Flooring insert incorporating a signage element

Abstract

The invention relates to a floor covering insert incorporating a signage element, the insert (1) comprising at least two pre-cut decorative structures (3, 4) assembled and positioned side by side with a gap and glued to a support (5) to form the signage element, said glue (6) also being present in the gap between the first and second decorative structures (3, 4). According to the invention: - the first and second decorative structures (3, 4) each comprise, from top to bottom, a decorative layer (3a, 4a) of plasticized PVC, bonded to a first reinforcing frame (3b, 4b), bonded to a lower layer (3c, 4c) of plasticized PVC; - the support (5) is flexible and rollable and comprises, from top to bottom, a second reinforcing frame (5a) bonded to a backing layer (5b) of plasticized PVC. Figure for the abstract: Fig. 3

Description

Title of the invention: Floor covering insert incorporating a signage element technical field

[0001] The present invention relates to the field of flexible, rollable floor coverings obtained from PVC, generally stored in roll form, for use in the field of transport or any field requiring the installation of floor markings.

[0002] By flexible and rollable, it is understood that during its storage or transport, said coating can be presented in a roll, wound upon itself or around a 120 mm diameter mandrel according to the criterion defined in ISO 24344:2008 method A, preferably on a 40 mm diameter mandrel, more preferably on a 20 mm diameter mandrel, without cracks or fissures forming. Prior art

[0003] This type of flexible, rollable floor covering can have a design: - within the thickness of the surface layer, which thus has a significant thickness, on the order of 0.3 to 2 mm, so that the design can withstand very heavy traffic. The design can be a solid color, for example produced by calendering, extrusion, coating, or more generally obtained from several types of PVC, rubber or other polymer granules, colored and hot-pressed to bind them together and form a heterogeneous design; - printed and protected by a transparent top layer. However, this type of construction is difficult to implement in the railway sector where fire resistance requirements are very high.

[0004] This type of floor covering is produced continuously in sheet form, then rolled into a roll. The decorative layer, whether printed or not, is thus identical over the entire surface produced.

[0005] Each production run yields several hundred square meters. Subsequently, for the production of a bus or train floor, a portion is pre-cut at the factory to the dimensions of the vehicle to be fitted (this portion is called a "kit"). Even in the case of printed graphics, it is not possible to predict during production which part of the graphics will correspond to each area of ​​the vehicle.

[0006] It therefore appears difficult to integrate into the decorative layer logos or other signage elements allowing, for example, the identification of access areas for people with reduced mobility, entrances, exits, etc.

[0007] There is currently a technique on the market for the creation of logos.

[0008] According to this technique, the logo is composed of two pre-cut decorative structures, namely a first one for the background color, and a second one for the logo as such, which are assembled and glued onto a laminated support of the phenolic resin type with a fiberglass fabric.

[0009] This product is manufactured in a factory and then delivered separately from the flooring. The customer thus receives a kind of insert with the logo, which must be integrated during the installation of the flooring. The insert therefore replaces part of the installed flooring.

[0010] Variations exist where the laminate may have a foam layer and / or an adhesive with a protective film to facilitate its application in the vehicle. Due to its rigidity, the laminate ensures good durability of the logo.

[0011] To make this insert, the laminate is coated with glue, and the two pre-cut surfaces are assembled and placed on the laminate.

[0012] The assembly is then hot-pressed, which allows the glue to rise between the two parts of the logo, then it cross-links to ensure optimal sealing.

[0013] This logo is therefore pre-welded and delivered flat on a pallet. However, the laminate is neither flexible, nor rollable, nor recyclable. These rigid logos must be installed by the customer, which results in wasted time and adds complexity, particularly for edge welding. Furthermore, the rigidity of the laminate prevents the logo from being placed near edges or from extending up skirting boards. Description of the invention

[0014] One of the aims of the invention is therefore to propose a floor covering insert incorporating a signage element, such as a logo used for example to identify access areas for people with reduced mobility, entrances, exits, etc... which is flexible and rollable, so that it can be shipped easily or integrated without difficulty into a floor covering which is also flexible and rollable.

[0015] Another objective of the invention is to provide a flexible and rollable floor covering incorporating such an insert, in order to allow the addition of logos or signage in the decorative layer of the floor covering, which is preferably recyclable, while exhibiting good long-term sealing and good resistance to traffic.

[0016] For this purpose, a floor covering insert has been developed incorporating a signage element such as a logo or other, in particular in the form of a patch or insert intended to replace part of the floor covering.

[0017] The insert comprises at least first and second pre-cut decorative structures, for example a first one for the background color, and a second one for the logo as such, assembled and positioned side by side with a gap, in particular of a few tenths of a millimeter, and glued onto a support to form the signage element, said glue also being present in the interplay between the first and second decorative structures, in particular to glue the lateral edges of said structures.

[0018] According to the invention: - the first and second decorative structures each comprise, from top to bottom, a decorative layer of PVC, possibly varnished, linked to a first reinforcing frame, linked to a lower layer of plasticized PVC; - the support is flexible and rollable and includes, from top to bottom, a second reinforcing frame linked to a backing layer of plasticized PVC.

[0019] In this way, the logo support is reinforced while remaining rollable, and is made from PVC, which facilitates its recycling. The two decorative structures forming the logo are pre-cut, maintaining a gap between each surface to allow adhesive to rise along their edges, thus promoting its watertightness and resistance to traffic.

[0020] The invention therefore makes it possible to integrate this insert, and therefore signage elements, in a harmonious, durable and watertight manner within flexible floor coverings, while remaining compatible with current industrial processes for laying floor coverings.

[0021] The invention also makes it possible to ship the rolled insert, alone or together with a roll of flooring into which the insert will be integrated on site, without difficulty and without the use of a pallet.

[0022] Given the flexibility of the insert, it is also possible to easily create skirting board extensions with the flexible covering that integrates it.

[0023] Furthermore, the combination of reinforcing armatures in the decorative structures and in the support makes it possible to improve the resistance to traffic of the whole while maintaining a coating that is easy to install.

[0024] According to a first embodiment, the decorative layer of the first and / or second decorative structures comprises a transparent PVC wear layer and a printed decoration: - under the wear layer, or; - on the first reinforcing frame, or; - on a film positioned between the wear layer and the first reinforcing frame, which film is part of the decorative layer.

[0025] This arrangement offers great flexibility in the customization and design of signage elements, while ensuring good resistance to wear and deformation.

[0026] This variant makes it possible to offer a printed decoration visible through a wear layer, for example to increase the contrast of the decoration in relation to the whole of the installation.

[0027] According to another embodiment, the decorative layer of the first and / or second decorative structures comprises a PVC wear layer with a decoration within the thickness of the wear layer.

[0028] To increase resistance to traffic, the first and second decorative structures each include a third reinforcing reinforcement, preferably made of non-woven polyester, bonded to an underside of the lower layer. This third reinforcement bonds effectively to the substrate and provides improved walking comfort.

[0029] According to a particular embodiment, the insert comprises an underlayer attached to a lower face of the underside layer in plasticized PVC, which includes, from top to bottom, a fourth reinforcing frame and an underside foam.

[0030] This underlay system (8) improves the acoustic and thermal performance of the flooring while increasing walking comfort. The backing foam also acts as a shock-absorbing layer, reducing the mechanical stresses experienced by the flooring.

[0031] This backing foam is obtained for example by extrusion or coating, is made of plasticized PVC, and has a thickness of between 3 and 5mm and a density of between 0.25 and 0.5. This ensures an optimal balance between comfort and resistance to traffic.

[0032] Preferably, the insert has a total thickness of between 2 and 3.5 mm, preferably between 2.2 and 2.8 mm.

[0033] This thickness ensures good resistance to traffic and loads while maintaining sufficient flexibility for easy winding, thus facilitating installation and transport.

[0034] The first and second decorative structures are bonded to each other and to the substrate with a hot melt adhesive, an MS polymer-based adhesive, a polyurethane-based adhesive, an acrylic-based adhesive, or a hot melt film, but increased adhesion has been observed with a two-component epoxy-urethane adhesive. Between 250 and 750 g / m² of adhesive, preferably from 350 g / m² to 600 g / m², are generally applied to the plasticized and reinforced PVC substrate before hot pressing to ensure good mechanical strength. The two-component epoxy-urethane adhesive provides durable adhesion and high mechanical strength, while offering good flexibility to prevent cracking due to ground movement or temperature variations. Furthermore, unlike a sealant, this type of adhesive hardens sufficiently to be effectively ground during recycling operations. This allows for better reuse of an end-of-life, ground-up insert according to the invention, for integration into new flexible PVC floor coverings comprising recycled products.

[0035] Advantageously and in order to simplify the installation process, the insert includes an adhesive underside coated with a peelable film.

[0036] The invention also relates to a flexible, rollable floor covering incorporating an insert as described above. The insert can be glued or welded to the floor covering, replacing a portion of said floor covering, directly on the construction site. Alternatively, advantageously, the insert is pre-positioned and integrated, i.e., glued or welded to the floor covering, which is then rolled up and marketed.

[0037] This facilitates on-site installation because the insert is in the right place on the roll, its integration is homogeneous.

[0038] The invention finally relates to a method of manufacturing a floor covering insert remarkable in that it comprises the following steps: - cutting a first motif in a first decorative structure, and a second complementary motif in a second decorative structure, made of plasticized and reinforced PVC; - coating of a layer of glue onto a flexible and rollable support made of plasticized and reinforced PVC; - assembly of the first and second decorative structures on the layer of glue to form the signage element, with a gap between them, in particular of a few tenths of a millimeter, to allow glue to rise into said gap; - optionally, installation of a structured plate in relation to the signage element; - hot pressing to crosslink the glue and bind everything together.

[0039] Hot pressing to cross-link the adhesive ensures a strong and durable bond, thus optimizing the mechanical strength and sealing of the insert. Preferably, the process includes a step prior to the hot pressing step, which consists of depositing a textured plate on the visible face of the first and second decorative structures. This plate helps to maintain, or even create, a surface relief on the decorative structures, particularly to improve slip resistance and reduce the risk of falls. The textured plate can be metallic, rubber, silicone, or equivalent. The depth of the relief created is generally between 0.05 and 0.5 mm. Brief description of the drawings

[0040] 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:

[0041] [Fig-1] is a schematic, top-view representation of a floor covering incorporating a insert according to the invention.

[0042] [Fig.2] is a view similar to that of [Fig.1], a cross-sectional view

[0043] [Fig.3] is an exploded view of the different layers of a first form of fabrication of the floor covering insert according to the invention.

[0044] [Fig.4] is an exploded view of the different layers of a second embodiment of the floor covering insert according to the invention, illustrating only one of the decorative structures.

[0045] [Fig.5] is an exploded view of the different layers of a third embodiment of the floor covering insert according to the invention, illustrating only one of the decorative structures

[0046] [Fig.6] is an exploded view of the different layers of a fourth embodiment of the floor covering insert according to the invention, illustrating only one of the decorative structures. Detailed description of the invention

[0047] With reference to figures 1 to 6, the invention relates to a flexible and rollable floor covering insert (1) comprising a signage element, such as a logo or any other type of marking.

[0048] The insert (1) is therefore intended to replace a cut-out area of ​​a floor covering (2), and to integrate into said floor covering (2).

[0049] The insert (1) comprises first and second decorative structures (3, 4) pre-cut, assembled and positioned side by side and glued onto a support (5) to form the signage element.

[0050] Depending on the signage to be created, the decorative structures (3, 4) can have any shape, design, or color; for example, a first decorative structure (3) is used for the background color, and a second decorative structure (4) for the logo itself. Of course, more than two structures can be used depending on the complexity of the logo to be created.

[0051] The decorative structures (3, 4) are positioned side by side with a gap, for example of a few tenths of a millimeter, so that the glue (6) used to glue them to the support (5) can rise into the gap and link the structures (3, 4) together.

[0052] The adhesive (6) used is preferably a two-component epoxy-urethane adhesive, capable of withstanding (5) mechanical and thermal stresses, in particular During the hot pressing process, which bonds the entire assembly, a layer of adhesive (5) between 250 and 750 g / m², preferably 350 g / m² to 600 g / m², is generally applied to the plasticized and reinforced PVC substrate (5) before hot pressing to ensure good mechanical strength. In addition to its role in adhering the decorative layers to the substrate (5), this adhesive (6) also fills the gaps between the motifs, thus reinforcing the watertightness of the inset (1).

[0053] Each decorative structure (3, 4) comprises, from top to bottom, the following different layers: - a decorative layer (3a, 4a) of plasticized PVC, possibly coated with a layer of varnish (V) to improve its resistance and protect its surface. The varnish (V) may be acrylic or polyurethane and include anti-slip particles, such as corundum or polyamide particles; - a first reinforcing frame (3b, 4b), made of glass fibers or non-woven polyester, which reinforces the strength of the structure; - a lower layer (3c, 4c) of plasticized PVC, serving as a bond with the support (5) of plasticized and reinforced PVC. This lower layer may contain mineral fillers and be reinforced with flame retardants, making it suitable for environments with high safety requirements, such as railway vehicles.

[0054] The decorative layer (3a, 4a) can be obtained by calendering, extrusion, pressing, or coating. It is made of plasticized PVC, with or without mineral fillers. It can be tinted or transparent. It may include anti-slip particles (corundum, polyamide particles, or equivalent). Its weight is generally between 300 and 2500 g / m².

[0055] The lower layer (3c, 4c) can be obtained by calendering, extrusion, pressing, or coating. It is made of plasticized PVC, with or without mineral filler. It is generally dyed. It may include recycled PVC. Its weight is generally between 300 and 2500 g / m².

[0056] These decorative structures (3, 4) are therefore resistant, flexible and rollable.

[0057] The support (5) for the decorative structures (3, 4) is also designed to be resistant, flexible and rollable, thus facilitating the integration of the insert (1) into a covering presented in roll form.

[0058] The support (5) comprises: - a second reinforcing frame (5a), similar to that of the decorative layers, to guarantee the solidity and stability of the insert (1) on the floor; - a backing layer (5b) of plasticized PVC, which may include recycled PVC for environmental reasons, and which offers good mechanical strength while maintaining the product's flexibility. The backing layer (5b) can be obtained by Calendering, extrusion, pressing or coating, preferably by calendering. It is made of PVC plasticized with mineral fillers. It generally comprises between 30 and 50 PCR of plasticizer and between 50 and 200 PCR of mineral fillers.

[0059] Based on this concept, several variations in the realization of the decorative layers can be envisaged.

[0060] According to a first embodiment illustrated in [Fig. 3], the decorative layer (3a, 4a) may comprise a wear layer of plasticized PVC with a design embedded within its thickness, for example, within the mass. The design may be a solid color, for example produced by calendering, extrusion, coating, or more generally obtained from several types of colored PVC, rubber, or other polymer granules, pressed under heat to bind them together and form a heterogeneous design.

[0061] According to a second embodiment illustrated in [Fig. 4], the decorative layer (3a, 4a) comprises a transparent wear layer made of plasticized PVC (3a1, 4a1) and a printed design (3a2, 4a2). The design can be printed directly under the wear layer, on the first reinforcing armature (3b, 4b), or on a film positioned between the wear layer and the first reinforcing armature (3b, 4b).

[0062] Of course, depending on the decoration and the logo to be produced, these two forms of embodiment can be combined, that is to say that one can be used for the first decorative structure (3), and the other for the second.

[0063] With reference to [Fig.5], the first and second decorative structures (3, 4) each include a third reinforcing frame (7) bonded to a lower face of the lower layer (3c, 4c), in order to improve its resistance to traffic.

[0064] The third reinforcing armature (7) is glued to the lower face of the lower layer (3c, 4c) by a layer of glue (6), which can be a hot melt glue or a hot melt film.

[0065] According to a particular embodiment illustrated in [Fig. 6], and to improve comfort and cushioning, a reinforced, plasticized PVC foam underlayer (8) can be bonded to the underside of the plasticized PVC backing layer (5b) of the support (5). This underlayer (8) comprises a fourth reinforcing reinforcement (8a) and a plasticized PVC foam backing layer (8b). The foam backing layer (8b) has a thickness of between 3 and 5 mm and a density of between 0.25 and 0.5, and provides improved shock absorption and sound insulation.

[0066] The various reinforcing frames described can be: - fiberglass or polyester sails, for example with a weight between 50 and 120g / m2; - fiberglass grids, for example weighing between 40-100g / m2 with a mesh size of 5mm X 3mm or tighter; - complexes comprising a veil and a grid, for example with a weight between 40-100g / m2.

[0067] The first reinforcing armature (3b, 4b) can be coated with a layer of gelled plastisol to serve as a printing support for the printed decoration layer.

[0068] All PVC layers may include flame retardants.

[0069] The manufacturing process for this floor covering insert (1) (2) follows the following steps: - decorative motifs are cut out of the different decorative structures (3, 4), which can be of different compositions, colours or patterns; - the two-component glue (6) is applied to the support (5) made of plasticized and reinforced PVC; - the pre-cut patterns are then assembled side by side on the support (5), leaving a slight gap between the patterns; -hot pressing is carried out to crosslink the glue (6) and firmly bond the different layers together.

[0070] The decorative insert (1) thus created can be delivered as is and installed directly on site, or pre-integrated into a flexible, rollable floor covering (2). For this purpose, the floor covering (2) is cut to create an opening with dimensions equivalent to those of the insert (1) and at the location where the insert (1) is to be integrated. The insert (1) is then glued or welded, preferably with a weld bead (9) to mechanically bond the floor covering (2) and the insert (1). This ensures a perfect seal, essential in environments subject to significant stress, such as high-traffic areas in public transport or public buildings.

[0071] The total thickness of the insert (1) is generally between 2 and 3.5 mm, preferably between 2.2 and 2.8 mm, to ensure a low thickness without compromising resistance to traffic.

[0072] The insert (1) has a limited weight so as not to increase fuel consumption, particularly in the case of its use in vehicles such as trains or buses.

[0073] The patterns may or may not match the overall design of the coating. They can be customized according to the customer's or application's needs, for example, specific logos, contrasting patterns, etc.

[0074] The invention provides a flexible, rollable, robust, and resistant flooring insert (1) (2) designed to incorporate signage elements such as logos. Thanks to its reinforced multi-layer structure and assembly method, this insert (1) can be easily integrated into a floor covering (2), while offering high durability and performance in the face of heavy traffic constraints and safety requirements, particularly in terms of sealing and fire resistance.

Claims

Demands

1. A floor covering insert (1) incorporating a signage element, the insert (1) comprising at least first and second decorative structures (3, 4) pre-cut, assembled and positioned side by side with a gap and glued onto a support (5) to form the signage element, said glue (6) also being present in the gap between the first and second decorative structures (3, 4) characterized in that: - the first and second decorative structures (3, 4) each comprise, from top to bottom, a decorative layer (3a, 4a) of plasticized PVC, bonded to a first reinforcing frame (3b, 4b), bonded to a lower layer (3c, 4c) of plasticized PVC; - the support (5) is flexible and rollable and comprises, from top to bottom, a second reinforcing frame (5a) bonded to a backing layer (5b) of plasticized PVC.

2. Floor covering insert (1) according to claim 1, characterized in that the decorative layer (3a, 4a) of the first and / or second decorative structures (3, 4) comprises a transparent wear layer (3al, 4al) of plasticized PVC and a printed decoration (3a2, 4a2): - under the wear layer (3al, 4al), or; - on the first reinforcing frame (3b, 4b), or; - on a film positioned between the wear layer (3al, 4al) and the first reinforcing frame (3b, 4b).

3. Floor covering insert (1) according to claim 1, characterized in that the decorative layer (3a, 4a) of the first and / or second decorative structures (3, 4) comprises a wear layer of plasticized PVC with a decoration in the thickness of the wear layer.

4. Floor covering insert (1) according to any one of the preceding claims, characterized in that the first and second decorative structures (3, 4) each comprise a third reinforcing frame (7) bonded to a lower face of the lower layer (3c, 4c).

5. A floor covering insert (1) according to any one of the preceding claims, characterized in that it comprises an underlayer (8) bonded to a lower face of the backing layer (5b) made of plasticized PVC, which includes, from top to bottom, a fourth reinforcing frame (8a) and a back foam (8b).

6. Floor covering insert (1) according to claim 5, characterized in that the backing foam (8b) is made of plasticized PVC, has a thickness of between 3 and 5mm and a density of between 0.25 and 0.

5.

7. A floor covering insert (1) according to any one of the preceding claims, characterized in that it has a total thickness of between 2 and 3.5 mm, preferably between 2.2 and 2.8 mm.

8. Inset (1) of floor covering according to any one of the preceding claims, characterized in that the first and second decorative structures (3, 4) are glued together and with the support (5) with a two-component epoxy-urethane based adhesive.

9. A floor covering insert (1) according to any one of the preceding claims, characterized in that it comprises an adhesive underside coated with a peelable film.

10. Flexible, rollable floor covering (2) incorporating a floor covering insert (1) according to any one of the preceding claims.

11. A method for manufacturing a floor covering (2) insert (1) according to any one of claims 1 to 9, characterized in that it comprises the following steps: - cutting a first motif from a first decorative structure (3), and a second complementary motif from a second decorative structure (4), made of plasticized and reinforced PVC; - coating a layer of adhesive (6) onto a flexible and rollable support (5) made of plasticized and reinforced PVC; - assembling the first and second decorative structures (3, 4) onto the layer of adhesive (6) to form the signage element, with a gap between them to allow adhesive (6) to rise into said gap; - optionally, placing a structured plate opposite the signage element; - hot pressing to cross-link the adhesive (6) and bond the assembly.