In particular, drying can be carried out using a hot air stream. Other methods enable partial or complete crosslinking of the fluid adhesive material, especially by exposing the material to infrared and / or near-infrared radiation.

[0027] Alternatively, in the case where the composition of the fluid adhesive material contains a photoinitiator, it can be partially or completely crosslinked by exposure to ultraviolet or excimer radiation or an electron beam.

[0028] The method according to the present invention can be carried out step by step, i.e., after each relief pattern is manufactured, the substrate coated with the relief pattern is moved relative to the deposition device, and a new substrate is moved towards the deposition device to be coated with the relief pattern. "Advancing" means that the substrate moves relative to the device for depositing the adhesive material and the particles, and / or the device for depositing the adhesive material and the particles moves relative to the substrate.

[0029] Alternatively, in order to make the method faster and cheaper, the method for manufacturing a floor or wall covering according to the present invention can be carried out continuously. For this purpose, the substrate is continuously advanced relative to the device for depositing the adhesive material and the particles, for example, at a speed of 1 to 25 meters per minute, advantageously 5 to 12 meters per minute. For example, a support in the form of a continuous belt can be advanced, which supports the substrate provided in the form of a roller and is continuously unwound by the advancement of the support. It is also possible to advance a support in the form of a continuous belt, which supports a series of substrates, said series of substrates being provided in the form of slats, slabs or sheets and being continuously advanced due to the advancement of the support.

[0030] Alternatively, the substrate can be continuously manufactured by any known method, such as calendering, coating then gelling, pressing or also by flat die extrusion, and continuously deposited on a continuously advancing support.

[0031] The adhesive material can also be deposited in multiple stages, or even multiple adhesive materials can be used. For this purpose, the method according to the present invention can include the following steps:

[0032] - Controlling a numerically controlled deposition device to deposit a first fluid adhesive material on the upper surface of the substrate according to a first part of a predetermined relief pattern;

[0033] - Controlling a numerically controlled deposition device to deposit at least one second fluid adhesive material on the upper surface of the substrate according to a second part of a predetermined relief pattern.

[0034] In this way, a floor covering with a relief pattern can be obtained, which is obtained from at least two parts of a predetermined pattern and is therefore more complex than a pattern made in one go. The first and second fluid adhesive materials can be the same or different. In particular, the adhesion characteristics of the fluid adhesive material to the upper surface of the substrate and / or the material particles can be adjusted according to the first and second parts of the pattern. Similarly, the surface appearance or color of the first and / or second fluid adhesive materials can be different in order to obtain a significantly richer relief pattern.

[0035] Multiple particle types can also be used in the method according to the present invention. For this purpose, the method according to the present invention can include the following steps:

[0036] - Controlling a numerically controlled deposition device to deposit a first type of material particles on the fluid adhesive material according to a first part of a predetermined relief pattern;

[0037] - Controlling a numerically controlled deposition device to deposit a second type of material particles on the fluid adhesive material according to a second part of a predetermined relief pattern.

[0038] In this configuration, various configurations can be considered. According to a first option, the step of depositing the first particle type can be carried out on a part of the fluid adhesive material itself deposited according to the entire relief pattern. Optionally, only some of the fluid adhesive material is deposited, and the numerically controlled deposition device can selectively deposit particles according to the first part of the pattern.

[0039] According to a second option, the step of depositing the first particle type can be carried out on the fluid adhesive material itself deposited according to the first part of the relief pattern.

[0040] This also applies to the step of depositing the second particle type on the fluid adhesive material, which is itself deposited according to all or part of a predetermined relief pattern.

[0041] The step of crosslinking the first fluid adhesive material can be carried out after the step of depositing the first particle type or after the step of depositing the second particle type.

[0042] In this way, a floor covering with a relief pattern can be obtained, which is obtained from at least two parts of a predetermined and thus more complex relief pattern. The first and second material particle types are preferably different, especially in terms of adhesion properties, mechanical properties, size, shape, wear resistance, color, composition, gloss, transparency, etc. to the fluid adhesive material.

[0043] Optionally, the method according to the invention includes the following additional steps after step c) or d):

[0044] - Coating a protective layer on the material particles such that the material particles are partially embedded in the thickness of the protective layer;

[0045] - Crosslinking the protective layer.

[0046] The protective layer is a layer that can be transparent, translucent or colored, obtained from a varnish, a PVC plastisol or a "thermal coating". Such a protective layer can improve wear resistance, scratch resistance and transport resistance. The deposited particles can be partially embedded in the thickness of the protective layer such that at least some of said particles are flush with the surface of the protective layer.

[0047] Alternatively, the deposited particles can be covered by the protective layer, thus molding the shape of the relief pattern. This makes it possible to maintain a very weakly structured surface relief while improving cleanability and protecting the deposited particles.

[0048] Optionally and finally, in order to improve the visual appearance and richness of the decoration presented by the covering, the method according to the invention includes at least one additional step:

[0049] - Printing a predetermined decorative pattern on the upper surface of the substrate (2) and / or on the material particles using an inkjet printing process.

[0050] Thus, before the step of depositing the fluid adhesive material, the base layer can be printed with a decorative pattern by any known method, in particular by an inkjet printing process. The base layer can also include a decorative layer in its thickness, which can be seen from the upper surface of the base layer. Thus, the base layer can include a translucent or transparent layer, a decorative layer, and a backing layer from the upper surface to the lower surface. The base layer can also include a decorative layer and a backing layer from the upper surface to the lower surface. The decorative layer can be obtained by any known method, in particular by an inkjet printing method, on a support film or on the backing of the translucent layer or directly on the backing layer.

[0051] A decorative pattern can also be printed on all or part of the material particles, preferably after the crosslinking step of the fluid adhesive material, by any known method, in particular by an inkjet printing process. In particular, this makes it possible to bring nuances to the relief, such as wood grain, color details, geometric patterns superimposed on the particles.

[0052] Alternatively, the base layer is made of polymer material particles in the form of granules and / or powders and / or dry mixtures aggregated according to a predetermined decorative pattern. Thus, the base layer includes material particles distributed to form a predetermined decorative pattern.

[0053] Thus, an alternative of the method makes it possible to obtain a covering including a decoration in the thickness of the base layer, which is obtained by a combination of patterns obtained by the distribution of polymer material particles (in the form of distributed granules and / or powders and / or dry mixtures) and of the possible other materials of the base layer.

[0054] According to an embodiment in which the base layer includes at least one decorative layer having a predetermined decorative pattern in thickness or a predetermined decorative pattern printed on the upper side of the base layer or a predetermined decorative pattern printed on the decorative layer included in the base layer, the method according to the invention can include the following steps:

[0055] - Depositing the fluid adhesive material according to the position of the predetermined decorative pattern.

[0056] This alternative makes it possible to mark a relief pattern with a decorative pattern, thus bringing more realism to the covering. Thus, a relief can be added to the front of the printed decorative pattern to highlight it. Alternatively, the part with the decorative pattern cannot be covered by the relief pattern, which highlights, for example, the part adjacent to the printed decorative pattern.

[0057] Preferably, the fluid adhesive material can be crosslinked in multiple steps in order to pre-crosslink it and / or fix it to the substrate, for example by exposure to infrared radiation. To this end, the method can include at least one additional step after step c) to partially crosslink the deposited fluid adhesive material. In particular, this makes it possible to temporarily fix the particles so that the substrate can be moved, or it can also be easier to deposit a second adhesive material and / or particle type.

[0058] After the step of crosslinking the fluid adhesive material, a step of heating the particles and / or pressing can be carried out. This makes it possible to slightly change the appearance of the particles or to slightly push them into the thickness of the layer to better fix them, while keeping the relief pattern flush with the upper surface of the substrate. This step can be carried out using an oven, by exposure to infrared or near-infrared radiation, hot pressing or cold pressing, a pressure cylinder.

[0059] The invention also relates to a floor or wall covering comprising at least one substrate, said substrate comprising a predetermined relief pattern obtained by the manufacturing method according to the invention. The covering thus comprises a predetermined relief pattern.

[0060] Regardless of the embodiment, the particle deposition device can include at least one particle storage device, which includes at least one outlet, such as a hopper, and at least one closing device for each outlet that can be numerically controlled in order to prevent or allow the flow of particles in a controlled manner. Each particle deposition device can, for example, include one type of particle, such as a color, in order to mix multiple types of particles in a pattern using multiple deposition devices.

[0061] Regardless of the embodiment, the device for depositing particles can include a numerically controlled device, the pattern being predefined in a digital file or any equivalent computer storage device. The numerically controlled device includes a device for parsing said file or a computer storage device for numerically controlling the deposition device according to the relief pattern and depositing particles according to the relief pattern. Description of the Drawings

[0062] Figure 1A is a side view of a first example of a covering obtained by the method according to the invention.

[0063] Figure 1B is according to Figure 1A a detail view of the first example of the covering.

[0064] Figure 2 is a side view of a second example of a covering obtained by the method according to the invention.

[0065] Figure 3 is a side view of a third example of a covering obtained by the method according to the invention.

[0066] Figure 4 Side view of a fourth instance of a covering obtained by the method according to the invention.

[0067] Figure 5 Side view of a fifth instance of a covering obtained by the method according to the invention.

[0068] Figure 6 Side view of a sixth instance of a covering obtained by the method according to the invention.

[0069] Figure 7 Side view of a seventh instance of a covering obtained by the method according to the invention.

[0070] Figure 8 Perspective view of a device capable of implementing the method according to the invention.

[0071] Figure 9 is Figure 8 Top view of the distribution device for the numerical control distribution of particles shown in

[0072] Figure 10 Side view of a second device capable of implementing the method according to the invention. Detailed description

[0073] Regardless of the embodiment, the material particles that can be distributed are in bulk, for example in the form of powder and / or granules and / or "dry mixtures". The particles that can be used to manufacture the relief according to the invention can be of the same or different nature. As an example, the polymer materials that can be used can be selected from PVC, pure PVC or plasticized PVC, PP, PE, PMMA, and product scraps or abrasives from the recycling channels of these materials. Naturally, a variety of materials to be deposited can be mixed to obtain the relief pattern according to the invention. As a non-limiting example, the materials that can be deposited can be granular materials in the form of powder, granules, grit, flakes, strips, or any other particulate or substantially particulate form of material. More specifically, these can be pearls, pigments (pure or pigments coated in the form of pigment pastes), anti-slip particles. The particles can also include linoleum, linoleum paste (also known as "linoleum cement"), thermosetting materials, inorganic particles (such as glass or corundum), natural mineral particles (such as mica, feldspar, basalt), glass particles or hollow polymers, etc.

[0074] The particles can optionally be slightly compressed to penetrate into the thickness of the base layer, but not completely penetrate, so as to keep at least a part flush with the predetermined relief pattern. They can also be heated before and / or after deposition to slightly change their surface appearance or help them adhere to the fluid adhesive material.

[0075] In the case of PVC, this can be used in different forms for the production of particles in granular form. For example, the granules are obtained from PVC, optionally mixed with fillers, optionally with plasticizers, and then gelled in a mixer. The conventional method for obtaining plasticized granules at least comprises the following steps:

[0076] - Heating a quantity of PVC powder to 60 °C to 90 °C and then adding a quantity of plasticizer;

[0077] - Heating the obtained mixture to about 100 °C - 110 °C so that the PVC is plasticized and optionally incorporating a quantity of filler, stabilizer, pigment or other additives and mixing;

[0078] - Cooling the plasticized PVC mixture to incorporate a quantity of filler, stabilizer, pigment or other additives and mixing. The resulting mixture is in the form of a powder and is called a "dry blend";

[0079] - Gelatinizing this "dry blend" by heating to 170 °C in a continuous extruder or batchwise in an "internal" mixer;

[0080] - Extruding the mixture through a die and then cutting the molten material beads to obtain granules with a cross-section of 0.5 to 5 mm and a length of 0.5 to 10 mm.

[0081] According to an alternative, the material particles distributed according to the invention are in powder form, even a "dry blend", i.e. in the form of a polymer material powder, such as plasticized and ungelled PVC. In this case, the method according to the invention comprises the following steps: depositing the particles in the form of a "dry blend" on a liquid adhesive material which itself is deposited according to a predetermined relief pattern, and then gelatinizing the "dry blend" by heating, for example. Using a dry blend can obtain better relief resolution in terms of the particle size achievable for this type of powder. Preferably, in order to facilitate its handling by the deposition device, the particle size of the deposited powder is 2 μm to 250 μm. For example, the dry blend commonly used for the preparation of PVC granules has a density of about 0.50, a volume average diameter of 136 μm, D50: 140 μm, D10 of 63 μm and D90 of 198 μm. By enabling the direct manufacture of relief patterns, using a dry blend also makes it possible to dispense with the granulation step usually used for the manufacture of PVC floor coverings. This granulation operation is costly in terms of time, equipment and energy. The distribution of the dry blend is also easier compared to granules which usually have a wider particle size distribution. Thus, it is easier to obtain a uniform thickness of deposition.

[0082] In the case of linoleum, the method according to the invention can be used in order to obtain a pattern from the distribution of the linoleum paste. A linoleum paste in powder form is obtained from a linoleum cement mixture mixed with cork powder, wood powder and a dye (such as a pigment). Thus, the method comprises the additional step of heating the particles comprising the linoleum paste in order to crosslink the paste and obtain a relief pattern. The particles may optionally be slightly pressed to penetrate into the thickness of the substrate, but not completely, so as to remain at least partly flush with the predetermined relief pattern.

[0083] The thickness of the substrate according to the invention is generally from 0.3 to 6 mm.

[0084] The substrate is made of a polymeric material and may be in the form of a single-layer or multi-layer structure. The lower surface of the substrate may optionally subsequently be bonded to other layers so as to form a heterogeneous floor covering and provide the covering with, for example, other damping, resistance or acoustic properties. In particular, the substrate may be obtained from PVC and may be manufactured, for example, by calendering, coating then gelling, by pressing or also by flat die extrusion, the layer being in the form of a sheet having two smooth upper and lower surfaces.

[0085] The substrate may be formed into a roll of floor or wall covering, or even cut into floor coverings in the form of slabs, thick plates or slats. The dimensions of the roll may be from 5 to 50 m in length and from 1 to 4 m in width.

[0086] In particular, assembly means may be machined on the edge of each slab or slat in order to join them together. Such means are described in particular in documents WO2016030627, US20130309441 or EP3105392. The dimensions of the slab, thick plate or slat may be from 0.10 to 3.5 m in length and from 0.10 to 2.6 m in width.

[0087] According to Figure 1A , a first example of a floor or wall covering (1) is described, comprising a substrate (2) advancing on a support (S). The substrate (2) has an upper surface (2a) and an opposite lower surface (2b) in contact with the floor. On the upper surface (2a), a first fluid adhesive material (4a) is deposited by numerical control according to a part of a predetermined relief pattern. Then particles of a first type of material (3a) are deposited on the fluid adhesive material (4a). Then the fluid adhesive material (4a) crosslinks so that the formed covering only retains the dry part of the adhesive material (4a). Figure 1B Shows Figure 1ADetails A, showing the overlap between two particle types (3a, 3b). To achieve this overlap, after the step of depositing the particles (3a), a fluid adhesive material (4b) is deposited according to a second part of a predetermined relief pattern. This step occurs before or after the step of crosslinking the fluid adhesive material (4a). After depositing the second particle type (3b), the adhesive materials (4a, 4b) are fully crosslinked. The material particles (3a, 3b) are thus connected to the substrate (2), thereby forming a predetermined relief pattern. The fluid adhesive materials (4a, 4b) can be applied in one or more deposition steps, each deposition also being able to be carried out according to a new predetermined relief pattern and / or with a new type of fluid adhesive material (4a, 4b). On the other hand, the particles (3a, 3b) can be deposited in one or more deposition steps, each deposition optionally being carried out according to a new predetermined relief pattern related to the relief pattern of the deposition of at least one fluid adhesive material and / or with a new particle type (3a, 3b).

[0088] According to Figure 2 , a second example of a floor or wall covering (1) is described, which has a substrate (2) showing Figure 1A elements, and further includes at least one decorative layer (5), which is printed with a predetermined decorative pattern by any known method, in particular by an inkjet printing process, and can be seen from the upper surface of the substrate (2a). The substrate (2) optionally includes a translucent or transparent layer (6) adhered to the decorative layer (5). The decorative layer (5) is thus optionally covered with a translucent or transparent layer (6) to protect it. Thus, in this example, the upper surface (2a) of the layer (2) is either formed by the upper surface of the decorative layer (5) or by the upper surface of the translucent or transparent layer (6). Thus, the fluid adhesive materials (4a, 4b) are deposited either on the printed pattern or on the translucent or transparent layer (6). Thus, the substrate (2) includes a decorative layer (5) that is adhered to a backing layer (11) intended to be in contact with the floor. The decorative layer (5) is, for example, a PVC film with a thickness of 50 to 150 μm.

[0089] According to Figure 3 , a third example of a floor or wall covering (1) is described, which includes a substrate (2) showing Figure 1A elements, and has a predetermined decorative pattern (7) printed on the upper surface of the substrate (2a).

[0090] According to Figure 4 , a fourth example of a floor or wall covering (1) is described, which has a substrate (2) showing 1A pattern elements, and has a predetermined decorative pattern (7) printed on the superimposed particles (3a, 3b).

[0091] Figure 3 and4 The pattern (7) can be printed by any known method, in particular by an inkjet printing process. The type of ink used can in particular be water-based or latex-based ink, and can be dried or crosslinked by any known method, in particular by a hot air stream or by exposure to ultraviolet radiation.

[0092] According to Figure 2 、 3 and 4, in the case where the base layer (2) includes at least one decorative layer (5) and the decorative layer (5) has a predetermined decorative pattern or a predetermined decorative pattern (7) printed on the upper surface of the base layer, the fluid adhesive material (4a, 4b) can be deposited according to the position of the predetermined decorative pattern.

[0093] According to Figure 5 , a fifth example of a floor or wall covering (1) is described, which has a base layer (2) showing a 1A pattern element and a crosslinked protective layer (8) pre-deposited on the material particles (3a, 3b) such that the material particles (3a, 3b) are partially embedded in the thickness of the protective layer (8). At least some of the particles are flush with the surface of the protective layer (8). Alternatively, in a manner not shown, the deposited particles can be covered by the protective layer, thus molding the shape of a relief pattern. This makes it possible to maintain a very weakly structured surface relief while improving cleanability and protecting the deposited particles (3a, 3b). In the case where a decorative pattern (7) is printed on the base layer (2) and / or the material particles (3a, 3b), the protective layer (8) can be deposited on the decorative pattern (7) to protect it. Alternatively, in a manner not shown, the protective layer (8) can be deposited on the material particles (3a, 3b) and then the decorative pattern (7) can be printed by any known method.

[0094] According to Figure 6 and 7 , a sixth example of a floor or wall covering (1) is described. In these examples, the base layer (2) can include polymer material particles (9a, 9b) which are distributed by a numerically controlled deposition device to form a decorative pattern along three axes (X, Y, Z) of a three-dimensional system and are distributed in all or part of the thickness of the base layer (2). Thus, before the step of depositing the fluid adhesive material (4a), the base layer is at least partially, or even completely, obtained from particles distributed by a numerically controlled deposition device. According to Figure 7 , polymer material particles (9b) enabling a predetermined decoration to be obtained can be deposited in a polymer matrix (10), such as a plastisol or powder layer. In the case of using a polymer matrix (10), the polymer particles (9b) can optionally be replaced by non-polymer particles. According to this example, a method of manufacturing a floor or wall covering having a base layer (2) made of a polymer material, the base layer including material particles distributed to form a predetermined pattern, the method at least includes the following steps:

[0095] - Controlling a numerically controlled deposition device to deposit material particles (9a, 9b) on a continuously or stepwise advancing support (S) to form a predetermined decorative pattern, or controlling the numerically controlled deposition device to deposit material particles (9a) on a polymer matrix (10) supported by a support (S) and continuously or stepwise advancing to form a predetermined decorative pattern;

[0096] - Heating the material particles (9a, 9b) and, if necessary, heating the polymer matrix (10) so that they adhere and form a base layer (2);

[0097] - Optionally, pressing the material particles (9a, 9b) and, if necessary, pressing the polymer matrix (10).

[0098] For obtaining the polymer material particles (9a, 9b) of the layer (2) according to Figure 6 and 7 The polymer material particles (9a, 9b) can exist in the form of powder, such as colored or uncolored PVC "dry blend", or even gelled PVC granules, either alone or in a mixture. Depending on the type of material, a hot pressing step may be required for the deposited particles to obtain a base layer (2) of uniform thickness.

[0099] Generally, the step of controlling the numerically controlled deposition device to deposit material particles on a support to form a pattern can be performed by a device for numerically controlled distribution of material particles (such as granules and / or powders). For example, the device can include at least one particle hopper having at least one outlet. The outlet can be closed or opened numerically so that the particles stored in the hopper flow onto the support in a controlled manner and according to a predetermined pattern.

[0100] According to the present invention, a variety of processes and devices enable the deposition of particles according to a predetermined relief pattern.

[0101] Figure 8 and Figure 9 An example of a device (110) capable of implementing the method according to the present invention is shown. In this case, the base layer (100) is shown in the form of a flat plate, although the same device (110) can be used for rolled products. The base layer (100) is supported by a support (111) and is advanced continuously or stepwise. The device also includes a device for advancing the support (111) to effect relative movement in at least one advancing direction (B) between the distribution device (170) and the base layer (100) on which the particles must be distributed. In this case, the support (111) is a continuous conveyor belt (111) that conveys the base layer (100) and is driven by an electrically controlled motor.

[0102] The device (110) includes at least one device (160) for depositing a fluid adhesive material on the upper surface of a substrate (100) according to a predetermined relief pattern.

[0103] The device (110) further includes at least one deposition device (170) for numerically controlled distribution of particles, wherein each deposition device (170) includes a hopper (103) for storing bulk material, the hopper being provided with a plurality of outlets (133), a plurality of distribution elements (104), each distribution element being positioned facing an outlet (133) such that the material leaving each outlet (133) can accumulate there without flowing. Each distribution element (104) is inclined with respect to the horizontal plane so as to define a direction in which the particles slide towards at least one descending edge (141) of the distribution element (104). The device (170) further includes a plurality of vibration devices (105, 150), each vibration device being associated with a respective distribution element (104) for vibrating the distribution element (104) such that when the distribution element (104) vibrates on the substrate (100), the accumulated particles slide upwards on the distribution element (104) until the particles fall from the descending edge (141) of the distribution element.

[0104] The distribution element (104) is inclined with respect to the horizontal plane at an inclination angle of 0° to 10°.

[0105] The device (110) further includes at least one device (180) for crosslinking the fluid adhesive material, such as a hot air dryer or an infrared lamp.

[0106] The numerically controlled device (190) controls the deposition device (160), the distribution device (170) for numerically controlled distribution of particles (in particular for independently activating each of the vibration devices (105, 150)) and the device (180) for crosslinking the fluid adhesive material according to a known predefined pattern of the control device (190). In particular, the numerically controlled device (190) can be a control / command computer, a microcontroller, which includes means for digitally storing a file defining the predetermined relief pattern.

[0107] The device (160) for depositing the fluid adhesive material, the device (170) for depositing particles and the device (180) for crosslinking are stably fixed to a fixed support (113, 102) relative to a support (111). As Figure 9As shown, a plurality of devices (170) may be arranged transversely to the support (111). In this way, each dispensing device (170) can act in sequence on the substrate (100) in order to increase the range of relief and / or decorative effects that can be achieved. In particular, the hopper (103) of the dispensing device (170) may be filled with particles having different colors, densities, hardnesses, and glosses, with the aim of obtaining a predefined pattern and / or texture and having multiple colors and / or materials. Thus, each dispensing device (170) is intended to deposit a specific material (e.g., color) on the substrate (100) according to a predefined pattern.

[0108] Figure 10 A second example of a device (210) capable of implementing the method according to the present invention is shown. In this case, the substrate (203) is shown in the form of a roll, although the same device (210) can be used for flat products. The substrate (203) is supported by a support (208) and is advanced continuously or step by step. The device also includes a support advancing device for achieving a relative movement in at least one advancing direction (A) between the dispensing device (205) and the substrate (203) on which the particles must be dispensed. In this case, the support (208) is a continuous conveyor belt for transporting the substrate (203) and is driven by an electrically controlled motor.

[0109] The device (210) enables the manufacture of a predefined relief pattern from a material in the form of particles by numerical control. It includes means (260) for depositing a fluid adhesive material by numerical control using a nozzle digital print head (202) provided with piezoelectric control. The digital print head (202) may also be provided with a plurality of corresponding independent heads, each head being equipped with a nozzle for ejecting the fluid adhesive material onto the upper surface of a substrate (203). The means (260) are thus capable of ejecting micro - droplets of the fluid adhesive material onto the surface of the substrate (203). Optionally, the means (260) include a radiation device (204) adapted to irradiate droplets of the fluid adhesive material deposited in a case where it can be hardened by exposure to radiation. For example, the fluid adhesive material, such as a varnish, can be defined such that irradiation of the fluid adhesive material for a preset time and amount of energy enables its pre - crosslinking. By rapidly turning into a substantially transparent film similar to glue, it is thus possible to subsequently deposit material particles on the adhesive material and obtain a first - stage adhesion before its complete crosslinking. Thus, the device (210) includes means (205) for depositing material particles (206) on the layer of adhesive material after the layer of adhesive material has been irradiated under the radiation device (204) and thus presents a consistency similar to glue. The means (205) for depositing material particles include, for example, a hopper (209) leading to a closable outlet (214) which, in the open position, allows the particles stored in the hopper (209) to flow regularly. The means (205) extend transversely along the Y - axis over all or part of the width of the substrate (208). The device (210) optionally includes means (207) for removing excess material particles (206) that are deposited on the substrate (203) without adhering to the fluid adhesive material. These means (207) make it possible to remove the material particles (206) that are not directly adhered to the adhesive material and are thus superfluous as they cannot be incorporated into the relief pattern being manufactured. The means (207) for removing excess material particles (206) include, for example, at least one suction hood (211) arranged such that the suction nozzle (212) is close to the upper surface of the substrate (203) supported by a continuous belt conveyor (208). The suction hood (211) may also include a discharge opening (213) through which the excess material particles (206) can be returned to the interior of the hopper (209) through a suitable conduit (not shown in the figure) or conveyed to a special collection area.

[0110] The substrate (203) is disposed on a continuous belt conveyor (208) and advances continuously or step - by - step in the direction A.

[0111] The device (210) also includes at least one means (280) for the complete cross - linking of the fluid adhesive material, such as a hot - air dryer or an infrared lamp.

[0112] The numerical control device (290) controls the device (260) for depositing a fluid adhesive material according to a predetermined pattern known to the control device (290), and controls the distribution device (205) for the controlled distribution of particles according to or not according to the pattern. Similarly, the suction system (207) and the device (280) for crosslinking the fluid adhesive material can optionally be controlled by the numerical control device (290). In particular, the numerical control device (290) can be a control / command computer, a microcontroller, which includes means for digitally storing a file defining a predetermined relief pattern.

Claims

1. A method for manufacturing a floor or wall covering, said floor or wall covering comprising at least one base layer (2) made of a polymeric material, said base layer (2) comprising an upper surface (2a) and a lower surface (2b), said upper surface comprising a predetermined relief pattern, characterized in that, said method comprises at least the following steps: a) advancing the base layer (2); b) controlling a numerically controlled deposition device to deposit a fluid adhesive material (4a, 4b) on the upper surface (2a) of the base layer (2) according to a predetermined relief pattern; c) depositing material particles (3a, 3b) on the fluid adhesive material (4a, 4b); d) crosslinking the deposited fluid adhesive material (4a, 4b) to attach the material particles (3a, 3b) to the base layer (2) and form a predetermined relief pattern.

2. The method for continuously manufacturing a floor or wall covering according to claim 1, characterized in that, the base layer (2) is advanced continuously.

3. The method for manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that, step b) comprises the following steps: - controlling a numerically controlled deposition device to deposit a first fluid adhesive material (4a) on the upper surface (2a) of the base layer (2) according to a first part of a predetermined relief pattern; - controlling a numerically controlled deposition device to deposit at least one second fluid adhesive material (4b) on the upper surface (2a) of the base layer (2) according to a second part of a predetermined relief pattern.

4. The method for manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that, step c) comprises the following steps: - controlling a numerically controlled deposition device to deposit material particles (3a, 3b) on the fluid adhesive material (4a, 4b) according to a predetermined relief pattern.

5. The method for manufacturing a floor or wall covering according to claims 3 and 4, characterized in that, step c) comprises the following steps: - controlling a numerically controlled deposition device to deposit a first type of material particles (3a) on the fluid adhesive material (4a, 4b) according to a first part of a predetermined relief pattern; - controlling a numerically controlled deposition device to deposit a second type of material particles (3b) on the fluid adhesive material (4a, 4b) according to a second part of a predetermined relief pattern.

6. The method for manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that, the method comprises an additional step after step c) or d): - applying a protective layer (8) on the material particles (3a, 3b) such that the material particles (3a, 3b) are partially embedded in the thickness of the protective layer (8); - crosslinking the protective layer (8).

7. The method for manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that, the method comprises at least one additional step: - printing a predetermined decorative pattern (7) on the upper surface (2a) of the base layer (2) and / or on the material particles (3a, 3b) using an inkjet printing process.

8. The method for manufacturing a floor covering according to any one of the preceding claims, characterized in that, The base layer (2) includes at least one decorative layer (5), the decorative layer having a predetermined decorative pattern or a predetermined decorative pattern (7) directly printed on the upper surface of the base layer (2a), and the method includes the following steps: - Depositing a fluid adhesive material (4a, 4b) according to the position of the predetermined decorative pattern (7).

9. A method of manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that the method includes at least one additional step after step c): partially crosslinking the deposited fluid adhesive material (4a, 4b).

10. A floor or wall covering including at least one base layer (2), characterized in that the base layer (2) includes a predetermined relief pattern obtained by the manufacturing method according to any one of the preceding claims.

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