Process for manufacturing floor or wall coverings, and associated coverings

Abstract

The invention relates to a process for manufacturing a floor or wall covering comprising at least one base layer (2) that is made of polymer materials and has an upper face (2a) and a lower face (2b), the upper face having a predefined relief pattern, the process involving at least the steps of: a) advancing the base layer (2); b) controlling numerical control deposition means to deposit a fluid adhesive material (4a, 4b) on the upper face (2a) of the base layer (2) according to the predefined relief pattern; c) depositing material particles (3a, 3b) on the fluid adhesive material (4a, 4b); d) crosslinking the deposited fluid adhesive material (4a, 4b) to bond the material particles (3a, 3b) to the base layer (2) and form the predefined relief pattern.

Description

Description Title of the invention: Method for producing raised floor or wall coverings and associated coverings Technical field

[0001] The present invention relates to the technical sector of floor and wall coverings made from polymer materials and their manufacturing processes. The invention relates more particularly to the manufacturing processes for coverings made from polyvinyl chloride or the like and, more particularly, to coverings comprising at least one layer having a raised surface. Prior art

[0002] In the field of floor or wall coverings, tiles, strips or rolls comprising at least one layer of plastic material, for example obtained from polyvinyl chloride (PVC), are well known. Known methods for producing such floor coverings generally comprise a first step consisting of depositing a first layer of plastic granules on a support, then melting and pressing this layer using a platen press, a double-belt press, or with a passage between two cylinders of a calender, in order to bind the granules and obtain a decorative floor covering layer. A floor or wall covering may also comprise a decorative layer in the form of a printed film protected by a transparent or translucent layer, the decorative layer being arranged in the upper part of the floor covering.

[0003] These floor coverings thus have decorations that imitate, or even are realistic. To improve the visual and tactile rendering of these coverings or to give them non-slip properties, processes for graining the upper surface of these coverings exist. These processes make it possible to give the covering a predefined relief pattern. Mechanical graining processes use, for example, cylinders having protuberances or cavities according to a predefined pattern and making it possible to apply the imprint of this relief pattern by cold or hot pressure on the surface of the covering. Other processes by adding material exist, such as for example the process described in patent EP2108524 consisting of apply superimposed layers of varnish by inkjet printing to form a relief on the surface of panels.

[0004] These different methods of obtaining reliefs do not, however, provide satisfaction in terms of flexibility, as cylinder changes are long and costly, or in terms of depth of relief obtained, or even resistance to abrasion. On the other hand, mechanical graining processes using graining cylinders are difficult to superimpose on a registered printed decoration and are quickly repeated. Indeed, the relief pattern cannot be longer than the developed length of the cylinder, generally less than three meters. Statement of the invention

[0005] One of the aims of the invention is to overcome the drawbacks of the prior art, in particular by proposing a method for manufacturing a floor or wall covering comprising at least one base layer made from polymeric materials comprising an upper face and a lower face, said upper face comprising a predefined relief pattern, the pattern being easily modifiable, without length limit and able to have a significant depth.

[0006] A second aim of the invention is to propose a method for manufacturing floor or wall coverings comprising a base layer having a decorative pattern, in the thickness of the base layer or on a printed film, the pattern being predefined, and a second relief pattern, the second relief pattern being predefined and preferably registered at the position of the decorative pattern.

[0007] To this end, a method has been developed for manufacturing a floor or wall covering comprising at least one base layer made from polymeric materials and comprising an upper face and a lower face, said base layer comprising a predefined relief pattern, the method comprising at least steps consisting of: a) scrolling the base layer; b) controlling deposition means by numerical control to deposit a fluid adhesive material on the upper face of the base layer according to the predefined relief pattern; c) depositing particles of materials on the fluid adhesive material; d) crosslinking the deposited fluid adhesive material to bind the material particles to the base layer and form the predefined relief pattern.

[0008] This process thus makes it possible to obtain a relief on the upper face of the base layer, the relief being obtained by the combination of the predefined relief pattern obtained by the distribution of the material particles and the crosslinked fluid adhesive material.

[0009] Advantageously, the steps of depositing the fluid adhesive material and depositing the particles can be repeated in order to obtain a more complex relief pattern.

[0010] A backing is generally used to support and roll the base layer. The backing is used only to obtain the floor or wall covering and is then detached from the covering. The backing may, for example, comprise a continuous conveyor belt, for example a metal belt, or a transfer paper, for example a paper coated with a layer of silicone on the side intended to receive the base layer, or a textile that does not bond to the material of the base layer.

[0011] The base layer is made from polymeric materials and can be in the form of a single layer or a multi-layer structure. The lower face of the base layer can optionally be subsequently bonded to other layers, so as to form a heterogeneous floor covering and to provide, for example, other damping, resistance or acoustic properties to the covering. A base layer can in particular be obtained from PVC and can for example be produced by calendering, coating then gelling, by pressing or by extrusion through a flat die, this layer being in the form of a sheet having two smooth faces, upper and lower.

[0012] The digitally controlled deposition means for depositing the fluid adhesive material may in particular be digital inkjet printing equipment and processes for depositing drops of fluid adhesive material according to a predefined relief pattern on the upper face of the base layer and according to coordinates obtained from a digital file representing the relief pattern.

[0013] Alternatively, numerically controlled deposition means for depositing the fluid adhesive material may be any means comprising at least one reservoir of adhesive material and at least one deposition nozzle in communication with the reservoir for depositing the fluid adhesive material in drops according to coordinates obtained from a digital file representing the relief pattern. The fluid adhesive material is advantageously deposited, thrown or sprayed in drops having a volume of between 1 picoliter and 1 milliliter. The fluid adhesive material may in particular be a varnish, in particular based on acrylic or polyurethane, a liquid glue, a plastisol.

[0014] Once the fluid adhesive material has been deposited, the step of depositing particles of material onto the fluid adhesive material may be carried out using any known means such as hoppers, sprinklers or other means of depositing, in bulk or in a controlled manner. Following the depositing step, it may be envisaged to carry out a step of removing, in particular by suction or blowing, the particles which have not been deposited onto the adhesive material and which remain free, so as not to degrade the final visual appearance of the coating.

[0015] Alternatively, step c) comprises a step of controlling deposition means by numerical control to deposit particles of materials on the fluid adhesive material according to the predefined relief pattern. This alternative makes it possible to limit the quantity of particles to be deposited and to avoid a step of removing particles not bound to the adhesive material. Indeed, despite the removal step, particles can pollute the desired relief pattern by remaining positioned in an undesired position.

[0016] The polymeric materials that can be used in the composition of the base layer and the particles of materials deposited to form the relief pattern are, for example, poly(vinyl chloride) (PVC), poly(vinyl butyral) (PVB), PLA or polylactic acid, thermoplastic polyurethane (TPU), polypropylene (PP), poly(methyl methacrylate acrylic) (PMMA), cellulose derivatives, elastomers, alone or in mixtures. The particles of materials deposited to form the relief pattern may also comprise at least one mineral, natural or synthetic filler.

[0017] The material particles deposited to form the relief pattern may also include at least one plasticizer. They may be colored, transparent or translucent.

[0018] The material particles deposited to form the relief pattern can come from a recycling channel.

[0019] The particles of materials deposited to form the relief pattern may have a spherical and / or ovoid shape to improve the flowability and fineness of the pattern as well as its repeatability. Indeed, coarse-shaped particles such as particles obtained by grinding post-consumer products or others do not flow homogeneously and can induce variability during the deposition step. Spherical and / or ovoid particles may in particular be obtained by well-known extrusion processes through a hole die with underwater blade cutting. Advantageously, the particles of materials deposited to form the pattern are particles made from polymeric materials such as PVC, polypropylene, polyethylene, PMMA, linoleum, thermosets, alone or in a mixture or even non-polymeric materials such as corundum, glass, natural mineral particles such as MICA, quartz, basalt.

[0020] Advantageously, the particles are granules having a particle size of between 0.5 mm and 10 mm or powders having a particle size of between 2 μm and less than 500 μm, preferably between 20 μm and 250 μm. Said particles may also comprise a mixture of granules and powders. Due to the variety of particles that can be used with the method according to the invention, it is thus possible to obtain reliefs having a significant depth of several millimeters and also a very fine resolution, down to a few microns.

[0021] The particles of material deposited to form the relief pattern may also be in the form of a PVC dry blend or in the form of granules obtained from a gelled polymeric material such as PVC. The particles of material deposited to form the pattern may be in the form of colored granules, each granule comprising one or more colors.

[0022] Several means are used to partially or completely crosslink the deposited fluid adhesive material to bind the material particles to the base layer and form the predefined relief pattern. Known means include drying, which allows the liquid portion of the adhesive material to evaporate without causing deformation of the base layer. Drying can be carried out, in particular, by a flow of hot air. Other means are used to partially or completely crosslink the fluid adhesive material, including exposing the material to infrared and / or near-infrared radiation.

[0023] Alternatively, in the case where the composition of the fluid adhesive material includes photoinitiators, it can be partially or totally crosslinked by exposure to ultraviolet, excimer radiation or even an electron beam.

[0024] The method according to the invention can be carried out step by step, that is to say that after each production of a relief pattern, the base layer coated with the relief pattern is moved relative to the deposition means and a new base layer is moved towards the deposition means to be coated with the relief pattern. By scrolling is meant that the base layer is moved relative to the means for depositing the adhesive material and the particles and / or that the means for depositing the adhesive material and the particles are moved relative to the base layer.

[0025] Alternatively, and in order to make the process faster and less expensive, the method for manufacturing floor or wall coverings according to the invention can be carried out continuously. For this purpose, the base layer moves continuously relative to the means for depositing the adhesive material and the particles, for example at a speed of between 1 and 25 meters per minute, advantageously between 5 and 12 meters per minute. It is for example possible to move a support in the form of a continuous strip supporting a base layer supplied in a roll and continuously unrolled by the movement of the support. It is also possible to move a support in the form of a continuous strip supporting a series of base layers supplied in strip, plate or slab and moving continuously thanks to the movement of the support.

[0026] Alternatively, the base layer can be manufactured continuously by any known means such as calendering, coating then gelling, pressing or even by extrusion through a flat die, and continuously deposited on the continuously moving support.

[0027] It is also possible to deposit the adhesive material in several stages, or even to use several adhesive materials. To this end, the method according to the invention may comprise the following steps consisting of: - control deposition means by numerical control to deposit a first fluid adhesive material on the upper face of the base layer according to a first part of the predefined relief pattern; - control deposition means by numerical control to deposit at least a second fluid adhesive material on the upper face of the base layer according to a second part of the predefined relief pattern.

[0028] In this way, it is possible to obtain a floor covering having a relief pattern obtained from at least two parts of the predefined pattern and therefore more complex than a pattern produced in one go. The first and second fluid adhesive material may be identical or different. In particular, the adhesion properties of the fluid adhesive material to the upper face of the base layer and / or to the material particles may be adapted depending on the first and second part of the pattern. Similarly, the surface appearance or the color of the first and / or second fluid adhesive material may be different in order to obtain a significant richness of the relief pattern.

[0029] It is also possible to use several types of particles in the method according to the invention. For this purpose, the method according to the invention may comprise the following steps consisting of: - control deposition means by numerical control to deposit a first type of material particles on the fluid adhesive material according to a first part of the predefined relief pattern; - control deposition means by numerical control to deposit a second type of material particles on the fluid adhesive material according to a second part of the predefined relief pattern.

[0030] In this configuration, several configurations can be envisaged. According to a first possibility, the step of depositing the first type of particle may be carried out on a part of the fluid adhesive material itself deposited according to the entire relief pattern. It is not necessary that only a part of the fluid adhesive material has been deposited, the digitally controlled deposition means allowing selective deposition of the particles according to a first part of the pattern.

[0031] According to a second configuration, the step of depositing the first type of particle may be carried out on the fluid adhesive material itself deposited according to a first part of the relief pattern.

[0032] The same applies to the step of depositing the second type of particle on the fluid adhesive material, itself deposited according to all or part of the predefined relief pattern.

[0033] The step of crosslinking the first fluid adhesive material may be carried out after the step of depositing the first type of particle or after the step of depositing the second type of particle.

[0034] In this way, it is possible to obtain a floor covering with a relief pattern obtained from at least two parts of the predefined and therefore more complex relief pattern. The first and second type of material particles are preferably different, in particular in terms of adhesion property to the fluid adhesive material, mechanical properties, size, shape, abrasion resistance, color, composition, gloss, transparency, etc.

[0035] Optionally, the method according to the invention comprises additional steps after step c) or d) consisting of: - coating a protective layer on the material particles so that the material particles are partially embedded in the thickness of the protective layer; - crosslink the protective layer.

[0036] The protective layer is a layer that can be transparent, translucent or colored, obtained from a varnish, a PVC plastisol or even a hot coating called "hotcoating" in English. This protective layer improves resistance to abrasion, scratching and traffic. The deposited particles can be partially embedded in the thickness of the layer. protective so that at least some of the particles are on the surface of the protective layer.

[0037] Alternatively, the deposited particles can be covered with the protective layer so that it matches the shape of the relief pattern. This allows for a very weakly structured surface relief to be maintained while improving cleanability and protecting the deposited particles.

[0038] Optionally and finally to improve the visual rendering and the richness of the decor presented by the coating, the method according to the invention comprises at least one additional step consisting of: - Printing a predefined decorative pattern on the upper side of the base layer (2) and / or on the material particles using an inkjet printing process.

[0039] The base layer may therefore, prior to the step of depositing the fluid adhesive material, have been printed with a decorative pattern by any known means, in particular by an inkjet printing process. The base layer may also comprise in its thickness a decorative layer visible from the upper face of the base layer. It is thus possible for the base layer to comprise, from the upper face to the lower face, a translucent or transparent layer, a decorative layer, a backing layer. It is also possible for the base layer to comprise, from the upper face to the lower face, a decorative layer and a backing layer. The decorative layer may be obtained by any known means, in particular by an inkjet printing process, on a support film or on the back of a translucent layer or directly on the backing layer.

[0040] It is also possible for all or part of the material particles to be printed with a decorative pattern, preferably after the step of crosslinking the fluid adhesive material, by any known means, in particular by an inkjet printing process. This makes it possible in particular to add nuances to the relief such as wood grain, color details, geometric patterns, superimposed on the particles.

[0041] Alternatively, the base layer is made from particles of polymeric materials in the form of granules and / or powders and / or dry- blend agglomerated according to a predefined decorative pattern. Said base layer thus comprises particles of materials distributed to form a predefined decorative pattern.

[0042] This alternative method thus makes it possible to obtain a coating comprising a decoration in the thickness of the base layer, this being obtained by the combination of the pattern obtained by the distribution of the particles of polymeric materials in the form of granules and / or powders and / or distributed dryblend and any other materials of the base layer.

[0043] According to the embodiments or the base layer comprises at least one decorative layer having a predefined decorative pattern in the thickness or a predefined decorative pattern printed on the upper face of the base layer or a predefined decorative pattern printed on a decorative layer included in the base layer, the method according to the invention may comprise a step consisting of: - Apply the fluid adhesive material according to the position of the predefined decorative pattern.

[0044] This alternative allows the relief pattern to be registered with the decorative pattern to bring more realism to the covering. Thus, a relief can be added to the right of a printed decorative pattern to accentuate it. Alternatively, the parts presenting a decorative pattern may not be covered with a relief pattern, this accentuating for example parts adjacent to the printed decorative pattern.

[0045] Preferably, the fluid adhesive material may be crosslinked in several steps so as to pre-crosslink it and / or maintain it on the base layer, for example by exposure to infrared radiation. For this purpose, the method may comprise at least one additional step after step c) consisting of partially crosslinking the deposited fluid adhesive material. This makes it possible in particular to temporarily maintain the particles in order to be able to move the base layer, or even to more easily deposit a second type of adhesive material and / or particles.

[0046] Following the crosslinking step of the fluid adhesive material, a step of heating the particles and / or pressing may be carried out. This may allow the appearance of the particles to be slightly modified or to be pushed slightly into the thickness of the layer to better hold them, while it retains a raised pattern flush with the upper face of the base layer. This step can be carried out using an oven, by exposure to infrared or near infrared radiation, a hot or cold press, or pressure cylinders.

[0047] The invention also relates to a floor or wall covering comprising at least one base layer comprising a predefined relief pattern obtained by a manufacturing method according to the invention as described. The covering thus comprises a predefined relief pattern.

[0048] Regardless of the embodiment, the particle depositing means may comprise at least one particle storage means comprising at least one outlet mouth, for example a hopper, as well as at least one means for closing each outlet mouth that can be controlled by numerical control so as to stop or allow the particles to flow in a controlled manner. Each particle depositing means may, for example, comprise a type of particle, a color for example, so as to mix several types of particles in the pattern using several depositing means.

[0049] Regardless of the embodiment, the particle deposition means may comprise digital control means, the pattern being predefined in a digital file or any equivalent computer storage means. The digital control means comprise means for interpreting said file or computer storage means to digitally control the deposition means according to the relief pattern and deposit the particles according to the relief pattern. Brief description of the drawings

[0050] [Fig.1 A] is a side view of a first example of coating obtained by a method according to the invention.

[0051] [Fig.1 B] is a detailed view of the first example of coating according to Figure 1 A.

[0052] [Fig.2] is a side view of a second example of coating obtained by a method according to the invention.

[0053] [Fig.3] is a side view of a third example of a coating obtained by a method according to the invention.

[0054] [Fig.4] is a side view of a fourth example of coating obtained by a method according to the invention.

[0055] [Fig.5] is a side view of a fifth example of a coating obtained by a method according to the invention.

[0056] [Fig.6] is a side view of a sixth example of a coating obtained by a method according to the invention.

[0057] [Fig.7] is a side view of a seventh example of a coating obtained by a method according to the invention.

[0058] [Fig.8] is a perspective view of a device allowing the implementation of a method according to the invention.

[0059] [Fig.9] is a top view of the dispensing device for digitally controlled dispensing of particles, shown in Figure 8.

[0060] [Fig.10] is a side view of a second device allowing the implementation of a method according to the invention. Detailed description of the invention

[0061] Regardless of the embodiment, the particles of materials that can be distributed are in bulk, for example in the form of powders and / or granules and / or dry blends. The granules that can be used to produce the relief according to the invention may be identical or of different types. For example, the polymer materials that can be used may be chosen from PVC, pure PVC or plasticized PVC, PP, PE, PMMA, as well as scraps or shredded products from the recycling channels for these materials. It is of course possible to mix several types of materials to be deposited to obtain a relief pattern according to the invention. By way of non-limiting examples, the materials that can be deposited may be granular materials in the form of powders, granules, shot, flakes, lamellae or any other materials in particulate or substantially particulate form.More specifically, these can be pearlescent pigments, pigments, pure or coated in the form of pigment paste, anti-slip particles. Particles can also. include linoleum, linoleum paste also called "linoleum cernent" in English, thermosets, inorganic particles such as glass or corundum, natural mineral particles such as mica, feldspar, basalt, hollow glass or polymer particles, ...

[0062] The particles may optionally be lightly pressed to penetrate the thickness of the base layer without, however, penetrating completely and so as to keep at least a flush part of the predefined relief pattern. They may also be heated before and / or after deposition to slightly modify their surface appearance or to help their adhesion to the fluid adhesive material.

[0063] In the case of PVC, it can be used in different forms for the production of particles in the form of granules. For example, the granules are obtained from PVC, possibly with a filler, possibly with plasticizer, mixed and then gelled in a mixer. A conventional process for obtaining plasticized granules comprises at least steps consisting of: - Heat a quantity of PVC powder between 60°C and 90°C then add a quantity of plasticizer; - Heat the mixture obtained to approximately 100°-110°C so that the PVC plasticizes and possibly incorporate a quantity of filler, stabilizers, pigments or other additives, and mix; - Cool the plasticized PVC mixture in order to possibly incorporate a quantity of filler, stabilizers, pigments or other additives, and mix. The mixture obtained is in the form of a powder called "dry blend" in English; - Gel this “dry blend” by heating it to 170°C in a continuous extruder, or in batches in an “internal” mixer; - Extrude the mixture through a die with holes, then cut the beads of molten material, in order to obtain granules of 0.5 to 10 millimeters in section, and a length of 0.5 to 10 millimeters.

[0064] According to an alternative, the particles of materials distributed according to the invention are in the form of powder or even “dry blend”, that is to say in the form of powder of polymeric materials, for example PVC, plasticized and not gelled. In this case, the method according to the invention comprises a step consisting of depositing the particles in the form of a "dry blend" on the fluid adhesive material, itself deposited according to a predefined relief pattern, then gelling this "dry blend" for example by heating. The use of dry blend makes it possible to obtain a better relief resolution with regard to the particle size that can be obtained with this type of powder. Preferably and in order to facilitate its handling by the deposition means, the deposited powder has a particle size of between 2 μm and 250 μm. For example, a dry blend commonly used for the preparation of PVC granules has a density of approximately 0.50, a volume average diameter of 136 μm, a D50: 140 μm, a D10 of 63 μm and a D90 of 198 μm.The use of dry blend also eliminates the granulation step commonly used for the production of PVC flooring by allowing a raised pattern to be created directly. This granulation operation is costly in terms of time, equipment and energy. Distributing a dry blend is also easier compared to granular materials, which generally have a wider particle size distribution. This makes it easier to obtain a uniform thickness.

[0065] In the case of linoleum, it is possible to adapt the method according to the invention in order to obtain a pattern from a distribution of linoleum paste. A linoleum paste is in the form of a powder obtained from a mixture of linoleum cement mixed with cork powder, wood flour and coloring materials such as pigments. The method then comprises an additional step consisting of heating the particles comprising the linoleum paste so as to crosslink this paste and obtain the relief pattern. The particles can optionally be lightly pressed to penetrate into the thickness of the base layer without, however, penetrating entirely and so as to keep at least a flush part of the predefined relief pattern.

[0066] The base layer according to the invention generally has a thickness of between 0.3 and 6 millimeters.

[0067] The base layer is made from polymeric materials and can be in the form of a single layer or a multi-layer structure. The underside of the base layer can optionally be subsequently bonded to other layers so as to form a heterogeneous floor covering and provide, for example, other damping, resistance or acoustic properties to the covering. A base layer can in particular be obtained from PVC and can for example be produced by calendering, coating then gelling, by pressing or even by extrusion through a flat die, this layer being in the form of a sheet having two smooth faces.

[0068] The base layer can be used as a floor or wall covering in rolls or even cut to form a floor covering in sheets, slabs or even strips. Rolls can be between 5 and 50 meters long and between 1 and 4 meters wide.

[0069] Assembly means may in particular be machined on the edges of each slab or blade in order to connect them together. Such means are described in particular in documents WO2016030627, US20130309441 or EP3105392. Plates, slabs or blades may have a dimension of between 0.10 and 3.5 meters long and 0.10 and 2.6 meters wide.

[0070] According to Figure 1 A, a first example of a floor or wall covering (1) is described comprising a base layer (2) running on a support (S). The base layer (2) has an upper face (2a) and an opposite lower face (2b) intended to be in contact with the floor. On the upper face (2a) is deposited by numerical control a first fluid adhesive material (4a) according to a part of a predefined relief pattern. Particles of materials (3a) of a first type are then deposited on the fluid adhesive material (4a). The fluid adhesive material (4a) is then crosslinked so that the coating formed retains only the dry part of the adhesive material (4a). Figure 1 B illustrates a detail A of Figure 1 A showing an overlap between two types of particles (3a, 3b). To achieve this overlap, the fluid adhesive material (4b) is deposited according to a second part of the predefined relief pattern after the step of depositing the particles (3a).This step occurs before or after the crosslinking step of the fluid adhesive material (4a). After depositing the second type of particles (3b), the adhesive material (4a, 4b) is completely crosslinked. The material particles (3a, 3b) are thus bonded to the base layer (2) so as to form the predefined relief pattern. The fluid adhesive material (4a, 4b) can be applied in one or more depositing steps, each depositing also being carried out according to a new pattern. predefined relief and / or with a new type of fluid adhesive material (4a, 4b). Furthermore, the particles (3a, 3b) can be deposited in one or more deposition steps, each deposition possibly being carried out according to a new predefined relief pattern in relation to the relief pattern for depositing at least one fluid adhesive material and / or with a new type of particles (3a, 3b).

[0071] According to Figure 2, a second example of floor or wall covering (1) is described comprising a base layer (2) reproducing the elements of Figure 1 A and also comprising at least one decorative layer (5) printed with a predefined decorative pattern, by any known means, in particular by an inkjet printing process, and visible from the upper face of the base layer (2a). The base layer (2) optionally comprises a translucent or transparent layer (6) bonded to the decorative layer (5). The decorative layer (5) is therefore optionally covered with a translucent or transparent layer (6) in order to protect it. Thus, in this example, the upper face (2a) of the layer (2) is either formed by the upper face of the decorative layer (5) or by the upper face of the translucent or transparent layer (6). The fluid adhesive material (4a, 4b) is thus either deposited on the printed pattern or on the translucent or transparent layer (6).The base layer (2) thus comprises a decorative layer (5) bonded to a backing layer (11) intended to be in contact with the ground. The decorative layer (5) is for example a PVC film with a thickness of between 50 and 150 μm.

[0072] According to Figure 3, a third example of floor or wall covering (1) is described comprising a base layer (2) reproducing the elements of Figure 1A and having a predefined decorative pattern (7) printed on the upper face of the base layer (2a).

[0073] According to Figure 4, a fourth example of floor or wall covering (1) is described comprising a base layer (2) incorporating the elements of Figure 1A and having a predefined decorative pattern (7) printed on the particles (3a, 3b), superimposed.

[0074] The pattern (7) of figures 3 and 4 can be printed by any known means, in particular by inkjet printing processes. The types of ink used may in particular be aqueous or latex-based inks and may be dried or crosslinked by any known means, in particular by hot air flow or by exposure to ultraviolet radiation.

[0075] According to figures 2, 3 and 4, in the case where the base layer (2) comprises at least one decorative layer (5) having a predefined decorative pattern or a predefined decorative pattern (7) printed on the upper face of the base layer, the fluid adhesive material (4a, 4b) can be deposited depending on the position of the predefined decorative pattern.

[0076] According to Figure 5, a fifth example of floor or wall covering (1) is described comprising a base layer (2) incorporating the elements of Figure 1A and comprising a crosslinked protective layer (8), previously deposited on the material particles (3a, 3b) so that the material particles (3a, 3b) are partially embedded in the thickness of the protective layer (8). At least some of the particles are flush with the surface of the protective layer (8). Alternatively, and in a manner not shown, the deposited particles may be covered with the protective layer so that it matches the shape of the relief pattern. This makes it possible to maintain a very weakly structured surface relief while improving cleanability and protecting the deposited particles (3a, 3b). In the case where the base layer (2) and / or the material particles (3a, 3b) are printed with a decorative pattern (7), the protective layer (8) may be deposited on the decorative pattern (7) in order to protect it. Alternatively, and in a manner not shown, the protective layer (8) may be deposited on the material particles (3a, 3b) and then printed with a decorative pattern (7) by any known means.

[0077] According to Figures 6 and 7, a sixth and seventh example of floor or wall covering (1) is described. In these examples, the base layer (2) may comprise particles of polymeric materials (9a, 9b) distributed by means of numerically controlled deposition to form a decorative pattern along the three axes of a three-dimensional reference frame (X, Y, Z) and so as to be distributed in all or part of the thickness of the base layer (2). The base layer is thus obtained at least partially or even entirely from particles distributed by means of numerically controlled deposition before the step of depositing the fluid adhesive material (4a). According to Figure 7, the particles of polymeric materials (9b) making it possible to obtain a predefined decoration, may be deposited in a polymeric matrix (10), for example a plastisol or a layer of powder. The polymeric particles (9b) may optionally be substituted by non-polymeric particles in the case of the use of a polymeric matrix (10). A method of manufacturing a floor or wall covering comprising a base layer (2) according to this example, is made from polymeric materials, said base layer comprising particles of materials distributed to form a predefined pattern comprises at least steps consisting of: - controlling deposition means by numerical control to deposit the material particles (9a, 9b) on a support (S) moving continuously or step by step to form the predefined decorative pattern, or, controlling deposition means by numerical control to deposit the material particles (9a) on a polymer matrix (10) supported by the support (S) and moving continuously or step by step to form the predefined decorative pattern; - heating the material particles (9a, 9b) and, where appropriate, the polymer matrix (10) to bind them and form the base layer (2); - optionally, pressing the material particles (9a, 9b) and, if applicable, the polymer matrix (10).

[0078] The particles of polymeric materials (9a, 9b) used to obtain the layer (2) according to figures 6 and 7 may be in the form of powders, for example of PVC “dry blend”, colored or not, or even of gelled PVC granules, alone or in mixtures. Depending on the type of materials, it may be necessary to carry out a step of hot pressing the deposited particles to obtain a base layer (2) of uniform thickness.

[0079] Generally, the step of controlling depositing means by numerical control to deposit particles of materials on a support to form the pattern, can be carried out by a device for digitally controlled distribution of particles of materials such as granules and / or powders. For example, this device can comprise at least one particle storage hopper having at least one outlet mouth. The outlet mouth can be closed or opened by numerical control so as to allow the particles stored in the hopper to flow onto a support in a controlled manner and according to a predefined pattern.

[0080] Several methods and devices make it possible to deposit particles in a predefined relief pattern according to the invention.

[0081] Figures 8 and 9 illustrate an exemplary implementation of a device (110) capable of implementing a method according to the invention. The base layer (100) is illustrated here in the form of plates, although the same device (110) can be used for products in rolls. The base layer (100) is supported by a support (111) and scrolls continuously or step by step. The device also comprises means for scrolling the support (111) for carrying out a relative movement in at least one scrolling direction (B) between a distribution device (170) and the base layer (100) on which the particles are to be distributed. The support (111) is here a continuous conveyor belt (111) transporting the base layer (100), the belt being driven by an electronically controlled motor.

[0082] The device (110) comprises at least one device (160) for depositing a fluid adhesive material on the upper face of the base layer (100) according to a predefined relief pattern.

[0083] The device (110) also comprises at least one depositing device for the digitally controlled distribution of particles (170), wherein each depositing device (170) comprises a hopper (103) for storing bulk material provided with a plurality of outlet mouths (133), a plurality of distribution elements (104), each being located opposite an outlet mouth (133) so that the material leaving each outlet mouth (133) can accumulate therein without flowing. Each distribution element (104) is inclined relative to a horizontal plane, in order to define a sliding direction of the particles towards at least one descending edge (141) of the distribution element (104).The device (170) also comprises a plurality of vibrating means (105, 150), each associated with a respective distribution element (104) for vibrating said distribution element (104), so that the accumulated particles slide upwards on the distribution element (104) until the particles fall off the descending edge (141) thereof when the latter is vibrating on the base layer (100).

[0084] The distribution elements (104) are inclined at an inclination of between 0° and 10° relative to the horizontal plane.

[0085] The device (110) also comprises at least one means (180) for crosslinking the fluid adhesive material, for example a hot air dryer or an infrared lamp.

[0086] Digital control means (190) control the depositing device (160) according to a predefined pattern known to the control means (190), the distribution device for the digitally controlled distribution of particles (170), in particular for the activation of each vibration means (105, 150) independently of each other, as well as the means for crosslinking the fluid adhesive material (180). Digital control means (190) may in particular be a control / command computer, a microcontroller comprising means for digital storage of a file defining the predefined relief pattern.

[0087] The devices for depositing the fluid adhesive material (160), for depositing the particles (170) and for crosslinking (180) are stably fixed to a support (113, 102) fixed relative to the support (111). As illustrated in FIG. 9, a plurality of devices (170) may be arranged transversely to the support (111). In this way, each dispensing device (170) may act in sequence on the base layer (100), in order to increase the range of reliefs and / or decorative effects that can be achieved. In particular, the hoppers (103) of the dispensing devices (170) may be filled with particles having a different coloring, density, hardness, gloss, in order to obtain predefined patterns and / or textures and having several colors and / or materials. Thus, each dispensing device (170) is intended to deposit a specific material, for example a color on the base layer (100) according to a predefined pattern.

[0088] Figure 10 illustrates a second example of a device (210) capable of implementing a method according to the invention. The base layer (203) is illustrated here in the form of a roll, although the same device (210) can be used for sheet products. The base layer (203) is supported by a support (208) and scrolls continuously or step by step. The device also comprises means for scrolling the support for carrying out a relative movement in at least one scrolling direction (A) between a distribution device (205) and the base layer (203) on which the particles are to be distributed. The support (208) is here a continuous conveyor belt transporting the base layer (203) and driven by an electronically controlled motor.

[0089] This device (210) allows the production of predefined relief patterns by numerical control from materials in the form of particles. It comprises means for depositing by numerical control of fluid adhesive material (260) from a digital print head (202) provided with piezoelectrically controlled ejection nozzles. The digital print head (202) can also be provided with several respective individual heads, each being equipped with nozzles for ejecting fluid adhesive material on the upper face of the base layer (203). The means (260) thus allow the ejection of microdrops of fluid adhesive material onto the surface of the base layer (203). Optionally, the means (260) comprise radiating means (204) adapted to irradiate the drops of fluid adhesive material deposited in the case where the latter can be hardened by exposure to radiation.It is for example possible to define a fluid adhesive material, for example a varnish, so that irradiation of the fluid adhesive material, for a predefined period and amount of energy, allows pre-crosslinking thereof. By rapid transformation into a substantially transparent and glue-like film, it is thus possible to subsequently deposit particles of materials on the adhesive material and obtain a first level of bonding before total crosslinking thereof. The device (210) thus comprises means (205) for depositing particles of materials (206) on the layer of adhesive material, after the latter has undergone irradiation under the radiating means (204) and has thus taken on a glue-like consistency.The means (205) for depositing the material particles comprise, for example, a hopper (209) opening onto a closable outlet (214) which, in the open position, allows the particles stored in the hopper (209) to flow out regularly. The means (205) extend transversely over all or part of the width of the base layer (208) along the Y axis. The device (210) optionally comprises means (207) for removing excess material particles (206), which are deposited on the base layer (203) without being bound to fluid adhesive material. These means (207) make it possible to remove the material particles. (206) which have not stuck directly to the adhesive material, and which therefore remain in excess since they cannot be incorporated into the relief pattern being produced. The means (207) for removing the excess material particles (206) comprise, for example, at least one suction hood (211) arranged so that its suction mouth (212) is close to the upper surface of the base layer (203) supported by a continuous belt conveyor (208). The suction hood (211) may also comprise an evacuation mouth (213) through which, by suitable conduits, not shown in the figures, the excess material particles (206) can be returned to the interior of the hopper (209), or conveyed to a special collection area.

[0090] The base layer (203) is arranged on the continuous belt conveyor (208) and moves in a direction A continuously or step by step.

[0091] The device (210) also comprises at least one means for total crosslinking (280) of the fluid adhesive material, for example a hot air dryer or an infrared lamp.

[0092] Digital control means (290) control the means for depositing the fluid adhesive material (260) according to a predefined pattern known to the control means (290), the distribution device for the controlled distribution of particles (205), depending on the pattern or not. Similarly, the suction means (207), as well as the means for crosslinking the fluid adhesive material (280) can possibly be controlled by the digital control means (290). Digital control means (290) can in particular be a control / command computer, a microcontroller comprising means for digital storage of a file defining the predefined relief pattern.

Claims

Claims [Claims 1] Method for manufacturing a floor or wall covering comprising at least one base layer (2) made from polymeric materials comprising an upper face (2a) and a lower face (2b), said upper face comprising a predefined relief pattern, characterized in that it comprises at least steps consisting of: a) scrolling the base layer (2); b) controlling deposition means by numerical control to deposit a fluid adhesive material (4a, 4b) on the upper face (2a) of the base layer (2) according to the predefined relief pattern; c) depositing material particles (3a, 3b) on the fluid adhesive material (4a, 4b); d) crosslinking the deposited fluid adhesive material (4a, 4b) to bind the material particles (3a, 3b) to the base layer (2) and form the predefined relief pattern. [Claims 2] Method for manufacturing a continuous floor or wall covering according to claim 1, characterized in that the base layer (2) runs continuously. [Claims 3] Method of manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that step b) comprises the following steps consisting of: - controlling deposition means by numerical control to deposit a first fluid adhesive material (4a) on the upper face (2a) of the base layer (2) according to a first part of the predefined relief pattern; - controlling deposition means by numerical control to deposit at least a second fluid adhesive material (4b) on the upper face (2a) of the base layer (2) according to a second part of the predefined relief pattern. [Claims 4] Method of manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that step c) comprises the following step consisting of: - controlling deposition means by numerical control to deposit material particles (3a, 3b) on the fluid adhesive material (4a, 4b) according to the predefined relief pattern. [Claims 5] Method of manufacturing a floor or wall covering according to claims 3 and 4, characterized in that step c) comprises the following steps consisting of: - controlling deposition means by numerical control to deposit a first type of material particles (3a) on the fluid adhesive material (4a, 4b) according to a first part of the predefined relief pattern; - controlling deposition means by numerical control to deposit a second type of material particles (3b) on the fluid adhesive material (4a, 4b) according to a second part of the predefined relief pattern. [Claims 6] Method of manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that it comprises the additional steps after step c) or d) consisting of: - coating a protective layer (8) on the material particles (3a, 3b) so that the material particles (3a, 3b) are partially embedded in the thickness of the protective layer (8); - crosslink the protective layer (8). [Claims 7] Method of manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that it comprises at least one additional step consisting of: - Printing a predefined decorative pattern (7) on the upper side (2a) of the base layer (2) and / or on the material particles (3a, 3b) using an inkjet printing process. [Claims 8] A method of manufacturing a floor covering or according to any one of the preceding claims, characterized in that the base layer (2) comprises at least one decorative layer (5) having a predefined decorative pattern or a predefined decorative pattern (7) directly printed on the upper face of the base layer (2a) and in that the method comprises a following step consisting of: - Apply the fluid adhesive material (4a, 4b) according to the position of the predefined decorative pattern (7). [Claims 9] Method of manufacturing a floor or wall covering according to any one of the preceding claims, characterized in that it comprises at least one additional step after step c) consisting of partially crosslinking the deposited fluid adhesive material (4a, 4b). [Claims 10] Floor or wall covering comprising at least one base layer (2) characterized in that the base layer (2) comprises a predefined relief pattern obtained by a manufacturing method according to any one of the preceding claims.

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