Process for manufacturing floor or wall coverings, and associated coverings

Abstract

The invention relates to a process for continuously manufacturing a floor or wall covering having at least one base layer made of polymer materials, said base layer comprising material particles that are distributed to form a pattern, the process involving at least the steps of: - controlling numerical control deposition means to deposit the material particles on a continuously advancing support to form the pattern, - heating the material particles to bond same and form the base layer, - separating the base layer from the support.

Description

Description Title of the invention: Method for producing 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 decorative layer whose decoration is distributed throughout the thickness of the layer. Prior art

[0002] In the field of floor 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 by means of a platen press, a double-belt press, or with a passage between two cylinders of a calender, this layer in order to bind the granules and obtain a decorative floor covering layer. The floor or wall covering obtained may consist of a single decorative layer to form a homogeneous covering or several layers bound together to form a heterogeneous covering, the decorative layer being arranged in the upper part of the floor covering.

[0003] This type of decorative layer has the advantage of presenting a decoration "in the mass", that is to say in the entire thickness of the decorative layer. In fact, the decoration presented by the layer does not deteriorate with wear and under successive cleaning, which gives a long life to the coating. However, these decorations are obtained by randomly sprinkling a thickness of granules over the entire surface of a pressing support, and it is not possible to reproduce a desired pattern, we then speak of "approximate" decoration.

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

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

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

[0008] To this end, a method has been developed for manufacturing a continuous floor or wall covering comprising at least one base layer made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern, comprising at least steps consisting of: - control deposition means by numerical control to deposit the material particles on a continuously moving support to form the pattern, - heat the material particles to bind them and form the base layer, - separate the base layer from the support.

[0009] This process thus makes it possible to obtain a decoration in the thickness of the base layer, the decoration being obtained by the combination of the pattern obtained by the distribution of the particles of materials and any other materials of the base layer. The base layer obtained forms a layer allowing the creation of a homogeneous, single-layer floor or wall covering, or which can possibly be subsequently linked to other layers so as to form a heterogeneous floor covering.

[0010] According to a first alternative, the support is therefore used solely for obtaining the floor or wall covering and is then separated from the covering. The support may, for example, comprise a continuous conveyor belt or transfer paper, for example a paper coated with a layer of silicone on the face intended to receive the distributed material particles, or even a textile. In this case, the floor or wall covering obtained from the process is a homogeneous covering, comprising only a single layer and the process according to the invention makes it possible to produce a decoration comprising a predefined pattern over all or part of the thickness of the base layer, and therefore of the covering.

[0011] Alternatively, the method of manufacturing a continuous floor or wall covering comprising at least one base layer made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern, comprises at least steps consisting of: - control deposition means by numerical control to deposit material particles on a continuously moving support to form the pattern - heating the material particles on the support to bind them and form the base layer, the support being integral with the base layer.

[0012] This process thus makes it possible to obtain a heterogeneous 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 distributed material particles and any other materials of the base layer. This process may require means for unrolling the support such as unwinders, rollers or conveyor belts, so as to unroll the support during the steps of deposition, heating, and possibly pressing.

[0013] In this second case, the support is therefore intended to be integral with the base layer and therefore with the floor or wall covering. It can then include a reinforcement such as a glass veil, a polyester non-woven fabric or a layer obtained from a thermoplastic, for example a layer obtained from PVC. This makes it possible to obtain a reinforced and / or heterogeneous floor or wall covering insofar as it comprises several layers. A layer obtained from PVC can for example be produced by calendering, coating then gelling, by pressing or even by extrusion through a flat die, this layer appearing in the form of a sheet with two smooth faces.

[0014] Regardless of the embodiment, the deposition 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, the particle storage means and the closing means together forming a distribution device. Each deposition means may, for example, store a type of particle, a color for example, so as to mix several types of particles in the pattern using several deposition means.

[0015] Regardless of the embodiment, the deposition means may comprise a dispensing device, the pattern being predefined in a digital file or any equivalent computer storage means, the dispensing device comprising means for reading and interpreting said file or computer storage means to digitally control the deposition means according to the pattern and to deposit the particles according to the pattern. The dispensing device may in particular comprise a control computer associated with a microcontroller controlling a particle dispensing device. The computer makes it possible to interpret the predefined pattern and to establish a series of operations of the microcontroller. The microcontroller makes it possible, for example, to control the particle dispensing device according to parameters of movement, position, and quantity of particles to be deposited established by the computer according to the predefined pattern.Thus, whatever the embodiment, the pattern can be predefined in a digital file and the invention makes it possible to obtain a decorative layer whose pattern is rarely repeated, unlike entirely mechanical processes. The invention makes it possible to avoid, for example, the use of gravure printing processes whose cylinders generally have a development of less than three meters. It is also possible for the pattern to be continuously renewed by computer-generated pattern generation means so as not to repeat itself identically but to provide, for example, slight variations in color or geometry, the pattern remaining predefined during the step of controlling the deposition means.

[0016] Whatever the embodiment, the method according to the invention may comprise several successive steps consisting of controlling deposition means by digital control to deposit the particles of materials on a continuously moving support to form the pattern, so as to obtain a defined pattern extending in the thickness of the base layer.

[0017] Regardless of the embodiment, by continuously scrolling, we mean that the support is in continuous movement relative to the depositing means or advances step by step relative to the depositing means.

[0018] Regardless of the embodiment, the polymeric materials for producing the base layer may be deposited in whole or in part during the step which consists of controlling deposition means by numerical control to deposit the material particles on a continuously moving support to form the pattern. In this case, the particles comprise particles made from polymeric materials.

[0019] Regardless of the embodiment, the polymeric materials for producing the base layer may be deposited in whole or in part before or after the step which consists of controlling deposition means by numerical control to deposit the material particles on a continuously moving support to form the pattern. In this case, the deposited particles may comprise particles made from polymeric and / or non-polymeric materials.

[0020] Several supports intended to be integral with the base layer are possible. The support may notably comprise a reinforcing framework such as a reinforcing grid or a layer of non-woven textile such as a glass or polyester veil. Materials in the form of fibers which can be used to obtain a reinforcing framework include polyethylene, polyethylene terephthalate (PET), glass fibers, polyester, aramid, carbon fibers, nitrile fibers, ethylene vinyl acetate (EVA), high-density polyethylene (HDPE), low-density polyethylene (LDPE), polyvinyl chloride (PVC).

[0021] The support may also comprise a backing layer made from polymeric materials. A backing layer in the form of a sheet may for example be obtained from tinted granules, for example made from PVC then pressed, or by coating and gelling a tinted PVC plastisol, by extrusion in a flat die or by calendering.

[0022] Polymeric materials that can be used in the composition of the base layer, particles and / or a backing layer are, for example, PVC, PVB, PLA, TPU, PPMA, cellulose derivatives, elastomers, alone or in mixtures.

[0023] According to an alternative, the method for manufacturing a continuous floor or wall covering according to the invention comprises at least one step, prior to the step of depositing the material particles by digitally controlled deposition means and consisting of: - deposit a layer of liquid plastisol on the continuously moving support - optionally, pre-gel the plastisol layer.

[0024] In this way, it is possible to integrate particles into a coating obtained by coating according to a predefined pattern. Depending on the density of the particles and the level of pre-gelation of the plastisol, it is possible to distribute the particles in the thickness of the base layer. The plastisol layer is in this case non-gelled or partially gelled. Indeed, unlike calendering, pressing or extrusion processes, plastisol coating processes do not allow recycled coating shreds from installation scraps or other recycled materials to be incorporated directly into the plastisol. The invention thus allows the production of layers and coatings obtained from coating processes comprising a predefined pattern and advantageously whose environmental footprint is reduced.

[0025] Alternatively, the method for manufacturing a continuous floor or wall covering according to the invention comprises at least one step prior to the step of depositing the particles and consisting of: - control deposition means by numerical control to deposit a layer of fluid adhesive material on a continuously moving support then deposit the material particles on the layer of fluid adhesive material to form the pattern. The fluid adhesive material may be, in particular, a varnish, in particular based on acrylic or polyurethane, a liquid glue, a plastisol.

[0026] The fluid adhesive material is advantageously deposited in drops having a volume of between 1 picoliter and 1 milliliter. Alternatively, the fluid adhesive material may be replaced by an adhesive material in powder form. For example, the adhesive material may comprise a hot-melt powder, a varnish in powder form.

[0027] Regardless of the embodiment and in order to obtain a uniform base layer and coating thickness, the manufacturing method according to the invention may comprise at least one additional step consisting of pressing the material particles onto the support. This step may be carried out before the heating step or simultaneously with the step of heating the deposited particles.

[0028] Whatever the embodiment and preferably, the manufacturing method according to the invention comprises deposition means movable relative to the continuously moving support. This makes it possible, for example in the case of a support moving in a plane (X,Y) along an axis (Y), to deposit particles transversely to the support, i.e. according to a position on the axis (X) and / or in the axis of the support (Y), without having to multiply the number of deposition means. In a complementary manner, the deposition means can be movable relative to the support along an axis (Z) perpendicular to the plane (X,Y) of movement of the support so as to produce a three-dimensional pattern, in the thickness of the base layer.

[0029] Preferably, the manufacturing method according to the invention comprises at least one additional step before the heating step consisting of: - deposit a layer of material particles on the continuously moving support

[0030] This step consists of depositing on the continuously moving support a "bed" of particles of a thickness that can be variable or constant. These particles are distributed randomly and form a non-predefined pattern. It is for example possible to deposit particles of materials in the form of granules, powders or "dry blend" according to a random pattern upstream of the step which consists of controlling deposition means by numerical control to deposit the particles of materials on a continuously moving support to form the pattern. The method can then comprise an additional step consisting of controlling deposition means by numerical control to deposit the particles of materials on the bed of particles deposited randomly to form the pattern. This alternative makes it possible, for example, to obtain marbled decorations with a base layer in a random pattern and veins obtained by the particles deposited in a predefined pattern. This alternative also makes it possible to integrate recycled materials into the layer of particles deposited in a random pattern, and therefore into coatings. The method according to the invention therefore makes it possible to obtain a new type of coating mixing recycled materials in a base layer made from polymeric materials.

[0031] The invention also relates to a floor or wall covering comprising at least one base layer obtained by a manufacturing method according to the invention. The covering thus comprises a predefined pattern extending "in the mass", that is to say in all or part of the thickness of the base layer. For example, a decoration is considered to be "in the mass" when it extends over a thickness of the base layer greater than 0.1 mm, or even greater than 0.3 mm and up to 6 mm in order to resist wear due to traffic.

[0032] Advantageously, the particles of materials deposited to form the pattern are particles made from polymeric materials such as PVC, polypropene, polyethylene, PMMA, linoleum, thermosets, alone or in a mixture or even non-polymeric materials such as corundum or glass.

[0033] 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. The method according to the invention may thus comprise a step consisting of controlling deposition means by numerical control to deposit granules and / or powders on a continuously moving support to form the pattern.

[0034] The particles of materials deposited to form the pattern may also include at least one mineral filler, natural or synthetic.

[0035] The material particles deposited to form the pattern may also include at least one plasticizer.

[0036] The material particles deposited to form the pattern can come from a recycling channel.

[0037] The particles of materials deposited to form the 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.

[0038] The material particles deposited to form the pattern may be in the form of a dry-blend of PVC or in the form of granules obtained from a gelled polymeric material such as PVC.

[0039] The material particles deposited to form the pattern may be in the form of colored granules, each granule comprising one or more colors. Brief description of the drawings

[0040] [Fig.1] is a side view of a first example of a base layer obtained by a method according to the invention.

[0041] [Fig.2] is a side view of a second example of a base layer obtained by a method according to the invention.

[0042] [Fig.3] is a side view of a third example of a base layer obtained by a method according to the invention.

[0043] [Fig.4] is a side view of a fourth example of a base layer obtained by a method according to the invention.

[0044] [Fig.5] is a perspective view of a dispensing device for the numerically controlled dispensing of particles.

[0045] [Fig.6] is a top view of the dispensing device for controlled particle dispensing shown in Figure 1.

[0046] [Fig.7] is a side view of a second dispensing device for numerically controlled dispensing of particles.

[0047] [Fig.8] is a side view of a fifth example of a base layer obtained by a method according to the invention.

[0048] [Fig.9] is a side view of a sixth example of a base layer obtained by a method according to the invention.

[0049] [Fig.10] is a side view of a seventh example of a base layer obtained by a method according to the invention.

[0050] [Fig.11] is a side view of an alternative showing a support printed with a decorative layer.

[0051] [Fig.12] is a side view of an alternative showing a base layer printed with a decor layer. Detailed description of the invention

[0052] 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. The granules that can be used for producing a base layer according to the invention can be of the same or different natures. For example, the polymer materials that can be used can be chosen from PVC, PP, PE, PMMA, as well as offcuts or shredded products from the recycling channels for these materials. Alternatively, the particles can comprise linoleum.

[0053] In the case of PVC, it can be used in different forms to make granules. For example, granules are obtained from PVC, possibly with a filler, possibly with a plasticizer, mixed and then gelled in a mixer. A classic process for obtaining plasticized granules includes at least the following steps: -Heat a quantity of PVC powder between 80°C and 90°C then add a quantity of plasticizer, - Heat the mixture obtained to approximately 110°C so that the PVC plasticizes, - 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 to obtain granules with a cross-section of 0.5 to 10 millimeters and a length of 0.5 to 10 millimeters.

[0054] According to an alternative, the 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 distributing the particles in the form of “dry blend” on a support according to a predefined pattern then gelling this “dry blend” for example using a heating press. The use of dry blend makes it possible to obtain a better resolution of decorations 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 1 μm and 250 μm.For example, a dry blend commonly used for preparing PVC granules has a density of approximately 0.50, a volume average diameter of 136 μm, a D50 of 140 μm, a D10 of 63 μm and a D90 of 198 μm. The use of dry blend also eliminates the granulation step commonly used for producing PVC flooring by allowing a 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 distributing granules, which generally have a wider particle size distribution. This makes it easier to obtain a uniform deposit in thickness, for example to create a "bed", a regular layer.

[0055] 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 powder obtained from a mixture of cement linoleum mixed with cork powder, wood flour and coloring materials such as pigments. The process then includes an additional step of pressing and heating the layer comprising the linoleum paste so as to crosslink this paste and obtain the base layer.

[0056] It is of course possible to mix several types of materials to be deposited to obtain a 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 may be mother-of-pearl, pigments, pure or coated in the form of pigment paste, or anti-slip particles.

[0057] Following the deposition step using digitally controlled deposition means, it may be possible to consider preheating the deposited materials so as to pre-gel them and / or maintain them on the support, for example by exposure to infrared radiation.

[0058] The presses which can be used with the method according to the invention are, for example, single-belt presses, double-belt presses or alternatively calenders comprising at least two cylinders.

[0059] The heating step can, for example, be carried out using an oven or by exposure to infrared radiation.

[0060] Continuous scrolling means capable of scrolling the media may, for example, include a belt conveyor, rollers, belts or the like.

[0061] The base layer according to the invention generally has a thickness of between 0.3 and 6 millimeters.

[0062] The base layer may optionally be varnished and / or bonded to a backing layer on its underside and / or bonded to a top layer on its upper side, for example a transparent wear layer.

[0063] The base layer can form a floor or wall covering in rolls or even be cut to form a floor covering in sheets, slabs or even strips. Assembly means can in particular be machined on the edges of each slab or blade in order to allow them to be linked together. Such means are notably described in documents WO2016030627, US20130309441 or EP3105392. Plates, slabs or blades may have a dimension between 0.10 and 3.5 meters long and 0.10 and 2.6 meters wide.

[0064] According to Figure 1, a first example of a floor or wall covering (1) is described comprising a base layer (2) obtained by a manufacturing method according to the invention. The base layer (2) is in the form of a film having an upper face intended to be in contact with the user and a lower face intended to be in contact with the floor. The covering (1) consists solely of the base layer (2), with the exception of a particular embodiment where the latter is covered with a varnish (not shown) on its upper face. The base layer (2) comprises particles of polymeric materials (3a, 3b) distributed by numerically controlled deposition means to form a 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 layer (2).The coating is thus obtained entirely from particles distributed by digitally controlled deposition means. A portion of the polymeric particles (3b) may optionally be substituted by non-polymeric particles. A method of manufacturing a continuous floor or wall covering comprising a base layer (1) according to this first example made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern comprises at least steps consisting of:. - control deposition means by numerical control to deposit the material particles (3a, 3b) on a continuously moving support (not shown) to form the pattern, - heat the material particles to bind them and form the base layer, - separate the base layer from the support.

[0065] The particles of polymeric materials (3a, 3b) can be in the form of powders, for example "dry blend" PVC, colored or not, or even gelled PVC granules, alone or in mixtures. Depending on the type of materials it can It may be necessary to carry out a hot pressing step of the deposited particles to obtain a base layer of uniform thickness.

[0066] According to Figure 2, a second example of floor or wall covering is described. (1) comprising a base layer (2) obtained by a manufacturing method according to the invention. The coating (1) consists solely of the base layer (2), with the exception of a particular embodiment where the latter is covered with a varnish (not shown) on its upper face. The base layer (2) comprises randomly deposited polymeric material particles (4) as well as material particles (3b) distributed by numerically controlled deposition means to form a 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 layer (2). The coating is thus obtained in part from particles (3b) distributed by means of numerically controlled deposition. A method of manufacturing a continuous floor or wall covering comprising at least one base layer according to this second example made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern, comprises at least steps consisting of: - randomly depositing polymer particles on a continuously moving support so as to form a layer (4), - control deposition means by numerical control to deposit material particles (3b) on the support or on the layer of randomly deposited polymer particles (4) to form the pattern, - heating the material particles on the support to bind them and form the base layer (2). In this example the material particles (3b) are not necessarily polymeric.

[0067] According to Figure 3, a third example of a floor or wall covering (1) is described comprising a base layer (2) obtained by a manufacturing method according to the invention. The covering (1) comprises a base layer (2) and a support (5), the upper face of the base layer (2) being able to be covered with a varnish (not shown) on its upper face. The support (5) is integral with the base layer (2) and can be for example a layer obtained from materials polymeric or a reinforcing frame. The base layer (2) of Figure 3 has the same characteristics as the base layer shown in Figure 1, namely that it comprises particles of polymeric materials (3a, 3b) distributed by numerically controlled deposition means to form a pattern along the three axes of a three-dimensional reference frame (X, Y, Z) and so as to be distributed throughout all or part of the thickness of the layer (2). The base layer (2) is thus obtained entirely from particles (3a, 3b) distributed by numerically controlled deposition means. A method for manufacturing a continuous floor or wall covering comprising at least one base layer (2) according to this third example made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern, comprises at least steps consisting of: - control deposition means by numerical control to deposit material particles (3a, 3b) on a support (5) moving continuously to form the pattern, - heating the material particles (3a, 3b) on the support (5) to bind them and form the base layer (2), the support being integral with the base layer. Advantageously, and as illustrated in Figure 11, the support (5) may, prior to the step of depositing the particles, have been printed with a decorative layer (8) by any known means, in particular by an inkjet printing process, the support being intended to remain integral with the base layer (2). Figure 11 shows the elements described according to Figure 3, a decorative layer (8) being interposed between the base layer (2) and the support (5). According to this embodiment, the method according to the invention may comprise a step preliminary to the step of depositing the particles consisting of providing a support (5) and printing the support (5) with a decorative layer (8) by any known means, in particular by an inkjet printing process. Advantageously, the pattern of the decorative layer (8) is known so that the method according to the invention comprises steps consisting of: - Recognize the position of the decorative layer pattern (8) on the support (5) - Deposit the material particles (3a, 3b) according to a predefined pattern depending on the position of the pattern of the decorative layer (8) on the support (5) and in such a way as to register the two patterns. The recognition step can be carried out using any known means such as positioning targets, cameras or other optical recognition means which can be interfaced with the digitally controlled deposition means.

[0068] Alternatively, the characteristics of the base layer (2) may take up the characteristics of the base layer shown in Figure 2, namely that the base layer comprises randomly deposited particles of polymeric materials as well as particles of materials deposited by numerically controlled deposition means. The coating is thus obtained in part from particles (3b) distributed by numerically controlled deposition means and the support (5) remaining integral with the base layer (2) thus formed.

[0069] According to Figure 4, a fourth example of a floor or wall covering (1) is described comprising a base layer (2) obtained by a manufacturing method according to the invention. The base layer (2) comprises a gelled plastisol layer (7) comprising particles of materials (3b) distributed by numerically controlled deposition means to form a 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 layer (2). The coating is thus obtained partially from particles distributed by numerically controlled deposition means. A method for manufacturing a continuous floor or wall covering comprising at least one base layer according to this fourth example made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern, comprises at least steps consisting of: - deposit a layer of liquid plastisol on a continuously moving support (not shown), - optionally, pre-gel the plastisol layer, - control deposition means by numerical control to deposit material particles (3b) on the plastisol layer, - heat the material particles on the support to bind them and form the base layer. In the above case, the step of forming the base layer comprises a step of gelling the plastisol layer. Of course, the base layer (2) comprising a gelled plastisol layer (7) can also be deposited on a support (5) intended to be integral with the base layer (2). In a complementary manner, the support (5) may have, prior to the step of depositing the particles, been printed with a decorative layer (8) in a manner similar to the example described according to figure 11.

[0070] According to Figure 8, a fifth example of a floor or wall covering (1) is described comprising a base layer (2) obtained by a manufacturing method according to the invention. The base layer (2) comprises a gelled plastisol layer (7) comprising material particles (3b) distributed by numerically controlled deposition means to form a 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 layer (2) and to form a relief pattern on the surface of the base layer (2), the pattern being predefined by the position of the particles (3b). At least a part of the particles (3b) are flush beyond the thickness of the plastisol layer (7) to form a relief. The particles (3b) can thus be anti-slip particles and / or form a decorative relief pattern.

[0071] According to Figure 9, a sixth example of a floor or wall covering (1) is described comprising a base layer (2) obtained by a manufacturing method according to the invention. The base layer (2) comprises a first gelled plastisol layer (7) comprising material particles (3b, 3c) distributed by numerically controlled deposition means to form a 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 layer (2). The base layer also comprises a second gelled plastisol layer (7') bonded to the first gelled plastisol layer (7) and comprising material particles (3b, 3c) distributed by numerically controlled deposition means to form a pattern along the three axes of a three-dimensional reference frame (X, Y, Z) and to form a relief pattern on the surface of the base layer (2), the pattern being predefined by the position of the particles (3b, 3c).At least a portion of the particles (3b, 3c) protrude beyond the thickness of the plastisol layer (7') to form a relief. The particles (3b, 3c) may thus be anti-slip particles and / or form a decorative pattern. second layer of plastisol (7') can be transparent or translucent to reveal the first layer of plastisol (7).

[0072] According to Figure 10, a seventh example of a floor or wall covering (1) is described comprising a base layer (2) obtained by a manufacturing method according to the invention. The base layer (2) is in the form of a film having an upper face intended to be in contact with the user and a lower face intended to be in contact with the floor. The covering (1) consists solely of the base layer (2), with the exception of a particular embodiment where the latter is covered with a varnish (not shown) on its upper face. The base layer (2) comprises particles of polymeric materials (3a, 3b) distributed by numerically controlled deposition means to form a 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 layer (2).The particles (3a, 3b) are of different size and / or shape so that at least a portion of the particles (3b) protrude beyond the general thickness of the layer (2) formed by the mixture of the particles (3a) and (3b) to form a relief according to a predefined pattern.

[0073] Alternatively and as illustrated in Figure 12 and regardless of the embodiment of the base layer (2), the method according to the invention may also comprise, after the step of heating the material particles, once the base layer (2) has been formed, a step of printing a surface decorative layer (9) by any known means, in particular by an inkjet printing method. This printing step may be carried out before or after the optional step of pressing the material particles onto the support. Advantageously, the pattern of the surface decorative layer (9) is known so that the method according to the invention comprises steps of: - Recognize the position of the base layer pattern (2), - Print the pattern of the surface decorative layer (9) according to the position of the pattern of the base layer (2) and in such a way as to register the two patterns. The recognition step can be carried out using any known means such as positioning targets, cameras or other optical recognition means which can be interfaced with the digitally controlled deposition means.

[0074] It is also possible to combine a base layer (2) printed with a surface decorative layer (9) with a support (5) previously printed with a decorative layer (8) so as to obtain a very complex visual appearance. The coating obtained then comprises, from top to bottom, a surface decorative layer (9) possibly varnished (not shown), a base layer (2) according to the invention, optionally a decorative layer (8) printed on a support (5) or an unprinted support (5).

[0075] Whatever the embodiment and as illustrated according to Figure 10, the particles (3a, 3b) deposited may appear in a sectional view in the plane (X,Z) as a cluster forming various shapes depending on their deposition method. Particles deposited during a first deposition step will have a frustoconical sectional view (I) whose width decreases towards the upper face of the layer (2). Particles deposited during a second deposition step along a first cluster will form a parallelepiped cluster (II). Separate particles (3a, 3b) deposited during a simultaneous deposition step may have the shape of two clusters, at least one edge of which is substantially vertical (III). Particles deposited during a second deposition step between two previously deposited frustoconical clusters will have the shape of a frustoconical cluster widening towards the surface of the layer (IV).

[0076] In a first case, the support may be temporary, for example a conveyor belt and the method comprises an additional step of separating the support from the base layer. In a second case, the support is intended to be integrated into the base layer and is for example made up of a reinforcing frame.

[0077] Generally, the step of controlling deposition means by numerical control to deposit particles of materials on a continuously moving support to form the pattern can be carried out by a device for 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.

[0078] Several existing methods and devices allow particles to be deposited in a digitally defined pattern. A first method is described in patent EP2257773 which presents a device and a method for the controlled distribution of solid bulk materials, granules and / or powder used in the manufacture of ceramic products.

[0079] In particular, a device is described which comprises a hopper capable of containing a bulk material to be dispensed, which is provided with at least one outlet mouth, through which the material flows freely from the hopper, for example solely by the force of gravity. The device further comprises a vibrating dispensing element, which is located below the outlet mouth, arranged vertically opposite the latter and a means for vibrating the vibrating dispensing element, making it possible to vibrate it by numerical control. In this way, the particles accumulated on the vibrating dispensing element slide at least towards a descending edge of the dispensing device, from which they can fall freely onto a support, only when the dispensing element is vibrating.The distribution element is inclined relative to a hypothetical horizontal plane, so as to define a sliding direction of the material towards at least one descending front.

[0080] The inclination is between 0° and 10° with respect to the horizontal so that the material leaving the outlet mouth can accumulate on the distribution element without sliding on it by simple effect of gravity. The outlet mouth is dimensioned according to the size of the particles to be deposited, so as to obtain a good flow of these. The dosage of the quantity of material to be deposited is obtained according to the time and intensity of the vibrations of the distribution element. In this way a digital control system of the vibration means of the vibrating distribution element makes it possible to carry out a selective distribution of the particles. Thus, by arranging a plurality of similar devices opposite a support, it is possible to obtain a predefined pattern digitally by controlling the selective deposit of each type of particle on the support according to its position defined in the pattern.For example, the pattern may be predefined in a digital file, and the device comprises means for reading and interpreting said file to digitally control the depositing means according to the pattern.

[0081] Figures 5 and 6 illustrate an example of implementation of such a device. This allows the manufacture of plate products by controlled deposition of particles on a support (100). It comprises at least one distribution device for the digitally controlled distribution of particles (101), in which each distribution device 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 there without flowing. Each distribution element (104) is inclined relative to a horizontal plane, in order to define a sliding direction of the material towards at least one descending edge (141) of the distribution element (104).The device also comprises a plurality of vibrating means (105, 150), each associated with a respective dispensing element (104) for vibrating said dispensing element (104), so that the accumulated material slides upwards on the dispensing element (104) until the material falls from the descending edge (141) thereof when the latter is vibrating.

[0082] The distribution elements are inclined at an inclination of between 0° and 10° relative to the horizontal plane. Digital control means for activating each vibration means (105, 150) independently of one another, not shown, are also provided. The device also comprises scrolling means (111) for carrying out a relative movement in at least one scrolling direction (B) between the distribution device (101) and the support (100) on which the particles are to be distributed. These scrolling means may for example comprise a continuous conveyor belt (111) transporting the support (100) on an upper face (112) of the belt, the latter being driven by an electronically controlled motor.

[0083] The dispensing device (101) is stably attached to a fixed support (113, 102) relative to the continuous conveyor belt (111). A plurality of devices (101) can thus be arranged transversely to the continuous conveyor belt (111). In this way, the dispensing device (101) can act in sequence on the support (100), in order to increase the range of patterns and / or decorative effects that can be achieved. In particular, the hoppers (103) of the dispensing devices (101) can be filled with particles having a coloring, density, hardness, different shine, in order to obtain predefined patterns and / or textures and presenting several colors and / or materials. Thus, each dispensing device (101) is intended to deposit a specific material, for example a color on the support (100).

[0084] A second method for controlling deposition means by numerical control to deposit material particles on a continuously moving support to form the pattern is described in patent EP2892657. This patent describes a method and a device (201) for producing predefined decorative patterns by numerical control on products from materials in the form of particles. According to Figure 7, this method comprises the steps of applying to the surface of a support (203), at least one layer of fluid adhesive material, depositing material particles (206) on the layer of adhesive material, and removing the excess material particles (206). The fluid adhesive material is of the type that cures by exposure to radiation or has a sticky consistency in contact with air or in contact with a "primer" previously spread on the surface of the support to be decorated (203).

[0085] The step of applying at least one layer of fluid adhesive material may comprise the ejection of microdrops of adhesive material onto the surface of the products to be decorated (203) by means of a digital printing head (202) provided with piezoelectrically controlled ejection nozzles. Still according to Figure 7, the device (201) comprises a digital printing head (202) for applying, onto the surface of the support (203), at least one layer of fluid adhesive material that can be cured by exposure to radiation. The device (201) comprises radiating means (204) adapted to irradiate the layer of adhesive material. The irradiation of the layer of adhesive material, for a predefined period of time, determines its rapid transformation into a substantially transparent and glue-like film that is suitable for the subsequent deposition of material particles.The device (201) thus comprises means (205) for depositing particles of materials (206) on the layer of adhesive materials, after the latter has undergone irradiation under the radiating means (204) and has thus taken on a consistency similar to glue. The means (205) for depositing the particles of materials comprise, for example, a hopper (209) opening onto a closable outlet (210) which, in the open position, allows the particles to flow out regularly. stored in the hopper (209). The device (201) also comprises means (207) for removing excess material particles (206), which are deposited on the support (203). These means (207) make it possible to remove the material particles (206) which have not stuck directly to the layer of adhesive material, and which therefore remain in excess since they cannot be incorporated into the 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 products to be decorated (203) supported by a continuous belt conveyor (208).The suction hood (211) may also comprise an exhaust outlet (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.

[0086] The supports to be decorated (203) are arranged on the continuous belt conveyor (208) and move continuously in a direction A. The digital printing head (202) is provided with one or more respective individual heads, each being equipped with nozzles for ejecting adhesive material onto the upper surface of the products (203) to be decorated.

Claims

Claims [Claims 1] Method for manufacturing a continuous floor or wall covering comprising at least one base layer made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern, characterized in that it comprises at least steps consisting of: - control deposition means by numerical control to deposit the material particles on a continuously moving support to form the pattern, - heat the material particles to bind them and form the base layer, - separate the base layer from the support. [Claims 2] Method for manufacturing a continuous floor or wall covering comprising at least one base layer made from polymeric materials, said base layer comprising particles of materials distributed to form a pattern, characterized in that it comprises at least steps consisting of: - control deposition means by numerical control to deposit material particles on a continuously moving support to form the pattern - heating the material particles on the support to bind them and form the base layer, the support being integral with the base layer. [Claims 3] Method for manufacturing a continuous floor or wall covering according to claim 1 or 2, characterized in that it comprises at least one step prior to the step of depositing the particles and consisting of: - deposit a layer of liquid plastisol on the continuously moving support - optionally, pre-gel the plastisol layer. [Claims 4] Method of manufacturing a continuous floor or wall covering according to claim 2, characterized in that the support is a reinforcing frame [Claims 5] Method of manufacturing a continuous floor or wall covering according to claim 2, characterized in that the support is a backing layer made from polymeric materials. [Claims 6] Method of manufacturing a continuous floor or wall covering according to any one of the preceding claims, characterized in that it comprises at least one additional step consisting of: - press the material particles onto the support [Claims 7] Method for manufacturing a continuous floor or wall covering according to any one of the preceding claims, characterized in that the deposition means are movable relative to the continuously moving support. [Claims 8] Method for manufacturing a continuous floor or wall covering according to any one of the preceding claims, characterized in that it comprises at least one additional step before the heating step consisting of: - deposit a layer of material particles on the support [Claims 9] Floor or wall covering comprising at least one base layer characterized in that the base layer is obtained by a manufacturing method according to any one of the preceding claims.

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