Multilayer structure for creating a loose-lay floor covering

Abstract

The invention relates to a rollable, multilayer structure (1) based on PVC for creating a loose-lay floor covering, comprising a total thickness of between 1.4 mm and 2 mm. According to the invention, the multilayer 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: Multilayer structure for creating 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 the standard NF EN ISO 11638. Previous art

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

[0004] This practice is not really regulated and is not subject to any certification, nor to any technical application document that 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 preservation of these properties.

[0006] Some have already tried to cover a VSM coating with a VSM coating, without any real guarantee as to the preservation of the aforementioned performance, 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 operates a rollable multilayer structure, based on PVC, and without coupling means for the production of a free-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 requirements for free mounting on VSM because it is too flexible, and does not allow for maintaining punching resistance performance.

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

[0011] The resulting drawback is that the overall thickness of the structure becomes excessive, which necessitates trimming the bottoms of doors when it covers an existing VSM-type coating that is already between 2.5 and 3.5 mm thick. Furthermore, this results in excessive weight, on the order of 5 to 7 kg / m², leading to logistical difficulties and environmental impact issues. Description of the invention

[0012] One of the aims of the invention is therefore to propose a rollable multilayer structure for the production of a loose-lay floor covering, which makes it possible to cover any type of existing floor covering, such as for example a VSM type floor covering, without degrading its puncture resistance performance, nor increasing the total thickness of the final covering too much 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 laying and without coupling means, with sufficient 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 multilayer 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 cutting the bottoms of the doors and would result in a heavy covering with the known disadvantages on logistics and environmental impact.

[0017] The multilayer structure comprises, from top to bottom: - a wear layer, in PVC, for example coated, having a higher thickness than that of the prior art, between 0.3 and 0.5 mm to allow to achieve the U2S classification of the UPEC standard; - a glass veil comprising a higher surface mass than that of the art of the product of the prior art, 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 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 possibly printed with a decorative layer; with a surface mass greater than 100 g / m2 the veil breaks when rolled up and the hand, i.e. the feel of the installer when laying, becomes too rigid; - a compact PVC backing layer, i.e. not foamed, preferably calendered, pressed or extruded, for example coated, having a higher thickness 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 thickness, which can be increased to decrease the thickness.

[0018] In this way, the invention makes it possible to provide a rollable multilayer structure allowing for the creation of a loose-lay floor covering, covering an existing VSM type floor covering, without degrading its puncture 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 coating with double-sided adhesive around the perimeter 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 needing to cut the bottoms of 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 performance of resistance to puncture, or even to improve it since the results showed a residual indentation of less than 0.04 mm at 2h30 and less than 0.02 mm at 24h.

[0022] The rigidity of the multilayer structure allows it to withstand heavy load traffic and to meet the test of the rolling chair according to the NF EN 425 standard in free-standing, or even semi-free-standing 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 percent parts of resin.

[0024] This reverse layer helps to balance the structure, without requiring an increase in thickness.

[0025] Given the low loading rate in the underside layer, another advantage lies in its low surface mass. In other words, the invention makes it possible to rebalance the structure with less weight compared to the solution of increasing the thickness of the underside layer.

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

[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 content of less than 5% by weight of the wear layer, or even zero filler content, and the multilayer structure includes a decorative layer positioned under the wear layer.

[0028] In this configuration, the low load rate in the plasticized PVC wear layer causes the phenomenon of "curving" or incurvation tending to unbalance the multilayer structure, compensated by the reverse layer.

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

[0030] According to another embodiment, the wear layer may be located under the The material consists of a layer of pressed granules, so that the wear layer itself forms the decorative pattern. The granules can be any desired color, as is well known in the prior art.

[0031] The layer of pressed granules is obtained from plasticized and filled PVC. Generally, the filling ratio of the pressed granules is well below 130 PCR, preferably below 100 PCR or even 80 PCR, in order to provide good scratch resistance. The layer of pressed granules thus tends to generate a "curving" phenomenon that tends to unbalance the multilayer structure, which is compensated for 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 including 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 / bulge phenomenon which is generated in front of the wheels of a heavy load, i.e. of the order of 200kg or more, circulating on the multilayer structure laid freely on a floor, the underside layer is preferably made by coating, calendering or extrusion, because these techniques make it possible to obtain a smoother contact surface with the floor than when the underside layer is made from pressed granules and then sanded.

[0034] According to another feature, 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 CSTB reference document QB 30 - Ml-Ueatc July 2015. In other words, a tensile force of between 7 and 9 daN / cm must be applied on either side of a sample of the structure to attempt to elongate it by at least 1% of its length.

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

[0036] Other features and advantages of the invention will become clear from the description given below, by way of example and not limitation, with reference to the accompanying figures in which:

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

[0038] [Fig. 2] is a view similar to that of [Fig. 1], 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 multilayer structure (1) for the production of a floor covering in free laying, 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 roll form.

[0041] To this end, the multilayer structure (1) exhibits a flexibility that allows it to comply with ISO 24344:2008. In this standard, flexibility is defined as the ability of a floor covering or a layer of a floor covering to be wound around a 20 mm mandrel without cracking or splitting. Thus, the multilayer structure according to the invention, as tested in this way, would not exhibit any breaks, splits, cracks, or other permanent defects.

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

[0043] With reference to [Fig.1], the multilayer structure (1) comprises successively, from top to bottom, a wear layer (2) 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 underlayer (4) 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) provides slip resistance, wear resistance, and ease of cleaning. It comprises 20 to 70 PCR of plasticizer.

[0045] The wear layer (2) can be obtained by extrusion, calendering, pressing, or by coating and 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 polyurethane-based or urethane-acrylate varnish. The wear layer (2) can be varnished and / or textured to improve stain and scratch resistance.

[0046] The wear layer (2) can also serve as a decorative layer, 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 1 Opm 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 long and cross directions, measured according to the ISO 1924 / 2 method.

[0051] The glass veil (3) improves the dimensional stability of the multilayer structure (1) as well as its resistance to indentation. 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 The bonding layer (6) is in the form of a gelled plastisol, such as a PVC plastisol, and its upper surface is coated with a gelled plastisol (5), such as a PVC plastisol, 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) to the glass grid (7) without complicating the manufacturing process or unduly increasing the weight of the structure, the binder comprises an acrylic adhesive, or ethylene-vinyl acetate (“EVA”), or a 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 strands of the glass grid (7) are, for example, obtained from glass fibers and are preferably spaced between 1 mm and 5 mm apart, preferably between 2 mm and 4 mm, depending on the longitudinal and transverse dimensions, and have a linear density 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, on the order of 0.1–0.2 mm, and a surface density between 30 g / m² and 60 g / m². The tensile strength of a glass grid implemented in the invention is advantageously between 400 N / 50 mm and 1000 N / 50 mm in both the longitudinal and transverse directions.

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

[0058] The reverse 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 incorporate recycled material into its composition with this manufacturing technique, without degrading the decoration or the appearance of the multilayer structure (1).

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

[0061] The backing layer (4) can be related to the wear layer (2) in terms of composition and properties, and thus allows the structure to be balanced by counteracting the curvature 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 content.

[0062] The fillers used in each layer of the structure may be calcium carbonate, clay, silica, kaolin, or talc. Preferably, the material should be powdered to prevent degradation of the filler during the mixing of the PVC masterbatch used to form the layers, but the use of fibers may be considered. The fillers may be used alone or in mixtures.

[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 including 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 coating covered, in loose laying, with a multilayer structure (1) presenting; - a total thickness of 1.6 mm: - a wear layer made of gelled PVC plastisol having 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 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 2h30 and less than 0.02 mm at 24h.

[0066] Furthermore, the Applicant also noted that when a heavy load, of the order of 200kg (100kg hospital bed with a 100kg weight), rolls over the structure, this does not generate any wave 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 Static punching shear (Building): ISO 24343-1 June 2007.

[0068] It follows from the above that the invention does indeed provide a multilayer structure (1) which makes it possible to cover a VSM type floor covering, without degrading its puncture 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 multilayer structure according to the invention is balanced and adapted for free laying and without coupling means, with sufficient 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.

Claims

Demands

1. A rollable, multi-layer structure (1) based on PVC, for the creation of 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) 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 PVC backing layer (4) having a thickness of between 0.3 and 0.7 mm, and a surface mass of between 360 and 840 g / m2.

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

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

5. Multilayer structure (1) rollable according to any 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. A rollable multilayer structure (1) according to any one of the preceding claims, characterized in that the wear layer (2) is transparent, comprises 30 to 50 PCR of plasticizer, and a filler content of less than 5% by weight of the wear layer (2), or even a zero filler content, and in that the multilayer structure (1) comprises a decorative layer positioned under the wear layer (2).

7. Multilayer structure (1) rollable according to any 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 any 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 multilayer structure (1) according to any one of the preceding claims, placed on a vinyl-on-foam coating, i.e. comprising at least one layer of PVC bonded to a backing layer of foamed PVC.