Multi-layer structure for the creation of a loose-lay floor covering

Abstract

The invention relates to a rollable multi-layer structure (1), based on PVC, for producing a loose-lay floor covering, comprising a total thickness of between 1.4 mm and 2 mm. According to the invention, the multi-layer structure comprises: - a PVC wear layer having a thickness of between 0.3 and 0.5 mm; - a glass veil comprising a surface mass of between 60 and 100 g / m², impregnated on both sides; - a compact PVC backing layer having a thickness of between 0.3 and 0.7 mm, and a surface mass of between 360 and 840 g / m². Figure for the abstract: Fig. 1

Description

Title of the invention: Multi-layer structure for the production of a loose-lay floor covering Technical field

[0001] The present invention relates to the field of floor coverings presented in rolls and intended for loose laying, for example used to cover existing floor coverings, without removing the latter.

[0002] The invention finds an advantageous application for covering the type of resilient floor coverings well known to those skilled in the art under the acronym VSM (Vinyl On Foam), notably defined by standard NF EN ISO 11638. Prior art

[0003] It is known from the state of the art to want to cover, in loose laying, a VSM type covering, that is to say a heterogeneous floor covering on PVC-based foam, with another covering for the purpose of changing the decor or renovating.

[0004] This practice is not really regulated and is not the subject of any certification, nor of any technical application document which would have been issued by an approved commission responsible for formulating this type of technical opinion or certification.

[0005] A VSM type coating has certain puncture resistance properties, and current practices do not provide any guarantee as to the retention of these properties.

[0006] Some have already tried to cover a VSM coating with a VSM coating, without any real guarantee as to the conservation of the aforementioned performances, but with the disadvantage of having to cut the bottoms of the doors because the total thickness becomes too great.

[0007] By way of example, the Applicant uses a rollable multi-layer structure, based on PVC, and without coupling means for the production of a loose-lay floor covering.

[0008] This structure comprises a total thickness of between 1.15 and 1.3 mm with a surface mass of 1100 g / m2, and: - a PVC coated wear layer with a thickness of 0.15 mm; - a glass veil comprising a surface mass of 40 g / m2, impregnated on its lower face with a bonding layer in the form of a gelled plastisol, such as a PVC plastisol, and on its upper face with a plastisol, such as a PVC plastisol, gelled and printed with a decorative layer, and with a total thickness of 0.9 mm; - a compact PVC coated backing layer with a thickness of 0.12 mm.

[0009] However, this structure does not meet the constraints of free installation on VSM because it is too flexible, and does not allow the performance of resistance to punching to be maintained.

[0010] To facilitate free laying, the structure must be balanced and, to do this, it is known to add fillers in the PVC backing layer or to increase its thickness to have a thickness greater than 1 mm.

[0011] The resulting disadvantage is that the total thickness of the structure becomes too great, which implies the disadvantage of having to cut the bottoms of the doors when it comes to cover an existing VSM type covering which already has a thickness of between 2.5 and 3.5 mm. Furthermore, this results in an excessive weight, of the order of 5 to 7 kg / m2, and therefore logistical difficulties and environmental impact issues. Statement of the invention

[0012] One of the aims of the invention is therefore to propose a rollable multi-layer structure for producing a loose-lay floor covering, which makes it possible to cover any type of existing covering, such as for example a VSM type floor covering, without degrading its punching resistance performance, nor excessively increasing the total thickness of the final covering so as not to have to cut the bottoms of doors.

[0013] By resistance to punching, we mean a residual indentation of less than 0.2 mm at 2h30 in the punching test carried out according to the ISO24343-1 standard of June 2007.

[0014] Another objective of the invention is to provide such a structure which is balanced and suitable for free installation and without coupling means, with satisfactory rigidity to withstand the passage of heavy loads, while having a mass of less than 2 kg / m2 to facilitate logistics and reduce environmental impact.

[0015] For this purpose, a rollable multi-layer structure, based on PVC, has been developed for the production of a loose-lay floor covering, comprising a total thickness of between 1.4 mm and 2 mm, or even between 1.5 mm and 1.7 mm.

[0016] A thicker structure would require having to cut the bottoms of the doors and would result in a heavy coating with the known disadvantages in terms of logistics and environmental impact.

[0017] The multi-layer structure comprises, from top to bottom: - a wear layer, made of PVC, for example coated, having a thickness greater than that of the prior art, between 0.3 and 0.5 mm to enable the U2S classification of the UPEC standard to be achieved; - a glass veil comprising a higher surface mass than that of the prior art product, and in particular between 60 and 100 g / m2, preferably between 70 and 80 g / m2, for example 75 g / m2, impregnated on both sides, for example on its lower side with a bonding layer in the form of a gelled plastisol, such as a PVC plastisol, and on its upper side with a plastisol, such as a PVC plastisol, gelled and possibly printed with a decorative layer; with a surface mass greater than 100 g / m2 the veil breaks when rolling and the hand, that is to say the feel of the installer when laying, becomes too rigid; - a compact PVC backing layer, i.e. one which is not foamed, preferably calendered, pressed or extruded, for example coated, having a thickness greater than that of the prior art, between 0.3 and 0.7 mm, preferably between 0.4 and 0.6 mm, for example 0.5 mm, and a surface mass between 360 and 840 g / m2, for example 635 g / m2 for 0.5 mm of thickness, which can be increased to reduce the thickness.

[0018] In this way, the invention makes it possible to provide a rollable multi-layer structure allowing the creation of a loose-lay floor covering, covering an existing VSM-type covering, without degrading its punching resistance performance, and with a minimized environmental impact.

[0019] For surfaces larger than 30 m2, or even larger than 50 m2, it is still advisable to install this type of covering with double-sided adhesive on the periphery of the surface to be covered.

[0020] The thickness of the coating of the invention is between 1.4 mm and 2 mm, or even between 1.5 mm and 1.7 mm, which makes it possible to cover an existing coating without having to cut the bottoms of the doors.

[0021] Furthermore, tests have been carried out by the Applicant and the multilayer structure of the invention makes it possible, when it covers a VSM type coating, to maintain the punching resistance performance, or even to improve it since the results showed a residual indentation of less than 0.04 mm at 2.5 hours and less than 0.02 mm at 24 hours.

[0022] The rigidity of the multi-layer structure allows it to withstand heavy load traffic and to satisfy the test of the chair on casters according to the NF EN 425 standard in free installation, or even semi-free installation with the use of double-sided adhesive on the periphery and on the edges of the strips.

[0023] Preferably, the backing layer comprises 20 to 70 PCR of plasticizer and a filler content of less than 5% by weight of the backing layer, or even a zero filler content. Preferably, the backing layer comprises 20 to 50 PCR of plasticizer, more preferably 30 to 50 PCR. PCR means one hundred parts of resin.

[0024] This backing layer allows the structure to be balanced, without requiring an increase in thickness.

[0025] Given the low charge rate in the backing layer, another advantage lies in the fact that it has a low surface mass. In other words, the invention makes it possible to rebalance the structure, with a lower weight, compared to the solution consisting of increasing the thickness of the backing layer.

[0026] According to a particular embodiment, the impregnated glass veil has a thickness of 0.8 mm, with the glass veil having a thickness of 0.2 mm.

[0027] In a particular embodiment, the wear layer comprises 20 to 70 PCR of plasticizer, preferably 20 to 50 PCR of plasticizer. For example, the wear layer is transparent and comprises 30 to 50 PCR of plasticizer, with a filler level of less than 5% by weight of the wear layer, or even a zero filler level, and the multilayer structure comprises a decorative layer positioned under the wear layer.

[0028] In this configuration, the low charge rate in the plasticized PVC wear layer causes the phenomenon of “curving” or incurvation tending to unbalance the multi-layer structure, compensated by the backing layer.

[0029] The wear layer is for example a layer of gelled PVC plastisol.

[0030] According to another embodiment, the wear layer may be in the form of form of a layer of pressed granules, so that the wear layer itself forms the decoration. The granules can be of any desired color, as is well known in the state of the art.

[0031] The layer of pressed granules is obtained from plasticized and loaded PVC. Generally, the loading rate of the pressed granules is much lower than 130 PCR, preferably lower than 100 PCR or even 80 PCR so as to have good scratch resistance. The layer of pressed granules thus tends to generate a phenomenon of "curving" or incurvation tending to unbalance the multilayer structure, which is compensated by the backing layer.

[0032] Preferably, and to ensure a good compromise between the total thickness of the multilayer structure and its weight, while having a balanced structure, a ratio between the thickness of the wear layer and the thickness of the assembly comprising the impregnated glass veil and the backing layer, is between 0.2 and 0.45.

[0033] In order to further reduce, or even avoid, the wave / swell phenomenon which is generated in front of the wheels of a heavy load, i.e. of the order of 200 kg or more, circulating on the multi-layer structure in free laying on a ground, the backing layer is preferably produced by coating, calendering or extrusion, because these techniques make it possible to obtain a smoother contact surface with the ground than when the backing layer is produced from pressed granules and then sanded.

[0034] According to another characteristic, the multilayer structure according to the invention preferably has a tensile modulus for 1% elongation of between 7 and 9 daN / cm, for example measured according to method M. 1 “determination of toughness” given by the QB 30 - Ml-Ueatc July 2015 reference of the CSTB. In other words, it is necessary to exert a traction of a force of between 7 and 9 daN / cm, on either side of a sample of the structure, to attempt to lengthen it by at least 1% of its length.

[0035] The invention also relates to an assembly comprising a multi-layer structure according to the aforementioned characteristics, laid, in particular loosely, on a vinyl-on-foam (VSM) type covering, i.e. comprising at least one layer of PVC bonded to a backing layer of foamed PVC. Brief description of the drawings

[0036] Other characteristics and advantages of the invention will emerge clearly from the description given below, for information purposes only and in no way limiting, with reference to the appended figures in which:

[0037] [Fig. 1] is a schematic sectional representation of an embodiment of the multilayer structure of the invention, with a decorative layer printed on a glass veil coated on both sides with a gelled PVC plastisol.

[0038] [Fig.2] is a view similar to that of [Fig.l], with a glass veil and glass grid complex, impregnated on both sides with a gelled PVC plastisol. Detailed description of the invention

[0039] The invention relates to a multi-layer structure (1) for producing a loose-laying floor covering, and without coupling means between two adjacent structures, which is balanced with a low weight, i.e. less than 5 kg / m2, while having a total thickness of less than 2 mm, and for example between 1.4 mm and 2 mm.

[0040] The multilayer structure (1) according to the invention can be wound on itself or on a mandrel to be presented in a roll.

[0041] For this purpose, the multi-layer structure (1) has a flexibility enabling it to comply with the ISO 24344:2008 standard. In this standard, flexibility is defined by the ability of a covering or a layer of a floor covering to be wound around a 20 mm mandrel, without cracks or crazing forming. Thus, the multi-layer structure according to the invention subjected to this test would not exhibit breaks, cracks, crazing and other permanent defects.

[0042] The multi-layer structure (1) according to the invention makes it possible to cover any type of existing covering, such as for example a VSM type floor covering, without degrading its punching resistance performance, nor increasing the total thickness of the final covering too much so as not to have to cut the bottoms of the doors.

[0043] With reference to [Fig.l], the multilayer structure (1) successively comprises, from the top to the ground, a wear layer (2) made of PVC having a thickness of between 0.3 and 0.5 mm with in particular a surface mass of for example between 350 and 600 g / m2, a glass veil (3) comprising a surface mass of between 60 and 100 g / m2, and impregnated on both sides, a compact backing layer (4) made of PVC having a thickness of between 0.3 and 0.7 mm, and a surface mass of between 360 and 840 g / m2.

[0044] The wear layer (2) allows control of slippage, wear resistance, ease of cleaning. It comprises 20 to 70 PCR of plasticizer.

[0045] The wear layer (2) can be obtained by extrusion, by calendering, by pressing, or by coating then gelling a plastisol. The wear layer (2) can be coated with a varnish without departing from the scope of the invention, such as a varnish based on polyurethane or urethane acrylate. The wear layer (2) can be varnished and / or grained in order to improve resistance to staining and scratching.

[0046] The wear layer (2) can also provide the decorative function, in particular if it is obtained from a tinted plastisol or by pressing tinted granules.

[0047] Preferably, the wear layer (2) is transparent or translucent so that a decorative layer is visible through the wear layer (2).

[0048] In this configuration, the wear layer (2) comprises 30 to 50 PCR of plasticizer, and a zero filler rate, or even less than 5% by weight of the wear layer (2).

[0049] The glass veil (3) comprises glass fibers of approximately 10 mm in diameter and 10 mm in length, randomly distributed and bonded together by a modified polyvinyl alcohol.

[0050] The tensile strength of a reinforcing web is generally chosen to be between 100 N / 50mm and 400 N / 50mm in the longitudinal and transverse directions, measured according to the ISO 1924 / 2 method.

[0051] The glass veil (3) makes it possible to improve the dimensional stability of the multilayer structure (1) as well as the resistance to punching. The multi-touch structure according to the invention can claim class U2S.

[0052] The glass veil (3) is for example impregnated on its lower face with a bonding layer (6) in the form of a gelled plastisol, such as a PVC plastisol, and on its upper face with a plastisol (5), such as a PVC plastisol, gelled and printed with a decorative layer.

[0053] To improve resistance to the passage of heavy loads and punching, the glass veil (3) forms a complex with a glass grid (7), the complex then being impregnated on both sides.

[0054] In the same way as for the glass veil alone, the glass veil (3) / glass grid (7) complex is for example impregnated on its lower face with a layer bonding layer (6) in the form of a gelled plastisol, such as a PVC plastisol, and on its upper face a plastisol (5), such as a PVC plastisol, gelled and printed with a decorative layer. The glass grid (7) is permeable and allows the impregnation layer to also impregnate the glass veil (3).

[0055] In order to bond the glass veil (3) with the glass grid (7) without complicating the manufacturing process, or unduly weighing down the structure, the binder comprises an acrylic glue, or ethylene-vinyl acetate ("EVA"), or plastisol such as a PVC plastisol. Preferably the binder is arranged in a thin layer, at a density of between 5 and 35 g / m2, or preferably between 10 g / m2 and 30 g / m2.

[0056] The threads of the glass grid (7) are for example obtained from glass fibers, and are preferably spaced from each other by between 1 mm and 5 mm, preferably by between 2 mm and 4 mm, depending on the longitudinal and transverse dimensions, and have a linear mass of between 20 g / m and 110 g / m, advantageously between 35 g / m and 70 g / m. The thickness of the glass grid (7) is small, of the order of 0.1-0.2 mm and a surface mass of between 30 g / m2 and 60 g / m2. The tensile strength of a glass grid used in the invention is advantageously between 400 N / 50mm and 1000 N / 50mm in the longitudinal and transverse directions.

[0057] This configuration also makes it possible to improve the dimensional stability of the multilayer structure (1) as well as the resistance to punching. The multi-touch structure according to the invention can claim the U2SP3 or even U4P3 classification according to the UPEC standard.

[0058] The backing layer (4) is made of compact plasticized polyvinyl chloride, i.e. which is not foamed.

[0059] The backing layer (4) is calendered, pressed, or extruded. Generally, a calendered backing layer (4) is preferred because it is easier to integrate recycled material into its composition with this manufacturing technique, without degrading the decoration or the appearance of the multilayer structure (1).

[0060] The backing layer (4) preferably comprises 20 to 70 PCR of plasticizer and a filler rate of less than 5% by weight of the backing layer, or even a zero filler rate. Preferably, the backing layer comprises from 20 to 50 PCR of plasticizer, more preferably from 30 to 50 PCR.

[0061] The backing layer (4) can be related to the wear layer (2), in terms of composition and properties, and therefore makes it possible to balance the structure by counterbalancing the curvature phenomenon generated by the wear layer (2), with a low weight. Preferably, the wear layer (2) and the backing layer (4) are obtained from a gelled PVC plastisol and have the same plasticizer level.

[0062] The fillers used in each of the layers of the structure may be calcium carbonate, clay, silica, kaolin, or talc. It is preferably a powdery material to avoid degradation of the filler during mixing of the PVC masterbatch intended to constitute the layers, but it may be possible to consider using fibers. The fillers may be used alone or in a mixture.

[0063] To ensure a good compromise between the total thickness of the multilayer structure (1) and its weight, while having a balanced structure, a ratio between the thickness of the wear layer (2) and the thickness of the assembly comprising the impregnated glass veil (3) and the backing layer (4), is between 0.2 and 0.45, for example 0.27 or 0.33.

[0064] Tests were carried out by the Applicant on an assembly comprising a VSM type covering covered, in loose laying, with a multi-layer structure (1) having; - a total thickness of 1.6 mm: - a wear layer of gelled PVC plastisol with a thickness of 0.3 mm and a surface mass of 350 g / m2; - a glass veil comprising a surface mass of between 75 g / m2, impregnated on its lower face with a gelled PVC plastisol, and on its upper face with a gelled PVC plastisol and printed with a decorative layer; the impregnated veil having a thickness of 0.8 mm; - a compact backing layer of gelled PVC plastisol, without filler, having a thickness of 0.5 mm, and a surface mass of 585 g / m2.

[0065] Tests carried out on this assembly showed a residual indentation of less than 0.04 mm at 2.5 hours and less than 0.02 mm at 24 hours.

[0066] Furthermore, the Applicant also noted that when a heavy load, of the order of 200 kg (100 kg hospital bed with a weight of 100 kg), rolls over the structure, this does not generate any waves in front of the wheels.

[0067] The values ​​cited in the description are values ​​measured according to the following standards: Total thickness: NF EN ISO 24346 April 2012 Layer thicknesses: NF EN ISO 24340 April 2012 Weight / Surface mass: ISO 23997 December 2007 Modulus at 1% elongation: QB 30 - Ml-Ueatc July 2015 Residual static punching (Building): ISO 24343-1 June 2007.

[0068] It is clear from the above that the invention does indeed provide a multi-layer structure (1) which makes it possible to cover a VSM type floor covering, without degrading its punching resistance performance, nor increasing the total thickness of the final covering too much so as not to have to cut the bottoms of doors.

[0069] Furthermore, the multi-layer structure according to the invention is balanced and suitable for free installation without coupling means, with satisfactory rigidity to withstand the passage of heavy loads, while having a mass of less than 2 kg / m2 to facilitate logistics and reduce the environmental impact.

Claims

Claims

1. Rollable multi-layer structure (1), based on PVC, for producing a loose-lay floor covering, comprising a total thickness of between 1.4 mm and 2 mm, characterized in that it comprises: - a wear layer (2) made of PVC having a thickness of between 0.3 and 0.5 mm; - a glass veil (3) comprising a surface mass of between 60 and 100 g / m2, impregnated on both sides; - a compact backing layer (4) made of PVC having a thickness of between 0.3 and 0.7 mm, and a surface mass of between 360 and 840 g / m2.

2. Rollable multi-layer structure (1) according to claim 1, characterized in that the glass veil (3) is impregnated on its lower face with a bonding layer (6) in the form of a gelled plastisol, such as a PVC plastisol, and on its upper face with a plastisol, such as a PVC plastisol, gelled and optionally printed with a decorative layer.

3. Rollable multilayer structure (1) according to one of the preceding claims, characterized in that the backing layer (4) comprises 20 to 70 PCR of plasticizer and a filler rate of less than 5% by weight of the backing layer, or even a zero filler rate, preferably, the backing layer comprises from 20 to 50 PCR of plasticizer, more preferably from 30 to 50 PCR.

4. Rollable multi-layer structure (1) according to one of the preceding claims, characterized in that the impregnated glass veil (3) has a thickness of 0.8 mm, with the glass veil (3) having a thickness of 0.2 mm.

5. Rollable multi-layer structure (1) according to one of the preceding claims, characterized in that the wear layer (2) comprises 20 to 70 PCR of plasticizer, preferably 20 to 50 PCR of plasticizer.

6. Rollable multi-layer structure (1) according to one of the preceding claims, characterized in that the wear layer (2) is transparent, comprises 30 to 50 PCR of plasticizer, and a filler rate of less than 5% by weight of the wear layer (2), or even a zero filler rate, and in that the multi-layer structure (1) comprises a decorative layer positioned under the wear layer (2).

7. Rollable multi-layer structure (1) according to one of the preceding claims, characterized in that the wear layer (2) is a layer of gelled PVC plastisol.

8. Rollable multilayer structure (1) according to one of the preceding claims, characterized in that the glass veil (3) forms a complex with a glass grid (7), the complex then being impregnated on both sides.

9. Assembly comprising a multi-layer structure (1) according to one of the preceding claims, placed on a vinyl-on-foam type covering, that is to say comprising at least one layer of PVC bonded to a backing layer of foamed PVC.

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