Method of manufacturing a floor or wall covering and related covering

Abstract

The invention relates to a method for the continuous production of a floor or wall covering having at least one base layer made of a polymeric material, said base layer comprising particles of a material distributed to form a pattern, said method comprising at least the following steps:-controlling a numerically controlled deposition device, the method includes depositing material particles on a continuously advanced support to form a pattern, heating the material particles to bond and form a base layer, and separating the base layer from the support.

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. More specifically, the present invention relates to methods for manufacturing polyvinyl chloride or similar coverings, and more specifically to coverings having at least one decorative layer, the decoration of which is distributed in the thickness of the layer. Background Art

[0002] In the field of floor coverings, thick plates, slats or rolls having at least one layer of plastic material (for example 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 can consist of a single decorative layer to form a homogeneous covering, or of multiple layers bonded together to form a heterogeneous covering, the decorative layer being provided on the upper part of the floor covering.

[0003] This type of decorative layer has the advantage of "solid" decoration, i.e. throughout the entire thickness of the decorative layer. In fact, the decoration presented by the layer does not degrade with wear and during successive cleaning operations, which gives the covering a long lifespan. However, these decorations are obtained by randomly spraying a certain thickness of granules over the entire surface of the pressed support, and it is not possible to reproduce the desired pattern, hence the term "approximate" decoration.

[0004] A known alternative is to replace the decorative layer with a printed decorative film covered with a transparent wear-resistant layer. However, once the wear-resistant layer is worn, the decorative layer is immediately damaged. 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 having a base layer comprising a pattern in the thickness of the layer, the pattern being predefined.

[0006] Another aim of the present invention is to propose a method for manufacturing a floor or wall covering having an upper layer comprising a relief pattern, the relief pattern being predefined.

[0007] A third aim of the present invention is to propose a method for manufacturing a floor or wall covering having a base layer and an upper layer, the base layer comprising a pattern in the thickness of the layer, the pattern being predefined, and the upper layer comprising a second relief pattern, the second relief pattern being predefined.

[0008] To this end, a method for continuously manufacturing a floor or wall covering having at least one base layer made of a polymeric material, said base layer comprising material particles distributed to form a pattern, the method comprising at least the following steps:

[0009] - Controlling a numerically controlled deposition device to deposit the material particles on a continuously advancing support to form a pattern,

[0010] - Heating the material particles to cause them to adhere and form the base layer,

[0011] - Separating the base layer from the support.

[0012] Thus, the method makes it possible to obtain a decoration in the thickness of the base layer, which is obtained by the combination of the patterns obtained by the distribution of the material particles and possibly other materials of the base layer. The base layer obtained forms a layer capable of manufacturing a homogeneous single-layer floor or wall covering, or this layer can optionally subsequently be joined to other layers to form a heterogeneous floor covering.

[0013] According to a first alternative, the support is thus only used to obtain the floor or wall covering and is then separated from the covering. The support can for example comprise a continuous conveyor belt or a transfer paper, such as a paper coated with a silicone resin layer on the surface intended to receive the distributed material particles, or can also be a textile. In this case, the floor or wall covering obtained by the method is a homogeneous covering having only a single layer, and the method according to the invention makes it possible to manufacture a decoration comprising a predetermined pattern in all or part of the thickness of the base layer and thus to manufacture the covering.

[0014] Or, a method for continuously manufacturing a floor or wall covering, said floor or wall covering having at least one base layer made of a polymeric material, said base layer comprising material particles distributed to form a pattern, the method comprising at least the following steps:

[0015] - Controlling a numerically controlled deposition device to deposit the material particles on a continuously advancing support to form a pattern,

[0016] - Heating the material particles on the support to cause said material particles to adhere and form the base layer, the support being fixed to the base layer.

[0017] Thus, the method makes it possible to obtain a heterogeneous covering comprising a decoration in the thickness of the base layer, which is obtained by the combination of the patterns obtained by the distribution of the material particles and possibly other materials of the base layer. The method may require means for advancing the support, such as a unwinder, rollers or a conveyor belt, in order to advance the support during the deposition, heating and possibly pressing steps.

[0018] In this second case, the support is thus intended to be fixed to the substrate and thus to the floor or wall covering. It may thus comprise a frame, such as a glass mesh, a polyester non-woven fabric or a layer obtained from a thermoplastic, such as a layer obtained from PVC. This makes it possible to obtain a reinforced and / or heterogeneous floor or wall covering, provided it comprises a plurality of layers. The layer obtained from PVC can be manufactured, for example, by calendering, coating then gelling, by pressing or also by flat die extrusion, and this layer is present in the form of a sheet having two smooth surfaces.

[0019] Regardless of the embodiment, the deposition device may comprise at least one particle storage device, which comprises at least one outlet, such as a hopper, and at least one closing device controllable numerically for each outlet so as to prevent or allow the flow of particles in a controlled manner, the particle storage device and the closing device together forming a distribution device. Each deposition device may, for example, store one type of particle, such as a color, so as to mix several types of particles in a pattern using a plurality of deposition devices.

[0020] Regardless of the embodiment, the deposition device may comprise a distribution device, the pattern being predefined in a digital file or any equivalent computer storage device, the distribution device comprising means or a computer storage device for reading and interpreting said file so as to numerically control the deposition device according to the pattern and deposit particles according to the pattern. The distribution device may in particular comprise a control computer associated with a microcontroller controlling the particle distribution device. The computer makes it possible to interpret the predefined pattern and establish a sequence of operations of the microcontroller. The microcontroller makes it possible, for example, to control the particle distribution device according to the movement, position and quantity parameters of the particles to be deposited established by the computer according to a predefined pattern. Thus, regardless of the embodiment, the pattern may be predefined in a digital file, and the invention makes it possible to obtain a decorative layer, the pattern of which is slightly repetitive, which is different from a completely mechanical method. The invention makes it possible to avoid using, for example, a gravure printing process, the cylinders of which generally have a development of less than three meters. The pattern can also be continuously updated by a computer pattern generation device so as not to be repeated identically, but to bring about, for example, slight variations in color or geometry, the pattern remaining predefined during the steps of controlling the deposition device.

[0021] Regardless of the embodiment, the method according to the invention may comprise a plurality of successive steps of controlling a numerically controlled deposition device to deposit material particles on a continuously advancing support to form a pattern, so as to obtain a defined pattern extending into the thickness of the substrate.

[0022] Regardless of the embodiment, continuous advancement means that the support moves continuously relative to the deposition device or advances step by step relative to the deposition device.

[0023] Regardless of the implementation, the polymeric material for manufacturing the base layer can be deposited in whole or in part in a step that includes controlling a numerically controlled deposition device to deposit material particles on a continuously advancing support to form a pattern. In this case, the particles include particles made of the polymeric material.

[0024] Regardless of the implementation, the polymeric material for manufacturing the base layer can be deposited in whole or in part before or after a step that includes controlling a numerically controlled deposition device to deposit material particles on a continuously advancing support to form a pattern. In this case, the deposited particles can include particles made of polymeric and / or non-polymeric materials.

[0025] Multiple supports intended to be fixed to the base layer can be considered. In particular, the support can include a reinforcing framework, such as a reinforcing grid or a non-woven fabric layer, such as a glass or polyester mesh. Materials in the form of fibers that can be used to obtain the reinforcing framework are specifically polyethylene, polyethylene terephthalate (PET), glass fibers, polyester fibers, aramid, carbon fibers, acrylic fibers, ethylene vinyl acetate (EVA), high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl chloride (PVC).

[0026] The support can also include a backing layer made of a polymeric material. The backing layer in the form of a sheet can be obtained, for example, from colored granules, such as made of PVC, and then pressed, or can also be obtained by coating and gelling with a colored PVC plastisol, by flat die extrusion or by calendering.

[0027] Polymeric materials that can be used in the compositions for the base layer, particles, and / or backing layer are, for example, PVC, PVB, PLA, TPU, PPMA, cellulose derivatives, elastomers, individually or in mixtures.

[0028] According to an alternative, the method for continuously manufacturing a floor or wall covering according to the invention includes at least one step before the step of depositing material particles by a numerically controlled deposition device, the step including:

[0029] - depositing a layer of liquid plastisol on a continuously advancing support,

[0030] - optionally, pre-gelling the plastisol layer.

[0031] In this way, the particles can be integrated into the coating obtained by coating according to a predetermined pattern. Depending on the density of the particles and the pre-gelling level of the plastisol, the particles can be distributed in the thickness of the substrate layer. In this case, the plastisol layer is non-gelled or partially gelled. In fact, contrary to calendering, pressing or extrusion processes, the plastisol coating process cannot directly incorporate the grindings of recycled coatings from scrap or other recycled materials into the plastisol. Therefore, the present invention enables the manufacture of layers and coatings including a predetermined pattern obtained by a coating process, and advantageously reduces the environmental footprint.

[0032] Alternatively, the method for continuously manufacturing floor or wall coverings according to the present invention includes at least one of the following steps before the step of depositing particles:

[0033] - Controlling a numerically controlled deposition device to deposit a layer of fluid adhesive material on a continuously advancing support, and then depositing material particles on the layer of fluid adhesive material to form a pattern.

[0034] The fluid adhesive material can in particular be a varnish (especially an acrylic or polyurethane-based varnish), a liquid adhesive, a plastisol.

[0035] The fluid adhesive material is advantageously deposited in the form of droplets with a volume of 1 picoliter to 1 milliliter. Optionally, the fluid adhesive material can be replaced by an adhesive material in powder form. For example, the adhesive material can include a hot melt powder, a varnish in powder form.

[0036] Regardless of the implementation, in order to obtain a uniform substrate and coating thickness, the manufacturing method according to the present invention can include at least one additional step of pressing the material particles onto the support. This step can be carried out before the heating step or simultaneously with the step of heating the deposited particles.

[0037] Regardless of the implementation, preferably, the manufacturing method according to the present invention includes a deposition device movable relative to the continuously advancing support. This enables, for example, in the case where the support advances in the plane (X, Y) along the axis (Y), to deposit particles transversely to the support, that is, according to the position on the axis (X) and / or on the support axis (Y), without having to increase the number of deposition devices. Additionally, the deposition device can move relative to the support along an axis (Z) perpendicular to the support advancing plane (X, Y), thereby creating a three-dimensional pattern in the thickness of the substrate layer.

[0038] Preferably, the manufacturing method according to the present invention includes at least one of the following additional steps before the heating step:

[0039] - Depositing a layer of material particles on a continuously advancing support.

[0040] This step consists in depositing a variable or constant "bed" of particles on a continuously advancing support. These particles are randomly distributed and form a non-predetermined pattern. For example, the material particles can be deposited in the form of granules, powders or "dry mixes" according to a random pattern upstream of this step, which upstream step consists in controlling a numerically controlled deposition device to deposit the material particles on a continuously advancing support to form a pattern. Therefore, the method can include an additional step of controlling a numerically controlled deposition device to deposit the material particles on a randomly deposited bed of particles to form a pattern. This alternative makes it possible, for example, to obtain a marbled decoration having a base layer according to a random pattern and a texture obtained by particles deposited according to a predetermined pattern. This alternative also makes it possible to integrate particles deposited according to a random pattern in a layer, and therefore in a covering, these materials coming from recycling. Therefore, the method according to the invention makes it possible to obtain a new type of covering, mixing materials coming from recycling in a base layer made of polymer material.

[0041] The invention also relates to a floor or wall covering having at least one base layer obtained by the manufacturing method according to the invention. The covering thus comprises a predetermined pattern and is "solid", ie extends into all or part of the thickness of the base layer. For example, the decoration is considered "solid" when it extends to a base layer with a thickness greater than 0.1 mm, even greater than 0.3 mm and up to 6 mm in height, so as to resist wear and tear caused by transport.

[0042] Advantageously, the particles of material deposited to form the pattern are particles made of a polymer material, such as PVC, polypropylene, polyethylene, PMMA, linoleum, thermosetting materials, alone or in a mixture, or can be particles made of a non-polymer material, such as corundum or glass.

[0043] Advantageously, the particles are particles 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 may also include a mixture of particles and powders. Therefore, the method according to the present invention may include a step of controlling a numerically controlled deposition device to deposit particles and / or powders on a continuously advancing support to form a pattern.

[0044] The particles of material deposited to form the pattern may also include at least one mineral filler, natural filler or synthetic filler.

[0045] The particles of material deposited to form the pattern may also include at least one plasticizer.

[0046] The material particles deposited to form the pattern may come from a recycling channel.

[0047] The material particles deposited to form the 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 a well-known extrusion process through a hole die with underwater blade cutting.

[0048] The material particles deposited to form the pattern can be in the form of a PVC dry blend or in the form of granules obtained from a coagulated polymer material such as PVC.

[0049] The material particles deposited to form the pattern can be in the form of colored granules, each granule containing one or more colors. Description of the Drawings

[0050] Figure 1 is a side view of a first example of a base layer obtained by the method according to the present invention.

[0051] Figure 2 is a side view of a second example of a base layer obtained by the method according to the present invention.

[0052] Figure 3 is a side view of a third example of a base layer obtained by the method according to the present invention.

[0053] Figure 4 is a side view of a fourth example of a base layer obtained by the method according to the present invention.

[0054] Figure 5 is a perspective view of a distribution device for controlling the distribution by numerical control of the particles.

[0055] Figure 6 is for Figure 1 is a top view of a distribution device for the controlled distribution of the particles shown in

[0056] Figure 7 is a side view of a second distribution device for controlling the distribution of the particles by numerical control.

[0057] Figure 8 is a side view of a fifth example of a base layer obtained by the method according to the present invention.

[0058] Figure 9 is a side view of a sixth example of a base layer obtained by the method according to the present invention.

[0059] Figure 10 is a side view of a seventh example of a base layer obtained by the method according to the present invention.

[0060] Figure 11 It is a side view of an alternative of a support with a printed decorative layer.

[0061] Figure 12 It is a side view of an alternative of a base layer with a printed decorative layer. Detailed implementation mode

[0062] Regardless of the implementation scheme, the material particles that can be distributed are presented in bulk, such as in the form of powder and / or granules. The granules that can be used to manufacture the base layer according to the present invention can be of the same or different properties. As an example, the polymer materials that can be used can be selected from PVC, PP, PE, PMMA, and product scraps or abrasives from the recycling channels of these materials. Alternatively, the particles can include linoleum.

[0063] In the case of PVC, this can be used in different forms to manufacture granules. For example, the granules are obtained from PVC, optionally mixed with fillers and optionally with plasticizers, and then gelled in a mixer. The conventional method for obtaining plasticized granules at least includes the following steps:

[0064] - Heating a certain amount of PVC powder to 80°C to 90°C, and then adding a certain amount of plasticizer thereto;

[0065] - Heating the obtained mixture to about 110°C so that the PVC is plasticized,

[0066] - Cooling the plasticized PVC mixture to incorporate a certain amount of fillers, stabilizers, pigments or other additives therein, and mixing. The obtained mixture is presented in the form of a powder called "dry blend",

[0067] - Gelatinizing the "dry blend" by heating it to 170°C in a continuous extruder or batch heating in an "internal" mixer,

[0068] - 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.

[0069] According to an alternative, the material distributed according to the invention is in powder form, even in the form of a "dry blend", i.e. in the form of a polymer material powder, such as plasticized and ungelatinized PVC. In this case, the method according to the invention comprises distributing particles in the form of a "dry blend" on a support according to a predetermined pattern, and then gelling the "dry blend", for example using a hot press. In terms of the particles that can be obtained with this type of powder, better decorative resolution can be obtained using a dry blend. Preferably, in order to facilitate handling by the deposition device, the particle size of the deposited powder is from 2 μm to 250 μm. For example, a dry blend commonly used for preparing PVC granules has a density of about 0.50, a volume average diameter of 136 μm, a D50 of 140 μm, a D10 of 63 μm and a D90 of 198 μm. Using a dry blend can also obviate the granulation step commonly used in the manufacture of PVC floor coverings by making it possible to directly manufacture the pattern. This granulation operation is expensive in terms of time, equipment and energy. The distribution of the dry blend is also easier compared to particles which usually have a relatively wide particle size distribution. Thus, it is easier to obtain a deposition with a uniform thickness, for example for manufacturing a "bed", i.e. a regular layer.

[0070] In the case of linoleum, the method according to the invention can be employed in order to obtain a pattern from the distribution of a linoleum paste. The 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 steps of pressing and heating the layer comprising the linoleum paste in order to crosslink the paste and obtain a base layer.

[0071] Naturally, a plurality of materials to be deposited can be mixed to obtain a pattern according to the invention. As non-limiting examples, 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 coated in the form of a pigment paste), anti-slip particles.

[0072] After the deposition step with a numerically controlled deposition device, it is possible to consider preheating the deposited material in order to, for example, pre-gel them and / or hold them on the support by exposure to infrared radiation.

[0073] The presses that can be used for the method according to the invention are, for example, single-belt presses, double-belt presses, or presses comprising at least two rollers.

[0074] The heating step can be carried out, for example, using a furnace or by exposure to infrared radiation.

[0075] The continuous advancement device that can advance the support can, for example, comprise a conveyor belt, rollers, belts or the like.

[0076] The thickness of the base layer according to the invention is generally from 0.3 to 6 mm.

[0077] The substrate may optionally be varnished and / or a backing layer attached to its lower surface and / or an upper layer attached to its upper surface, such as a transparent wear-resistant layer.

[0078] The substrate may be formed in rolls to form floor or wall coverings and may even be cut to form floor coverings in the form of boards, slabs or slats. In particular, assembly means may be machined on the edges 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 boards, slabs or slats may be from 0.10 to 3.5 m in length and from 0.10 to 2.6 m in width.

[0079] According to Figure 1 , a first example of a floor or wall covering (1) having a substrate (2) obtained by a manufacturing method according to the invention is described. The substrate (2) is in the form of a film which has an upper surface intended to be in contact with the user and a lower surface intended to be in contact with the floor. The covering (1) consists only of the substrate (2), except in a particular embodiment in which the upper surface of the substrate is covered with varnish (not shown). The substrate (2) comprises polymer material particles (3a, 3b) which are distributed by a numerically controlled deposition device to form a pattern along three axes (X, Y, Z) of a three-dimensional system and thus are distributed throughout all or part of the thickness of the layer (2). Thus, the covering layer is entirely obtained from particles distributed by a numerically controlled deposition device. Some of the polymer particles (3b) may optionally be replaced by non-polymer particles. According to this first example, a method for continuously manufacturing a floor or wall covering, said floor or wall covering comprising a substrate (1) made of a polymer material, said substrate comprising material particles distributed to form a pattern, said method comprising at least the following steps:

[0080] - controlling a numerically controlled deposition device to deposit material particles (3a, 3b) on a continuously advancing support (not shown) to form a pattern,

[0081] - heating the material particles to cause them to adhere and form the substrate,

[0082] - separating the substrate from the support.

[0083] The polymer material particles (3a, 3b) may be in the form of a powder, such as a coloured or uncoloured 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 on the deposited particles to obtain a substrate of uniform thickness.

[0084] According to Figure 2, a second example of a floor or wall covering (1) having a base layer (2) obtained by the manufacturing method according to the present invention is described. The covering (1) consists only of the base layer (2), except for a specific embodiment in which the upper surface of the base layer is covered with varnish (not shown). The base layer (2) includes randomly deposited polymer material particles (4), and material particles (3b) distributed by a numerically controlled deposition device to form a pattern along the three axes (X, Y, Z) of a three-dimensional system, and thus are distributed in all or part of the thickness of the layer (2). Therefore, the covering is partially obtained from the particles (3b) distributed by the numerically controlled deposition device. A method for continuously manufacturing a floor or wall covering having at least one base layer made of a polymer material according to this second example, the base layer including material particles distributed to form a pattern, the method comprising at least the following steps:

[0085] - Randomly deposit polymer particles on a continuously advancing support to form a layer (4);

[0086] - Control the numerically controlled deposition device to deposit the material particles (3b) on the support or on the layer (4) of randomly deposited polymer particles to form a pattern;

[0087] - Heat the material particles on the support to cause them to adhere and form the base layer (2).

[0088] In this example, the material particles (3b) do not have to be polymers.

[0089] According to Figure 3 , a third example of a floor or wall covering (1) having a base layer (2) obtained by the manufacturing method according to the present invention is described. The covering (1) includes a base layer (2) and a support (5), and the upper surface of the base layer (2) can be covered with varnish (not shown) on its upper surface. The support (5) is fixed to the base layer (2) and can be, for example, a layer obtained from a polymer material or a reinforcing frame. Figure 3 The base layer (2) of Figure 1 shows the characteristics of the base layer shown, that is, it includes polymer material particles (3a, 3b) that are distributed by a numerically controlled deposition device to form a pattern along the three axes (X, Y, Z) of a three-dimensional system, and thus are distributed in all or part of the thickness of the layer (2). Therefore, the base layer (2) is completely obtained from the particles (3a, 3b) distributed by the numerically controlled deposition device. A method for continuously manufacturing a floor or wall covering having at least one base layer (2) made of a polymer material according to this third example, the base layer including material particles distributed to form a pattern, the method comprising at least the following steps:

[0090] - Control a numerically controlled deposition device to deposit material particles (3a, 3b) on a continuously advancing support (5) to form a pattern.

[0091] - Heat the material particles (3a, 3b) on the support (5) so that the material particles adhere and form a base layer (2), and the support is fixed to the base layer.

[0092] Advantageously, as Figure 11 shown, before the particle deposition step, the support (5) can be printed with a decorative layer (8) by any known means (in particular by an inkjet printing process), and the support is intended to remain fixed to the base layer (2). Figure 11 Shows the elements according to Figure 3 description, and the decorative layer (8) is placed between the base layer (2) and the support (5). According to this embodiment, the method according to the invention can include the step before the particle deposition step: providing the support (5) and printing the decorative layer (8) on the support (5) by any known means (in particular by an inkjet printing method). Advantageously, the pattern of the decorative layer (8) is known, so that the method according to the invention includes the following steps:

[0093] - Identify the position of the pattern of the decorative layer (8) on the support (5).

[0094] - Deposit the material particles (3a, 3b) according to a predetermined pattern based on the position of the pattern of the decorative layer (8) on the support (5), thereby marking the two patterns.

[0095] The identification step can be performed using any known device, such as a positioning card, a camera, or other optical identification devices capable of being connected to the numerically controlled deposition device.

[0096] Alternatively, the characteristics of the base layer (2) can exhibit Figure 2 shown characteristics of the base layer, that is, the base layer includes randomly deposited polymer material particles and material particles deposited by a numerically controlled deposition device. Thus, the covering is partially obtained from the particles (3b) distributed by the numerically controlled deposition device, and the support (5) remains fixed to the base layer (2) thus formed.

[0097] According to Figure 4, a fourth example of a floor or wall covering (1) having a base layer (2) obtained by the manufacturing method according to the present invention is described. The base layer (2) comprises a gelled plastisol layer (7), the plastisol layer comprising material particles (3b) distributed by a numerically controlled deposition device to form a pattern along three axes (X, Y, Z) of a three-dimensional system, and thus distributed in all or part of the thickness of the layer (2). Accordingly, the covering layer is partly obtained from particles distributed by the numerically controlled deposition device. A method for continuously manufacturing a floor or wall covering, said floor or wall covering having at least one base layer made of a polymeric material according to this fourth example, said base layer comprising material particles distributed to form a pattern, said method comprising at least the following steps:

[0098] - depositing a liquid plastisol layer on a continuously advancing support (not shown),

[0099] - optionally, pre-gelling the plastisol layer,

[0100] - controlling the numerically controlled deposition device to deposit the material particles (3b) on the plastisol layer,

[0101] - heating the material particles on the support to cause them to adhere and form the base layer.

[0102] In the above case, the step of forming the base layer includes the step of gelling the plastisol layer.

[0103] Naturally, the base layer (2) having the gelled plastisol layer (7) can also be deposited on a support (5) intended to be fixed to the base layer (2). Additionally, before the particle deposition step, the support (5) can have been printed with a decorative layer (8), similar to that according to Figure 11 the described example.

[0104] According to Figure 11 , a fifth example of a floor or wall covering (1) having a base layer (2) obtained by the manufacturing method according to the present invention is described. The base layer (2) comprises a gelled plastisol layer (7), the plastisol layer comprising material particles (3b) distributed by a numerically controlled deposition device to form a pattern along three axes (X, Y, Z) of a three-dimensional system, and thus distributed in all or part of the thickness of the layer (2) and forming a relief pattern on the surface of the base layer (2), the pattern being predetermined by the positions of the particles (3b). At least some of the particles (3b) protrude flush beyond the thickness of the plastisol layer (7) to form a relief. The particles (3b) can thus be anti-slip particles and / or form a decorative relief pattern.

[0105] According to Figure 9, a sixth example of a floor or wall covering (1) having a base layer (2) obtained by a manufacturing method according to the present invention is described. The base layer (2) comprises a first gelled plastisol layer (7), the plastisol layer comprising material particles (3b, 3b) distributed by a numerically controlled deposition device to form a pattern along three axes (X, Y, Z) of a three-dimensional system, so as to be distributed in all or part of the thickness of the layer (2). The base layer (2) comprises a second gelled plastisol layer (7'), the second gelled plastisol layer (7') being connected to the first gelled plastisol layer (7) and comprising material particles (3b, 3c) distributed by a numerically controlled deposition device to form a pattern along three axes (X, Y, Z) of a three-dimensional system, so as to be distributed in all or part of the thickness of the layer (2) and form a relief pattern on the surface of the base layer (2), the pattern being predetermined by the positions of the particles (3b, 3c). At least some of the particles (3b, 3c) project flush beyond the thickness of the plastisol layer (7') to form a relief. The particles (3b, 3c) can thus be anti-slip particles and / or form a decorative pattern. The second plastisol layer (7') can be transparent or translucent to expose the first plastisol layer (7).

[0106] According to Figure 10 , a seventh example of a floor or wall covering (1) having a base layer (2) obtained by a manufacturing method according to the present invention is described. The base layer (2) is in the form of a film having an upper surface intended to be in contact with the user and a lower surface intended to be in contact with the floor. The covering (1) consists only of the base layer (2), except in a particular embodiment in which the upper surface of the base layer is covered with a varnish (not shown). The base layer (2) comprises polymer material particles (3a, 3b) distributed by a numerically controlled deposition device to form a pattern along three axes (X, Y, Z) of a three-dimensional system, so as to be distributed in all or part of the thickness of the layer (2). The particles (3a, 3b) have different sizes and / or shapes such that at least some of the particles (3b) project flush beyond the total thickness of the layer (2) formed by the mixture of the particles (3a) and (3b) to form relief elements according to a predetermined pattern.

[0107] Optionally, as Figure 12 shown, regardless of the embodiment of the base layer (2), the method according to the present invention may further comprise: after the step of heating the material particles, after forming the base layer (2), a step of printing a surface decorative layer (9) by any known method, in particular by an inkjet printing method. This printing step can be carried out before or after an optional step of pressing the material particles onto the support. Advantageously, the pattern of the surface decorative layer (9) is known, such that the method according to the present invention comprises the following steps:

[0108] - identifying the position of the pattern of the base layer (2),

[0109] - Print the pattern of the surface decoration layer (9) according to the position of the pattern of the base layer (2), thereby marking the two patterns.

[0110] The recognition step can be performed using any known device, such as a positioning card, a camera, or other optical recognition devices capable of being connected to the numerically controlled deposition device.

[0111] The base layer (2) printed with the surface decoration layer (9) can also be combined with the support (5) pre-printed with the decoration layer (8), thereby obtaining a very complex visual appearance. The resulting covering includes, from top to bottom, an optionally varnished surface decoration layer (9) (not shown), the base layer (2) according to the present invention, an optionally printed decoration layer (8) on the support (5), or an unprinted support (5).

[0112] Regardless of the implementation, as Figure 10 shown, the deposited particles (3a, 3b) can appear as clusters of various shapes formed according to their deposition method in a cross-sectional view on the plane (X, Z). The particles deposited during the first deposition step will present a frustum-conical cross-sectional view (I), the width of which decreases towards the upper surface of the layer (2). The particles deposited along the first cluster during the second deposition step will form a parallelepiped cluster (II). The different particles (3a, 3b) deposited during the simultaneous deposition step can have the form of two clusters, at least one edge of which is substantially vertical (III). The particles deposited between two previously deposited frustum-conical clusters during the second deposition step will have the shape of a frustum-conical cluster that widens towards the surface of the layer (IV).

[0113] In the first case, the support can be temporary, such as a conveyor belt, and the method includes an additional step of separating the support from the base layer. In the second case, the support is intended to be integrated into the base layer, for example, consisting of a reinforcing frame.

[0114] Generally, the step of controlling the numerically controlled deposition device to deposit material particles on a continuously advancing support to form a pattern can be carried out by a device for the 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 to allow the particles stored in the hopper to flow onto the support.

[0115] A variety of processes and devices enable the deposition of particles according to a digitally defined pattern. The first method is described in patent EP2257773, which presents a device and method for the controlled distribution of solid bulk, granular, and / or powder materials used in the manufacture of ceramic products.

[0116] In particular, a device is described which comprises a hopper capable of containing a bulk material to be distributed, the hopper being provided with at least one outlet through which the material freely flows out of the hopper, for example only by gravity. The device further comprises a vibrating distribution element arranged below the outlet and facing the outlet vertically, and means for vibrating the vibrating distribution element such that the vibrating distribution element can be vibrated numerically controlled. In this way, only when the distribution element vibrates, the particles accumulated on the vibrating distribution element slide at least towards the descending edge of the distribution device, and the descending edge freely falls onto a support. The distribution element is inclined with respect to a hypothetical horizontal plane so as to define the sliding direction of the material towards at least one descending front.

[0117] The inclination is from 0° to 10° with respect to the horizontal plane such that the material leaving the outlet can accumulate on the distribution element without sliding thereon only due to gravity. The size of the outlet is determined according to the size of the particles to be deposited in order to obtain a good flow of these particles. The dose of a certain amount of material to be deposited is obtained over time and according to the vibration intensity of the distribution element. In this way, the numerically controlled system of the vibration means for vibrating the distribution element enables the selective distribution of the particles. Thus, by arranging a plurality of similar devices facing a support and controlling the selective deposition of each particle type on the support according to the positions defined in a pattern, a predetermined pattern can be obtained digitally. For example, the pattern can be predefined in a digital file, and the device comprises means for reading and interpreting said file in order to numerically control the deposition device according to the pattern.

[0118] Figure 5 and 6 An example of an embodiment of such a device is shown. This enables the manufacture of sheet products by the controlled deposition of particles on a support (100). It comprises at least one distribution device (101) for the numerical control of the distribution of particles, wherein each distribution device comprises a bulk material storage hopper (103) 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 the direction in which the particles slide towards at least one descending edge (141) of the distribution element (104). The device further comprises a plurality of vibration means (105, 150), each vibration means being associated with a corresponding distribution element (104) for vibrating said distribution element (104) such that when vibrated, the accumulated particles slide upwards on the distribution element (104) until the material falls from the descending edge (141) of the distribution element.

[0119] The distributing element is inclined at an angle of inclination of from 0° to 10° with respect to the horizontal plane. There is also provided a numerical control device (not shown) for activating each vibration device (105, 150) independently of one another. The device also includes a propulsion device (111) for relative movement between the distributing device (101) and the support (100) on which the particles must be distributed in at least one propulsion direction (B). These propulsion devices may include, for example, a continuous conveyor belt (111) that conveys the support (100) on the upper surface (112) of the conveyor belt and is driven by an electrically controlled motor.

[0120] The distributing device (101) is stably fixed to the fixed brackets (113, 102) relative to the continuous conveyor belt (111). Thus, a plurality of devices (101) may be arranged transversely to the continuous conveyor belt (111). In this way, the distributing device (101) can act on the support (100) in sequence in order to increase the range of patterns and / or decorative effects that can be achieved. In particular, the hopper (103) of the distributing device (101) may be filled with particles having different colors, densities, hardnesses, and glosses, with the aim of obtaining a predetermined pattern and / or texture and having multiple colors and / or materials. Thus, each distributing device (101) is intended to deposit a specific material (such as a color) on the support (100).

[0121] A second method is described in patent EP2892657, which is capable of controlling a numerically controlled deposition device to deposit material particles on a continuously advancing support to form a pattern. The patent describes a method and device (201) for manufacturing a predetermined decorative pattern on a product by numerically controlling a material in the form of particles. According to Figure 7 , the method includes the following steps: applying at least one layer of a fluid adhesive material on the surface of the support (203), depositing material particles (206) on the adhesive material layer, and removing the excess material particles (206). The fluid adhesive material is of the radiation exposure hardening type or has a viscous consistency when in contact with air or with a "primer" pre-coated on the surface of the support (203) to be decorated.

[0122] The step of applying at least one layer of the fluid adhesive material may include ejecting micro-droplets of the adhesive material onto the surface of the product (203) to be decorated using a digital print head (202) equipped with a piezoelectrically controlled nozzle. Still according to Figure 7, the device (201) includes a digital print head (202) for applying at least one layer of a fluid adhesive material capable of hardening upon exposure to radiation onto the surface of a support (203). The device (201) includes a radiation device (204) adapted to irradiate the adhesive material layer. The adhesive material layer is irradiated for a predetermined period of time to rapidly transform it into a substantially transparent glue-like film that is suitable for the subsequent deposition of material particles. Thus, the device (201) includes a device (205) for depositing material particles (206) onto the adhesive material layer after the adhesive material layer has been irradiated under the radiation device (204) and thus exhibits a glue-like consistency. The device (205) for depositing material particles includes, for example, a hopper (209) leading to a closable outlet (210) which, in the open state, allows the particles stored in the hopper (209) to flow regularly. The device (201) also includes a device (207) for removing excess material particles (206) deposited on the support (203). The said device (207) makes it possible to remove the material particles (206) that are not directly adhered to the adhesive material and which are superfluous as they cannot be incorporated into the relief pattern being manufactured. The device (207) for removing excess material particles (206) includes, for example, at least one suction hood (211) which is arranged such that its suction nozzle (212) is close to the upper surface of the product to be decorated (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.

[0123] The support to be decorated (203) is set on a continuous belt conveyor (208) and is continuously advanced in the direction A. The digital print head (202) is provided with one or more corresponding independent print heads, each print head being equipped with an adhesive material ejection nozzle on the upper surface of the product to be decorated (203).

Claims

1. A method for continuously manufacturing a floor or wall covering, the floor or wall covering having at least one base layer made of a polymeric material, the base layer comprising material particles distributed to form a pattern, characterized in that, The method comprises at least the following steps: - Controlling a numerically controlled deposition device to deposit material particles on a continuously advancing support to form a pattern, - Heating the material particles to cause them to adhere and form a base layer, - Separating the base layer from the support.

2. A method for continuously manufacturing a floor or wall covering, the floor or wall covering having at least one base layer made of a polymeric material, the base layer comprising material particles distributed to form a pattern, characterized in that, The method comprises at least the following steps: - Controlling a numerically controlled deposition device to deposit material particles on a continuously advancing support to form a pattern, - Heating the material particles on the support to cause the material particles to adhere and form a base layer, with the support fixed to the base layer.

3. The method for continuously manufacturing a floor or wall covering according to claim 1 or 2, characterized in that, The method comprises at least one of the following steps prior to the step of depositing the particles: - Depositing a liquid plastisol layer on a continuously advancing support, - Optionally, pre-gelling the plastisol layer.

4. The method for continuously manufacturing a floor or wall covering according to claim 2, characterized in that, The support is a reinforcing frame.

5. The method for continuously manufacturing a floor or wall covering according to claim 2, characterized in that, The support is a backing layer made of a polymeric material.

6. The method for continuously manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that, The method comprises at least one of the following additional steps: - Pressing the material particles onto the support.

7. The method for continuously manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that, The deposition device is movable relative to the continuously advancing support.

8. The method for continuously manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that, The method comprises at least one of the following additional steps prior to the heating step: - Depositing a layer of material particles on the support.

9. A floor or wall covering having at least one base layer, characterized in that, The base layer is obtained by the manufacturing method according to any one of the preceding claims.

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