Surface covering product and preparation method thereof

Abstract

The invention provides a surface covering product. The surface covering product comprises a decorative material surface layer (110), a buffer layer (105), a supporting layer (106) and a bottom layer (109). The decorative material surface layer (110) has an upper surface and a lower surface. The buffer layer (105) is made of a porous material and has an upper surface and a lower surface. The supporting layer (106) is made of foaming high polymer materials and provided with an upper surface and a lower surface. The bottom layer (109) has an upper surface and a lower surface. The lower surface of the decorative material surface layer (110) is attached to the upper surface of the buffer layer (105), the lower surface of the buffer layer (105) is attached to the upper surface of the supporting layer (106), and the lower surface of the supporting layer (106) is attached to the upper surface of the bottom layer (109).

Description

TECHNICAL FIELD

[0001] The present application relates to a surface covering product and a method for making the same. BACKGROUND

[0002] Polyvinyl chloride (PVC) flooring has gained great popularity in the market due to its superior properties such as water resistance, wear resistance, design versatility, and stain / chemical resistance. Among the PVC flooring categories, the rigid core PVC flooring category has become the fastest growing category. It retains all the superior properties of PVC flooring while demonstrating superior performance in dimensional stability, mechanical locking strength, low VOC emissions, and scratch and tear resistance. Due to its value contribution, it has become a substitute for traditional hardwood, ceramic tile, laminate flooring, etc., and has become an increasingly popular choice for residential and commercial buildings.

[0003] There is a floor panel having a layered structure and comprising from top to bottom: a rigid top layer including a support layer consisting essentially of a non-foamed material of relatively high density; a flexible core layer having voids in the form of air cavities, thus of relatively low density; and a bottom layer. The support layer in the rigid top layer contains almost no plasticizer and contains calcium carbonate (CaC03) as a filler material. The thickness of the flexible core layer is less than the thickness of the support layer.

[0004] There is another floor product having a layered structure and comprising from top to bottom: a decorative top layer, a compressible layer, and a core layer. The compressible layer includes at least one intermediate acoustic impedance layer. The decorative top layer has an elasticity range of 300 to 900 Mpa. In addition, at least a portion of the upper surface of the core layer and / or at least a portion of the lower surface of the core layer includes a plurality of cavities formed by stamping.

[0005] There is another floor product having a layered structure and comprising from top to bottom: a coating layer, a wear-resistant layer, a decorative top layer, a rigid core layer, a glass fiber layer, and a flexible substrate layer. Adjacent floor panels are interlocked together by a specially designed tongue / groove mechanical locking system.

[0006] There is still another floor product having a layered structure and comprising a top layer and a rigid substrate layer. The top layer is a layered structure comprising from top to bottom: a coating layer, a wear-resistant layer, a decorative layer, a flexible or semi-rigid polymer layer, at least one reinforcement layer, and an optional bottom layer. The rigid substrate layer is based on Portland cement or magnesium oxide cement. The top layer includes a polymer layer.

[0007] There is still another floor product having a layered structure and comprising from top to bottom: a top layer, a second substrate layer, an intermediate layer, and a first substrate layer. The intermediate layer has a Shore A hardness that is 10 units lower than the first and / or second substrate layer and a modulus of elasticity (MOE) that is at least 10% lower than the first and / or second substrate layer.

[0008] There is also another flooring product having a layered structure and comprising from top to bottom: a decorative layer and a substrate layer. The substrate layer also has a layered structure and comprises from top to bottom: a third non-foamed thermoplastic layer, a second non-foamed thermoplastic layer, a glass fiber reinforced layer, a foamed thermoplastic layer, a glass fiber reinforced layer and a first non-foamed thermoplastic layer. The foaming in the foamed thermoplastic layer is achieved by a mechanical or chemical foaming process and is preferably carried out between the pressing belts of a continuous process. SUMMARY

[0009] The present application aims to provide a surface covering product which provides good acoustic performance and / or a high content of renewable materials to achieve excellent sustainability from an environmental point of view.

[0010] According to a first aspect of the present application, the present application provides a surface covering product comprising a decorative material facing layer, a cushioning layer, a support layer and a base layer. The decorative material facing layer has an upper surface and a lower surface. The cushioning layer is made of a porous material and has an upper surface and a lower surface. The support layer is made of a foamed high molecular material and has an upper surface and a lower surface. The base layer has an upper surface and a lower surface. The lower surface of the decorative material facing layer is attached to the upper surface of the cushioning layer, the lower surface of the cushioning layer is attached to the upper surface of the support layer, and the lower surface of the support layer is attached to the upper surface of the base layer.

[0011] In the surface covering product of the first aspect, the porous material is a renewable composite material having a cellular structure.

[0012] In the surface covering product of the first aspect, the porous material is a softwood with a polymeric binder.

[0013] In the surface covering product of the first aspect, the foamed high molecular material is PVC, polyolefin (PO) or polyester (PET).

[0014] In the surface covering product of the first aspect, the surface covering product further comprises a first adhesive layer and a second adhesive layer. The lower surface of the decorative material facing layer is attached to the upper surface of the cushioning layer by the first adhesive layer. The lower surface of the cushioning layer is attached to the upper surface of the support layer by the second adhesive layer.

[0015] In the surface covering product of the first aspect, the lower surface of the decorative material facing layer is attached to the upper surface of the cushioning layer by a hot press bonding process, the lower surface of the cushioning layer is attached to the upper surface of the support layer by a hot press bonding process, and the lower surface of the support layer is attached to the upper surface of the base layer by a hot press bonding process.

[0016] In the surface covering product of the first aspect, the decorative material face layer includes a pre-support layer having an upper surface and a lower surface, wherein the modulus of elasticity (MOE) of the pre-support layer is between the cushion layer and the support layer, and the hardness of the pre-support layer is higher than the cushion layer.

[0017] In the surface covering product of the first aspect, the decorative material face layer further includes a coating layer, a wear-resistant layer, and a decorative layer. The wear-resistant layer is attached between the coating layer and the decorative layer, the decorative layer is attached between the wear-resistant layer and the pre-support layer, and the upper surface of the cushion layer is attached to the lower surface of the pre-support layer.

[0018] In the surface covering product of the first aspect, the modulus of elasticity (MOE) of the pre-support layer is not less than 1500 MPa, and the Shore D hardness is 60-80.

[0019] In the surface covering product of the first aspect, the pre-support layer is prepared using a formulation including PVC 100 phr, CaCO3 300-450 phr, and at least one plasticizer 12-17 phr, by steps including mixing, banburying, and calendering.

[0020] In the surface covering product of the first aspect, the thickness of the pre-support layer is 0.5-3.5 mm.

[0021] In the surface covering product of the first aspect, the Shore A hardness of the cushion layer is 30-55.

[0022] In the surface covering product of the first aspect, the thickness of the cushion layer is 0.5-4 mm.

[0023] In the surface covering product of the first aspect, the density of the cushion layer is 100-400 kg / m 3 .

[0024] In the surface covering product of the first aspect, the support layer has a relatively uniform foamed structure.

[0025] In the surface covering product of the first aspect, the density deviation of different positions on the support layer is not higher than ±50 kg / m 3 .

[0026] In the surface covering product of the first aspect, the Shore D hardness of the support layer is 70-90.

[0027] In the surface covering product of the first aspect, the support layer is prepared from a foamed polymer material with CaCO3 as a filler material, wherein the foamed polymer material is obtained in an extrusion process.

[0028] In the surface covering product of the first aspect, the support layer is made of a foamed polyvinyl chloride (PVC) material with CaCO3 as a filler material, wherein the foamed polyvinyl chloride is obtained in an extrusion process.

[0029] In the surface covering product of the first aspect, the support layer comprises PVC 100 phr, CaCO3 100-400 phr, at least one inorganic foaming agent 1-3 phr, at least one organic foaming agent 1-3 phr, and at least one processing aid 10-20 phr, and the support layer is made by a mixing and extrusion process.

[0030] In the surface covering product of the first aspect, the average particle size of the at least one organic foaming agent is not higher than 10 microns.

[0031] In the surface covering product of the first aspect, the density of the support layer is 1350-2000 kg / m 3 .

[0032] In the surface covering product of the first aspect, the thickness of the support layer is 2-8 mm.

[0033] In the surface covering product of the first aspect, the thickness of the support layer is 2-4 mm.

[0034] In the surface covering product of the first aspect, the thickness of the support layer accounts for 40%-60% of the total thickness of the surface covering product.

[0035] In the surface covering product of the first aspect, the support layer does not contain plasticizer.

[0036] In the surface covering product of the first aspect, the Shore A hardness of the bottom layer is 15-55.

[0037] In the surface covering product of the first aspect, the bottom layer has a foamed porous structure and can be made at least partially of any combination of one or more materials, including polyvinyl chloride (PVC), polyolefin (PO), polyester (PET), ethylene-vinyl acetate copolymer (EVA), polyurethane (PU), and cork.

[0038] In the surface covering product of the first aspect, the density of the bottom layer is 70-400 kg / m 3 .

[0039] In the surface covering product of the first aspect, the thickness of the bottom layer is 0.5-2.0 mm.

[0040] In the surface covering product of the first aspect, the thickness ratio of the buffer layer to the decorative material top layer is 0.4:1-1:1.

[0041] In the surface covering product of the first aspect, a thickness ratio of the cushion layer to the support layer is 0.1:1 to 0.5:1.

[0042] In the surface covering product of the first aspect, the support layer further comprises a coupling structure formed by cutting at least a portion of the support layer, the coupling structure being used to connect adjacent surface covering products in a plurality of surface covering products.

[0043] In the surface covering product of the first aspect, a thickness of the surface covering product is 4.0 to 12.0 mm.

[0044] According to a second aspect of the present application, the present application provides a surface covering product comprising a decorative material face layer, a cushion layer, a support layer and a bottom layer. The decorative material face layer has an upper surface and a lower surface. The cushion layer is made of a porous material and has an upper surface and a lower surface. The support layer has an upper surface and a lower surface. The bottom layer has an upper surface and a lower surface. The lower surface of the decorative material face layer is attached to the upper surface of the cushion layer, the lower surface of the cushion layer is attached to the upper surface of the support layer, and the lower surface of the support layer is attached to the upper surface of the bottom layer.

[0045] According to a third aspect of the present application, the present application provides a surface covering product comprising a decorative material face layer, a cushion layer, a support layer and a bottom layer. The decorative material face layer has an upper surface and a lower surface. The cushion layer has an upper surface and a lower surface. The support layer is made of a foamed high polymer material and has an upper surface and a lower surface. The bottom layer has an upper surface and a lower surface. The lower surface of the decorative material face layer is attached to the upper surface of the cushion layer, the lower surface of the cushion layer is attached to the upper surface of the support layer, and the lower surface of the support layer is attached to the upper surface of the bottom layer.

[0046] According to a fourth aspect of the present application, the present application provides a support layer of a surface covering product, characterized in that the support layer is made of a hard foamed high polymer material, wherein the hard foamed high polymer material comprises: a high polymer material 100 phr; CaCO3 100 to 400 phr; at least one inorganic foaming agent 1 to 3 phr; at least one organic foaming agent 1 to 3 phr; and at least one processing aid 10 to 20 phr.

[0047] In the support layer of the fourth aspect, a density deviation of different positions on the support layer is not higher than ±50 kg / m 3 .

[0048] In the support layer of the fourth aspect, a Shore D hardness of the support layer is 80 to 95.

[0049] In the support layer of the fourth aspect, the high polymer material is PVC.

[0050] In the support layer of the fourth aspect, the at least one inorganic foaming agent is sodium bicarbonate, and the at least one organic foaming agent is azodicarbonamide.

[0051] In the support layer of the fourth aspect, the at least one organic foaming agent has an average particle size of no more than 10 microns.

[0052] In the support layer of the fourth aspect, the at least one processing aid is an acrylate copolymer.

[0053] According to a fifth aspect of the present application, the present application provides a method for manufacturing a surface covering product, characterized by comprising the following steps: obtaining a decorative material face layer, a buffer layer made of porous material, a support layer made of foamed polymer material, and a bottom layer; adhering the decorative material face layer, the buffer layer, the support layer, and the bottom layer together to attach a lower surface of the decorative material face layer to an upper surface of the buffer layer, attach a lower surface of the buffer layer to an upper surface of the support layer, and attach a lower surface of the support layer to an upper surface of the bottom layer; and cutting opposite sides of the support layer to construct a coupling structure.

[0054] According to the fifth aspect of the present application, obtaining the decorative material face layer comprises the following steps: obtaining a pre-support layer, a wear-resistant layer, and a decorative layer; adhering the pre-support layer, the wear-resistant layer, and the decorative layer together to attach an upper surface of the decorative layer to a lower surface of the wear-resistant layer, and attach a lower surface of the decorative layer to an upper surface of the pre-support layer; and obtaining a coating layer by applying paint on the wear-resistant layer. BRIEF DESCRIPTION OF DRAWINGS

[0055] The present application will be described in more detail below with reference to the accompanying drawings, in which: Figure 1A is a perspective view of an exemplary surface covering product according to the present application.

[0056] Figure 1B is Figure 1A is a cross-sectional view along line A-A.

[0057] Figure 2A is a perspective view of another exemplary surface covering product according to the present application.

[0058] Figure 2B is Figure 2A is a cross-sectional view along line A-A.

[0059] Figure 3 is an exemplary cross-sectional view showing Figure 1A several surface covering products connected together.

[0060] Figure 4Ais a flow chart showing the steps of preparing a surface covering product according to the present application.

[0061] Figure 4B is a flow chart showing the steps of preparing a surface covering product according to the present application. DETAILED DESCRIPTION

[0062] The present application discloses a broad description of various exemplary embodiments of the present application. The description is to be construed as illustrative only and not as a limitation on the scope of every possible embodiment, as describing every possible embodiment is impractical, if not impossible. It is understood that any feature, characteristic, component, composition, ingredient, product, step, or method described herein can be deleted, combined, or substituted with any other feature, characteristic, component, composition, ingredient, product, step, or method described herein, in whole or in part. Numerous alternative embodiments could be implemented using currently technology or technology developed after the filing date of this patent application, while remaining within the scope of the claims. All publications and patents cited herein are incorporated by reference in their entirety for all purposes.

[0063] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. If there is a conflict between the definitions of terms in this disclosure including the definitions of terms throughout this application (including appended claims) and the meanings of such terms as limited in patent laws, the definitions throughout this application (including appended claims) shall control. In addition, unless otherwise specified, singular terms shall include pluralities and plural terms shall include the singular. All publications, patents, and other references cited herein are incorporated by reference in their entireties for all purposes.

[0064] Unless otherwise specified, the following abbreviations have the following meanings when used throughout this application: The terms "comprising," "including," "having," "containing," or any other similar word, as used herein, will be understood to encompass the meaning of "consisting of" and will be used synonymously with the term "comprising" unless otherwise stated. For example, the compositions, methods, articles, or apparatuses described herein that comprise, have, include or contain an element or list of elements can include additional elements that are not expressly listed or inherent to such compositions, methods, articles, or apparatuses. In addition, the use of "or" means "and / or" unless stated otherwise. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0065] Further, the indefinite articles "a" and "an," as used in this application are to be construed as non-limiting terms meaning "one or at least one" unless otherwise indicated. Thus, "a" or "an" should be read to include one or at least one, and the singular also includes the plural unless it would plainly be otherwise apparent to those skilled in the art.

[0066] The term "application" or "this application" as used herein is a non-limiting term and is not intended to refer to any single embodiment of the application but encompasses all possible embodiments described in the application.

[0067] The terms "about" and "approximately," when used in relation to a numerical value or a range of values, are intended to encompass values that might arise as a result of experimental error. Concentrations, amounts, and other numerical data can be presented herein in range format. It is to be understood that such range format is used only for convenience and brevity and should be construed as having been followed only to the extent that such ranges explicitly recited as such in the specification and / or claims were intended. For example, a weight range of from about 1 weight percent to about 20 weight percent should be interpreted to include not only the explicitly recited concentrations of from 1 weight percent to about 20 weight percent, but also to include individual concentrations, such as 2 weight percent, 3 weight percent, 4 weight percent, and sub-ranges, such as 5 weight percent to 15 weight percent, 10 weight percent to 20 weight percent, etc.

[0068] Reference is now made to the drawings, Figure 1A a perspective view of a surface covering product 100 according to the present application, and Figure 1B a cross-sectional view of a surface covering product 100 according to the present application. The surface covering product 100 has a layered structure comprising, from top to bottom, a decorative material face layer 110, a first adhesive layer 121, a cushion layer 105, a second adhesive layer 122, a support layer 106, a third adhesive layer 123, and a backing layer 109. The upper surface of the cushion layer 105 is attached to the lower surface of the decorative material face layer 110 by the first adhesive layer 121, while the lower surface of the cushion layer 105 is attached to the upper surface of the support layer 106 by the second adhesive layer 122. The lower surface of the support layer 106 is attached to the upper surface of the backing layer 109 by the third adhesive layer 123. In one exemplary embodiment, the thickness of the surface covering product ranges from 4.0 to 12.0 mm.

[0069] In one exemplary embodiment of the present application, the first bonding layer 121 for bonding the decorative material top layer 110 and the cushion layer 105, the second bonding layer 122 for bonding the cushion layer 105 and the support layer 106, and the third bonding layer 123 for bonding the support layer 106 and the base layer 109 are adhesive layers. In some embodiments, the first, second, and third bonding layers 121, 122, and 123 comprise a hard-set reactive hot-melt adhesive (including but not limited to polyurethane reactive (PUR) adhesive), a two-component AB epoxy adhesive, or a water-based adhesive.

[0070] In another exemplary embodiment of the present application, it is understood by those skilled in the art that the bonding method of the lower surface of the decorative material top layer 110 and the upper surface of the cushion layer 105, the upper surface of the support layer 106 and the lower surface of the cushion layer 105, and the upper surface of the base layer 109 and the lower surface of the support layer 106 can be at least partially replaced by other bonding methods, such as but not limited to a heat-pressing lamination process. Figure 2A and 2B Another exemplary structure of a surface covering product 200 is shown, which is made by bonding together the decorative material top layer 110, the cushion layer 105, the support layer 106, and the base layer 109 via a heat-pressing lamination process.

[0071] A coupling structure is provided into the support layer 106 for interlocking with an adjacent surface covering product 100. As shown, the coupling structure comprises a tongue structure 108 and a groove structure 107, which are respectively built on opposite sides of the support layer 106. Two adjacent surface covering products 100 are connected together by inserting the tongue structure 108 of one surface covering product 100 into the groove structure 107 of the adjacent surface covering product 100. Figure 3 Three surface covering products, namely 100a, 100b, and 100c, are provided, a cross-sectional view of which are connected together.

[0072] In one exemplary embodiment of the present application, the decorative material top layer 110 has a layered structure, comprising from top to bottom: a scratch-resistant coating layer 101, a wear-resistant layer 102, a decorative layer 103, and a pre-support layer 104. These layers can be bonded together by heat-pressing lamination or gluing. In one exemplary embodiment, these layers are bonded together by heat-pressing lamination. The decorative material top layer 110 provides various properties to the surface covering product 100, including but not limited to stain resistance, scratch resistance, wear resistance, slip resistance, indentation resistance, tear resistance, and transparency. In addition, the decorative material top layer 110 provides aesthetics to the surface covering product 100, including color, gloss, luster, and decorative features.

[0073] In one exemplary embodiment of the present application, the coating 101 is a wear resistant, radiation cured topcoat layer. In one exemplary embodiment, the coating 101 is a UV cured polyurethane acrylate system. In one exemplary embodiment, the coating 101 is a two-coat matte finish system with a primer (e.g., Akzo Nobel 971-FJS-388) and a topcoat (e.g., Akzo Nobel 973-FJS-588). The curing energy for curing the primer and topcoat liquids is approximately 550 mJ / cm2and 1000 mJ / cm2, respectively. In another exemplary embodiment, the coating 101 is a two-coat finish system cured with 172 nm excimer UV lamps. In one exemplary embodiment, the thickness of the coating 101 is approximately 0.01-0.1 mm. The coating 101 provides improved surface properties to the surface covering product 100, including stain resistance, antimicrobial functionality, scratch & mar resistance, and wear resistance, among others.

[0074] The wear resistant layer 102 can be made of polyvinyl chloride (PVC), polyolefin (PO), polyester (PET), polylactic acid (PLA), or other thermoplastic materials. In one exemplary embodiment of the present application, the wear resistant layer 102 is made of a clear PVC composition that is free of phthalate plasticizer components. The clarity of the wear resistant layer 102 allows the attractive pattern on the decorative layer 103 to be seen through it. Although the thickness of the wear resistant layer 102 can vary, it can range from approximately 0.1 mm to 1 mm. The wear resistant layer 102 protects the attractive appearance of the underlying decorative layer 103 from the effects of foot traffic and other damaging forces.

[0075] In one exemplary embodiment of the present application, the composition of the wear layer 102 includes at least one polyvinyl chloride and at least one plasticizer. In some embodiments, the plasticizer is at least one selected from the group consisting of non-phthalate plasticizers (e.g., dioctyl terephthalate (DOTP), diisononyl 1,2-cyclohexane dicarboxylate (DINCH), diethylene glycol dibenzoate (DEGDB), dipropylene glycol dibenzoate (DPGDB), and a bio-based plasticizer (i.e., a plant oil-based PVC plasticizer having 10-chloro-9-methoxy-octadecanoic acid methyl ester as its main component). However, one skilled in the art will appreciate that other plasticizers can be used in other embodiments. In one exemplary embodiment of the present application, the wear layer 102 further includes at least one stabilizer. In some embodiments, the stabilizer is a non-toxic metal soap stabilizer. In some embodiments, calcium stearate, zinc stearate, or a mixture thereof is used as the stabilizer. In one exemplary embodiment of the present application, the wear layer 102 further includes at least one co-stabilizer. For example, the co-stabilizer is epoxidized soybean oil. In one exemplary embodiment of the present application, the wear layer 102 further includes at least one ultraviolet (UV) light stabilizer. In some embodiments, the UV light stabilizer includes a UV light absorber and a hindered amine to maximize the efficiency of the UV light stabilization. In one exemplary embodiment of the present application, the wear layer 102 further includes at least one processing aid. The decorative layer 103 can be made by printing a polyvinyl chloride (PVC) film, printing melamine paper, or other printed decorative film. In one exemplary embodiment of the present application, the decorative layer 103 is a pre-printed PVC film having a thickness ranging from 0.05 to 1.5 mm. In one exemplary embodiment, the thickness of the decorative layer 103 is about 0.07 mm. The decorative layer 103 provides a unique aesthetic design and color to the surface covering product 100.

[0076] The modulus of elasticity (MOE) of the pre-support layer 104 should be between the cushion layer 105 and the support layer 106. The minimum MOE of the pre-support layer 104 is 1500 Mpa. In one exemplary embodiment of the present application, the MOE of the pre-support layer 104 ranges from 1600 to 3000 Mpa. The hardness of the pre-support layer 104 should be higher than the cushion layer 105. The Shore D hardness of the pre-support layer 104 ranges from 60 to 80. In one exemplary embodiment, the Shore D hardness of the pre-support layer 104 is between 70 and 80. The balanced hardness and MOE of the pre-support layer 104 provides excellent indentation resistance and a comfortable feel to the surface covering product 100. In one exemplary embodiment, the thickness of the pre-support layer 104 ranges from about 0.5 to 3.5 mm. In another exemplary embodiment, the thickness of the pre-support layer 104 ranges from about 0.8 mm to 2.0 mm.

[0077] In one example embodiment, the pre-support layer 104 is made of a polymer resin composite containing inorganic fillers and additives. The polymer resin is at least one selected from the group consisting of thermoplastic materials including, but not limited to, polyvinyl chloride (PVC), polyolefin (PO), polyester (PET), polylactic acid (PLA), or other similar materials. In one example embodiment, the pre-support layer 104 is made of polyvinyl chloride filled with calcium carbonate (CaC03) and additives such as at least one non-phthalate plasticizer or bio-plasticizer and at least one non-toxic metal soap stabilizer. In one example embodiment, the composition of the pre-support layer 104 includes at least one bio-plasticizer 12 to 17 parts per hundred parts of polymer resin weight (“phr”), soybean oil 2 to 5 phr, calcium carbonate powder 300 to 450 phr, at least one stabilizer 3 to 5 phr, and carbon black 0 to 0.5 phr. In one example embodiment, the polymer resin in the above composition is polyvinyl chloride (PVC).

[0078] The Shore A hardness of the cushioning layer 105 ranges from 30 to 55, measured with a durometer according to ASTM D2240 method. In one example embodiment, to achieve the best balance of indentation resistance and sound insulation, the Shore A hardness of the cushioning layer 105 ranges from 35 to 50, and the density ranges from 100 to 400 kg / m 3 In another embodiment, the thickness of the cushioning layer 105 ranges from 0.5 to 4.0 mm. In yet another embodiment, the thickness of the cushioning layer 105 ranges from 0.6 to 1.5 mm. In one example embodiment, the thickness ratio of the cushioning layer 105 to the decorative surface layer 110 is 0.4:1 ~ 1:1. In another embodiment, the thickness ratio of the cushioning layer 105 to the decorative surface layer 110 is 0.45:1 to 0.66:1.

[0079] The cushioning layer 105 is made of a porous material. When sound waves enter a porous material, acoustic energy is dissipated due to thermal losses caused by air molecules rubbing against the pore walls and viscous losses from viscous air flow within the material. In addition to the acoustic advantage, porous materials are generally low in density and widely available in natural materials with high bio-based content, which can be almost carbon neutral. In one example embodiment, the cushioning layer 105 is made of a renewable composite material with a porous cellular structure. In another example embodiment, the cushioning layer 105 is made of a natural cellular material. In yet another embodiment, the cushioning layer 105 is made of cork, a closed-cell biological material with a porous structure full of air. The cushioning layer 105 made of cork greatly promotes the acoustic performance and sustainability features of the surface covering product 100.

[0080] The support layer 106 is made of a foamed material. As Figures 1A to 2BExemplarily, the foamed density of the foamed material is relatively uniform from the center to the side. The density deviation at different locations on the support layer 106 is not higher than ±50 kg / m 3 . Thus, the foamed material provides the support layer 106 with a strong foamed structure.

[0081] The support layer 106 is made of a foamed polymer material containing inorganic fillers and containing no or only a small amount (not higher than 2 phr) of plasticizers. The Shore D hardness of the support layer 106 ranges from 70 to 90. The modulus of elasticity (MOE) of the support layer 106 ranges from 3000 MPa to 7000 MPa. The density ranges from 1350 to 2000 kg / m 3 , and the density deviation within the entire layer is not higher than ±50 kg / m 3 from the target value. In an exemplary embodiment, the density of the support layer 106 ranges from 1600 to 1800 kg / m 3 . The density deviation at different locations on the support layer 106 is not higher than ±50 kg / m 3 . Compared with the conventional rigid layer, the foamed structure of the support layer 106 brings a variety of advantages, including lighter weight (convenient to carry and lower transportation cost) and better acoustic performance (i.e., sound transmission and sound radiation). In addition, compared with the conventional rigid core layer, the high uniformity of the foamed structure also endows the support layer 106 with good rigidity and indentation resistance. In order to facilitate installation, the coupling structure (or the locking profile) can be completely constructed on the side of the support layer 106, and still maintain satisfactory locking strength. In other embodiments, the coupling structure can extend to other one or several layers of the surface covering product 100. The thickness of the support layer 106 ranges from 2.0 to 8.0 mm, and accounts for 40% to 60% of the thickness of the surface covering product 100. In an exemplary embodiment, the thickness of the support layer 106 ranges from 2.0 to 3.9 mm. The thickness ratio of the cushion layer 105 to the support layer 106 ranges from 0.1:1 to 0.5:1. In an exemplary embodiment, the thickness ratio of the cushion layer 105 to the support layer 106 ranges from 0.2:1 to 0.27:1.

[0082] In an exemplary embodiment, the support layer 106 is made of a rigid foamed polyvinyl chloride (PVC) material. In another exemplary embodiment, the support layer 106 is made of a non-polyvinyl chloride foamed polymer material, such as a foamed PET material or a foamed polyolefin (PO) material. In another exemplary embodiment, the support layer 106 is made of a foamed PVC material containing no or only a small amount (not higher than 2 phr) of plasticizers and using calcium carbonate (CaCO3) as the filler material. In another embodiment, the calcium carbonate filler accounts for 70% of the total formulation weight.

[0083] In one exemplary embodiment, the composition of the support layer 106 includes dry ground calcium carbonate (CaC03) 100-400 parts per hundred of polymer resin weight ("phr"), at least one inorganic blowing agent 1-3 phr, at least one organic blowing agent 1-3 phr, and at least one processing aid 10-20 phr. In another embodiment, the composition of the support layer 106 also has at least one lubricant and colorant. In some embodiments, the lubricant includes at least one internal lubricant 1-3 phr and at least one external lubricant 1-3 phr. In some embodiments, the inorganic blowing agent is sodium bicarbonate (baking soda), the organic blowing agent is azodicarbonamide, the processing aid is an acrylate copolymer, the lubricant is a polyethylene wax, and the colorant is carbon black. In some embodiments, the average particle size of the organic blowing agent is no greater than 10 microns. In some embodiments, the average particle size of the organic blowing agent is 8-10 microns. A suitable particle size of the organic blowing agent helps the process achieve a uniform pore size and density distribution. In some embodiments, the composition of the support layer 106 also includes at least one additional lubricant selected from the group consisting of oxidized polyethylene, glycerol monostearate, or mixtures thereof. The foamed structure of the support layer 106 provides a lightweight feature to the product compared to conventional non-foamed products, without the need to reduce weight by physically removing mass (e.g., stamping cavities).

[0084] The bottom layer 109 is made of a flexible material having a cellular structure. The Shore A hardness of the bottom layer 109 ranges from 15 to 55, the density ranges from 70 to 400 kg / m 3 , and the thickness ranges from 0.5 to 2.0 mm. In one exemplary embodiment, the density of the bottom layer 109 ranges from 100 to 250 kg / m 3 . In another embodiment, the thickness of the bottom layer 109 ranges from 0.7 to 1.5 mm. The cellular structure of the bottom layer 109 includes open and closed cell structures, which improves the acoustic performance of the surface covering product 100. In addition, the cellular structure can further reduce the overall weight of the surface covering product 100. In one exemplary embodiment, the bottom layer 109 is a foamed flexible material having a cellular structure, which can be made at least partially from any combination of one or more of the following materials, including polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyolefin (PO), ethylene-vinyl acetate copolymer (EVA), thermoplastic polyurethane (TPU), and cork.

[0085] Figure 4A and Figure 4B An exemplary process of making the surface covering product 100 is described, wherein Figure 4A The overall manufacturing process of the surface covering product 100 is described, Figure 4B The manufacturing process of the decorative material face layer 110 is described. As Figure 4AThe manufacturing process of the surface covering product 100 is shown in the order of the following pre-made layers being adhered together, these pre-made layers include: the decorative material face layer 110, the cushion layer 105, the support layer 106 and the backing layer 109. As mentioned above, the decorative material face layer 110, the cushion layer 105, the support layer 106 and the backing layer 109 are adhered to each other by a hot melt adhesive gluing process via the first, second and third adhesive layers 121, 122 and 123 (see Figure 1A and 1B ), or by a hot press adhering process (adhered to each other see Figure 2A and 2B ). In an exemplary embodiment, the adhesive forming the first, second and third adhesive layers 121, 122 and 133 is selected from a hard set reactive hot melt adhesive, a two-component AB epoxy adhesive, a water-based adhesive or other similar. When using a PUR adhesive, the adhesive is applied using a roll coater, the application temperature is 130-150°C, the application amount is 40~90g / m 2 , the adhesive viscosity is about 7000~12000 MPa.s at 130°C, and the open time is 1~5 minutes. After the decorative material face layer 110, the cushion layer 105, the support layer 106 and the backing layer 109 are adhered together, a surface covering sheet is obtained. Then, the surface covering sheet is cut or sliced into the desired size (i.e., a plank or a tile). The surface covering product is obtained by cutting the coupling structure in the support layer at each end of the plank or tile.

[0086] An exemplary process of manufacturing the decorative material face layer 110 is first adhering together in the order listed: the wear resistant layer 102, the decorative layer 103 and the pre-support layer 104. Then, the coating layer 101 is applied to the upper surface of the wear resistant layer 102. The last step is to perform an annealing process. The wear resistant layer 102, the decorative layer 103 and the pre-support layer 104 can be adhered to each other by a hot press adhering or gluing process. In an exemplary embodiment, the hot press adhering process is a batch hot press process or a continuous roll press hot lamination process. The coating layer 101 is a UV cured polyurethane acrylate system applied using a two-pass roll coating process. The primer is applied at an amount of about 7 to 12 g / m 2 , and cured by a UV lamp at a curing energy of no less than 350 mj / cm 2 . The topcoat is applied at an amount of about 9 to 15 g / m 2 , and cured by a UV lamp at a curing energy of no less than 700 mj / cm 2 . After the surface coating, the product is further processed by an annealing process to release the internal stress generated by the previous processes. If there is no proper annealing, the dimensional stability of the product can be affected.

[0087] An exemplary process for manufacturing the pre-supported layer 104 begins by mixing PVC powder, a bio-based plasticizer, a stabilizer, a lubricant, and a colorant in a high-speed mixer until the temperature reaches 70 to 100°C. The mixture is then discharged into a cold mixer and mixed with CaCO3 for 8 to 15 minutes. Next, the mixture is discharged into a Banbury internal mixer, which includes two mixing rotors rotating within a mixing chamber and an upper plug that slides the mixture into the mixing chamber through a channel opening. The mixture is mixed in the Banbury internal mixer until the target temperature is reached. At this stage, the mixture is in a molten state at a temperature of 150°C to 215°C. The melt is then processed by a hot calender. The shearing and mixing action on the calender roll surfaces homogenizes the melt and forms a polymer sheet. The thickness of the polymer sheet is controlled by adjusting the distance between the calender rolls. The sheet is then cooled and wound onto a spool or cut into sheets.

[0088] An exemplary process for manufacturing the support layer 106 includes the following steps: 1) According to the formula of support layer 106, accurately feed / meter all materials into the high shear mixer and mix for 10-15 minutes until the target temperature is reached. Once the temperature of the mixture reaches about 120-140°C, the material is discharged into the cold mixer and mixed at a relatively low speed for about 10-20 minutes.

[0089] 2) The uniformly mixed material is fed into a twin-screw extruder for further mixing, plasticizing, and foaming. In one exemplary embodiment, the twin screws in the extruder may be conical or parallel screw configurations. The fully processed and properly foamed material is pushed through a slotted die by screw rotation to form a uniform polymer sheet of controllable thickness. In one embodiment, the extrusion temperature is set to 160–220°C, and the discharge temperature at the extrusion die is approximately 180–230°C.

[0090] 3) After extrusion through the die, the polymer sheet in the molten state is further adjusted to the target thickness through a two-roll mill.

[0091] 4) Sheets of the required thickness are then passed through a cooling rack, a cutting device for width control, and precisely cut into plates of the required dimensions.

[0092] Embodiment I of this application In this embodiment, the product according to this application and as described above is manufactured according to the following characteristics. Figure 1A and 1B The surface coating product 100 shown: Coating 101 is a UV-curable polyurethane acrylate system, comprising a primer and a topcoat. The target application rates for the primer and topcoat are 10 g / m². 2 .

[0093] The wear layer 102 is made of a transparent PVC composition with DOTP as plasticizer. The target thickness is 0.5 mm.

[0094] The decorative layer 103 is a pre-printed PVC film with a thickness of 0.07 mm.

[0095] The pre-support layer 104 has a thickness of about 1.0 mm and a Shore D hardness of about 80 and a MOE of about 1600 MPa. One example of a pre-support layer composition is disclosed in Table 1 below: Table 1 The bio-based plasticizer used in Example I comprises a plant oil-based PVC plasticizer with 10-chloro-9-methoxy-octadecanoic acid methyl ester as the main ingredient.

[0096] The decorative material top layer 110 is obtained by laminating together from top to bottom the wear layer 102, the decorative layer 103 and the pre-support layer 104. A UV coating is then applied on the upper surface of the wear layer 102 to form the coating layer 101.

[0097] The cushion layer 105 has a thickness of 1.0 mm and is made of cork with a polymeric binder. The Shore A hardness of the cushion layer 105 is 48 and the density is about 250 kg / m 3 Cork is an ideal sound insulator due to its unique multi-faceted closed honeycomb cell structure. These cells are filled with air and are impermeable to liquids and gases. These cells can deform under compression forces but do not break and the cells have elasticity and return to their original shape once the compression forces are removed. These many tiny sealed air cavities can strongly dissipate sound wave energy generated by a falling object impact, a hard-soled footstep or similar action.

[0098] The support layer 106 has a thickness of about 3.7 mm, a density of about 1750 kg / m 3 , a Shore D hardness of 80 and a MOE of 3900 MPa. One example of a support layer composition is disclosed in Table 2 below.

[0099] Table 2 The average particle size of the azodicarbonamide is 8-10 microns.

[0100] The bottom layer 109 in this example is also made of cork with a polymeric binder. The thickness of the bottom layer 109 is 1.0 mm.

[0101] Comparative Example I A so-called Stone Plastic Composite (SPC) surface covering product was produced in a similar manner as the surface covering product of Example I of the present application, which has a structure consistent with the most common structure on the market, as Comparative Example I of the present application.

[0102] The surface covering product of this comparative example has a layered structure in nature, comprising from top to bottom: a decorative material face layer, a support layer, and a bottom layer. The decorative material face layer here is composed of: a surface coating with the same UV coating system as Example I of the present application, the same wear-resistant layer with the same thickness as Example I of the present application, and the same decorative layer (i.e. printed layer) as Example I of the present application. Unlike Example I of the present application, Comparative Example I does not have a pre-support layer and a buffer layer. In addition, the support layer in this comparative example is different from the support layer 106 of Example I of the present application. The support layer in this comparative example is a common SPC core layer, with a formulation as described in Table 3. The thickness of the support layer is about 6.0 mm. The bottom layer in this comparative example is made of softwood with a polymer adhesive, the same as in Example I of the present application, and has a thickness of 1.0 mm.

[0103] Table 3 Comparative Example II A surface covering product with a layered structure was prepared as Comparative Example II of the present application in a similar manner as the surface covering product of Example I of the present application.

[0104] The surface covering product of this comparative example has a layered structure in nature, comprising from top to bottom: a decorative material face layer, a buffer layer, a support layer, and a bottom layer. The decorative material face layer comprises from top to bottom: a coating layer, a wear-resistant layer, a printed layer, and a pre-support layer. This example differs from Example I of the present application in the pre-support layer, the buffer layer, and the support layer.

[0105] Specifically, the pre-support layer in Comparative Example II is made of PVC with CaCO3 as filler material and containing additives including plasticizers. The thickness is 1 mm. Compared with the pre-support layer in Example I of the present application, this pre-support layer has a smaller modulus of elasticity (MOE).

[0106] The buffer layer in Comparative Example II is made of soft and elastic PP foamed material, with a thickness of 1.0 mm and a density of 200-300 kg / m 3 .

[0107] The support layer in Comparative Example II is made of non-foamed PVC material with CaCO3 as filler and without plasticizers. CaCO3 accounts for about 70% of the weight of the support layer. The thickness is 4.0 mm and the density is about 1900-2100 kg / m 3.

[0108] The bottom layer in Comparative Example II was made of cork with a polymeric adhesive, as in Example I of the present application. The thickness was 1.0 mm.

[0109] Comparative Example III A surface covering product having a layered structure was prepared as Comparative Example III of the present application, in a similar way to the surface covering product of Example I of the present application.

[0110] The surface covering product of this comparative example essentially had a layered structure, comprising from top to bottom: a decorative material face layer, a cushioning layer, a support layer and a bottom layer. The decorative material face layer comprised from top to bottom: a coating layer, a wear layer, a printed layer and a pre-support layer. This example differed from Example I of the present application in the pre-support layer, the cushioning layer, the support layer and the bottom layer.

[0111] In particular, the pre-support layer in Comparative Example III was made of PVC with CaC03 as filler material and containing additives including plasticizers. The thickness was 1 mm. CaC03 represented about 55% of the weight of the pre-support layer. This pre-support layer had a lower rigidity and a smaller modulus of elasticity (M0E) compared to the pre-support layer of Example I of the present application.

[0112] The cushioning layer in Comparative Example III of the present application was made of soft and elastic EVA foamed material, with a thickness of 1.0 mm and a density of 200-300 kg / m 3 .

[0113] The support layer in Comparative Example III was made of non-foamed PVC composite material with CaC03 as filler and without plasticizers. CaC03 represented about 70% of the weight of the support layer. The thickness was 4.5 mm and the density was about 1900-2100 kg / m 3 .

[0114] The bottom layer in Comparative Example III was a radiation-crosslinked polyethylene (IXPE) foamed material, with a thickness of 1.0 mm and a density of 50-100 kg / m 3 .

[0115] Test results All samples have been subjected to the following tests: - The acoustic test was carried out in a self-developed acoustic test equipment, simulating the impact sound insulation class (IIC) as specified in the ASTM E492 standard. The higher the IIC, the better the soundproofing effect.

[0116] - Acoustic testing was performed according to a self-developed test method following similar concepts as the EN 16205 method to evaluate the noise emitted by the product when subjected to an impact. The impact was generated by a dropped steel ball instead of the striker described in EN 16205. The test method is briefly described now. The product under test was first acclimated for 24 hours at room temperature (25°C). Then the product was placed on a flat surface in a specially built room with concrete walls and sealed doors that effectively block ambient noise. Then, a solid steel ball with a diameter of 36.5 mm and a weight of approximately 198 g was dropped freely from a height of 1 meter onto the decorative surface of the test sample. A sound receiving device was placed in a fixed position in the same room to measure the sound pressure generated by the impact of the steel ball on the sample. The sound receiving device then sent a signal to a computing device connected to it, which output the result in decibels (dB). In this test, the smaller the number, the better the acoustic performance in terms of noise emission.

[0117] - Residual indentation testing was performed according to ASTM F1914.

[0118] - Locking strength testing was performed according to ISO 24334. The result was expressed in kN / m, where kN represents the breaking force of the lock and m represents the average width of the sample surface on the clamping side of the test sample.

[0119] - Dimensional stability testing was performed according to ISO 23999.

[0120] - Coefficient of thermal expansion (CTE) testing was performed according to the following test method. The sample under test was first acclimated for 24 hours at room temperature (25°C). After acclimation, the dimensions in the machine direction (MD) and across the machine direction (AMD) were measured using a caliper. Then the sample was placed in an oven set to a temperature of 50°C for 2 hours. After heating, the dimensions in the MD and AMD directions were immediately measured. Then the CTE was calculated based on the change in dimensions before and after heating.

[0121] - Bio-based carbon content was measured according to ASTM D6866-22 method.

[0122] The results are shown in Table 4.

[0123] Table 4 * Calculated from test results of products with similar structure and formulation.

[0124] Based on the test results listed in Table 4, it is clear that the surface covering product according to the present application outperforms the comparative examples in terms of acoustic performance, including sound insulation class and impact sound radiation. In addition, due to its unique structure and formulation, the surface covering product according to the present application also has a higher bio-based carbon content and a lower density than the comparative examples, the higher bio-based carbon content indicating a higher renewable biomass content. All these improvements are achieved while other key physical properties, such as indentation resistance, lock strength, dimensional stability and thermal CTE, are all at satisfactory values.

[0125] As a summary, the product according to the present application achieves at least the following technical effects: - The support layer of the product according to the present application is made of a rigid foamed high molecular material. Compared with the traditional rigid support layer, the present application presents obvious advantages, including light weight, good rigidity, better acoustic performance, easy to carry / transport and comfortable foot feeling. In addition, due to the rapid dissipation of sound energy when sound passes through the air holes in the foamed structure, the large number of air holes in the foamed structure positively contribute to the acoustic performance.

[0126] - Due to the formulation and process technology, the density distribution of the rigid foamed support layer in the present application is very uniform. This feature endows the support layer in the present application with similar rigidity as the non-foamed support layer in the traditional SPC product. In addition, it makes the entire coupling structure can be built in the support layer, without the need for additional reinforcing layers or a high proportion of support layer thickness relative to the total thickness of the product.

[0127] - The cushion layer according to the present application can be made of bio-based renewable materials. Compared with traditional petroleum-based products, this feature significantly increases the biomass content in the product. Therefore, the carbon footprint can be greatly reduced.

[0128] - The pre-support layer according to the present application has a balanced feature between rigidity and elasticity due to its hardness and modulus of elasticity (MOE). This rigidity endows the product with satisfactory indentation resistance. While the elasticity ensures the acoustic performance.

Claims

1. A surface covering product, characterized in that Comprising: a decorative material face layer (110) having an upper surface and a lower surface; a cushioning layer (105) made of a porous material and having an upper surface and a lower surface; a support layer (106) made of a foamed high polymer material and having an upper surface and a lower surface; and a bottom layer (109) having an upper surface and a lower surface; wherein the lower surface of the decorative material face layer (110) is attached to the upper surface of the cushioning layer (105), the lower surface of the cushioning layer (105) is attached to the upper surface of the support layer (106), and the lower surface of the support layer (106) is attached to the upper surface of the bottom layer (109).

2. The surface covering product of claim 1, wherein, The porous material is a renewable composite material having a cellular structure.

3. The surface covering product of claim 2, wherein, The porous material is softwood with a polymer binder.

4. The surface covering product of claim 1, wherein, The foamed high polymer material is PVC, PO, or PET.

5. The surface covering product of claim 1, wherein, Further comprising: a first adhesive layer (121); a second adhesive layer (122); and a third adhesive layer (123); wherein the lower surface of the decorative material face layer (110) is attached to the upper surface of the cushioning layer (105) through the first adhesive layer (121), the lower surface of the cushioning layer (105) is attached to the upper surface of the support layer (106) through the second adhesive layer (122), and the lower surface of the support layer (106) is attached to the upper surface of the bottom layer (109) through the third adhesive layer (123). The lower surface of the decorative material face layer (110) is attached to the upper surface of the cushioning layer (105) through a hot-pressing process, the lower surface of the cushioning layer (105) is attached to the upper surface of the support layer (106) through a hot-pressing process, and the lower surface of the support layer (106) is attached to the upper surface of the bottom layer (109) through a hot-pressing process.

6. The surface covering product of claim 1, wherein, The decorative material face layer (110) comprises a pre-support layer (104) having an upper surface and a lower surface, wherein the modulus of elasticity (MOE) of the pre-support layer (104) is between the cushioning layer (105) and the support layer (106), and the hardness of the pre-support layer (104) is higher than that of the cushioning layer (105).

7. The surface covering product of claim 1, wherein, The decorative material face layer (110) further comprises:

8. The surface covering product of claim 7, wherein, a coating layer (101); a wear-resistant layer (102); and a decorative layer (103); wherein the wear-resistant layer (102) is attached between the coating layer (101) and the decorative layer (103), the decorative layer (103) is attached between the wear-resistant layer (102) and the pre-support layer (104), and the upper surface of the cushioning layer (105) is attached to the lower surface of the pre-support layer (104). The modulus of elasticity (MOE) of the pre-support layer (104) is not less than 1500 MPa, and the Shore D hardness is 60-80.

9. The surface covering product of claim 7, wherein, ​ 10. The surface covering product of claim 7, wherein, The pre-support layer (104) is prepared by a formulation comprising PVC 100 phr, CaCO3 300~450 phr and at least one plasticizer 12~17 phr, through steps including mixing, banburying and calendering.

11. The surface covering product of claim 7, wherein, The pre-support layer (104) has a thickness of 0.5~3.5 mm.

12. The surface covering product of claim 1, wherein, The cushion layer (105) has a Shore A hardness of 30~55.

13. The surface covering product of claim 1, wherein, The cushion layer (105) has a thickness of 0.5~4 mm.

14. The surface covering product of claim 1, wherein, The density of the buffer layer (105) is 100-400 kg / m 3 .

15. The surface covering product of claim 1, wherein, The support layer (106) has a relatively uniform foamed structure.

16. The surface covering product of claim 14, wherein, The density deviation of different positions on the support layer (106) is not higher than ±50 kg / m 3 .

17. The surface covering product of claim 1, wherein, The support layer (106) has a Shore D hardness of 70~90.

18. The surface covering product of claim 1, wherein, The support layer (106) is prepared by a foamed high polymer material with CaCO3 as a filler material, wherein the foamed high polymer material is obtained in an extrusion process.

19. The surface covering product of claim 18, wherein, The support layer (106) is prepared by a foamed polyvinyl chloride (PVC) material with CaCO3 as a filler material, wherein the foamed polyvinyl chloride is obtained in an extrusion process.

20. The surface covering product of claim 19, wherein, The support layer (106) comprises PVC 100 phr, CaCO3 100~400 phr, at least one inorganic foaming agent 1~3 phr, at least one organic foaming agent 1~3 phr and at least one processing aid 10~20 phr, and the support layer (106) is prepared by mixing and extrusion process.

21. The surface covering product of claim 19, wherein, The at least one organic foaming agent has an average particle size of no more than 10 microns.

22. The surface covering product of claim 1, wherein, The density of the support layer (106) is 1350-2000 kg / m 3 .

23. The surface covering product of claim 1, wherein, The support layer (106) has a thickness of 2~8 mm.

24. The surface covering product of claim 20, wherein, The support layer (106) has a thickness of 2~4 mm.

25. The surface covering product of claim 23, wherein, The thickness of the support layer (106) accounts for 40%~60% of the total thickness of the surface covering product.

26. The surface covering product of claim 1, wherein, The support layer (106) does not contain plasticizer.

27. The surface covering product of claim 1, wherein, The bottom layer (109) has a Shore A hardness of 15~55.

28. The surface covering product of claim 1, wherein, The bottom layer (109) has a foamed porous structure, and can be at least partially made of any combination of one or more of the following materials, including polyvinyl chloride (PVC), polyolefin (PO), polyester (PET), ethylene-vinyl acetate copolymer (EVA), polyurethane (PU) and cork.

29. The surface covering product of claim 1, wherein, The density of the bottom layer (109) is 70-400 kg / m 3 .

30. The surface covering product of claim 1, wherein, The bottom layer (109) has a thickness of 0.5~2.0 mm.

31. The surface covering product of claim 1, wherein, The thickness ratio of the cushion layer (105) to the decorative material surface layer (110) is 0.4:1~1:

1.

32. The surface covering product of claim 1, wherein, The thickness ratio of the cushion layer (105) to the support layer (106) is 0.1:1~0.5:

1.

33. The surface covering product of claim 1, wherein, The support layer (106) further comprises a coupling structure formed by cutting at least a portion of the support layer (106), the coupling structure being used to connect adjacent surface covering products (100) in a plurality of surface covering products (100).

34. The surface covering product of claim 1, wherein, The surface covering product (100) has a thickness of 4.0~12.0 mm.

35. A surface covering product, characterized by Comprising: a decorative material surface layer (110) having an upper surface and a lower surface; a cushion layer (105) made of a porous material and having an upper surface and a lower surface; a support layer (106) having an upper surface and a lower surface; and a bottom layer (109) having an upper surface and a lower surface; wherein a lower surface of the decorative material surface layer (110) is attached to an upper surface of the buffer layer (105), a lower surface of the buffer layer (105) is attached to an upper surface of the support layer (106), and a lower surface of the support layer (106) is attached to an upper surface of the bottom layer (109).

36. A surface covering product, characterized by comprising: a decorative material surface layer (110) having an upper surface and a lower surface; a buffer layer (105) having an upper surface and a lower surface; a support layer (106) made of foamed polymer material and having an upper surface and a lower surface; and a bottom layer (109) having an upper surface and a lower surface; wherein a lower surface of the decorative material surface layer (110) is attached to an upper surface of the buffer layer (105), a lower surface of the buffer layer (105) is attached to an upper surface of the support layer (106), and a lower surface of the support layer (106) is attached to an upper surface of the bottom layer (109).

37. A backing layer for a surface covering product, characterized in that the support layer is made of hard foamed polymer material, wherein the hard foamed polymer material comprises: 100 phr of polymer material; 100-400 phr of CaCO3; 1-3 phr of at least one inorganic foaming agent; 1-3 phr of at least one organic foaming agent; and 10-20 phr of at least one processing aid.

38. The backing layer for a surface covering product of claim 37, wherein, The density deviation of different positions on the support layer is not higher than ±50 kg / m 3 .

39. The backing layer for a surface covering product of claim 37, wherein, the support layer has a Shore D hardness of 80-95.

40. The backing layer for a surface covering product of claim 37, wherein, the polymer material is PVC.

41. The backing layer for a surface covering product of claim 37, wherein, the at least one inorganic foaming agent is sodium bicarbonate, and the at least one organic foaming agent is azodicarbonamide.

42. The backing layer for a surface covering product of claim 37, wherein, the at least one organic foaming agent has an average particle size of no more than 10 microns.

43. The backing layer for a surface covering product of claim 37, wherein, the at least one processing aid is an acrylate copolymer.

44. A method of manufacturing a surface covering product (100) characterized by comprising the following steps: obtaining a decorative material surface layer (110), a buffer layer (105) made of porous material, a support layer (106) made of foamed polymer material, and a bottom layer (109); attaching the decorative material surface layer (110), the buffer layer (105), the support layer (106), and the bottom layer (109) together to attach a lower surface of the decorative material surface layer (110) to an upper surface of the buffer layer (105), attach a lower surface of the buffer layer (105) to an upper surface of the support layer (106), and attach a lower surface of the support layer (106) to an upper surface of the bottom layer (109); and cutting opposite sides of the support layer (106) to create a coupling structure.

45. The method of claim 44, wherein, obtaining the decorative material surface layer (110) comprises the following steps: obtaining a pre-support layer (104), a wear-resistant layer (102), and a decorative layer (103); attaching the pre-support layer (104), the wear-resistant layer (102), and the decorative layer (103) together to attach an upper surface of the decorative layer (103) to a lower surface of the wear-resistant layer (102), and attach a lower surface of the decorative layer (103) to an upper surface of the pre-support layer (104); and A coating is obtained by applying a paint on the wear-resistant layer (102).

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