Method for producing floor or wall coverings and associated coverings

Abstract

The invention relates to a method for manufacturing a continuous floor or wall coating comprising at least one base layer made from polymeric materials, said base layer comprising material particles distributed to form a pattern, the method comprising at least the steps of: - controlling numerically controlled deposition means to deposit the material particles onto a continuously moving substrate to form the pattern, - heating the material particles to bond them and form the base layer, - separating the base layer from the substrate. Figure for the abstract: Fig. 1

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 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 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. 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 cleanings, which gives great longevity 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 deteriorated. 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] 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.

[0007] This method 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 production of a homogeneous, single-layer floor or wall covering, or possibly being able to be subsequently linked to other layers so as to form a heterogeneous floor covering.

[0008] 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 at the end of 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.

[0009] Alternatively, the 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, comprises at least steps consisting of: - controlling deposition means by numerical control to deposit particles of materials 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.

[0010] This method 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 particles of distributed materials and any other materials of the base layer. This method may require means of scrolling of the support such as unwinders, rollers or conveyor belts, so as to scroll the support during the stages of removal, heating, and possibly pressing.

[0011] 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 comprise 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 being in the form of a sheet having two smooth faces.

[0012] Whatever 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 allow the particles to flow in a controlled manner. Each deposition 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 deposition means.

[0013] Whatever the embodiment, the method according to the invention may comprise several successive steps consisting of controlling deposition means by numerical 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.

[0014] Whatever the embodiment, by continuously scrolling, it is meant that the support is in continuous movement relative to the depositing means or advances step by step relative to the depositing means.

[0015] 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 particles of materials on a continuously moving support to form the pattern. In this case, the particles comprise particles made from polymeric materials.

[0016] Whatever 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 particles of materials 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.

[0017] Several supports intended to be secured to the base layer are conceivable. The support may in particular comprise a reinforcing frame 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 may be used to obtain a reinforcing frame are in particular 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).

[0018] 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 and then pressed or by coating and gelling a tinted PVC plastisol, by flat die extrusion or by calendering.

[0019] The polymeric materials that can be used in the composition of the base layer, the particles and / or a backing layer are, for example, PVC, PVB, PLA, TPU, cellulose derivatives, elastomers, alone or in mixtures.

[0020] 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 numerically controlled deposition means and consisting of: - deposit a layer of liquid plastisol on the continuously scrolling support - optionally, pre-gel the plastisol layer.

[0021] 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-gelling 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 laying 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.

[0022] Whatever the embodiment and so as 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 particles of materials onto the support. This step may be carried out before the heating step or simultaneously with the step of heating the deposited particles.

[0023] 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.

[0024] 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.

[0025] 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 having a base layer according to a random pattern and veins obtained by the particles deposited according to a predefined pattern.This alternative also makes it possible to integrate recycled materials into coatings. The process 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.

[0026] 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.

[0027] Advantageously, the particles of materials deposited to form the pattern are particles made from polymeric materials such as PVC, polypropene, polyethylene, linoleum, thermosets, alone or in a mixture or even from non-polymeric materials such as corundum or glass.

[0028] Advantageously, the particles are granules having a particle size of between 0.5 mm and 10 mm or else powders having a particle size of between between 20 pm and 500 pm. The method according to the invention can thus comprise a step consisting of controlling deposition means by digital control to deposit granules and / or powders on a continuously moving support to form the pattern.

[0029] The particles of materials deposited to form the pattern may also comprise at least one mineral, natural or synthetic filler.

[0030] The particles of materials deposited to form the pattern may also comprise at least one plasticizer.

[0031] The particles of materials deposited to form the pattern may come from a recycling channel.

[0032] The particles of materials deposited to form the pattern may be in the form of a PVC dry-blend or in the form of granules obtained from a gelled polymeric material such as PVC. Brief description of the drawings

[0033] [Fig-1] is a side view of a first example of a base layer obtained by a method according to the invention.

[0034] [Fig.2] is a side view of a second example of a base layer obtained by a method according to the invention.

[0035] [Fig.3] is a side view of a third example of a base layer obtained by a method according to the invention.

[0036] [Fig.4] is a side view of a fourth example of a base layer obtained by a method according to the invention.

[0037] [Fig.5] is a perspective view of a dispensing device for dispensing controlled by numerical particle control.

[0038] [Fig.6] is a top view of the dispensing device for dispensing controlled particle size presented [Fig.l].

[0039] [Fig.7] is a side view of a second dispensing device for dispensing controlled by numerical particle control. Detailed description of the invention

[0040] Whatever 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, as well as offcuts or shredded products from the recycling channels for these materials. Alternatively, the particles can comprise linoleum.

[0041] In the case of PVC, it can be used in different forms for the production of granules. For example, granules are obtained from PVC, optionally with a filler, optionally 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 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.

[0042] 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 pm and 250 pm.For example, a dry blend commonly used for preparing PVC granules has a density of approximately 0.50, a volume average diameter of 136 pm, a D50 of 140 pm, a D10 of 63 pm and a D90 of 198 pm. The use of dry blend also makes it possible to eliminate the granulation step commonly used for the production of PVC flooring by making it possible to directly produce a pattern. This granulation operation is costly in terms of time, equipment and energy. The distribution of a dry blend is also easier compared to that of granules which generally have a wider particle size distribution. It is therefore easier to obtain a homogeneous deposit in thickness, for example for the production of a "bed", a regular layer.

[0043] 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.

[0044] It is of course possible to mix several types of materials to be deposited in order to obtain a pattern according to the invention. By way of non-limiting examples, the materials which can be deposited may be granular materials in the form of powders, granules, shot, flakes, lamellae or any other material in particulate or substantially particulate form. More precisely, these may be nacres, pigments, pure or coated in the form of pigment paste, anti-slip particles.

[0045] Following the step of deposition by the digitally controlled deposition means, it may be envisaged to preheat the deposited materials so as to pre-gel them and / or maintain them on the support, for example by exposure under infrared radiation.

[0046] 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.

[0047] The heating step can for example be carried out using an oven or by exposure to infrared radiation.

[0048] The continuous scrolling means capable of scrolling the support may for example comprise a belt conveyor, rollers, belts or the like.

[0049] The base layer according to the invention generally has a thickness of between 0.3 and 6 millimeters.

[0050] 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.

[0051] According to [Fig.l], 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 covering is thus obtained entirely at from particles distributed by numerically controlled deposition means. 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.

[0052] The particles of polymeric materials (3a, 3b) may be in the form of powders, for example of PVC “dry blend”, colored or not, or even of gelled PVC granules. Depending on the type of materials, it may be necessary to carry out a step of hot pressing of the deposited particles to obtain a base layer of uniform thickness.

[0053] According to [Fig. 2], a second 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) 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 particles of polymeric materials (4) as well as 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 covering is thus obtained in part from particles (3b) distributed by numerically controlled deposition means.

[0054] A method for 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 polymeric particles on a continuously moving support so as to form a layer (4), - controlling deposition means by numerical control to deposit particles of materials (3b) on the support or on the layer of randomly deposited polymeric particles (4) to form the pattern, - heating the material particles on the support to bind them and form the base layer (2).

[0055] In this example the particles of materials (3b) are not necessarily polymeric.

[0056] According to [Fig. 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 polymeric materials or a reinforcing frame. The base layer (2) of [Fig. 3] has the characteristics of the base layer presented [Fig. 1], namely that it comprises particles of polymeric materials (3a, 3b) distributed by means of numerically controlled deposition 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 (2) is thus obtained entirely from particles (3a, 3b) distributed by means of numerically controlled deposition. A method of 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: . - controlling 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.

[0057] Alternatively, the characteristics of the base layer (2) may repeat the characteristics of the base layer shown in [Fig. 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.

[0058] According to [Fig. 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 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 covering is thus obtained partially from of particles distributed by numerically controlled deposition means. A method of 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: - depositing a layer of liquid plastisol on a continuously moving support (not shown), - optionally, pre-gelling 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.

[0059] 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.

[0060] 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.

[0061] Several existing methods and devices make it possible to deposit particles according to a digitally defined pattern. A first method is described in patent EP2257773 which presents a device and a method for controlled distribution of solid bulk materials, in granules and / or powder used in the manufacture of ceramic products.

[0062] 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 the latter 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 on a support, only when the distribution 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 edge.

[0063] The inclination is between 0° and 10° 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 the 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.

[0064] 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.

[0065] 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 each other, 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.

[0066] The dispensing device (101) is stably fixed 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 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 (101) is intended to deposit a specific material, for example a color on the support (100).

[0067] 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 [Fig. 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).

[0068] 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 [Fig.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 which can be hardened 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, glue-like film suitable for the subsequent deposition of material particles. The device (201) thus comprises means (205) for depositing material particles (206) on the adhesive material layer, 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 (210) which, in the open position, allows the particles stored in the hopper (209) to flow out regularly. 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 eliminate the particles of materials (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 eliminating the excess particles of materials (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 evacuation mouth (213) through which, by suitable conduits, not shown in the figures, the excess particles of materials (206) can be returned to the inside of the hopper (209), or conveyed to a special collection area.

[0069] 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

1. Method for manufacturing a continuous floor or wall covering (1) comprising at least one base layer (2) made from polymeric materials (3a, 3b), said base layer (2) comprising material particles (3a, 3b) distributed to form a pattern, characterized in that the material particles (3a, 3b) are in the form of granules, powders or plasticized PVC powder, and in that it comprises at least steps consisting of: - controlling deposition means by numerical control to deposit the material particles (3a, 3b) on a support (5) moving continuously to form the pattern using a distribution device, - heating the material particles (3a, 3b) to bind them and form the base layer (2),- dissociating the base layer (2) from the support (5) and in that the pattern is predefined in a digital file and the dispensing device comprises means for reading and interpreting said file to digitally control the depositing means according to the pattern.,

2. Method for manufacturing a continuous floor or wall covering (1) comprising at least one base layer (2) made from polymeric materials (3a, 3b), said base layer (2) comprising material particles (3a, 3b) distributed to form a pattern, characterized in that the material particles (3a, 3b) are in the form of granules, powders or plasticized PVC powder and in that it comprises at least steps consisting of: - controlling deposition means by numerical control to deposit material particles (3a, 3b) on a support (5) moving continuously to form the pattern using a distribution device, - heating the material particles (3a, 3b) on the support (5) to bind them and form the base layer (2), the support (5) being integral with the base layer (2) and in that the pattern is predefined in a digital file and the distribution device comprises reading means and interpretation of said file to digitally control the means of removal according to the pattern.

3. Method for manufacturing a continuous floor or wall covering (1) 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: - depositing a layer of liquid plastisol on the support (5) moving continuously, - optionally, pre-gelling the layer of plastisol.

4. Method of manufacturing a continuous floor or wall covering (1) according to claim 2, characterized in that the support (5) is a reinforcing frame.

5. Method for manufacturing a continuous floor or wall covering (1) according to claim 2, characterized in that the support (5) is a backing layer made from polymeric materials (3a, 3b).

6. Method for manufacturing a continuous floor or wall covering (1) according to any one of the preceding claims, characterized in that it comprises at least one additional step consisting of pressing the material particles (3a, 3b) onto the support (5).

7. Method for manufacturing a continuous floor or wall covering (1) according to any one of the preceding claims, characterized in that the deposition means are movable relative to the continuously moving support (5).

8. Method for manufacturing a continuous floor or wall covering (1) according to any one of the preceding claims, characterized in that it comprises at least one additional step before the heating step consisting of depositing a layer of material particles (3a, 3b) on the support (5).

9. Floor or wall covering (1) comprising at least one base layer (2) characterized in that said covering (1) is obtained by a manufacturing method according to any one of the preceding claims

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