Flexible flooring with a backing layer made of non-woven natural fibers

Abstract

The invention relates to a flexible floor covering (10, 20, 30) comprising: - a surface layer (1) made from PVC, - a backing layer (3) made from fibers, the surface (1) and backing (3) layers being bonded together by a middle layer (2) made from PVC and characterized in that the backing layer (3) comprises natural fibers. Abstract figure: Figure 1

Description

Title of the invention: Flexible floor covering with a backing layer made of non-woven natural fibers technical field

[0001] The present invention relates generally to the field of floor coverings, in particular flexible floor coverings made from polyvinyl chloride (PVC). Previous art

[0002] Floor coverings are known in the prior art. The applicant's document EPI360366 describes in particular a covering comprising a transparent PVC wear layer, an intermediate layer obtained from a reinforcement impregnated with a gelled plastisol on both sides and printed, a PVC bonding layer and a non-woven polyester backing layer.

[0003] However, this type of coating does not provide complete satisfaction in terms of recyclability and use of fossil materials.

[0004] The use of a non-woven polyester backing layer provides a compromise between sound attenuation and puncture resistance that is advantageous for certain markets. However, the use of this petroleum-based polymer contributes to the depletion of fossil resources.

[0005] Current PVC flooring manufacturing processes can incorporate, mixed with virgin material, a portion of end-of-life PVC flooring that has been shredded. However, in the case of flooring comprising a non-woven polyester layer bonded to the PVC layers, the resulting heterogeneous product cannot be incorporated by these processes and is therefore not recyclable. Indeed, in a heating transformation process that reuses this heterogeneous material, the polyester fibers do not melt at the same temperatures as the PVC and will create defects when reintroduced as is into manufacturing processes, whether they use virgin polyester or virgin PVC.

[0006] An alternative is to separate the PVC layers from the polyester non-woven layer. However, this type of process is costly, and even if the polyester non-woven layer is separated, it remains partially contaminated with PVC residue and is therefore not reusable. In this alternative, only the PVC portion is recyclable, and the polyester non-woven layer is discarded.

[0007] On the other hand, the fire behavior of this type of coating is not satisfactory.

[0008] The present invention thus aims to propose a new construction of flexible floor covering, improving the fire resistance characteristics, of Recyclability and environmental impact. The invention aims in particular to improve the carbon footprint of this type of coating and to reduce its dependence on fossil resources.

[0009] In a first aspect, the invention relates to a flexible floor covering comprising: - a surface layer made from PVC, - a backing layer intended to be in contact with the ground made from fibers, the surface and backing layers being linked together by a middle layer made from PVC and characterized in that the backing layer comprises natural fibers.

[0010] The invention thus makes it possible to offer a floor covering comprising a renewable material of biological origin while maintaining or improving the properties of the floor covering, in particular those related to walking comfort, acoustic and thermal insulation, mechanical resistance, flatness, fire resistance, which are thus improved compared to previous coverings.

[0011] It is thus possible to replace the polyester fiber-based backing layers of the prior art with backing layers made from natural fibers, whether linen, hemp, jute, or any other natural material. Current processes allow the entire coating to be ground up at the end of its life for direct reuse in a mixture containing virgin PVC, particularly in calendering, pressing, or extrusion processes for coatings made from PVC. Alternatively, current processes allow the separation of the backing layer, preferably made of non-woven fabric, from the surface and core layers made from PVC, and allow the natural fibers of the backing (i.e., the non-woven fabric) to be reused, or even reintegrated into processes using PVC resins.

[0012] PVC flooring is preferably presented in rolls, but can also be presented in rollable tiles or planks, in order to be easily transportable.

[0013] The invention can also be defined according to the following characteristics, taken individually or in combination.

[0014] Advantageously, the backing layer is made from non-woven fibers. The use of this type of layer allows, in particular, good bonding of the middle layer to the backing layer due to the interlocking of the fibers.

[0015] The invention preferably relates to a floor covering comprising a backing layer of natural fibers, preferably made from non-woven fibers, said backing layer having a tensile strength greater than 25N, namely a breaking strength greater than 25N according to ISO 1421:2016, method 1. This breaking strength allows this type of layer to resist the continuous processes used for manufacturing flexible floor coverings and allows the layer comprising natural fibers to have sufficient mechanical resistance not to tear during manufacturing, particularly during the unwinding and transport phases on mandrels.

[0016] Preferably, natural fibers can also be blended with synthetic or mineral fibers to improve the tensile strength of the backing layer. In this case, the natural fibers remain separable from the synthetic or mineral fibers at the end of their life.

[0017] The backing layer made from non-woven natural fibers is more specifically obtained by a dry process followed by mechanical needle punching to bond the fibers together. This type of process results in better durability of the flooring over time, in particular better resistance to traffic and to the transfer of defects from the covered subfloor to the surface of the flooring.

[0018] Depending on the type of fiber used, their diameter, their length, the surface mass of the backing layer made from natural fibers, and to improve its tensile strength, fiber blends may be used, possibly in combination with the addition of a binder between the fibers and / or the use of mechanical reinforcement processes such as needle punching.

[0019] Advantageously, natural fibers, such as natural fibers of plant origin or natural fibers of animal origin, are selected from flax, hemp, jute, bamboo, cotton, wood pulp, cellulose, silk, sheep's wool, alpaca wool, angora wool or cashmere, alone or in combination.

[0020] Advantageously, the reverse layer has a thickness of between 0.5 and 3 mm, preferably between 1.1 and 2.5 mm.

[0021] Advantageously, the back layer has a surface mass between 50 and 350 g / m2, preferably between 150 and 250 g / m2.

[0022] Note that natural fibers are often coarser and heterogeneous, so the minimum useful thickness is greater than when using a non-woven layer using only polyester (PET) fibers.

[0023] Advantageously, the reverse layer comprises between 50 and 95% natural fibers by mass of the total mass of the reverse layer, or even between 50 and 100%.

[0024] Advantageously, the reverse layer comprises a mixture of natural fibers (of biological origin) and synthetic fibers (such as polyester, polyamide, polypropylene), the mixture comprising between 50 and 95% natural fibers by mass of the total mass of the reverse layer, or even between 50 and 100%.

[0025] Advantageously, the reverse layer comprises a mixture of natural fibers (of biological origin) and mineral fibers (such as glass fibers, mineral fibers) basalt...), the mixture comprising between 50 and 95% natural fibers by mass of the total mass of the reverse layer, or even between 50 and 100%.

[0026] Advantageously, the reverse layer further comprises synthetic fibers such as polyester, coated polyester, polyamide, elastane or polypropylene and / or mineral fibers, such as glass fibers.

[0027] Advantageously, the surface layer and / or the middle layer is made from a gelled plastisol, preferably a PVC plastisol.

[0028] Advantageously, the surface layer comprises a transparent surface layer, for example made from a gelled plastisol, preferably a PVC plastisol, or by extrusion or calendering.

[0029] Advantageously, the surface layer further comprises a decorative layer, preferably a printed decorative layer.

[0030] Advantageously, the surface layer comprises a PVC film on which a design is printed opposite the transparent surface layer.

[0031] Advantageously, the surface layer further comprises a reinforcement, such as a fiberglass reinforcement, preferably coated with a gelled PVC plastisol on both sides and printed with a design opposite the transparent surface layer.

[0032] Advantageously, the surface layer further comprises a varnish layer on its visible upper face, preferably with a thickness of between 10 and 30 microns and giving the whole specific properties, such as resistance to ultraviolet radiation, resistance to soiling, scratching, traffic, and / or abrasion.

[0033] Advantageously, the middle layer comprises a foam layer.

[0034] Advantageously, the floor covering further comprises a bonding layer made from a gelled PVC plastisol, arranged between the middle layer and the reverse layer so as to bind them together.

[0035] Advantageously, the floor covering is rollable (or rolled) onto a mandrel or onto itself, preferably a mandrel of 40 mm diameter, more preferably a mandrel of 20 mm diameter.

[0036] Advantageously, the flexible floor covering is sufficiently flexible to be rolled without defect onto a 120 mm diameter mandrel according to the criterion defined in ISO 24344:2008 method A, preferably onto a 40 mm diameter mandrel, more preferably onto a 20 mm diameter mandrel.

[0037] In this method, flexibility is defined by the ability of a floor covering to be wound around a 40 or 20 mm mandrel without cracks or fissures forming.

[0038] An advantage of the invention is also to obtain a floor covering with a soft, pleasant and natural feel.

[0039] Other features and advantages of the present invention will become more apparent from the following detailed description, embodiments of the invention given by way of non-limiting example and illustrated by the accompanying drawings. Brief description of the drawings

[0040] [Fig. 1] represents a cross-sectional view of a first embodiment of the floor covering.

[0041] [Fig.2] represents a cross-sectional view of a second embodiment of the floor covering.

[0042] [Fig.3] represents a cross-sectional view of a third embodiment of the floor covering. Detailed description of the invention

[0043] According to Figures 1 to 3, the flexible floor covering (10, 20, 30) comprises: - a surface layer (1) made from PVC; - a reverse layer (3) made from natural fibers, preferably non-woven; the surface layers (1) and reverse layer (3) being linked together by a middle layer (2) made from PVC.

[0044] Natural fibers, such as natural fibers of plant origin or natural fibers of animal origin, are preferably chosen from flax, hemp, jute, bamboo, cotton, wood pulp, cellulose, silk, sheep's wool, alpaca wool, angora wool or cashmere, alone or in combination.

[0045] The reverse layer (3) preferably comprises between 50 and 95% natural fibers by mass of the total mass of the layer.

[0046] The reverse layer (3) preferably has a thickness between 0.5 and 3 mm, preferably between 1.1 and 2.5 mm.

[0047] The reverse layer (3) preferably has a surface mass between 50 and 350 g / m2, preferably between 150 and 250 g / m2.

[0048] Regardless of the embodiment, the surface layer (1) and the middle layer (2) are bonded by thermolamination or via a bonding layer (not shown), such as an adhesive layer or a layer of gelled plastisol. The middle layer (2) is made from PVC, for example by calendering, coating, extrusion, or pressing.

[0049] In the embodiment of [Fig. 1], the floor covering (10) may comprise, at the surface layer (1), one or more layers, such as an optional varnish layer (11), a transparent surface layer (12) obtained from a gelled PVC plastisol, a decorative layer comprising a printed design (13) on a reinforcement (14) coated on both sides with gelled PVC plastisol (preferably fiberglass). The coated reinforcement (14), for example a fiberglass mesh, generally has a thickness of between 0.5 and 1.2 mm

[0050] In the embodiment of [Fig. 1], the floor covering (10) may comprise, at the level of the middle layer (2), one or more layers, such as the middle layer (15) made of PVC, either solid or foamed, and / or a bonding layer (16) made of PVC (gelled PVC plastisol, hot melt adhesive, or equivalent) to bond the backing layer (3) and the middle layer (2). A bonding layer thus provides the interface between two layers to bind them together.

[0051] In the embodiment of [Fig.1], the floor covering (10) may include, at the level of the underlayer (3), one or more layers made from natural fibers, such as a layer made from non-woven natural fibers.

[0052] Figure 2 represents a second embodiment of the floor covering (20).

[0053] In the embodiment of Figure 2, the floor covering (20) may include, at the level of the surface layer (1), one or more layers, such as an optional varnish layer (21), a surface layer made from a transparent gelled PVC plastisol (22), a decorative layer comprising a printed design (23) on a PVC film (24).

[0054] In the embodiment of [Fig.2], the floor covering (20) may include, at the level of the middle layer (2), one or more layers, such as the middle layer (25) made of PVC, compact or foamed, and / or a bonding layer (26) made of PVC (gelled PVC plastisol, hot melt adhesive or equivalent) to make the bond with the back layer (3).

[0055] In the embodiment of [Fig.2], the floor covering (10) may include, at the level of the underlayer (3), one or more layers made from natural fibers, such as a layer made from non-woven natural fibers.

[0056] Fig. 3 represents a third embodiment of the floor covering (30).

[0057] In the embodiment of [Fig. 3], the floor covering (30) may comprise, at the surface layer (1), one or more layers, such as an optional varnish layer (31), and a decorative surface (32) made of plasticized PVC. The decorative layer (32) may be uniform and is obtained, for example, by coating with a colored plastisol, by extrusion, by pressing, or by calendering. The decorative layer (32) may also be textured and obtained, for example, from pressed PVC granules.

[0058] In the embodiment of [Fig.3], the floor covering (30) may include, at the level of the middle layer (2), one or more layers, such as the middle layer (33) made of PVC, compact or foamed, and / or a bonding layer (34) made of PVC (obtained from gelled PVC plastisol, hot melt glue or equivalent) to make the bond with the back layer (3).

[0059] In the embodiment of [Fig.3], the floor covering (30) may include, at the level of the underlayer (3), one or more layers, such as a layer made from non-woven natural fibers.

[0060] Regardless of the embodiment, the surface layer (1) has a thickness of between 0.1 and 2 mm. Preferably, the transparent layer (12, 22) has a thickness of between 0.15 and 1 mm, more preferably between 0.15 and 0.7 mm.

[0061] Regardless of the embodiment, the middle layer has a thickness of between 0.05 and 2 mm. The middle layer (2) more preferably has a thickness of between 0.05 and 0.59 mm when it does not include a foam layer and a thickness generally of between 0.6 and 2 mm, or even between 1 and 1.5 mm when it includes at least one foam layer.

[0062] Regardless of the embodiment, the flexible floor covering (10, 20, 30) preferably has a thickness between 1 and 6 mm, preferably between 2 and 4.5 mm.

[0063] Other examples of embodiments of the present invention are listed below.

[0064] Example 1:

[0065] Floor covering with an underlayer (3) made from flax, 1.35 mm thick and with a surface mass of 180 g / m2, the composition of which is 85% flax fibers and 15% Polyester fibers by mass of the underlayer.

[0066] The proportion of flax fibers can also be between 50 and 100% flax, preferably between 60 and 85% flax fibers. The proportion of polyester fibers is between 0 and 50%, preferably between 15 and 40%.

[0067] It should be noted that the quantity of polyester fibers may consist of virgin or recycled fibers, as well as bi-component fibers which ensure and reinforce the mechanical strength of the backing layer. The bi-component fibers are made up of two types of polyester with different melting points.

[0068] Example 2:

[0069] Floor covering with a hemp-based backing layer (3) 1.20 mm thick and with a surface mass of 200 g / m2, composed of 70% hemp fibers and 30% polyester fibers.

[0070] The proportion of hemp fibers can also be between 50 and 100% hemp, preferably between 60 and 85% hemp fibers. The proportion of polyester fibers is between 0 and 50%, preferably between 15 and 40%.

[0071] Note that the quantity of polyester fibers may consist of virgin or recycled fibers as well as bi-component fibers (coated polyester fibers) which ensure and reinforce the mechanical strength of the product.

[0072] Example 3:

[0073] Floor covering with an underlayer (3) made from jute fibers of thickness 0.6 mm and surface mass 250 g / m2, the composition of which is 100% jute fibers.

[0074] Example 4:

[0075] A floor covering according to [Fig.1] with a total thickness of 2 mm is produced.

[0076] The coating comprises: - A transparent layer (12) of 0.3mm thick gelled PVC plastisol; - A glass veil frame (14) coated with a gelled PVC plastisol on both sides and printed (13) on its face opposite the transparent layer (12), with a thickness of 0.6mm; - A middle layer comprising a layer made from PVC and compact (15) of 0.1 mm and a bonding layer (16) of gelled PVC plastisol of 0.4 mm of which approximately 0.1 mm thick is impregnated into the reverse layer to bind it; - A backing layer (3.17) made from non-woven, needle-punched flax fibers with a thickness of 0.7 mm, of which approximately 0.1 mm is impregnated in the bonding layer. The backing layer (3.17) is a layer of non-woven natural flax fibers with a surface mass of 200 g / m².

[0077] The coating thus produced is tested according to three criteria: sound insulation, walking noise and fire resistance.

[0078] [Tables] Test Method Technical Characteristics Units Results NF EN ISO 717-2 May 2013 / NF EN ISO 10140-3 March 2013 Sound Insulation dB 12 dB at 20.7 °C NF EN 16205 August 2013 / NF EN 16205 / IN1 May 2018 Walking Sound dB 68 dB at 20.7 °C NF EN ISO 9239-1 February 2013 Reaction to Fire CHF (kW / m2) Smoke Density (%° min) class BflSl 9.29 108.5

[0079] By way of comparison, a similar coating whose backing layer (3) is made entirely from 200 g / m² polyester only achieves class CflSl fire resistance. The acoustic insulation and walking noise performance are comparable.

[0080] The coating according to the invention thus allows the integration of a component made from natural raw materials such as flax, hemp, or any other natural material of biological, plant, or animal origin. The invention therefore improves the performance of the coating compared to the prior art, namely all the points mentioned above, as well as fire resistance.

[0081] It will be understood that various modifications and / or improvements obvious to a person skilled in the art can be made to the different embodiments of the invention described in this description.

[0082] Finally, it should be noted that it is possible to combine the embodiments as much as possible or necessary.

Claims

Demands

1. Flexible floor covering (10, 20, 30) comprising: - a surface layer (1) made from PVC, - a backing layer (3) made from fibers, the surface (1) and backing (3) layers being linked together by a middle layer (2) made from PVC, characterized in that the backing layer (3) comprises natural fibers.

2. Floor covering (10, 20, 30) according to the preceding claim, characterized in that the backing layer (3) has a tensile strength greater than 25N according to ISO 1421:2016, method 1.

3. Floor covering (10, 20, 30) according to the preceding claim, characterized in that the backing layer (3) is made from non-woven fibers.

4. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that the natural fibers, such as natural fibers of plant origin or natural fibers of animal origin, are selected from flax, hemp, jute, bamboo, cotton, wood pulp, cellulose, silk, sheep's wool, alpaca wool, angora wool or cashmere, alone or in combination.

5. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that the backing layer (3) has a thickness of between 0.5 and 3 mm, preferably between 1.1 and 2.5 mm.

6. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that the backing layer (3) has a surface mass between 50 and 350 g / m2, preferably between 150 and 250 g / m2.

7. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that the backing layer (3) comprises between 50 and 95% natural fibers by mass of the total mass of the layer.

8. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that the backing layer (3) further comprises synthetic fibers such as polyester, polyester coated, polyamide, elastane or polypropylene; and / or mineral fibers, such as glass fibers.

9. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that the surface layer (1) further comprises a decorative layer (13, 23, 32), preferably a printed decorative layer.

10. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that the surface layer (1) comprises a printed PVC film (24).

11. Floor covering (10, 20, 30) according to any one of claims 9 to 10, characterized in that the decorative layer further comprises a reinforcement (14), such as a fiberglass reinforcement, preferably coated with a gelled PVC plastisol on both sides.

12. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that it further comprises a bonding layer (16, 26, 34) made from a gelled PVC plastisol, arranged between the middle layer (2) and the underside layer (3) to bind them together.

13. Floor covering (10, 20, 30) according to any one of the preceding claims, characterized in that it can be rolled without defect onto a 120 mm diameter mandrel according to the criterion defined in ISO 24344:2008 method A, preferably onto a 40 mm diameter mandrel, more preferably onto a 20 mm diameter mandrel.

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